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ORGANIZATION OF INDUSTRIAL APPLICATION OF ACADEMIC RESEARCH ON BIO-CATALYTIC PRE-TREATMENT PROCESSES OF COTTON
IPTB 2011/Milan/Italy
Presentation March 3, 2011
Gerrit Bouwhuis
Cotton
Annual production: 25 million ton
Most important natural textile fibre
Application:
Garments
Household
Safety
Technical
Cotton: personalization and protection
Goal of pre-treatment
Prepare cotton for dyeing/printing/finishing
Objective of preparation:
Removal of starch (desizing)
Removal of waxes and pectins (scouring)
Removal of natural colour (bleaching)
Removal of impurities as ash, salts etc. (washing)
Resulting in:
Even whiteness
Even and sufficient hydrophilic properties
Aim of this research
Design of a novel, environmentally improved, industrial cotton
pre-treatment process
Pre-requisites
No capital investment
Quality at least as good as conventional treatment
Full width treatment of the fabrics
Continuous treatment
Opportunities for industry
Development of a new innovative sustainable (bio)catalytic
pre-treatment process for cotton on industrial scale.
Keywords
Bio-catalytic process
Benign treatment
Water reduction 20% (EuropaBio 2003)
Energy reduction 20% (EuropaBio 2003)
Waste water reduction 40% (europaBio 2003)
Sustainability
Development steps
1. Organisation of the collaboration
2. Research of the enzymatic treatment step
3. Research of the bleaching treatment step
4. Installed base/mechanical energy
5. Design and implementation of the new process
Organization of the collaboration I
> 4 years < 2years < 1 year
Academic orexplorative
research
Innovative or
appliedresearch
Development
KNOW
LEDGE
TECHNO
LOGY
INFO PRODUCTPROCESS
Organization of the collaboration II
Know how institutes
University of Twente Academic research
Saxion University of Applied Science Applied Research
Industry
Royal TenCate Finisher
Vlisco/Gamma Holding Finisher
Tanatex Chemicals
Organization of the collaboration IIIAcademic orexplorative
research
Innovative or
appliedresearch
Development
KNOW
LEDGE
TECHNO
LOGY
INFO PRODUCTPROCESS
UTwente
Saxion
Tanatex
Textile industry
Research of the enzymatic treatment step
Starting point: The research of Agrawal
Development:
Enzyme cocktail containing
Amylase
Cutinase
Pectinase
Operating window:
pH 8, T 30 – 50°C
Performance
Desizing and hydrophilicity
Starting point: Research of Topalovic
Development
The use of the bleaching agents: activators (manganese catalyst
and NaOH)
Operating window:
Continuous and discontinuous
30-50°C process bleach and rinse temperature, pH 10,5
Performance:
Whiteness in CIE-lab
Research of the bleaching treatment step
Installed base/mechanical energy
Installed base for pad batch – hot bleach
Aspects of mass transfer
Textile substrate (stagnant and convective region)
Squeezing model
Mass transfer model
Adsorption limitation in textile pores
Design and implementation of the new process I
Conventional Desizing: Amylase
Scouring: NaOH (100°C rinse)
Bleaching: H2O2 and NaOH
Washing (100°C)
High water consumption
High temperature
New process (lab scale) Desizing: Amylase
Scouring: Pectinase and
cutinase (30°C rinse)
Bleaching: H2O2 and
MnTACN or reduced NaOH
Washing (40°C)
Reduced water consumption
Reduced temperature
Conclusions
Low temperature rinsing after bio-scouring
Sufficient hydrophilicity
Sufficient pectin removal
Low temperature rinsing after bleaching
Whiteness to be improved
Reduced waste water pollution (38% reduction on COD)
Decrease in cost per kg fabric: € 0,08 (excl. effect of cost of chemicals)
Collaboration supports implementation of new processes
Bio-catalytic treatment is profitable!!