A FABRIC-YARN WET TREATMENT MACHINE WITH RECYCLING WASTE WATER The Related Art

The invention is related to a finishing machine which used for wet treatments of fabrics and yarns wounded beam in textile.

The invention is particularly related to a machine which will be applied by using minimum water and which can process the water it used by regaining, according to exhausting method individually or combined (in one bath) and in open-width form of wet processes such as pretreatment, dyeing, after-washing, giving effect, chemical finishing treatment, stripping dyestuff etc. for woven, knitted, denim fabrics and every kinds of dyed yarns wound to beam.

The Prior Art

Nowadays, there are a lot of machines which have different structures and work according to exhaust method in textile sector. There are sortie examples about wet treatment machines as jet and overflow which both liquor and material are active, about dyeing apparatus which the material is stable and jigger which the material is active and liquor is stable.

It is known that there are difficulties about working with the woven fabrics which are produced especially from natural raw materials (cotton, wool etc.) in the existing machines because of their sensibilities. Besides, it's an another deficiency in known machines that systems such as ozone gas, -UV (Ultraviolet)- US (Ultrasound) individually or/and combined that qualified as innovative and can used in process development are absent.

Furthermore, in conventional machines, it's limited to combine process and use of these combined process. The other disadvantage of conventional machine is producing a lot of wastewater and the obligation of transferring these wastes to treatment systems without doing any treatments (discoloring, filtering, etc.). The existing machines worked according to exhaust method take treatment water with chemicals, bring together the fabric during the process and then transfer to the waste-treatment system directly. Weanwhile, these machines cannot provide the opportunities such as ozone gas application, US treatment or UV light application that make the process easier and faster to the fabric.

This design of the existing machines prevent the combination of wet treatments such as pretreatment-dyeing-finishing and the re-usage of the wastewater obtained from wet processes. These machines restrict the use of advanced technologic equipments (ozone-UV-ultrasound) in textile processes, it hinders sustainable processes in wet textile treatments.

The existing machines hinder applications of some enzymes especially in the cotton woven sector.

The existing machines hinder the formation of factories in the concept of green factory. In the existing machines, the possibility of development of more economic processes is restricted because of limited machine construction. In the existing machines it's not possible to use ozone gas injection in the water or air and the US energy cannot be transmitted efficiently to the water process water. In addition, in the existing machines, UV energy cannot be transmitted to process water and the textile material.

The invention numbered as EP2122032B1 and titled as "Fabric Process Machine" in the existing method, is related to a machine which the fabrics are kept in extensive form during process and used for fabric treatments, for example cleaning, bleaching, dyeing, washing etc.

The invention numbered as EP1682714B1 , and titled as "Discontinue dyeing apparatus for open- width fabric and production method", includes an apparatus that has a tank including dyeing liquor in which the fabric opened in opening roll pass through while going to winding roll, an enlargement balancer which provides dyeing of the most delicate fabrics without wrinkling, a steamy heating apparatus for dyeing liquor, a hood in order to prevent dispersing of produced steam to air while that apparatus is using and an apparatus which used for sensitive controls of operating tension on the fabric; its characteristic is at least one of the opening roll or winding roll has the first dispersion equipment of dyeing liquor for the fabric that wounded on and is for the dyeing fabrics in the form of discontinue open-width.

Aim Of The Invention

To remove of the disadvantages of the known case of technic, one of the aim of the invention is that the machine can do the pretreatment processes (desizing, scouring, bleaching, washing etc.) of cotton fabrics in the single bath as combined.

Another aim of the invention is to combine the pretreatment processes of the cotton fabrics with dyeing process in the single bath.

Another aim of the invention is to apply pretreatment processes which are sustainable by usage of ozone-UV-US technologies together, work without using chemical or with consuming less water and energy. Another aim of the invention is to increase the activations of the chemicals used in the processes and decrease their consumptions by using UV and US.

Another aim of the invention is to clean the wastewater of every wet treatment applied at the point of use and reuse in the same machine again.

Another aim of the invention is to inject and disperse the ozone gas in the air or water with different alternatives to a textile finishing machine.

Another aim of the invention is to use the UV technology actively in the textile wet processes.

Another aim of the invention is to use the US technology actively in the textile wet processes.

Another aim of the invention is to include the combination of the ozone gas-UV-US applications that existing machines have not.

Another aim of the invention is to include an injection system which provides the mixture of ozone gas in the water and to form an important dominance of the mobile diffusers in the injection system for mixture of gas in the water.

Another aim of the invention, as different from the conventional ones, is that the machine has the characteristic of reusing again the wastewater produced after the wet treatments. The machine contributes to environmentally-friendly production approach with this feature.

Another aim of the invention is having internally generator structure producing ozone gas.

Another aim of the invention is to perform all the controls of ozone production and transfer to the process point-measurements about ozone gas- UV usage - US usage- wastewater treatment-all the wet processes with an automation which will be prepared special for the machine.

In order to provide the advantages mentioned above, the invention is a machine which will be applied by using minimum water and can process the water it used by regaining, according to exhausting method individually or combined (in one bath) and in open-width form of wet processes such as pretreatment, dyeing, after-washing, chemical finishing, giving effect, for woven, knitted, denim fabrics and every kinds of dyed yarns wound to beam in textile; which is characterized by including the constant diffusers each are positioning under a cylinder and applying the ozonized water to the material directly from reaction tank, diffusers taking ozone gas from generator directly and transferring to the water and applying to the material, the UV applicator placing in a protective glass in the foulard and the US transducers located at the bottom of the foulard(18).

Brief Description Of The Figures

Figure 1 general view of waste and process sections of the invention

Figure 2 general view of process section of the invention

Figure 3 general view of waste section of the invention

Figure 4 general view of mobile diffuser and nozzle of the invention

Reference Numbers

Detailed Description Of The invention The invention is an innovative machine based on a jigger used in industry, used for different wet processes (pretreatment, dyeing, finishing, giving effect, washing, chemical finishing, stripping dyestuff) for different kinds of woven fabric and open-width wrapped yarn according to exhaust process (16).

The invention especially will have some functions such as applicability of the textile wet treatments in an textile finishing mill in a single bath as combined, providing easy application of processes with enzymes, providing opportunity of reusing of wastewater by processing and thus leading up sustainable wet treatments.

In addition, the invention is related to a design which has the (15, 3, 5) ozone gas, ultraviolet (UV) and ultrasound (US) systems in a single machine as combined. These advanced methods will be able to be used for improving of method with desired combinations in accordance with selected wet processes.

Also, the invention will be used for wet treatments of textile materials in the form of woven fabric and the open-width yarn. In Figure 1 , general view of waste and process sections can be seen. The invention consists of four basic sections according to the figure. These are process (application) unit (A), reaction tanks (11 , 12), ozone generator (15) and intermediate storage (14). However, it mainly consists of two functional sections as process (A) and waste treatment (B).

The first section of invention is called as Process (application) Unit (B). In Figure 2, there is a general view of process section (b). The nozzles (1 , 2) working in water and air and the UV applicator (3) were placed in them main part of the machine but the dry part of machine where liquor doesn't contact (16) according to the Figure. The stable diffuser set (49) and the other UV applicator (5) are placed in the foulards (18) in which application is carried out. The stable diffuser can have different constructions which enhance the mixture in the water. The UV applicator (5) will work in a protection box in order not to be affected negatively by water contact. The US transducers (6) working in the system are placed under the application foulard in a suitable form of not redeeming each other. The static blender (7) and mobile diffuser (8) are placed out of the main application shaft. The ozone generator will be placed on the main control shaft. The valves (9) and pumps (10) will act as auxiliary equipments for system, transfers and automation.

In Figure 3, there is detailed technical drawing of waste treatment section (A) working in/out of the main machine shaft. The waste section (A) consists of reaction tank with mobile diffuser (8) working in it, intermediate storage with mobile diffuser (8) working in it, the UV applicator (5) working in the intermediate storage and water tank (13). The valves (9) and pumps (10) will act as auxiliary equipments for system and automation. The invention will have a design of working both open to the atmosphere and with pressure. There will be "n" numbers of foulard (18) in the machine. Thus, it is lead up applying different processes in each foulard (18).

The ozone gas produced by generator will be applied to the textile material in the machine by two ways. Firstly, the ozone gas will be sprayed from the stable nozzle (2) to the material as it comes directly from generator in the form of mixed with the air. This will provide advantage of using ozone gas in the machine continuously and lead up the ozone application in the air for related processes. In the other case, the ozone gas will be mixed with water via venturi (17) by following a pipeline and it will be obtained ozon gas-water mixture in the reaction (12) tank by following mobile diffuser. The P3 pump (10) will provide the circulation in the tank. Afterwards, in order to enhance the mixture, the ozonized water will be transferred through the static blender (7) and transfer to the water spray nozzles (1) in the machine. Thus, in this machine, ozone application in the water will be able to be applied. Both air (2) and water (1) nozzles will be able to move in the angular actions (Figure 4) and placed by adjusting application length and angular position to the material moving in the machine.

Applying individually or combined of ozone application system in the air-water is an advantage of designed application system. Different form the conventional jigger machine, air-water ozone application systems that adapted to the machine will lead up applying the bleaching and giving effect treatments with a new method. In addition, the transferring systems (1 , 2) of ozonized water will be important sections for performing the bleaching, washing and giving effect processes without using chemicals or consuming minimum chemical. The transferring systems of ozonized water and ozone generator are connected to main automation system of machine and can be controlled from single point.

In order to make use of the whitening (bleaching) property of the UV energy, a UV lamp system (3) is added into the machine. This system will be applied to textile material in the air condition. The UV lamp can be moved, the distance of lamp with textile material and power can be adjusted. It will be connected to the automation system. The UV lamp (3) is used for bleaching and giving effect processes and this provides some advantages regarding as shortening of process time, activation and combining of chemicals.

The innovations explained up to now will not be in the foulards (18), it is existed out of the foulards (18), in the main shaft of the machine which is not to be associated to water. The invention has five innovations in the application foulard (18) in comparison with conventional ones. These are stable diffusers (4) each are positioned under a cylinder and applying ozonized water from reaction tank (12) or the ozone gas from generator (15) to the material directly, diffusers (8) taking ozone gas from generator (15) directly and transferring to the water and applying to the material, the UV applicator (5), placing in a protective glass in the foulard (18) and the US transducers (6) located at the bottom of the foulard (18). Finally, the ozone gas will be given to foulards (18) through a venturi (17-b) directly in the the foulard (18) without using reaction tank (12). The application water is continuously circulated into the machine through a pump (P1) (10), thus it can be ozonized continuously. In the foulard (18), diffusers (4, 8) seen in the Figure 4, ozone generator (15) and UV applicators (3, 5) are placed for bleaching and giving effect processes and these two apparatus are designed in order to take the place of textile chemicals.

The second reaction tank (12) is the unit which will provide the ozone-water mixture in the application machine (jigger) (16). In this system, the mixture is provided by the combination of venturi (17-a)-mobile diffuser (8)-static blender. The diffuser (8) works mobile in this system. This is shown in Figure 4. In order to enhance the mixture of ozone in the water, mobile diffuser is an advantage.

Especially, the working ability of the invention without chemical consumption or with minimum consumption and applying combined processes is provided by ozone, US, UV application equipments (1 ,2,3,4,5,6). These parts have innovation property for the invention.

The US (Ultrasound) system (6) placing under the foulard (18) will be functional for all the planned wet treatments. Especially, it increases the mass transfer in the foulard ( 8) and thus makes the chemical consumption minimal, increase the efficiency of the process. The US systems (6) placed under the foulard (18) will work in groups and the power of application can be controlled. US (6) systems are important elements for advantageous processes of machine. This system is also connected with automation control.

The other important part of system is the section of "wastewater treatment -cleaning and reusage". The section does not exist in classical machines and systems. It is shown in Figure 3 in detail. The systems working in this part have innovation qualification for this kind of machine. There are 1. reaction tank (1 ), intermediate storage (14) and the diffuser (8) working in it, UV applicator (5), wastewater tank (13), valves (9) and pumps (10) in this unit.

It is developed two approaches in the content of the invention. The first of them is wastewater recycling with continuous system in the part defined as "intermediate storage part (14)" in the machine, the other is the collecting of wastewater and the discontinuous wastewater recycling in the part defined as " 1. reaction tank (1 1 )". In this part of the invention, the process water treated in the foulard (18) is taken to the intermediate storage (14) as soon as the wet process finish. As soon as the water transferred to the intermediate storage (14), the stable diffuser (8) starts to pump the mixture of ozone gas-water with pump (10, P4) through the venturi (17) to the system. After the cleaning of water and reach the desired quality, it is taken to the wastewater tank (13) in order to rest and then the water is ready to re-usage.

In the second approach, 1. reaction tank ( ) is used for re-usage of the wastewater. In this approach, the process water is transferred to reaction tank (11) with P4 pump (10). In this point, the flow way is determined by the valves of V6-V7-V8 (9). The process water taken to tank (11) is ozonized via both diffuser (8) and venturi (17-c) after collecting in the tank (11). After obtaining wastewater at desired quality, it is taken to wastewater tank (13) through P6 pump (10).

Except this system, the mobile diffusers (8) in the invention can be used in the different ozone systems. The second wastewater treatment part (13) can be adapted to several textile wet treatment machines.