New wastewater treatment and recovery systems in textile: history, evolution, future

Water biological techniques
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Let’s start with some good news: over the past two decades, the textile industry has made significant strides in adopting water treatment and recovery systems, and I’ve witnessed it firsthand.

The sector is still undergoing a phase of continuous evolution and the search for sustainable and efficient solutions, primarily driven by three factors:

  1. a growing environmental awareness
  2. stricter regulations
  3. the need to reduce operational costs.

This evolution is being led by companies specializing in water treatment, especially those born in the last decade, paving the way to make the textile industry a model of sustainability.

How do these companies play this key role? Where and how has their research advanced technologies for water recovery? And ultimately, what are the water treatment and recovery systems to choose for the textile sector today?

Let’s understand the problem to be solved, and together, let’s revisit the key milestones from 2000 onwards to discover the most advanced technologies available today.

INTRODUCTION

Numbers in the textile industry history

Let’s frame the issue.

According to EEA (European Environment Agency), global textile production nearly doubled between 2000 and 2015. The textile sector ranks 3rd in terms of water consumption and land use, and 5th in terms of primary raw material consumption.

Considering these figures, the industry’s focus appears to be increasingly geared towards the total reuse of water, with the implementation of the so-called ‘zero liquid discharge’ systems.

Then there’s the changing global climate context: the ongoing and increasingly frequent drought situations, even in countries where water seemed to be an unlimited resource until a few years ago, have led major Western buyers to demand an escalating percentage of water recovery from their suppliers by 2030.

We are, therefore, facing a significant environmental challenge, primarily involving the textile sector, whose destiny appears to be on a constant upward trajectory.

Let’s then review the main stages in the treatment of industrial wastewater over the last decades, the evolution of systems and technologies, and future prospects.


Wastewater treatment history - infographic
Wastewater treatment history – Infographic

HISTORY

1995-2000: environmental awareness

The history of environmental awareness starts in the late 1990s. The textile industry (finally) became aware of the environmental impacts resulting from fabric production and processing. Consequently, companies in the sector began introducing the first wastewater treatment systems.

What were these systems? Primarily, they were based on sedimentation processes, flocculation, and traditional chemical-physical treatments. Without delving into the details of these technologies, it can be said that it was a good start.

However, it was not perfect. These processes were costly to implement and manage. While highly efficient in removing suspended solids and inorganic substances, they were less effective against organic pollutants and nutrients.

Wastewater to be treated
Wastewater to be treated

2000-2010: biological techniques

Up to 50% recovery.

To overcome the limitations of the initial methods, technological advancements in just a few years brought about significant innovations and changes in water treatment for the textile industry. This period witnessed the adoption of water treatment technologies based on entirely biological processes, harnessing the activity of microorganisms (bacteria).

This type of treatment originated from the use in municipal wastewater treatment, where pollution is primarily organic. The groundbreaking innovation lay in applying this technology to textile water, characterized by high levels of non-biodegradable pollution.

So, were the problems finally solved? Certainly, biological treatments proved to be more sustainable, as they are less invasive to the environment, hastening the transition towards more eco-friendly water treatment systems.

However, even more advanced technologies were about to emerge.

2010-2020: evolution of water recovery technologies

The second decade of the 21st century continued the revolution in the textile industry, driven by the need to reduce the substantial water consumption inherent in this sector. This need was translated into regulatory measures, particularly in countries where water is not an unlimited resource.

One such country is undoubtedly India, which, starting from 2009, mandated local companies to achieve ‘zero discharge’ into the environment, emphasizing the reuse of water already used in processes. This accelerated the development of water recovery technologies in the textile sector and the entry of new specialized companies into the market.

WHAT ARE THESE SPECIALIZED COMPANIES?
Let me clarify what I mean by ‘specialized companies’: these are firms capable of introducing technologically advanced and highly customized solutions, leveraging knowledge and applications of specifically ‘selected’ membranes (which I will discuss in a dedicated paragraph below).

Initially, water recovery did not surpass 50%. Why? Because it involved technologies (e.g., filtration using anionic resins) that allowed the removal of pollutants, including color but not salt. Therefore, reuse could not exceed this percentage.

FOCUS

Today’s evolution of technologies

Reverse osmosis (RO)

From 50% to 80% recovery.

The significant leap forward was achieved through reverse osmosis, one of the most advanced and innovative water treatment and recovery systems in the textile sector. We were almost there: the recovery percentage was already high, but there was a need to refine intermediate filtrations. Processes like sedimentation, multimedia filtration, ultra-filtration, etc., made the recovery costly both in terms of CAPEX (capital expenditure) and OPEX (operational costs). Management was also quite challenging.

So, how did we overcome these challenges?

Reverse osmosis plant
Reverse osmosis plant

Membrane Biological Reactor (MBR)

From 80% to 95% recovery!

Alongside reverse osmosis, the implementation of Membrane Biological Reactor (MBR) filtration has been the true evolution in water recovery over the last 10 years. The application of this technology, already known in municipal wastewater treatment, has allowed bypassing intermediate filtrations and transitioning directly from the biological reactor to the MBR system and from there to reverse osmosis.

Membrane Biological Reactor
Membrane Biological Reactor

ANALYSIS

Advantages of modern wastewater recovery systems

The revolution brought about by reverse osmosis has enabled achieving a water recovery percentage of up to 95%, thanks to the high filtration degree ensured by MBR. The benefits extend far beyond, including:

  • significant reduction in the required space for the recovery plant
  • substantial reduction in necessary equipment
  • considerable decrease in operational costs
  • lower investment costs
  • greater ease of plant management
  • total automation of the plant
  • elimination of risks of R.O. membrane clogging
  • extension of the life of the R.O. plant.

Ultimately, this evolution has allowed for more efficient water recovery, reducing overall consumption and enhancing the sustainability of textile operations.

Advantage for the planet

Wastewater treatment plays a crucial role in the path towards sustainability, aligning with the United Nations Sustainable Development Goal (SDG) number 6, which aims to ensure access to clean water and sanitation. In other words, wastewater treatment is crucial to mitigate the negative impacts on human health and the environment resulting from contaminated water.

Recent and future research and analysis, focused on wastewater treatment, enable the implementation of increasingly effective solutions to reduce water pollution, preserving aquatic biodiversity, and safeguarding water resources. Moreover, investing in advanced technologies and water purification processes allows for sustainable management of water resources, contributing to achieving the global goal of ensuring a cleaner and healthier future for generations to come.

CONCLUSIONS

About the near future

Many pioneering companies are researching and investing in water recycling techniques, enabling the reuse of treated water for industrial purposes or fabric washing.

Particularly, these are young companies with innovative capabilities surpassing those engaged in water treatment for over 20-30 years. Their approach will further reduce the environmental impact of the textile industry.

Disclaimer: This article is based on published scientific research and actual case studies. The sources used are available upon request.
This article provides general information and does not constitute professional advice. It is always advisable to consult with qualified experts for specific water treatment needs.

Picture of Massimiliano Previdi
Massimiliano Previdi
Italian doctor of environmental engineering with over 25 years of experience in the water treatment field. He has developed and patented innovative technologies, including high-efficiency biological treatment systems.

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