WO2014045309A2

WO2014045309A2 - Efficient yarn dyeing plant

Info

Publication number: WO2014045309A2
Application number: PCT/IN2013/000570
Authority: WO
Inventors: Ponnusamy Venkates SALEM
Original assignee: Salem Ponnusamy Venkates
Priority date: 2012-09-24
Filing date: 2013-09-20
Publication date: 2014-03-27
Also published as: WO2014045309A3

Abstract

According to an aspect of the present invention a dyeing plant is provided with a reduced water usage for dyeing the yarns. Due to use of lesser water, the plant installation cost and running cost may be reduced. In one embodiment, the yarns are loaded in to multiple dyeing chambers and the liquid is filled into one chamber. The liquid in the chamber is circulated into multiple chambers thereby washing, dyeing the yarns in the multiple chambers. As a result, less water is used to dye the yarns. In another alternative, a hank yarn dyeing machine is provided comprising two chambers. The yarns are loaded into both the chambers. A pump and pipe system is used to circulate the liquid in one chamber, transfer the liquid to other chamber, circulate the liquid in the second chamber, and transfer the liquid into first chamber. The process is repeated several times so that the yarns in both the chambers are dyed effectively. The circulation and transfer to liquid is performed for predetermined time duration so that the yarn remains adequately wet during the dyeing process.

Description

The following specification particularly describes the invention and manner in which it is to be performed

Description

TECHNICAL FIELD

Embodiments of the present disclosure relate generally to a dyeing plant, and more specifically to method, system, and apparatus for efficient yam dyeing plant.

RELATED ART

[0001] The yarns are often dyed in a dyeing plant to provide different colour, hues to the yarns. In general, the cost of the installation and recurring running cost of the plant depends on the volume or capacity of the plant. The capacity of the plant is generally measured in terms of Kilo grams of yarn the plant may dye or handle per day. Typically, the cost of each component in the plant increases with increase in the capacity of the plant. One component that may contribute the cost is the amount of water used per kg of yarn. Thus it is desirable to reduce the amount of water used for dyeing the yarn.

SUMMARY

[0002] According to an aspect of the present invention a dyeing plant is provided with a reduced water usage for dyeing the yarns. Due to use of lesser water, the plant installation cost and running cost may be reduced.

[0003] In one embodiment, the yarns are loaded in to multiple dyeing chambers and the liquid is filled into one chamber. The liquid in the chamber is circulated into multiple chambers thereby washing, dyeing the yarns in the multiple chambers. As a result, less water is used to dye the yarns.

[0004] In another alternative, a hank yarn dyeing machine is provided comprising two chambers. The yarns are loaded into both the chambers. A pump and pipe system is used to circulate the liquid in one chamber, transfer the liquid to other chamber, circulate the liquid in the second chamber, and transfer the liquid into first chamber. The process is repeated several times so that the yarns in both the chambers are dyed effectively. The circulation and transfer to liquid is performed for predetermined time duration so that the yarn remains adequately wet during the dyeing process.

BRIEF DESCRIPTION OF DRAWINGS

[0005] Example embodiments will be described with reference to the accompanying drawings briefly described below.

[0006] Figure 1 depicts an example yarn dyeing plant. [0007] Figure 2 is a prior cabinet hank yarn dyeing machine (CHYDM) shown with overall volume A.

[0008] Figure 3 is a flow chart illustrating the efficient dyeing process in a dyeing plant.

[0009] Figure 4 is the efficient yarn dyeing plant shown with efficient Cabinet hank yarn dyeing machine.

[0010] Figure 5 is an example efficient cabinet hank yarn dyeing machine.

[0011] Figure 6 illustrates the initial filling of water in first chamber.

[0012] Figure 7 illustrates the circulation of water or dye mixture within the first chamber.

[0013] Figure 8 illustrates the water movement from first chamber to second chamber.

[0014] Figure 9 illustrates the circulation of water within the second chamber.

[0015] Figure 10 illustrates the water movement from second chamber to the first chamber.

[0016] Figures 11 to 14 pictorially represent the flow of water from first chamber to second chamber.

[0017] Figure 15 illustrates the internal structure of an example steam exchange chamber.

[0018] Figure 16A and 16B respectively illustrates example top side and bottom side perforated filters.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Figure 1 depicts an example yarn dyejng plant. The yarn dyeing plant is shown containing Cabinet hank yarn dyeing machine (CHYDM) 105, collection tanks 110 and 115, nano filtration 120, reverse osmosis system 130, evaporators 145 and dry solar bed 150. Each element of the plant is described below in further detail.

[0020] CHYDM 105 rinses and dyes the yarn material placed in the yarn sticks. CHYDM discharges dye bath water (or effluent) after rinsing and dyeing of yarn material. The amount of water used for dyeing is generally determined based on the type of CHYDM. One prior CHYDM is described with reference to figure 2 in the sections below. The volume of discharged water also depends on type of yarn dyed in the dyeing machine. The discharged dye bath water is fed to the collection tank 110 and 115 sequentially. Alternatively, the discharge may be sent in parallel to both collection tank and processed independently (not shown).

[0021] The collection tank 115 may be used to store excess effluent discharged by the CHYDM. The collection tank 115 is constructed based on the expected effluent discharge from the CHYDM 105. An example collection tank may store more than 300000 litres of effluent. The volume (dimension) of the example collection tank can be 6 X 3.8 X 4.8 (I X w X h) in metres. The effluent may have inorganic salts and small amount of organic matter that is dissolved in water which can be termed as total dissolved solids (TDS). TDS is measured in ppm (mg/litre). The collection tanks 110 and 115 accumulate all organic material from the CHYD and pass the effluent to the nano filtration 120.

[0022] The nano filtration 120 removes colours and salt from the effluent (dye bath solution). The salt solution may be recovered from the effluent through nano filtration membrane system 125. The nano filtration may also include colour removal electrodes, carbon filters and sand filters. The clarifier tank 128 stores the effluent from the nano filtration chamber and used to separate the sludge material from the effluent. Also, the separated effluent is flown into the reverse osmosis 130 stage through a pipe. The sludge material is processed separately and is not shown for conciseness. The RO 130 is shown comprising stage 135 and stage 140 (or more stages). After pre-treatments of the dye bath, the final outlet water is fed to the Reverse Osmosis membrane system which gives , permeate as pure water with approximately 90% salt rejection. RO systems also include poly-amide low fouling. The solution from the reverse osmosis system 130 is fed into the evaporator 145.

[0023] Evaporator comprises one or more heat source. The applied heat converts the water in the solution into vapour. The vapour is removed from the rest of the solution and is condensed while the now-concentrated solution is either fed into a second evaporator or is removed. The evaporator may generally have four sections. The heating section, concentrating section, separating section and condenser. The heating section contains the heating medium that may consist of parallel tubes, plates and/or coils. Steam may be fed into this section. The concentrating and separating section removes the vapour being produced from the solution. The condenser condenses the separated vapour, then the vacuum or pump provides pressure to increase circulation. The condensed sediment solution is fed on the dry solar bed 150.

[0024] Solar bed 150 is plain surface for the evaporation of the sediment solution. This process may provide zero discharge of waste material to the ground surface.

[0025] Each waste water treatment elements 110, 115, 130, 145, and 150 is designed to handle the particular discharging capacity and thus the plant's initial cost and the recurring cost related to waste water processing depends on the capacity of each element. [A cost associated in setting up and maintaining a dyeing plant is illustrated below for an example plant capacity. The numbers mentioned are merely for illustration and understanding].

[0026] For example, a 100KG Hank yarn dyeing machine using 1600 litres of water may discharge water in proportion (example 1200Lts) per cycle ( the 400 litre may be absorbed by the yarn material). Typically 10 such cycles are conducted for wetting, soaking, bleaching, multiple washings, acid washing, dyeing, soaping, hot washing etc. The number of cycles conducted depends on the yarn and the quality desired. Thus the collection tank should be built proportionately to hold the dye bath water from the CHYDM. Similarly, other components such as nano filtration electrodes, reverse osmosis system, evaporators and solar bed should be built to hold and treat the proportionate effluent. Thus, the cost of a plant in installing the components 105 through 150 is proportional to the waste water discharged per kg of yarn.

[0027] For example, a plant for dyeing 2000KG of yarn per day may discharge 320000 litres of waste water (effluent). The initial cost to build the components 105 through 150 for processing such capacity of waste water may be approximately Rs 2, 00, 00,000.

[0028] Further, the recurring cost like electricity, labour, maintenance, etc to manage the plant in treating the waste water may be approximated to 20 Paisa/litre. Thus, a recurring cost of approximately Rs 60,000 may be spent for processing and discharging 320000 litres of water per day.

[0029] Though the cost is mentioned here as illustration only, the real cost may vary depending on the number of stages etc., thus it is desirable to reduce the overall cost of the dyeing plant. One reason for large discharge of water is due to use of more water in prior CHYDM. Thus, a prior cabinet machine is described below.

[0030] Figure 2 is a prior cabinet hank yarn dyeing machine (CHYDM) shown with overall volume A. The overall inner volume of machine is divided into two chambers (compartments). The CHYDM is shown with inlet pipe with valve 205, dosing valve 210, safety valve 215, pressure gauge 220, steam of coils 225 fitted with inlet and outlet pipes to inject the steam or to cool the water and outlet the steam respectively, wall of the machine 230, top side perforated filter 233, bottom side perforated filter 253, holder 235, yarn sticks 240, yarn material 250, middle rod 255, impeller 260, hand valve for dyes pump motor 265, dyes pump motor 270, dyes tank 275, hand valve for dyes tank 280, outlet pipe with valve [0031] The cabinet hank yarn dyeing machine (CHYDM) is divided in to two chambers. Chambers are surrounded with the wall of the machine 230. A middle (central) wall separates the chamber 1 and chamber 2. The yam material is tufted in the yarn sticks and placed on the yarn sticks. The uniform pressure in the chambers is maintained by the top and bottom side filters (233 and 253). Water may be heated by the coils placed between the impeller and yarn material of the CHYDM. Impeller 260 with rotating middle rod is fitted and operated by motor 228. The motor 228 rotates in both forward and reverse directions to appropriately circulate the water in the chambers. Other water circulation techniques are implemented using motor. Impeller 260 is used to circulate the water or dye mixture in the chambers. Pressure is monitored and maintained by the pressure gauge 220. Safety valve 215 is used to drive away excessive pressure in the chamber.

[0032] Hanks (generally referred to group of yarn windings) are arranged or loaded in both the chambers to the capacity of the CHYDM. Water is evenly filled and spread in both the chambers. Thus, the total volume of water used is nearly equal to the volume of the cabinet hank yarn dyeing machine or combined volume of both the chambers and impeller cabinet. Excessive water is adjusted in the chambers and equal spreading of water in chambers is maintained. After the rinsing and dyeing operations, the dye bath water in both the chamber is discharged to the collection tank. Thus, a large quantity of water is discharged from the prior cabinet hank yarn dyeing machine.

[0033] Manner in which less water may be used and discharged in dyeing the same amount of yarn in an embodiment of the present invention is described below.

[0034] Figure 3 is a flow chart illustrating the efficient dyeing process in a dyeing plant. The flowchart begins in step 301 and control passes to step 310.

[0035] In Step 310, the yarn material is loaded in both the chambers of the cabinet hank yarn dyeing machine. Yarn material is tufted in the hank bar and placed one by one in the chamber. The tufted yarn called Hanks may be arranged in such a way that, one inch of hank bar holds 70 gram of yarn material and the space between hank bars may be selected in the ranges of 2.0 inches or 2.1 inches or 2.25 inches. For example, the cotton yarns with the cotton count of 2No, 6No, lONo, 14No, 20No, 2/17No etc are tufted and placed appropriately in the yarn sticks. Various other techniques may be used for loading the yarn in to the machine chamber. The doors of the cabinet hank yarn dyeing machine are closed after loading the yarn material. [0036] In Step 320, one of the chambers in cabinet hank yarn dyeing machine is filled with water. Due to filling of water in to one chamber of the cabinet hank yarn dyeing machine while the yarns are loaded in the both the chambers, the water ratio for a kilogram yarn may be reduced. The water may be filled in such a manner that the yarn materials are completely immersed in water. The filling of water may be performed by injecting water into one of the chamber from top through any pipe and valve arrangement (inlet pipe). The pipes connected to the chamber may be closed to prevent flow of water to the other chamber. Normal water may be used to rinse and dye yarns. Often the yarn material to water ratio may vary based on the capacity (volume) of the cabinet hank yarn dyeing machine. Generally the larger the size of the cabinet hank yarn dyeing machine the ratio appears to be better. Yam material is rinsed with the water.

[0037] In Step 330, the water present in the chamber 1 is transferred to chamber 2. The water may be moved to chamber 2 through a pipe and pump arrangement. Any flow technique may be used to transfer the water from one chamber to other. The water may be transferred to the other chamber within a pre-specified time gap. Similarly the water may be exchanged from one chamber to other chamber based on the predetermined time cycle to ensure the yarns are wet enough to absorb the dye.

[0038] In Step 340, the dye chemicals are added with water. The dye chemical mixture may be slowly pumped into the main pipe that circulates the water from one chamber to other through the dyes pump motor. The dye chemicals are mixed with water and become a dye mixture or dye bath water. The dye bath water or dye mixture may be heated using a steam chamber controlled by the pressure gauge.

[0039] In Step 350, the dye mixture is transferred from chamber 2 to chamber 1 or vice versa for a specific time period through the circulating pipe and pump arrangement. Thus the dye water is circulated from one chamber to other chamber thereby dyeing yarns in both the chambers. The dye water may be circulated in one chamber for a pre specified time and then may be transferred to the other chamber. The dye water may be circulated in the other chamber also for a pre specified time period and again may be transferred to the first chamber. The process may be continued for a desired time period for effective dyeing of the yarns.

[004O] In Step 360, the dye mixture is discharged to the collection tank through the outlet pipe connected at the bottom of the chambers. The dye water (mixture) or effluent may be discharged after the yarns determined to have been dyed to a desired quality. The outlet pipe having outlet valve connected to both the chambers may be opened to discharge dye bath water (dye mixture) or effluent to collection tank. After discharging to the collection tank, the flowchart ends in step 399. Thus, only a half quantity of water compared to the CHYDM capacity is discharged while dyeing the yarns with full capacity. Thus the water discharged is reduced. Due to use of the technique of figure 3, the yarn to water ratio may be in the range of 1:8, 1:10, 1:12.

[0041] Further, though the description is made referring to exchange of water from one chamber to other, the water may also be exchanged from one cabinet hank yarn dyeing machine to another by appropriate pump and pipe arrangement. For example, the yarn may be loaded in two cabinet hank yam dyeing machines and the water may be filled in only one cabinet hank yarn dyeing machine (CHYDM) and the same water may be circulated between the two CHYDMs as described above. Further, the water may be circulated over more than two CHYDMs to enhance the ratio.

[0042] Due to reduction in the discharge of the effluent, the elements 105 through 150 may be implemented with the lesser capacity thereby reducing the initial cost of deploying the plant. Further the recurring cost associated with the running of the plant may also be reduced. An example reduction in the cost is diagrammatically depicted in figure 4 for illustration. (Figure 4 may be read with reference to figure 1).

[0043] Figure 4 is the efficient yarn dyeing plant shown with efficient Cabinet hank yarn dyeing machine 410, collection tank 420, nano filtration electrodes 430, clarifier tank 438, reverse osmosis 440, evaporators 460 and dry solar bed 470. As may be appreciated, each element is shown with half the capacity as compared to the corresponding deployment in figure 1. For example, a single collection tank may be used to store the dye bath water, a single set of electrodes may be used in nano filtration 430, only one stage may be used in RO system, and a smaller solar bed with half the capacity as compared to figure 1 may be used . At the same time, the yarn handling capacity of the plant may be retained the same. Alternatively, the plant of figure 1 may be used to double the plant capacity by incorporating the efficient cabinet hank yarn dyeing machine described with reference to figure 3. Typical cost installation and the recurring cost reduction due to use of technique of figure 3 is illustrated below. T/IN2013/000570

[0044] For example, a plant for dyeing processes 2000KG of yarn per day may discharge 160000 instead of 320000 litres of waste water. The initial cost to build the components 410 to 470 for processing 160000 litres of waste water may be approximately Rs 1, 00, 00,000. Further, the recurring cost to manage the plant in treating the waste water like electricity, labour, maintenance, etc may be approximated to a 20 paisa/litre. Thus, a plant discharging the 160000 litres of water per day may have to spend a recurring cost of approximately Rs.30, 000 per day. Though the cost is mentioned here as illustration only, the real cost may vary depending on the number of stages etc., thus an efficient dyeing plant reduces the water usage per KG of yarn and cost of installation and maintenance.

[0045] Practically while using the efficient dyeing plant, half of actual dyeing plant elements may displace and this decreases the overall area and volume acquired by the dyeing plant and the components. The efficient yarn dyeing machine may use half the amount of water compare to the prior cabinet hank yarn dyeing machine to rinse and dye the yams through the pipe and valve arrangement. Thus, the area required by the collection tank to accumulate the discharged water may also be reduced (since the discharged water is low compared to the prior dyeing plant as shown in figure 1).

[0046] An example working structure of the efficient cabinet hank yarn dyeing machine with two chambers is further described below. The process of flow of water may be implemented for more than two chambers.

[0047] Figure 5 is an example efficient cabinet hank yarn dyeing machine. The hank yarn dyeing machine is shown comprising, first chamber 510, second chamber 520, dye tank 530, pump 550 operated by motor 555, yarns on the hank 560 and 565, heat exchange chamber 570, top side perforated filter 580, and bottom side perforated filter 590. Each component is described below in further detail.

[0048] The pipe system for water circulation is shown containing pipe sections 513, 514, 515, 516 feeding water or dye mixture to chamber 1 and 523, 524, 525, 526 feeding water or dye mixture to chamber 520 along with main pump 559 connected to main motor 555, water circulation control valves 1, 2, 3, 4, 5, and 6 connected with respective pipes which are described further. Alternatively, water or any liquid that may contain appropriate composition for the purpose of dyeing, washing in a dyeing plant can be used.

[0049] The inlet 511 of chamber 510 is connected with pipes 513,514,515,516. The outlet connected with pipes 523,524,525,526. The small pipes (514,524) are used to pour the water or dye mixture into the chamber 520, when the water is flown from one chamber to another. The outlet 596 of chamber 520 is connected to pipe 529. The standard pipe categories may include stainless steel (S.S) pipe categories 304, 316, 304-L and 316-L as is well known in the industry. Inlet 552 and outlet 558 of main motor is connected to pipes 551 and 559 respectively. The main motor 555 pumps the water or dye mixture into the chambers (510,520) through main pipe 559 and other interconnected pipes to the chamber. The other end of main pipe 559 is divided in to two pipes namely 513 and 523 at heat exchange chamber 570.

[0050] The yarns 560 and 565 to be dyed are freely tufted and placed in the hank using holding bars 562 and 569 in to both the chambers 510 and 520. The holding bars can be termed as "yarn sticks". Various other techniques may be used to load the yarns in to the chambers 510 and 520. The holding bars are attached to the wall of the CHYDM through a holder 561. As an example yarn material may be arranged in such a way that, 70 gram of yarn material per inch (for example, cotton) may be tufted. The number of holding bars in the chamber may be suitably selected to hang the yarns in multiple rows (segments) and multiple columns. Figure 5 shows two segments and four holding bars in each chamber. Each segment has one top and one bottom holding bar 562 and 569 respectively in chamber 1 and 562 and 569 in chamber 2. The doors of both the chambers are closed upon placing the yarn material. Various other holding bar arrangements, yarn stick arrangements may be used to load the yarn into the chamber for dyeing.

[0051] Each chamber 510 and 520 of the efficient CHYDM is fitted with the top side perforated filters 580 and bottom side perforated filters 590. Perforated filters are fitted at top and bottom of the chambers as shown. The bottom side perforated filter 590 may be used to avoid the yarn entanglement during the liquor (dye mixture or water) flow. The filters may control the water pressure while injecting and removing water or dye mixture and/or chemicals into the chambers. Due to this, the dyes are evenly absorbed by the yarn.

[0052] Heat exchange chamber 570 having heating coils are placed on top of the efficient CHYDM. The heating coils emit heat and the heat is spread in the chamber 570. The water which flows through the pipes 513 and 523 is heated up due to the steam present in the heat exchange chamber. A pressure gauge 513 is connected to the efficient cabinet hank yarn dyeing machine to monitor and maintain the pressure and temperature within the cabinet hank yarn dyeing machine. A pressure release valve may be used to release the pressure from the cabinet machine under excessive pressure values. The arrangement with in the heat exchange chamber 570 is shown with multiple water carrying pipes for efficient heat exchange. Other type of heat exchanger may be used to heat the water injected to the chambers.

[0053] One end of the dyes pump motor 535 is connected to the dyes tank 530 where dyes are mixed and stored. Dyes tank 530 is connected with the hand valve which may be manually operated (initially set to close position) to unlock the dye mixture from dyes tank 530. The valves may be of butterfly valves types. The other end of the dyes pump motor 535 is connected to the main pipe 559. A hand valve 533 is fixed in between the main pipe 559 and the dyes pump motor 535. The functionality of the dyes pump motor 572 is to gradually pump the dyes from the dyes tank 530 into the main pipe 559.

[0054] An inlet pipe 503 attached with inlet hand valve 504 is connected to the CHYDM may be used to fill water in chamber 510 directly through the inlet pipe 503 and upon closing the valves 1 and 2.

[0055] A set of 6 valves (1, 2, 3, 4, 5, 6) are used to circulate the water or dye mixture in the chambers or between the chambers 510 and 520 at different points in time. The pipes (519, 529) fitted with valve 1 and valve 4, placed at the bottom of the chamber 1 and 2 which are connected directly to the main motor 555. The pipes (513, 516, 523, 526, ) fitted with valve 2 and valve 5 are connected to the top side of chamber 1 and chamber 2 and also pipes (515,525) fitted with valve 3 and. valve 6 are connected to the bottom side of chamber 1 and chamber 2. An outlet pipe 589, with an outlet hand valve 581 is connected to bottom of both the chambers (510, 520) and to discharge dye mixture (effluent) to the collection tank. The manner in which water may be filled in to the efficient cabinet hank yarn dyeing machine 500.

[0056] Figure 6 illustrates the initial filling of water in chamber 510. The inlet pipe 503 is opened through the inlet hand valve in which water 610 is filled in the chamber 510. Water 610 is poured on to the perforated filter 580. The perforated filter 580 controls the rate of water flow within the chamber 510. The water level gradually increases from the bottom of the chamber 510. The hank yarns (560 and 565) are completely immersed in water. Water may be filled to a level above the top side perforated filter 580. Thus, water is filled into only one chamber 510 of the CHYDM 500. The manner in which the water in the chamber 510 is used to wash, dye the yarns in both the chamber by operating the pump 550 and valves 1,2,3,4,5 and 6 is described below in further detail.

[0057] Figures 7 to 10 is used to first illustrate the process of rinsing (the first stage of dyeing) and the same figures are used to illustrate the dyeing process in the later sections below.

[0058] Continuing with the description of rinsing process, the figure 7 illustrates the circulation of water within the chamber 510 for wetting or rinsing or washing the yams as a first stage of dyeing. As shown there, valves 1 and 2 are opened, thus, the motor pump 550 takes the water from the outlet pipe 519 connected to chamber 510 and pumps the water in to the inlet 516 of chamber 510 through pipe 559 and 513 as shown in the figure 7.

[0059] During this process of rinsing, water is continuously circulated in the first chamber through the pipe connected to the first chamber. The motor pump is used to circulate the water in the first chamber where the hand valves 1 and 2 are kept open and other hand valves 3, 4, 5 and 6 are kept closed. Hence water is pumped repeatedly into the first chamber. The water from valve 2 is sprayed on the hank yarn with the help of perforated filters where as the water from valve 1 gradually drowned through the pipe connected with valve 1. The water is heated when the water flows through heat exchanger 570. A steam bleeding pipe may be used for direct heating of the water. Over a period of time, (as pre determined) yarns may be completely washed by the water. During this process the hank yarn may absorb some amount of water. The yarn may be completely swilled by the flow of the water. The flow or movement of water in the chamber 510 is depicted by the arrow marks in the Figure 7. As an example the process of rinsing in one chamber may continue for 120 seconds (or in the range of 90 seconds to 120 seconds). The time of rinsing in the chamber 510 may be determined based on the yarn type, thickness, chamber size, etc. Once the yarns are rinsed in chamber 510 for a predetermined time, the water in the chamber 510 is transferred to chamber 520. Manner in which the water is transferred from chamber 510 to chamber 520 is described below.

[0060] Figure 8 illustrates the water movement from chamber 510 to the chamber 520. As shown there, valves 1 and 3 are opened and other valves are closed. Thus, the motor pump 550 takes the water from the outlet 519 of chamber 510 and pumps the water in to the inlet 525 of chamber 520 through pipe 559, and 523 as shown in the figure 8. Thus the water in the chamber 510 is removed and flown into the chamber 520. IN2013/000570

[0061] The valve 1 which is connected to the main motor pump and valve 3 which connects the main pump and second chamber may be kept open. Other valves 2, 4, 5 and 6 are kept close. During the process of filling the water in second chamber, the water may be filled from the bottom inlet pipe 525. Alternatively, a small amount of water may be poured on the hank yarn through small pipe 524 which may be connected to pipe 525 and 526. As a result the water is fed to chamber 520 from both top and bottom directions. Thus, the water level recedes from chamber 510 and flows into chamber 520 and fills the chamber 520 as indicated with the arrows in figure 8. As an example, the total time required to transfer the water from first chamber to the second chamber may require less than 180 seconds. Based on various parameters the time may be varied. Horse power of the pump and the diameter of the pipes may be adjusted to transfer the water within a predetermined time to ensure that the yarns maintain desired wetness. Once the water is filled in chamber 520, the manner in which water is circulated to rinse the yam in the chamber 520 is described below in further detail.

[0062] figure 9 illustrates the circulation of water within the chamber 520 for wetting, rinsing or washing the yarns as a first stage of dyeing. As shown in figure, valves 4 and 5 may be opened, and thereby allowing the pump to take water from the outlet 529 of chamber 2 and pumps the water in to the inlet pipe 526 of chamber 520 through pipe 559 as shown in the figure 9.

[0063] During this process of rinsing, water may continuously circulate in the chamber 520 through the pipes connected to the chamber 520. The motor pump (550 and 555) may be used to circulate the water in the chamber 520. The valves 4 and 5 are kept open and other valves 1, 2, 3 and 6 may be kept close. Hence water may be pumped repeatedly into the chamber 520. The water from valve 5 is sprayed on the hank yarn with the help of top side perforated filters 580 where as the water from valve 4 may be gradually drawn out through the pipe 529 connected with valve 4. The water is heated when the water flows through heat exchanger 570. A steam bleeding pipe can be used for direct heating of the water. Over a period of time, (as pre determined) yarns may be completely washed/rinsed/wetted by the water. During this process the hank yarn may absorb some amount of water. The yarn may completely swilled by the flow of water. The flow or movement of water in the chamber 520 is depicted by the arrow marks in the Figure 9. As an example the process of rinsing in one chamber may continue for 120 seconds (or in the range of 90 seconds to 120 seconds). The time of rinsing in the chamber 520 may be determined based on the yam type, thickness, chamber size, etc. The amount of water absorbed by the yarns in chamber 510 and 520 may be added (if required) through the inlet pipe 503.

[0064] Once the yarns are rinsed in chamber 520 for a predetermined time, the water in the chamber 520 is transferred to chamber 510. Manner in which the water is transferred from chamber 520 to chamber 510 is described below.

[0065] Figure 10 illustrates the water movement from chamber 520 to the chamber 510. As shown there, valves 4 and 6 are opened and other valves may be closed. Thus, the pump takes the water from the outlet pipe 529 of chamber 2 and pumps the water in to the inlet pipe 515 of chamber 510 through pipe 559, and 513 as shown in the figure 10. Thus the water in the chamber 520 is removed and flown into the chamber l.The valve 4 and the valve 6 may be kept open. Other valves 1, 2, 3 and 5 may be kept close.

[0066] During the process of filling the water into chamber 510, the water may evenly occupy in the chamber. A small amount of water may be poured on the hank yarn through small pipe 514 connected to pipes 515 and 516. As a result the water is fed to chamber 510 from both top and bottom direction. Thus the water may fill in the chamber 510 as shown by the arrows in the figure 10. As an example, the total time required to transfer the water from chamber 520 to chamber 510 may be less than 180 seconds. Based on various parameters, the time may be varied. Horse power of the pump and the diameter of the pipes may be adjusted to transfer the water within a predetermined time to ensure that the yarns maintain desired wetness. The process described with reference to figure 7 through 10 may be repeated multiple times to rinse the yarn repeatedly in both the chambers. Once the washing/wetting/rinsing process is completed, the yarn may be dyed. The^' manner in which dyeing of the yarns may be performed is described below in further detail.

[0067] In Dyes tank 530, the water is mixed with dyes and chemicals. The dyes in dyes tank is the mixture of chemicals of various colours, alkaline and salt. The dye mixture is slowly pumped into the main pump 559 through the dyes pump motor 535. The water required for preparing the dye may be supplied to dyes tank 530 through pipe 539 during the rinsing or washing or at any of the stages described in above sections. The dye may be prepared in the dye tank and may be kept ready for injecting into the chambers. The pump 535 operates to inject the dye to the water flowing in the pipe 559. Thus, by operating the pump 535 and valve 533 the dye may be injected into the outlet of main motor 558 connected to the pipe 559 there by mixing the dye with the water in the pipe 559 (the mixture is referred to as dye mixture). The capacity of the pump 535 may be adjusted to release the required amount of dye to the pipe 559. Manner in which the dye mixture may be circulated in the chambers for dyeing the hank yarns is described below.

[0068] Referring again to figures 7 through 10, the process of dyeing the yarn in both the chambers 510 and 520 is described. As described above with reference to figure 7, the dye mixture (the dye mixed with water in pipe 559) may be circulated within the chamber 510 for dyeing the yarns. As shown there, valves 1 and 2 are opened, thus, the motor pump 550 takes the dye mixture from the outlet 519 of chamber 510 and pumps the dye mixture in to the inlet 516 of chamber 510 through pipe 559.

[0069] During this process of dyeing, dye mixture is continuously circulated in the chamber 510 through the pipes (519,559,513 and 516) connected to the chamber 510. Over a period of time, (as pre determined) yarns may be completely or partially dyed by the dye mixture. During this process the hank yarn may absorb some amount of dye mixture. The flow or movement of dye mixture in the chamber 510 is depicted by the arrow marks in the Figure 7.

[0070] As an example the process of circulating the dye mixture in chamber 1 as shown in figure 7 may continue for 120 seconds (or in the range of 90 seconds to 120 seconds). The time of dyeing in the chamber 510 may be determined based on the yarn type, thickness, chamber size, etc. Once the yarns are dyed to a desired level, the dye mixture in the chamber 510 may be transferred to chamber 520. Manner in which the dye mixture is transferred from chamber 510 to chamber 520 is described below.

[0071] Again, Figure 8 illustrates the dye mixture movement from chamber 510 to the chamber 520. As shown there, valves 1 and 3 are opened and other valves are closed. Thus, the motor pump 550 takes the dye mixture from the outlet 519 of chamber 510 and pumps the dye mixture in to the inlet pipe 526 of chamber 520 through pipe 559 and 523 as shown in the figure 8. Thus the dye mixture in the chamber 510 is removed and may be flown into the chamber 520.

[0072] The filling of dye mixture into the chamber 520 is as shown by the arrows in the figure 8. As an example, the total time required to transfer the dye mixture from chamber 510 to chamber 520 may be less than 180 seconds. Based on various parameters, the time may be varied. Horse power of the pump and the diameter of the pipes may be adjusted to transfer the dye mixture within a predetermined time to ensure that the yarns maintain desired wetness. Once the dye mixture is transferred to the chamber 520, the dye mixture may be circulated for a predetermined time to dye the yarns for a desired level. Figure 9 depicts the manner in which the dye mixture is circulated within the chamber 520.

[0073] Briefly describing again for continuity, the figure 9 illustrates the circulation of dye mixture within the chamber 520 for dyeing the yarns. As shown there, valves 4 and 5 may be opened, thus, the motor pump 550 takes the dye mixture from the outlet pipe 529 of chamber 520 and pumps the dye mixture in to the inlet 526 of chamber 2 through pipe 559 as shown in the figure 9.

[0074] During this process of dyeing, dye mixture is continuously circulated in the chamber 520 through the pipes (529, 559, 523 and 526) connected to the chamber 520. Over a period of time, (as pre determined) yarns may be dyed to a desired level. During this process the hank yarn may absorb some amount of dye mixture. The flow or movement of dye mixture in the chamber 520 is depicted by the arrow marks in the Figure 9. As an example the process of dyeing in chamber 520 may continue for 120 seconds (or in the range of 90 seconds to 120 seconds). The time of dyeing in the chamber 520 may be determined based on the yarn type, thickness, chamber size, etc. Once the yarns are rinsed in chamber 520 for a predetermined time, the dye mixture in the chamber 520 may be transferred to chamber 510. Manner in which the dye mixture is transferred from chamber 520 to chamber 510 may be as described with reference to figure 10.

[0075] For continuity, the transfer process is again described briefly. Figure 10 illustrates the dye mixture movement from chamber 520 to the chamber 510. As shown there, valves 4 and 6 may be opened and other valves may be closed. Thus, the motor pump 550 takes the dye mixture from the outlet 529 of chamber 520 and pumps the dye mixture in to the inlet pipe 515 of chamber 510 through pipe 559, and 513 as shown in the figure 10. Thus the dye mixture in the chamber 520 may be removed and flown into the chamber 510 and the dye mixture in the chamber 520 is removed and flown into the chamber l.The valve 4 and the valve 6 may be kept open. Other valves 1, 2, 3 and 5 may be kept close and the dye mixture fills in the chamber 510 as shown by the arrows in the figure 10.

[0076] As an example, the total time required to transfer the dye mixture from chamber 520 to the chamber 510 may be less than 180 seconds. Based on various parameters, the time may be varied. Horse power of the pump and the diameter of the pipes may be adjusted to transfer the dye mixture within a predetermined time to ensure that the yarns maintain desired wetness. The Pump power and the pipe size may be adjusted to transfer the dye mixture within a predetermined time to ensure the yarns maintain desired wetness.

[0077] The steps of figure 7 through 10 as described above with respect to dye mixture may be repeated several times_^ until the yarns are dyed to desired level. Thus it may be appreciated that the water of volume equal to volume of one of the chambers 510 or 520 may be used and exchanged between the chambers to dye the yarns in both the chambers 510 and 520 thereby reducing the use of water. Once the dyeing process is completed, the effluent water may be discharged through the outlet pipe 589 by operating the valve 581.

[0078] Figures 11 to 14 pictorially represent the flow of water from chamber 510 to chamber 520. As may be seen there, as the water or dye mixture is transferred, the level of water in one chamber (510) recedes while the level of water in the other chamber rises. The receding of water in chamber 510 is shown with levels 1110, 1210, 1310 in figure 11, 12, 13. The water in chamber 510 is shown completely empty in figure 14. Similarly, water level is shown to increase in chamber 520 with levels 1120, 1220, 1320. The chamber is shown completely filled with water/dye mixture in figure 14. Implying that the total water in the CHYDM 500 is only half the volume of the entire CHYD 500.

[0079] Figure 15 illustrates the internal structure of an example steam exchange chamber. The water or dye liquor in the chambers may gradually heated to certain predefined temperature to acquire ample dyeing of the yarn material. The Steam coils in the steam exchange chamber 570 may be used to heat the water for the dyeing process and the water may be cooled after dyeing process. The main pipe 1540 is connected to chamber 510 and chamber 520 through various small pipes 1520. One end of main pipe 1540 is connected to the steam exchange chamber 570 and other end is connected to the motor pump 550. The water 1530 from the main motor may flow through the small pipes 1520. The temperature of heat steam in steam chamber 570 may be monitored and controlled by temperature gauge or pressure gauge. Steam release valve may be used to release the excess steam and temperature from the steam chamber. The temperature may be set through the pressure gauge which may depend on the type of yarn material. For example, the temperature of heat steam for polyester material is 130° C to 140° C and the temperature of heat steam for cotton material is set to 90° C. The water or dye mixture may be heated when the water is shifted to one chamber to another. Alternatively, the water may be circulated in one of the 2013/000570 chamber through the process of rinsing or dyeing. One end of the small pipe 1620 is connected to main pipe and the other end is connected to respective chambers controlled by hand valves. The Steam exchange chamber 570 may be connected to the inlet 1510 for inserting the heat steam and may be connected to the outlet 1560 for discharging the heat steam from the heat chamber.

[0080] Figure 16A and 16B respectively illustrates example top side 580 and bottom side 590 perforated filters placed in the chamber 510 and 520 respectively. Both the filters control the pressure of water entering into the chamber. In figure 16A, the top side perforated filter 580 may be used to shower the water on the hank yarn material tufted on hank sticks. Pipes may be connected at the top of the chamber for injecting water into the chamber. The water through the pipe 1610 may be poured at the top side of the perforated filter for providing a uniform showering to the hank yarn material. The Filters 1630 may be attached to the grids 1620.

[0081] In figure 16B, the bottom side perforated filter 590 is used to fill the chamber from the bottom side. Pipes 1660 may be connected at the bottom of the chamber for injecting water into the chamber. Alternatively, the perforated filter may be used to drain the water from the chamber through pipes. Filters 1680 may be attached to the grids 1670. Whenever water is removed through the bottom perforated filter 590, the yams may be straightened. During the process of rinsing or dyeing, water or dye mixture may be continuously circulated in the one of the chambers. The perforated filters (580 and 590) may be used to provide a uniform pressure inside the chamber.

[0082] While various examples of the present disclosure have been described above, it should be understood that they have been presented by way of example, and not limitation. Thus, the breadth and scope of the present disclosure should not be limited by any of the above-described examples, but should be defined in accordance with the following claims and their equivalents.

Claims

I/We claim,

1. A method in a yarn dyeing plant comprising:

loading yarns into plurality of cabinet chambers;

filling a first liquid into a first cabinet chamber in the plurality of cabinet chambers; and circulating the first liquid in the first cabinet chamber through plurality of cabinet chambers.

2. The method of claim 1, wherein the liquid is one of dye liquor, water, water composition to wash the yarns and wherein the first liquid occupies a first volume is equal to a volume of the first cabinet chamber.

3. The method of claim 2, further comprising:

circulating the first liquid within the first cabinet chamber for a first pre-determined time; transferring the first liquid to a second cabinet chamber in the plurality of chambers;

circulating the first liquid within the second cabinet chamber for a second pre-determined time;

transferring the first liquid from second cabinet chamber to first cabinet chamber:

4. The method of claim 3, further comprising:

controlling the pressure of water entering and exiting the plurality of chambers by plurality of filters;

5. A cabinet hank yarn dyeing machine comprising:

plurality of yarn dyeing chambers for loading the hank yarn for dyeing; and

a first pump and a first pipe arrangement to inject a liquid into plurality of dyeing chambers wherein the first pump and first pipe arrangement circulates the first liquid in the first cabinet chamber through plurality of cabinet chambers.

6. The cabinet hank yarn dyeing machine of claim 5 further comprising a dye tank containing dye liquor, wherein a second pump pumps the dye liquor from the dye tank to the first pipe arrangement such that the first pump and first pipe arrangement circulate the dye liquor through plurality of cabinet chambers there by dyeing the hank yarns in the plurality of cabinet chambers.

7. The cabinet hank yarn dyeing machine of claim 6, further comprising:

plurality of filters disposed within each cabinet chamber controlling the pressure of water flow.

8. The cabinet hank yarn dyeing machine of claim 7, further comprising a heat exchanger to heat the liquid circulated through the plurality of cabinet chambers.

9. An efficient cabinet hank yarn dyeing machine comprising:

a first chamber and a second chamber;

a first inlet pipe connected to first chamber at the top of the first chamber and its flow is controlled by first valve;

a second inlet pipe connected to the first chamber at the bottom of the first chamber and its flow is controlled by second valve;

a third inlet pipe connected at the top of the second chamber and its flow is controlled by third valve;

a fourth inlet pipe connected at the bottom of the second chamber and its flow is controlled by fourth valve;

a first outlet pipe connected at the bottom of the first chamber and its flow is controlled by fifth valve;

a second outlet pipe connected at the bottom of the second chamber and its flow is controlled by sixth valve;

a first pump with an pump outlet and a pump inlet, wherein the first outlet and second outlet pipes are connected to the first pump inlet, and the first inlet pipe , the second inlet pipe, the third inlet pipe and the fourth inlet pipe connected to the first pump outlet, wherein the first pump is operative to circulating the liquid within the first chamber when first valve and fifth valve are open and other valves are closed, transferring the liquid from first chamber to second chamber when fifth valve and fourth valve are open and other valves are closed, circulating the liquid within the second chamber when third valve and sixth valve are open and other valves are closed, transferring the liquid from second chamber to first chamber when sixth valve and second valve are open and other valves are closed.

10. An efficient cabinet hank yarn dyeing machine of claim 9 further comprising:

a dye tank storing dye mixture;

a second pump operative to inject the dye mixture into the outlet of first pump.