WO2017066000A1 - Élimination de couleur de l'eau avec de l'ozone dans un procédé de blanchiment de textiles - Google Patents

Élimination de couleur de l'eau avec de l'ozone dans un procédé de blanchiment de textiles Download PDF

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Publication number
WO2017066000A1
WO2017066000A1 PCT/US2016/054680 US2016054680W WO2017066000A1 WO 2017066000 A1 WO2017066000 A1 WO 2017066000A1 US 2016054680 W US2016054680 W US 2016054680W WO 2017066000 A1 WO2017066000 A1 WO 2017066000A1
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WO
WIPO (PCT)
Prior art keywords
ozone
machine
water
barrel
bleaching
Prior art date
Application number
PCT/US2016/054680
Other languages
English (en)
Inventor
Thomas R. Allen
Charles Smith
Thoram Charanda
Original Assignee
Guardian Manufacturing, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Guardian Manufacturing, Inc. filed Critical Guardian Manufacturing, Inc.
Priority to EP16779310.8A priority Critical patent/EP3362412A1/fr
Publication of WO2017066000A1 publication Critical patent/WO2017066000A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/15—Locally discharging the dyes
    • D06P5/153—Locally discharging the dyes with oxidants
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/008—Control or steering systems not provided for elsewhere in subclass C02F
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/72—Treatment of water, waste water, or sewage by oxidation
    • C02F1/78—Treatment of water, waste water, or sewage by oxidation with ozone
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B23/00—Component parts, details, or accessories of apparatus or machines, specially adapted for the treating of textile materials, not restricted to a particular kind of apparatus, provided for in groups D06B1/00 - D06B21/00
    • D06B23/20—Arrangements of apparatus for treating processing-liquids, -gases or -vapours, e.g. purification, filtration or distillation
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B23/00—Component parts, details, or accessories of apparatus or machines, specially adapted for the treating of textile materials, not restricted to a particular kind of apparatus, provided for in groups D06B1/00 - D06B21/00
    • D06B23/20—Arrangements of apparatus for treating processing-liquids, -gases or -vapours, e.g. purification, filtration or distillation
    • D06B23/205—Arrangements of apparatus for treating processing-liquids, -gases or -vapours, e.g. purification, filtration or distillation for adding or mixing constituents of the treating material
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F35/00—Washing machines, apparatus, or methods not otherwise provided for
    • D06F35/001—Washing machines, apparatus, or methods not otherwise provided for using ozone
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06L—DRY-CLEANING, WASHING OR BLEACHING FIBRES, FILAMENTS, THREADS, YARNS, FABRICS, FEATHERS OR MADE-UP FIBROUS GOODS; BLEACHING LEATHER OR FURS
    • D06L4/00—Bleaching fibres, filaments, threads, yarns, fabrics, feathers or made-up fibrous goods; Bleaching leather or furs
    • D06L4/50—Bleaching fibres, filaments, threads, yarns, fabrics, feathers or made-up fibrous goods; Bleaching leather or furs by irradiation or ozonisation
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06L—DRY-CLEANING, WASHING OR BLEACHING FIBRES, FILAMENTS, THREADS, YARNS, FABRICS, FEATHERS OR MADE-UP FIBROUS GOODS; BLEACHING LEATHER OR FURS
    • D06L4/00—Bleaching fibres, filaments, threads, yarns, fabrics, feathers or made-up fibrous goods; Bleaching leather or furs
    • D06L4/70—Multi-step processes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06L—DRY-CLEANING, WASHING OR BLEACHING FIBRES, FILAMENTS, THREADS, YARNS, FABRICS, FEATHERS OR MADE-UP FIBROUS GOODS; BLEACHING LEATHER OR FURS
    • D06L4/00—Bleaching fibres, filaments, threads, yarns, fabrics, feathers or made-up fibrous goods; Bleaching leather or furs
    • D06L4/70—Multi-step processes
    • D06L4/75—Multi-step processes combined with cleaning or washing
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00—Nature of the contaminant
    • C02F2101/30—Organic compounds
    • C02F2101/308—Dyes; Colorants; Fluorescent agents
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/30—Nature of the water, waste water, sewage or sludge to be treated from the textile industry
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2201/00—Apparatus for treatment of water, waste water or sewage
    • C02F2201/78—Details relating to ozone treatment devices
    • C02F2201/782—Ozone generators
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F2101/00—User input for the control of domestic laundry washing machines, washer-dryers or laundry dryers
    • D06F2101/02—Characteristics of laundry or load
    • D06F2101/04—Quantity, e.g. weight
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F2101/00—User input for the control of domestic laundry washing machines, washer-dryers or laundry dryers
    • D06F2101/20—Operation modes, e.g. delicate laundry washing programs, service modes or refreshment cycles
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F34/00—Details of control systems for washing machines, washer-dryers or laundry dryers
    • D06F34/28—Arrangements for program selection, e.g. control panels therefor; Arrangements for indicating program parameters, e.g. the selected program or its progress

Definitions

  • Embodiments of the present disclosure relate generally to methods and systems for bleaching textiles using ozone gas that incorporates a color removal step.
  • a hybrid machine that incorporates certain features of a washer, but that also includes an integrated blower for gas distribution inside the machine.
  • an ozone dosing control system that allows for maintenance of a constant concentration of ozone in the machine.
  • the ozone output measured in grams/hour at this constant concentration in conjunction with the weight of product measured being treated may be referred to as the ' " bleaching factor.”
  • an in-process water dye removal step and a wastewater dye removal step in which ozone is used to clean the water and remove dyes and other colors that may be deposited via denim or other garments, for further use in a continuing step or to remove color prior to draining and discharge to a downstream water treatment system (such as a reuse system or city sewer).
  • Embodiments of the invention described herein thus provide systems and methods for bleaching textiles that are more reliable and reproducible.
  • This disclosure provides for process control that allows a particular dosage rate or concentration of ozone to be held throughout the process.
  • This disclosure also provides a hybrid washing machine that includes an integrated blowing system for circulating ozonated air inside the machine during the bleaching process.
  • the hybrid washing machine may incorporate features of a sealed vessel, a washing machine, and the air circulation volume typically associated with commercial dryers.
  • Embodiments also provide methods for removing indigo dyes, reactive dyes, vat dyes, acid dyes, pigment dyes, or any other dyes in the process water contained within the machine in use. BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1A shows a front perspective view of one embodiment of an ozone bleaching system described herein.
  • FIG. I B shows a front plan view of the ozone bleaching system of FIG. 1A.
  • FIG. 2 shows a front perspective view of one embodiment of a hybrid washing machine for ozone treatment.
  • FIG. 3 shows a rear perspective view of the hybrid washing machine of FIG. 2.
  • FIG. 4 shows a front view schematic illustrating air flow circulation through a hybrid washing machine for ozone treatment.
  • FIG. 5 shows a side schematic view of the airflow circulation of FIG. 4.
  • FIG. 6 shows a front plan view of airflow through an alternate embodiment of a hybrid washing machine for ozone treatment.
  • FIG. 7 shows a front perspective view of the machine of FIG. 6.
  • FIG. 8 shows a rear plan view of the machine of FIG. 6.
  • FIG. 9 shows a front view schematic illustrating water flow circulation through a hybrid washing machine for ozone treatment.
  • FIG. 10 shows a side plan view of the machine of FIG. 9.
  • FIG. 11 shows a side plan view of water flow through an alternate embodiment of a hybrid washing machine for ozone treatment.
  • FIG. 12 shows a front plan view of the machine of FIG. 1 1.
  • FIGS. 13A and 13B show a schematic illustrating various components of an ozone bleaching system.
  • FIG. 14 shows a schematic illustration of one embodiment of an ozone dosing control system.
  • FIG. 15 shows a schematic of a water sample point on a hybrid washing machine.
  • FIGS. 16A and 16B show a schematic of ozone gas flow whether used in a dry process or a wet process. These figures also illustrate that a single ozone generator may supply multiple ozone treatment components.
  • FIG. 17 shows a schematic of a dry process treatment.
  • FIG. 18 shows a schematic of a wet process treatment.
  • FIG. 19 illustrates a flow chart of a color removal process.
  • FIG. 20 shows a side perspective view of an alternate hybrid washing machine that may be used in the processes described herein.
  • FIG. 21 shows a top perspective view of the alternate hybrid washing machine on FIG. 20.
  • FIG. 22 shows a top plan view of a machine with the blower ducting removed, illustrating the blower duct inlet, the blower duct outlet for recirculation, and a spray bar.
  • FIG. 23 shows a perspective view of the machine of FIGS 20-22.
  • FIG. 24 shows a schematic view of a spray bar that may be used with a hybrid washing machine.
  • embodiments of the present invention provide methods and systems for bleaching textiles with ozone using a hybrid washing machine that is specifically designed to be ozone compatible.
  • embodiments provide an ozone system having specific dosing capability, such that a precise and reproducible bleaching factor may be programmed.
  • embodiments provide a wet ozone bleaching process.
  • the wet ozone bleaching process provides for recirculation of ozonated water contained in the machme.
  • a dry ozone bleaching process there is provided a dry ozone bleaching process.
  • the dry ozone bleaching process provides for circulation and continued introduction of ozone in the air contained in the machine.
  • FIGS. 1A and I B illustrate one example of various views of one embodiment of an ozone bleaching system 10.
  • This system embodiment is provided with an ozone generator 12, a textile ozone treatment component 14, and an ozone destruct unit 16.
  • Tire ozone generator 12 is shown having an oxygen supply rack 18, but it should be understood that the ozone generator may have an oxygen generator integrally formed therewith.
  • the oxygen generator (and/or oxygen supply rack) and the ozone generator may be contained in the same housing.
  • the ozone generator 12 may also be provided with a high concentration ozone analyzer 13. High concentration ozone analyzers are generally used for measuring the output of the ozone generator 12, in real time while in operation.
  • the ozone generator 12 may be fluidiy connected with the textile ozone treatment component 14.
  • the textile ozone treatment component 14 is the portion of the system that is loaded with the textiles to be treated.
  • the treatment component 14 may be designed as a hybrid washing machine, as described further below.
  • the ozone generator is configured such that, when the ozone generator starts up, it generally makes a predetermined fixed amount of ozone, as soon as it receives an ozone request from of the connected washers. It will then continue to make that amount of ozone for a programed (and variable) amount of time after all ozone demand (from any connected washer) has ended. If excess ozone is generated that is not actually needed in a washer, is it simply directed to the ozone destruct unit. This allows for a complete cycle to be run in any washer, with only one potential wait time, for the ozone system to stabilize and reach proper concentration and output.
  • An ozone destruct unit 16 is fluidiy connected with an outlet of the textile ozone treatment component 14.
  • the ozone destruct unit 16 is a safety measure used when dealing with high concentrations of ozone. Because ozone is toxic and can be harmful, before ozonated air can leave the treatment component 14, the high concentrations of ozone must be removed.
  • the ozone destruct unit 16 provides a catalytic destruct process that will safely destroy (and convert back to oxygen) any- excess ozone that is present in the air that is to be off gassed from the treatment component 14.
  • An optional deniister 15 may also be included. The demister 15 can help remove any excess moisture from the air to be off gassed before it enters the ozone destfiict unit 16.
  • the ozone bleaching system 10 described herein may also have a user interface screen.
  • This user interface screen may communicate with a computer or processor or other electronic component for controlling weight percent (%wt) of ozone delivered.
  • the system may also be designed to control flow rate, temperature, or any other variable that may be determined as useful to the bleaching processes described herein. Dry Bleaching Features.
  • the textile ozone treatment component 14 may be provided with an integrated blower component 20,
  • the blower component 20 Circulates air flow volume within the treatment component 14. This may be particularly useful for a dry bleaching process.
  • the blower component 20 forces ozonated air (and in some instances, fresh air) through the treatment component 14. In one specific design, the blower component 20 may turn over the volume of air in the treatment component 14 as quickly as about once every second.
  • the blower component 20 may include a centrifugal fan 38 and a fan exhaust 42.
  • the blower component 20 may be a high flow blower that is built into the washer or textile ozone treatment component 14 to allow quick turnover of the air volume in the machine. Forced airflow is believed to provide good contact of the ozone with the textiles/fabrics to be bleached. It is also believed to ensure that proper bleaching occurs in a uniform manner, throughout the load of garments. (At the end of the process, the blower component 20 may also be used to create a force of air to purge the machine during the destruct step. This can eliminate the need for use of a separate external fan for this process.)
  • the treatment component 14 may also incorporate features of a washer for performing pre-rinsing and for uniform wetting of the fabric prior to ozonation. It may also incorporate features that allow circulation of ozonated water for bleaching treatment. This may be particularly useful for a wet bleaching process.
  • FIGS. 2 and 3 One example of such a hybrid washing machine 14 is illustrated by FIGS. 2 and 3.
  • This hybrid washing machine 14 has features of both a washing unit and a drying unit incorporated into the same machine 14.
  • the machine 14 is shown as having a barrel 24 (or cylinder) for holding textiles to be treated and to provide an enclosed space in which the treatment takes place.
  • the barrel 24 may have a door 25 that is openable and closeable to maintain a closed system.
  • the door 25 may contain door security provided by a pneumatic cylinder.
  • the machine 14 is also shown as having a fluid/water inlet 26 (and accompanying valve) and a fresh air inlet/valve 30.
  • the machine 14 may also have a pressure equalization port 31 .
  • the pressure equalization port 31 may be connected to a dedicated ozone gas release tube 68.
  • This release tube 68 may be directly connected to plumbing of the ozone destract unit 16 in order to allow for ozone gas to escape during the ozonation process and to prevent over-pressurization of the machine. Over pressurizing of the machine could cause ozone leaks and stop gas flow from maintaining proper ozone levels in the vessel, so this port 31 allows ozone to escape the barrel 24 and to be delivered to the ozone destract unit 16.
  • the port 31 may be provided as an open pipe on the highest part of the machine (so that water does not reach it) that directs ozone toward the ozone destruct unit.
  • the port 31 is intended to avoid any pressurization in the machine while injecting ozone.
  • Water or other solvent may be delivered to the barrel 24 through the fluid/water inlet 26.
  • water may be injected to wet or dampen the textiles prior to the dry bleaching treatment.
  • the ozone destruct valve 50 is opened when fluid is being injected into the barrel 24 to help equalize pressure inside the barrel 24.
  • the blower component 20 causes the air to have a high flow rate with generally good air circulation. This can help provide uniform distribution of ozone within the barrel 24, leading to a uniform bleaching treatment of the textiles contained therein.
  • the barrel 24 in order to maintain air circulation/air flow, the barrel 24 may be maintained at a slightly positive pressure in use. In another example, the barrel may be maintained at essentially ambient pressure due to the open decompression valve/port 31 which has a tube 68 connected to the destruct unit 16. It has been found that this may be conducive to creating a generally uniform ozone atmosphere. As the ozone generator 12 injects ozonated air into the machine at the ozone inlet 46, the blower component 20 forces movement of the air. As the barrel 24 becomes filled with ozonated air, the decompression valve/pressure equalization port 31 may maintain a near ambient pressure level within the barrel 24. In other examples, the pressure may be slightly positive. This allows continued flow?
  • ozonated air can be continually injected into the barrel through ozone inlet 46,
  • the pressure equalization port 31 assists with depressurization of the barrel 24.
  • most ozonated air is re-circulated away from and back into the barrel 24 through the blower component 20 at a recirculation inlet 40.
  • FIGS. 4 and 5 illustrate schematics of air recirculation through the hybrid washing machine 14. Air flow is generally shown with arrows "A.” In these figures, the machine 14 is shown with a fan portion 38 of the blower component 20. There is also provided a fan exhaust 42, which serves as an air conduit for directing air from the fan portion 38 to the barrel.
  • An ozone destruct valve 50 may be provided in order to control the flow of air back into the barrel or out of the barrel. When the ozone destruct valve 50 is closed, ozonated air is recirculated back into the barrel 24. When the ozone destruct valve 50 is opened at the end of the process, all of the ozonated air in the barrel 24 v ill be forced out of the ozone outlet 52 and into the ozone destruct unit 16.
  • the ozone destruct valve/outlet configuration may be considered a high volume flow valve/outlet because it is used for quickly moving ozonated air out of the barrel 24 and into the ozone destruct unit 16.
  • the ozone destruct valve 50/outlet 52 work in conjunction with the high volume blower component 20 and the fresh air valve 30 in order to force ozonated air out of the barrel 24 and replace it with fresh air during the destruct step.
  • the fresh air valve 30 is opened during die ozone destruction step so that fresh air can be pulled in w r hile destructing the ozonized air.
  • FIGS. 6-8 show alternate embodiments of a hybrid washing machine.
  • the ozone destruct valve 50 may be located closer to the fan 38, allowing the fan exhaust 42 to be shortened.
  • FIG. 6 further illustrates one embodiment of a door security feature, which may be provided as a door security cylinder 88.
  • the hybrid washing machine embodiment It is also possible for the hybrid washing machine embodiment to provide for steam and/or humidity to be added during the dry ozone bleaching treatment processes. The use of steam may help make the ozone destruction process proceed more quickly.
  • FIG. 6 illustrates a humidity injector nozzle 82 and a steam inlet/valve 54. It should be understood that these features may be located at any appropriate location on machine 14.
  • the ability to add humidity may be related to holding a constant moisture level in the fabric throughout the bleaching process. Without humidity or steam, the level of moisture in the barrel may potentially decrease from both the air circulation and the addition of dry ozone gas.
  • water or another liquid solvent may be added through the water inlet 26 in order to wet the materials. This may be done as a pre-rinse procedure, with one or more cycles to wet and extract fluid from the textiles. For example, there may be a spin cycle that will allow for various options of moisture retention and/or moisture removal. In other embodiments, it is possible to move directly into an ozonation process, particularly if it is desirable to conduct the bleaching process on soaking wet textiles. (It should also be understood that any water or fluid delivery steps may be eliminated if the process to be conducted on dry textiles.)
  • the pressure equalization port 31 remains open any time that ozone is being injected into the machine 14. This is the only place that air can escape the machine, so it provides a depressurization function. Generally, whether in gas injection or just water fill, the port 31 remains open in order to allow air to escape the machine to avoid pressurization. Ozone may then be added into the ozone inlet 46 while the blower component 20 forces its circulation into the barrel 24. In one example, this may be accomplished by injecting ozone from the ozone generator 12 into the ozone/oxygen inlet 46 on the treatment component 14.
  • the ozone generator 12 may include one or more pressure gauges in order to confirm that the ozone to be delivered is at an adequate pressure.
  • the ozone/oxygen inlet 46 may be directly connected to the ozone generator 12. In one embodiment, the ozone/oxygen inlet 46 may be positioned on the fan exhaust 42. In another embodiment, the ozone/oxygen inlet 46 may have a hose connected therewith. This may allow the ozone generator 12 and the treatment component 14 to be positioned a distance from one another, if desired.
  • FIG. 8 shows one potential location for ozone inlet 46. Ozone inlet 46 is generally fluidly connected to an ozone generator 12 (not shown in these figures).
  • the ozone inlet is positioned on the fan exhaust 42 such that injected ozone will be blown directly into the barrel 24.
  • Ozone injected into the ozone inlet 46 is delivered to the barrel 24 due to the force of air from the blower component fan.
  • the blower component 20 pushes air from the fan 38, through the fan exhaust 42, picks up ozonated air injected through the ozone inlet 46, and directs the ozonated air into the barrel 24, causing circulation of the ozonated air.
  • This ozone recirculation is one of the features that allows the system described herein to be more effective and repeatable than prior systems.
  • the blower component 20 causes circulation and re-circulation of ozone through the system. It can also help with off-gassing or de-gassing processes. For example, when the fan 38 is activated and the ozone destruct valve 50 is open, it is possible to quickly purge ozone from the interior of the machine 14. For example, as ozone is injected into the treatment component 14 and as the blower component 20 circulates ozone, the ozone destruct valve 50 remains closed so that the ozone remains in recirculation.
  • the ozone destruct valve 50 When the ozone destruct valve 50 is opened, the ozonated air in the system is forced out through the ozone destruct outlet 52, to the ozone destruct unit 16. The exhausting of air from the barrel 24, through the ozone destruct valve 50, will start to create a vacuum on the barrel 24 void.
  • the fresh air valve 30 is opened shortly after the ozone destruct valve 50 to allow fresh air into the barrel 22, satisfying the vacuum being created by ozonated air being forced out of the barrel 24 by the blower component 20, through ozone destruct valve 50 to ozone destruct 16.
  • the fresh air valve 30 is only opened as part of the ozone destruct process. It allows fresh air to be pulled into the system and helps push the ozonated air out through the ozone destruct outlet 52.
  • FIG. 8 also illustrates an ozone safety sensor 72.
  • This may be an ambient ozone sensor provided in order to detect whether there is a proper/safe ozone level in washer, prior to unlocking the machine door 25.
  • This sensor 72 may be activated after the bleaching process has been completed and the ozone has been evacuated from the barrel 24.
  • FIGS. 9 and 18 generally show schematics illustrating water circulation through the machine 14. Water re-circulation may be useful for conducting wet bleaching processes. Water is shown with arrows "W.”
  • ozonated water may be injected into the barrel 24 through a ventun injector 100, shown in FIGS. 11 and 12.
  • the venturi injector 100 combines ozone from an ozone generator 12 with water in order to provide ozonated water for a bleaching treatment.
  • the venturi injector 100 may also be associated with a dynamic gas reactor 102 which can help agitate/mix ozone and water together.
  • the dynamic gas reactor 102 may also be referred to as a static mixer. It is generally provided in order to dissolve the ozone gas into the water, increasing the transfer efficiency of the ozone into the water.
  • tap water may be introduced to the barrel 24 via valve 26 in a certain volume, based on the dry weight of the textiles to be treated. Ozone is then dosed into the water, via the water recirculation loop, to reach a programmed dissolved ozone level, tailored for a particular bleaching process that is to be conducted. For example, ozone may be delivered to the water (via an injector 100) being recirculated and then now ozonated water may be re-injected into the barrel 24 through ozonated water inlet 104. Ozonated water may be introduced into the barrel 24 at a certain volume depending on the dry weight of the textiles to be treated. This weight is generally measured in kilograms, but it should be understood that other weight units may be used.
  • the dry weight of garments may be correlated or related to the volume of water per garment; in this example, the formula for ozone dosage may be related to the total liters of water inside the machine.
  • water may be injected into the barrel 24 through the water inlet 26 prior to a dry bleaching process, in order for the textiles to be wet and rinsed.
  • extraneous water may be extracted prior to ozonation.
  • the machine will generally be provided with extraction controls that can control and vary the amount of water or moisture that is allowed to remain in the machine. It also may be desirable to be able to van' the amount of water and moisture in order to obtain various bleaching effects.
  • ozonated water remains in the barrel 24 throughout the bleaching process.
  • a fluid or water re-circulation path is shown by arrows "W" in FIGS. 9 and 11.
  • the fluid may flow in a continuous loop.
  • a fluid recirculating pump 32 may be provided for maintaining a flow of water between the barrel 24 and the venturi injector 100.
  • Fluid recirculating pump 32 may have a pump inlet line 34 and a pump outlet ime 36.
  • the pump inlet line 34 may have a barrel connection point 56 at the barrel 24 and a pump connection point 58 at the pump 32.
  • the pump outlet line 36 may have a pump connection point 60 at the pump 32 and a barrel connection point 64, leading back into the barrel 24.
  • the fluid recirculating pump 32 is a pump capable of pumping lint. This can ensure that the pump can accommodate and provide proper flow through the system. Once the bleaching treatment cycle has been completed, any water remaining in the barrel 24 may exit through drain 28.
  • FIGS. 11 and 12 show water flow "W" through the alternate hybrid washing machines of FIGS 6-8.
  • FIGS. 20-23 illustrate an alternate embodiment, in which the barrel connection point 64' (for the pump outlet line 36' earning water being recirculated back into the barrel 24') is located along an upper portion 500 of the barrel 24'. This can help ensure that water is more evenly distributed in the barrel.
  • the garments to be treated are generally located beneath the water reentry point 502.
  • FIGS. 23 and 24 An exemplary- spray bar 504 is illustrated by FIGS. 23 and 24. The figures show the spray bar 504 located along an upper portion 500. It should be understood, however, that it is possible a spray bar 504 to be used as an initial point of ozonated water entry, as well. For example, a spray bar may additionally or alternatively be positioned along the water inlet 26.
  • the spray bar 5 4 allows water to be injected into the top of the barrel 24' in a continuous and more even spray. Openings 506 along the spray bar cause the water to be dispersed along the bar 504, rattier than having water injected at only a single entry point. Use of spray bar 504 can allow water to contact the garments more evenly.
  • the openings 506 may be holes that are made along the bar body. In other examples, the openings 506 may be fitted with one or more spray jets or nozzles that can disperse or spray the water more finely or evenly.
  • the spray bar 504 may have a length that extends the length or depth of the barrel 24 '' , as illustrated by FIG. 23.
  • the spray bar 504 may be mounted into the actual body of the barrel housing 508. In another example, the spray bar 504 is mounted in a curved enclosure 520 that is formed into the barrel. This is the example illustrated by FIGS. 22 and 23. This means that rather than injecting water back into the machine at a door or other side port, the water is injected into the top of the barrel. [0062 J As illustrated by FIG. 22, it is possible for the spray bar 504 to be directly adjacent to the blower circulation duct 508.
  • the blower circulation duct 508 is where ozonated air may be recirculated into the machine (after initially being injected at the blower inlet 512).
  • the spray bar 504 is where ozonated water may be recirculated back into the machine.
  • the dosing check loop 1 10 may include a sample point 76, at which water may be removed from the barrel 24 of the hybrid washing machine 14.
  • the sample point 76 may be used for obtaining sample water out the machine 14, without the need for filtration.
  • the machine 14 may be designed with a fine mesh lint screen 77 that is screwed into the washer body via a custom fitting that may be welded onto the washer body in production.
  • FIG. 16 illustrates a schematic of an exemplary dosing check loop in combination with ozone gas flow.
  • the sample volume may then be pumped through a dissolved ozone sensor 114 via a small peristaltic pump 116.
  • the dosing check loop system may also be provided with a temperature sensor T in order to measure the ozone washer temperature level. This data may help the system obtain accurate readings in order to alter ozone dosing.
  • the dosing check loop 110 may be used to ensure that the water being circulated through the machine 14 is properly ozonated at the desired concentration.
  • the dissolved ozone sensor 114 may be a fast response, high-range dissolved ozone sensor that is used to maintain a programmed set point for ozone dosing during a wet bleaching process.
  • the dissolved ozone sensor 114 may be designed to measure up to 20 PPM of dissolved ozone, controlled precisely by the PID loop.
  • the water makeup system may include a solenoid valve and a roto-meter.
  • the makeup water system may pump tested water directly back into the system.
  • makeup water may be added through the water inlet 26, In any event, the water makeup system may be used to replace sample water that has been removed from the machine at a rate that is generally equal to the water loss. This can ensure that proper water volume is maintained throughout a complete wet ozone bleaching process.
  • the wet process features may be designed to operate without the need for filtration.
  • the dynamic gas reactor 102 may be designed without edges or baffles that would otherwise trap lint. This can eliminate filter cleaning as a maintenance item. A clogged or inoperable filter may cause a critical variable or process failure point.
  • the dry process may include the following process steps. Although the steps are numbered for ease of review, they may occur in any appropriate order: 1. Enter garment weight and select desired process program number on washer 14 user interface screen.
  • a timer on the user interface may count down (for operator information) and the system may maintain dosing of ozone at the indicated level for the appropriate time duration (as described further below).
  • the pressure port 31 will bleed a small amount of ozonated gas to the ozone destruct unit. (This is likely to be controlled by the computer that is used to set the bleaching the factor, but it should be understood that these steps may be conducted manually, if desired.)
  • Ozone destruct valve 50 and fresh air valve 30 opened, and ozone destruct unit 16 then catalyzes ozone until a safe concentration is reached (as indicated by a sensor).
  • the blower 20 forces air out of the barrel 24 and into the ozone destruct unit 16.
  • the garments may be rinsed with water with steam heating. Water may be delivered, drained and extracted (for example, by spinning of the barrel), (it should also be understood that rinsing and/or pre-wetting steps may also accompany the dry process, and would generally take place prior to # 3 above.)
  • the wet process may include the following process steps. Although the steps are numbered for ease of review, they may occur in any appropriate order:
  • Fluid recirculation pump 32 maintains flow of ozone-depleted water out of the barrel 24, through the venturi injector 100 to add ozone back into the water, and delivers the re-ozonated water back into the barrel 24.
  • the system may maintain dosing of ozone at the indicated level for the appropriate time duration.
  • a water testing/measuring loop may pull out a small amount of ozonated water for testing and to provide feedback to the computer about the amount of ozone to be injected at the venturi injector 100 in order to maintain the set dissolved ozone level, for the programmed bleaching process.
  • the garments may be rinsed with water with steam heating. Water may be delivered, drained and extracted (for example, by spinning of the barrel).
  • the water recirculation lines 34, 36 may be flushed via the pump 32 with the drain 28 open, so that the new cycle begins with a clean system.
  • the hybrid washing machine embodiment described herein thus provides the benefits of a commercial washing machine, along with the high volume blower of a commercial dryer. Additionally, one of the additional benefits of the hybrid washing machine is that it can be used for "normal" washing procedures with no ozone applied. This features adds to the versatility of the equipment. It is possible to use the machine 14 as a dry process, in which the water recirculation flow is not used. it is also possible to use the machine 14 for wet ozone bleaching, due to the presence of the fluid recirculating pump 32. Thus, the ozone bleaching system 10 allows wet processes or dry processes to be conducted in the same machine.
  • Providing a fluid re-circulating pump 32, a venturi ozone injector 100, and an integral blower component 20 on a single hybrid washer 14 delivers a system that provides a complete process solution for chemical treatments, neutralizing, wetting, wet ozone, damp ozone gas application, dry ozone gas application, oxidation by-product removal, and final extraction— all in one machine.
  • a fluid re-circulating pump 32, a venturi ozone injector 100, and an integral blower component 20 on a single hybrid washer 14 delivers a system that provides a complete process solution for chemical treatments, neutralizing, wetting, wet ozone, damp ozone gas application, dry ozone gas application, oxidation by-product removal, and final extraction— all in one machine.
  • water may be re-circulated through the machine for a rinsing process.
  • Use of the system described herein does not require removal of the textiles from one machine to another. Instead, all processes may take place in the same treatment component/machine.
  • the hybrid washing machine blower component 20 may be a variable speed blower that can controlled by the machine PLC to provide different air circulation speeds for dry ozone bleaching processes.
  • the blower component 20 may be oversized so that it can generate more air circulation flow than the blower outlet duct 42 can pass into the washer.
  • the restriction created in the blower component 20 outlet duct will generate heat in the machine barrel. This feature can be used to quickly dry the barrel of the machine, after a washer program, is completed and garments are removed. Dry bleaching process may then follow wet machine processes, without an extended wait for the machine to dry.
  • the hybrid washing machine embodiment provided by this disclosure thus prevents operators from having to prepare wet textiles in one machine and then move the wetted textiles to the ozone process machine.
  • the ozone generator 12 may also include an ozone dosing system control 64.
  • One example of a dosing schematic is illustrated in FIG. 14.
  • the dosing control system 64 allows a single ozone generator 12 to deliver ozone to multiple textile ozone treatment components 14/hybrid washing machines.
  • the dosing control system 64 is designed to control the concentration of ozone delivered so that the ozone concentration may be held constant as the flow rate increases and/or decreases.
  • the dosing control system 64 may include a proportional integral derivative (PID) controller.
  • PID proportional integral derivative
  • the general goal is to maintain the concentration of ozone in the gas that is delivered to each component 14/hybrid washing machine at a constant dosing concentration. Maintaining a constant dosing concentration of ozone allows the process to be reliable and repeatable.
  • FIG. 14 shows a schematic illustrating information flow for dosing control.
  • the ozone generator 12 may have a high ozone concentration analyzer 13 associated therewith.
  • the bleaching factor may be set at grams of ozone to be delivered per hour per weight of textiles (g/hr/weight units). In one specific example, the weight of textiles is measured in kilograms, such that the bleaching factor may be expressed as (g/h/r/kg).
  • a software program/computer associated with the system may be designed to receive that input and create the proper ozone flow based thereon.
  • a first PID loop measures and controls the power delivered to the ozone generator.
  • a second PID loop measures and controls the ozone gas flow rate.
  • the second PID loop may include a mass flow meter (MFM) and a proportional valve (PV).
  • MFM mass flow meter
  • PV proportional valve
  • the system may adjust the ozone flow and the generator power in order to achieve the desired output in grams per hour at a desired specified ozone concentration. This allows a constant concentration of ozone gas to be applied
  • the dosing control system 64 delivers the same amount of ozone per unit weight, regardless of the number of machines 14 being serviced by the ozone generator 12 and its ozone dosing system. 64.
  • This constant concentration may be referred to as a "bleaching factor.”
  • the bleaching factor is defined as the rate of ozone production per kilogram of denim (or other textile) material, generally based on dry weight.
  • Multiple treatment machines of different sizes may call for different amounts of ozone, but by maintaining a constant dosing concentration by weight constant (e.g., 5-20% wt%), the treatment process conducted by all machines may result in a similar bleaching factor delivered to textiles treated by the different machines.
  • the dosing system provides rate equations such that dosing may be done automatically by the computer controlling the ozone generator 12, [0077]
  • prior art machines have not addressed specific dosing of ozone or the concentration by weight concept. Instead, they focused only on measuring ozone once it was delivered to the machine. Once operators loaded textiles into an ozone processing machine, they could not set a bleaching factor (i.e., a rate of ozone production per kilogram of textile) to be delivered. Instead, they had to input several process variables, such as time, ozone generator power output, de struct time, among others. Sensors inside the machines gave a reference of the ozone in the machine, but they did not control level of ozone present via PID loop. The results of treatment depended upon expertise and knowledge of the operator, as opposed to a consistent and reliable setting. The present inventors have solved this problem, at least by recognizing the benefits of dosing ozone vs. measuring ozone already in the machine.
  • the ozone generator 12 of the ozone bleaching system. 10 may use an ozone analyzer 13 in order to supply an exact dose of ozone in the gas processes.
  • the ozone analyzer 13 is a high concentration ozone analyzer.
  • the ozone analyzer 13 may provide precise ozone dosing by maintaining a constant concentration by weight. The dose may be controlled by providing a specified amount of ozone at a constant concentration by weight. This will allow for programming of a given "grams hr/kg of fabric" dose of ozone, at a specific programmed ozone gas concentration by weight, to be supplied for any number of formulas.
  • Previous systems have simply used high level sensors to measure the resulting ozone level in the washing machine, as a function of the power percentage setting programmed in before each cycle. They have not used ozone analyzers in the ozone generator itself. They also have not used active PID or %wt concentration controls utilized on previous ozone bleaching systems.
  • Each system may be provided with a programmable logic controller (PLC).
  • PLC programmable logic controller
  • a specific ozone bleaching system may provide ozone dosing and concentration controls programmed into washer formulas.
  • the valves and ozone flow- may be controlled by the PLC, as illustrated by FIG. 16.
  • the ozone dosing information is communicated to the ozone system's PLC.
  • the equation may calculate the ozone delivery from the data entered into the washer programs. For example, the operator need only enter the weight of garments put into the machine (generally in kilograms) and a desired fabric bleaching factor (measured by g/hr/kg).
  • the ozone concentration by mass can be calculated without any further operator input, and the process equation may be run by the machine automatically.
  • Multiple actuation signals may be communicated between the washer and the ozone system during an ozone wet or dry process.
  • Exemplary communications include but are not limited to an "operational ready" signal, and signals indicating when to add ozone, how much ozone to add, and the type of ozonation method to use (e.g., wet vs. dry).
  • Tlie communications may also include control of some of the washer process valves by the ozone generator system 12. These signals are received by the ozone dosing control system 64, and the system 64 implements changes. They are not operator dependent.
  • the wet processing part of the process may allow for a precise dose of water in liters, with an analog flow meter, to each load for uniform pre-wetting of garments. This feature may be used in flushing dye, pre-wetting, equalizing moisture content, and removal of dye and unreacted dye materials.
  • the hybrid washing machine 14 has controls that integrate the washer-related functions with ozone systems. These controls may be represented on a control panel or other appropriate user interface. The panel may be a touch screen, may have knobs/levers, may have buttons, or any other appropriate input mechanism.
  • the washer machine may be a Tupesa machine and the ozone generator system may be a Guardian Manufacturing, Inc.
  • the ozone generator 12 may allow for modular expansion of ozone output capability and number of washers that are utilized.
  • the system can simultaneously provide individualized ozone output to a single washer or to multiple washers, from a single ozone system.
  • the combination of integrated controls with tlie machine and ozone system can provide precise and repeatable processes for tlie textile industry.
  • the ozone bleaching system 10 can allow operators to create and tailor formulas for specific processes to be run over and over in order to produce tens of thousands of product pieces, with uniform results.
  • the various production programs, with cycle steps and ozone bleaching factor, may be programmed directly into the washers.
  • each hybrid washer machine 22 will then communicate with the ozone generator 12 to "request” the amount of ozone needed to be sent for each process formula.
  • These dosing controls can allow the textile producer to easily train employees on the automated process use.
  • the washer and ozone system dosing control system 64 can ensure precise wetting, ozone dosing, neutralizing, rinsing, and extracting for any number of customer designed applications.
  • valves and check valves may be provided for proper timing of machine pressurization, continuous process flow when needed, and for controlled ozone gas removal when needed in both dry and wet ozone processes.
  • Such valves may be provided at or near the water inlet 26, the ozone inlet 46, the ozonated water inlet 104, and/or the ozone de struct outlet 52 (i .e., the ozone destruct valve 50).
  • exemplary materials include, but are not limited to, stainless steel, or any- other appropriate materials.
  • the barrel and other materials in contact with ozone are made of SS316L stainless steel; the door gasket may be made with silicone; the pneumatic valves may be made with PTFE (Teflon) or Kalrez; the bearings and oil seals may be made with a synthetic rubber and flouropolymer elastomer, such as Viton.
  • PTFE Teflon
  • Kalrez Kalrez
  • the bearings and oil seals may be made with a synthetic rubber and flouropolymer elastomer, such as Viton.
  • an ozone bleaching system comprising: an ozone generator comprising an ozone dosing control system; a textile ozone treatment component fluidly coupled to the ozone generator, the textile ozone treatment component comprising a barrel for containing textiles to be treated and an integrated blower component for circulating ozonated air through the barrel; and an ozone destruct valve fluidly coupled to an ozone destruct unit.
  • Ozone injected into the textile ozone treatment component may be recirculated by the blower component.
  • the system may also include a fluid recirculating pump. This allows the textile ozone treatment to be used for wet and dry processes.
  • the system may also include a venturi injector for injecting ozonated water into the barrel .
  • the ozone dosing control system may control a concentration of ozone delivered to the hybrid washing machine so that the ozone concentration in the machine is held constant as the flow rate increases and/or decreases.
  • One exemplary method for dry treating textiles to be bleached with ozone comprises: loading textiles into a hybrid washing machine/blower system as described; delivering water into a water inlet in order to wet the textiles prior to treatment; removing excess water from the textiles; injecting ozone into the barrel of the system; circulating ozone through the system using the blower component; maintaining and appropriate pressure of the barrel using the decompression valve; and evacuating ozone from the barrel via the ozone destruct valve for direction to the ozone destruct unit.
  • This process can also eliminate chemical and/or temperature neutralizing steps that might otherwise be required in order to deactivate, or kill, residual enzymes used in denim processing, (A kill step is normally needed to prevent the further degradation of the garment material, beyond the desired level with the chemistry levels being used.) Eliminating this extra step and use of chemicals is beneficial and can lead to cost savings.
  • ozone can be used to remove residual dyes such as indigo dye, sulfur dyes, reactive dyes, direct dyes, vat dyes, pigment dyes, acid dyes and any other dyes from denim processing water. It is also believed to be potentially beneficial in removing other dyes from various processing water environments.
  • water dye/color removal is conducted with ozone, before the ozone gas bleaching process. This can remove a kill step and extra rinses. Instead, only one dump and fill of the machine may be needed prior to the ozone bleaching steps.
  • Using the ozone treatment for color removal during a water step with recirculation may cause excess dyes/color that may be present to be removed from the water and oxidized by ozone in the water stream.
  • Processcesses described herein may also be used to remove dyes from the garment itself. For example, excess dye can be rinsed from the garment in a first, or subsequent, rinse normally.
  • the ozone treatment in circulation continue removing color from the water as it is released during a rinse step.
  • Example 1 Denim wash formula using ozone color removal and ozone gas
  • the water cleaning process for the above example may include the following steps. (It should be understood that the weights and times, step order, and percentages provided are for illustrative purposes only and may be changed based on different requirements).
  • the machine and the ozone system communicate with one another.
  • the machine control system indicates how much ozone to dose in the color removal process and the gas bleaching steps. It may use a calculation based on the total weight of the garments being washed.
  • Step 1 Machine Loading and Formula Selection [ ⁇ 99] Once the machine is loaded with the appropriate total weight of denim or garment to be bleached (in this example, 200 kg), the operator selects the correct machine program for the denim loaded and starts the machine. Step 2: Desizing and first color removal
  • the machine will fill with water to the programmed volume, Desizing chemistry (normally enzymes) may be added.
  • Desizing chemistry normally enzymes
  • the machine increases temperature, adding steam as needed in order to raise temperature to desired level. It tumbles the denim for a programmed amount of desizing step time, depending on the treatment to be applied.
  • the machine may then activate the "Ozone Color Removal" process, prior to draining the water.
  • the machine will start the fluid recirculation pump 32 to pull water out of the machine sump and push it through the venturi inductor 100 and dynamic gas reactor 102. The machine then sends a request to the ozone generator system 12, requesting the proper ozone dosage.
  • a wash program step was created with a water color removal factor of 10, at 10% ozone concentration by weight.
  • the bleaching factor for a program's Color Removal step is determined by identifying which step in the wash formula should be treated and the fabric or garment type. This in turn will determine the amount of free dye expected in the water that will need to be oxidized with ozone.
  • the machine ' s programmable logic controller will calculate the required ozone dose as Bleaching Factor of 10 (lOg/hr) x Load Weight (200 kg of denim), which equals 2000 g/lir, at the called for concentration by weight of 10%. Accordingly, in this example, the ozone generator will receive the request for 2000 g/hr @ 10% wt.
  • the ozone generator 10 will adjust the Proportional Flow Control Valve (PV) for the target gas volume for the required ozone dose.
  • PV Proportional Flow Control Valve
  • Each machine may be provided with an ozone compatible Mass Flow Meter (MFM) installed thereon, to work in conjunction with the Proportional Flow Control Valve and a PID to achieve proper flow rates to achieve precise Ozone Dosing, in each formula step that requires ozone.
  • MFM Mass Flow Meter
  • the ozone generator (10) powers up and adjusts the correct number of ozone generators (if more than one is provided) or generator racks that will be needed in order to deliver the current set total ozone output being called for by the machine(s).
  • the ozone generator (10) communicates with the machine when it is receiving the correct Ozone Dose to start the timer, for the programmed Color Removal step time.
  • the amount of Color Removal time programmed into a program step may be determined by the amount of water volume present in the step, and the flow rate of the circulation loop on the machine.
  • the pump (32) will need to run long enough to turn the water volume a sufficient number of times to allow the proper Ozone Dose to remove the dye color to a desired level.
  • the machine relays and instruction to the ozone system to stop the ozone flow to the circulation loop.
  • the machine will stop the circulation loop pump (32), and drain the water from the machine. Alternatively, the machine will continue to the next wash program step, continuing to use the same water, further reducing the total water needed in program.
  • Step 3 Stone wash and second color removal.
  • Color removal may also take place during stone washing. This may be in addition to or an alternate to the above described color removal during desizing.
  • the machine is re- ill led with water to a programmed volume or simply continues using the same water if a drain process was not performed.
  • Color Removal is programmed for the stone wash step, the machine and ozone generator will repeat the above processes to dose the proper ozone level, for the programmed time.
  • the difference between the dosages for stone washing step and/or bleaching factor shows are examples only. The actual dose (or grams used) will vary with the types of fabric used, fabric finish, weight and fiber content, dye type, and other parameters. Water is drained from the machine and excess water is extracted from the denim to a desired moisture retention level . Step 4: Rinsing and third color removal.
  • Color removal may also take place during rinsing. This may be in addition to or an alternate to the above described color removal during desizing and/or stonewashing.
  • the machine is then filled with water to a programmed volume. If Color Removal is programmed for the rinse step, the machine and ozone generator will repeat the above processes to dose the proper ozone level, for the programmed time. Water is drained from the machine and excess water is extracted from the denim to a desired moisture retention level.
  • the denim is now ready for ozone gas bleaching step.
  • the machine will slow down to the programmed tumbling speed programmed for the Ozone Gas Bleaching step.
  • the machine will activate the integrated blower (20) in the cylinder (24) to circulate the air volume at a high rate.
  • the machine then sends a request to the ozone generator system (10), requesting the proper ozone dosage for the bleaching factor selected, as described above.
  • the steps for calculation, turning on, and feeding the ozone remain constant, while tlie load type, weight and bleaching factors can vary.
  • a sample wash program step was created with a water color removal factor of 9, at 10% ozone concentration by weight.
  • the bleaching factor for a program's Ozone Gas Bleaching step is generally determined by which step in tlie wash formula is being treated and the fabric or garment type, which in turn will determine tlie amount of free dye expected in the water that will need to be oxidized with ozone.
  • the machine PLC will calculate the required ozone dose as Bleaching Factor of 8 (8g/hr) X Load Weight (200 Kg of denim), which equals 1800 g/hr, at the called for concentration by weight of .10%.
  • the ozone generator (10) will receive the request for 1800 g/hr @ 10% wt.
  • the ozone generator (10) will adjust tlie Proportional Flow Control Valve, for the target machine to send the correct gas volume for the required ozone dose.
  • the ozone generator supplies ozone to a pipe header that can feed multiple washers, and a Proportional Flow Control Valve is installed the machine.
  • the PLC on each washer will adjust its own Proportional Flow Control Valve to flow the correct gas volume for the required ozone dose.
  • the ozone generator (10) powers up and adjusts the correct number of ozone generator(s) or generator racks needed for the current total ozone output being called for by the machine(s).
  • the ozone generator (1) communicates the machine when it is receiving the correct Ozone Dose to start the timer, for the programmed Color Removal step time, as described above. Tl e ozone gas is fed into the integrated blower outlet, for proper mixing into tlie machine cylinder (24) volume and proper contacting with tlie garments.
  • the machine may have a humidity addition function that adds water back into the process in vapor fonn.
  • the rate of water addition will be comparable to the evaporation rate caused by the dry oxygen and ozone feed gas entering the machine each minute, along with the drying effect of the high velocity airflow circulating in the machine cylinder.
  • the equation for determining the water volume needed during an Ozone Gas Bleaching step may be written into the machine software, or the ozone generator software.
  • the ozone generator calculates the water dose based on the gas flow needed to deliver the Ozone Dose
  • the water volume may be communicated back to the machine controller.
  • the machine communicates with the ozone system to stop the ozone flow to the blower outlet flow and to stop the blower.
  • the machine is re-filled with water to a programmed volume. No ozone (dry or wet) is used in this step. Chemical neutraiizer may be added to remove any ui) reacted dye material from the garments and to kill residual ozone.
  • the machine will tumble for the programmed rinse time, drain, and if the program calls for it, extract as programmed. In one example, the extraction includes removing water or residual moisture by spinning the machine at medium or high speeds. Step 7 - Clear Rinse.
  • the machine is then refilled with water to a programmed volume. Again, no ozone is used in this step. Finishing and/or softening chemistry may be added to this step. The machine will tumble for the programmed rinse time, drain, ad if the program calls for it, extract as programmed. Step 8 - Ozone Level Safety Check.
  • an ozone gas sensor (72) may be connected to the gas exit
  • FIG. 19 provides a flow chart of the color removal process described.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Hydrology & Water Resources (AREA)
  • Environmental & Geological Engineering (AREA)
  • Water Supply & Treatment (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Accessory Of Washing/Drying Machine, Commercial Washing/Drying Machine, Other Washing/Drying Machine (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

La présente invention concerne de manière générale des modes de réalisation de procédés et systèmes pour le blanchiment de textiles à l'aide d'ozone gazeux qui incorpore une étape d'élimination de couleur. Dans un exemple, l'invention concerne une machine hybride qui incorpore certaines caractéristiques d'un lave-linge, mais qui comprend également un ventilateur intégré pour la distribution de gaz à l'intérieur de la machine. L'invention concerne également un système de commande de dosage d'ozone qui permet le maintien d'une concentration constante d'ozone dans la machine. Dans un mode de réalisation, la production d'ozone mesurée en grammes/heure à cette concentration constante conjointement avec le poids de produit mesuré étant traité peut être dénommée le « facteur de blanchiment ». L'invention concerne en outre une étape d'élimination des colorants des eaux usées, dans laquelle on utilise de l'ozone pour nettoyer l'eau et enlever les colorants et autres couleurs qui peuvent être déposés par l'intermédiaire d'un jean ou d'autres vêtements.
PCT/US2016/054680 2015-10-14 2016-09-30 Élimination de couleur de l'eau avec de l'ozone dans un procédé de blanchiment de textiles WO2017066000A1 (fr)

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CN107587342A (zh) * 2017-10-24 2018-01-16 广州番禺高勋染整设备制造有限公司 一种基于臭氧的纱线或织物漂白工艺方法和装置
KR101918154B1 (ko) * 2018-06-28 2019-01-29 이효진 오존을 이용한 의류 제품 탈색 장치 및 방법
CN113993660A (zh) * 2019-03-27 2022-01-28 臭氧水技术有限责任公司 臭氧洗涤系统
WO2023059290A3 (fr) * 2021-10-04 2023-06-08 Wiser X Teknoloji Araştirma Geliştirme Anonim Şirketi Système de mesure de concentration d'ozone

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