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Home My WebLink AboutNC0006033_Report_20030902C TOWN OF �rON CSL. 1921 September 2, 2003 Mr. David A. Goodrich NC DWQ / NPDES Unit 1617 Mail Service Center Raleigh, NC 27699-1617 Dear Mr. Goodrich E C E 0 V E SEP - $, 2003 i Yc N R WATER OU/1 u FY POIF41 SOURCE BRAPICH Please find enclosed the color reduction study as required under special condition A. (3) of our NPDES Permit No. NC0006033 If you have any questions please call 704-825-7499 Thank You Jamie Shytle POTW Director cc: Jay Stewart, Mastercraft Fabrics, LLC David Young, Town of Cramerton POTW Permit file 155 North Main Street Cramerton, NC 28032 704/824-4337 0 _ C o� s= of _oo �� bLJ.Ilf1DN s� z P'y$ Division of Pollution Prevention and Environmental Assistance North Carolina Department of Environment and Natural Resources Color Reduction Assessment Lakewood Yarns Cramerton, North Carolina DPPEA John Burke August 5, 2003 Post Office Box 29569, Raleigh, North Carolina 27626-9569 Telephone: (919) 715-6500; FAX: (919) 715-6794 Lakewood Yarns - I - August 22, 2003 Disclaimer This report is intended to offer information and guidance for identifying opportunities and options for waste reduction. Compliance with environmental and occupational safety and health laws is the sole responsibility of each business. All legal and regulatory references within this document are intended only for informational purposes and are not to be taken as reliable sources of legal reference. Businesses should contact the appropriate legal and regulatory authorities for current regulatory requirements as well as for interpretation and implementation. All references and vendor materials (when available) mentioned in the report are included. Mention of a vendor or manufacturer does not represent an endorsement by the State of North Carolina. Neither the State of North Carolina nor the authors of this report are responsible for practices or procedures implemented by individual firms. Lakewood Yarns - 2 - August 229 2003 Lakewood Yarns: Color Reduction Assessment 1.0 Introduction The City of Cramerton and Lakewood Yams requested assistance from the Division of Pollution Prevention and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent color. The City of Cramerton was required by the North Carolina Division of Water Quality to perform a color reduction assessment to identify best management practices for the major sources of color in its wastewater. Table 1 provides the most recent ffi I data fo th Table 1 Effluent Color Data 250 - 200 150 — 100 /- 50 - 0 e uent co or r e City of Cramerton. Lakewood Yams was identified by the City of Cramerton as the major source of color. On August 5'hl John Burke, of DPPEA, met with Jay Stewart, Environmental Engineering Manager, and other representatives of Lake Yams to discuss current operations and tour the facility. On August 8"', John Burke returned to Lakewood Yams to sample selected dyebath discharges. The following report provides information on the generation of color from the Lakewood Yams' operations and options for potentially reducing the level of color. 2.0 Facility Background and Color Analysis Lakewood Yams dyes and finishes synthetic and natural yarn for the bedding and upholstery market. The facility operates 3 shifts per day 5 to 6 days per weer. The dyehouse is equipped with 15 Thies and 2 Gaston County pressurized package -dyeing machines that operate at an 8:1 liquor ratio. Lakewood currently produces an average of 200,000 pounds per week of dyed yarn and discharges approximately 1 million gallons per day of wastewater. Table 2 provides an approximate breakdown of the dyestuffs used and volume of production. DPPEA targeted dark shade reactive dyeing of Cotton yam f)r Color analysis due to the comparatively low exhaustion and fixation of Table 2 Dvestuffs Dyestuff Disperse Direct Basic Acid 1Xapme DirectslReactiva S'am Pohxottou Ra�ron Acntic NVlo¢ 1polvest, Cotton Production 1 Zee 40-0 20' 1e0 50' 32°' these dyes on cotton substrate. DPPEA sampled two dyebaths to estimate the percent fixation of dye on the yam for a red shade reactive dyeing (procedure 0313) and a black shade reactive dyeing (procedure 0223). The reactive red shade was dyed on rayon yam, the black shade was died on cotton yam. Table 3 provides the ADMI analysis of the initial dyebath and the spent dyebath just prior to discharge. DPPEA used these two Table 3 Red. Red., Black B1ad., ADAH ADAH ADAH ADAH ors. PH adj, pH org. pH adj. pH Initial bath 710.0001 750,0001 770.000 960,000 mt 6ath 78.000 71,000 d60.000 370, Fshausliou 890. 91-. 40a, 57" Lakewood Yarns -3- August 22, 2003 values to estimate the amount of color that exhausted and fined onto the yam during the dyeing process. In addition to the ADW analysis, DPPEA performed a visual determination of the fixation for these two shades by comparing the spent bath color to a series diluted samples of the initial dyebath (i.e. 75%, 50°/% 25% dilution). Based on this analysis, the red reactive shade was estimated at 90% dye fixation while the black shade was in the 50% range. The visual analysis of these baths supported the ADNH results with the red shade spent bath much lighter that the 75% dilution of the initial bath and the black shade spent bath darker or as dark as the 50% dilution of the initial bath. Additionally, the estimated amount of dye that remains on the fabric will be reduced even further through the rinsing stages. 3.0 Color Reduction Options Based on the discussions with the plant personnel, wastewater plant operators and the dyebath analysis performed by DPPEA, Lakewood Yarns should focus on optimizing the black shade dyeing to assist in reducing effluent color. While all dyebaths discharge some color, it appears that the black shade and possibly a few other dark reactive and or direct shades on cotton yarn generate problematic effluent color. There may be opportunities to reduce this amount of color through process optimization. The following actions are being taken by Lakewood Yarns to try and increase exhaustion and fixation on the black shades: ➢ Working with dye suppliers to evaluate opportunities to use higher affinity and more compatible dyestuffs to improve exhaustion. Figure 1 Black Shade Procedure Add dye 4 min Top up 1 min Circulate 140T 14 min Add Salt 100g/1 0 min Circulate 140`'F 20 min Sample/Salt check 5 min Add Soda Ash 5% 0 min Circulate 140oF 60 min Drain 5 min Total 109 min ➢ Evaluating the improved exhaustion of extending the hold time after alkali addition by 30 minutes. ➢ Evaluating the improved exhaustion through initiating the dyeing at 100°F, increasing to 120OF and holding for 30 minutes and then rising to 1407 for 30 minutes. In addition to work related to increasing the fixation of dyes in the black shade, Lakewood Yams should consider the following housekeeping activity if not already in place to assure minimal discharge of raw dyestuffs: ➢ Plug drain in dye room and require spilled dyes to be collected with a dry vacuum. Lakewood Yarns - 4 - August 22, 2003