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Ozone In Textile Industry

OZONE IN TEXTILE INDUSTRY

Enterprises in the textile industry are the most environmentally polluting enterprises. The main emission source results from fabric design, where decorative design or text is applied using various screen printing methods. This process leads to recalcitrant molecules and Volatile Organic Content (VOC) gas in the production of wastewater. Applying environmental constraints requires efficient functioning of air or water flows to ensure a healthy working environment and to avoid contaminated water receivers. In many plants, jeans or other garments are often bleached to create a “washed” look.

In the textile industry, the effective method of reducing operational costs and reducing environmental emissions compared to traditional techniques is ozonation.

Ozonization for screen printing emissions:

Wastewater;

Ozone technology is an effective method to treat organic molecules in both wastewater and VOC by oxidation. Wastewater typically contains a high level of COD with a COD: BOD ratio of 4: 1 to 5: 1.

Ozone not only oxidizes organic pollutants, but it can also convert the biodegradable COD into easily biodegradable BOD, then reduce the ratio of COD: BOD for biological treatment. Depending on the COD and BOD concentration, ozone can oxidize most of the compounds that reduce wastewater load to acceptable legal levels.

Ozone system for textile wastewater saves significant operating costs and reduces operational footprint.

VOC Ozone Treatment:

Burning VOC fugitive gases by burning is an effective but very costly method. Ozone can be applied in place of the burning process with high energy consumption and can decrease operating costs by 1000 times.

Ozone reacts effectively with these pollutants in the gas phase compared to typical processes by combustion of volatile compounds. This eliminates the main energy demands following the combustion process. Ozone for VOC gases typically has been found that ozone treatment with secondary polishing reduces VOC gases by 90% to completely reduce fugitive gases.

Textile Bleaching Through Ozone:

In modern design garment production, fabrics such as jeans are bleached by chemicals using oxidation to achieve a washed look.

The high oxidative properties of ozone provide a sustainable bleaching method without excessive chemical treatment or cost. In addition, as a result of bleaching by ozonation, no by-products are formed.

Removing Color by Ozone:

Textile wastewater is treated in the field, mostly using biological wastewater treatment processes. This can result in approximately 90% reduction in incoming COD and BOD. The remaining COD and BOD can still generate significant environmental loads. Typically, it is not possible to remove the discolouration of the wastewater caused by the textile production described above.

Ozone is a very effective colour removal technology as part of the tertiary treatment step. Depending on the ozone capacity, full-colour removal can be achieved with 5-15 minutes of ozone exposure.

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Ozone Applications In Sewage Treatment Plants

OZONE IN WASTEWATER DISINFECTION

Ozone used for wastewater disinfection became popular after its widespread use in the 1970s and 1980s. The reason why it is popular; it is due to improved equipment reliability and low cost; However, the main reason for the increase in the use of ozone in the sector is the economic benefits offered by ozone, as well as the increased secondary benefits that create an economic advantage.

Among the secondary benefits of ozone; colour removal in wastewater, odour control, removal of micropollutants and reduction of total suspended solids (TSS).

The use of ozone for wastewater disinfection is gaining popularity due to strict regulations on fecal coliform and other pathogens. As chemical costs increase, ozone becomes a more cost-effective solution for wastewater disinfection. Ozone can be produced on-site using oxygen in the ambient air. Only electrical power is required for the process.

When discharge limits on pathogens are reduced, the natural solution is to add additional chemicals to meet these new limits. Adding more chemicals to the wastewater stream for disinfection may seem an easy solution at first; However, in most cases, these chemicals must be removed from the waste water prior to discharge due to limitations on these chemicals.

For example, if chlorine is used to reduce E.coli, chlorine is required from chlorine before the discharge of wastewater. If 20% more chlorine is required to meet the new wastewater discharge limits, 20% de-chlorination should be applied to this water. This application increases the costs very much over time.

Ozone is a green solution for wastewater disinfection. Ozone is produced on-site and is completely natural, it consists only of oxygen. No by-products or waste products are formed in the formation of ozone.

– The use of ozone eliminates the need to move chemicals into the field.
– With the use of ozone, the need to store chemicals is eliminated.
– After ozone dissolves in water, it does not leave residue in water; it returns to its original form, oxygen.

PROCESS IN WASTEWATER CHLORINE OZONE
Oxidation Potential (Volts) 1,36 2,07
Disinfection of Bacterias Moderate Perfect
Disinfection of Viruses Moderate Perfect
Eco Friendly No Yes
Colour Removal Moderate Perfect
Carcinogen formation Possible Not Possible
Organic Oxidation No Moderate
Micro Clumping No Moderate
Ph effect Variable Low
Half-life 2-3 Hours 20 Minutes
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Brewery & Winery Ozone Applications

OZONE IN BEER AND WINE INDUSTRY

Ozone technology can be used as a replacement for disinfection chemicals and can be integrated into an existing Clean In Place (CIP) system for cleaning all beer processing equipment. In fermentation and lager tanks cleaning; sanitation cycles can be shortened up to 30 minutes per CIP. Ozone is an alternative to hot water disinfection, which causes frequent thermal expansion of pipes, joints and tank materials.

Using ozone as part of CIP effectively disinfects pipes. Since no by-products remain in the system, water and time savings can be achieved.

All components of the filling line can be disinfected with ozone as part of the CIP cycle. Hot water, which is especially common for filling machine sanitation, can be replaced with ozonized water to save time and energy.

Also suitable for ozone water, keg filling machines and CIP system. In these applications, ozone can reduce costs by using steam and hot water.

Cross-contamination can occur in breweries that produce various types of drinks consecutively. Ozone, as an effective oxidizer, prevents flavour contamination in products.

Ozone water is an effective surface cleaner. It can be used on conveyor belts (eg filling line) and on the floor of the brewery.

In recent years, anaerobic bacteria such as various Pectinatus and Megaspaera species have emerged as a serious problem in brewery processes and are often found in beer and fermentation tanks and filling machines. The superior disinfection capacity of ozone as a strong oxidizing agent reduces the microbial load at the factories.

The source of sterilized and clean water for industrial use is an issue in food and beverage production in many parts of the world. Ozone is a cost-effective method for brewing, cleaning process equipment and disinfecting the water used for rinsing throughout the facility.

Ozone not only provides effective cleaning conditions but also eliminates BOD and COD. In addition, it provides clear water by removing particles and discolourations.

Ozone leaves no by-products or flavours. It is an excellent alternative to chlorine dioxide sanitation, which is generally used in large breweries.

To get more information about ozone applications, contact us.