Certification

This is to certify that this thesis entitled " Recycling of Solid Fiber Waste to Prepare
Insulating Materials for Electrical Applications" is done by the following students under
my direct supervision and this work has been carried out by them in the laboratories of the
Department of Textile Engineering under the Faculty of Textile Engineering of Green
University of Bangladesh in partial fulfillment of the requirements for the degree of Bachelor
of Science in Textile Engineering. The presentation of the work was held on March, 2024

Signature of the Candidates Signature of the Candidates

———————— ————————
Al Mumin Md. Mehedi Hasan
ID: 201003006 ID: 201003028

Signature of the Candidates Signature of the Candidates

———————— ————————
Mehedi Hasan Apu Joyanta Chandra Barman
ID: 201003033 ID: 201003043

Signature of the Candidates

————————
Hasanur Rahman Hemel
ID: 201003064

Signature of Supervisor
————————
Md. Mahbubur Rahman
Assistant Professor
Department of Textile Engineering
Green University of Bangladesh

Acknowledgment
i
All appreciation goes to the Almighty Allah to give us strength and ability to complete this
project work. It was great opportunity for us to complete the project work with the assistance
of persons employed in GIANT Textile Ltd. We would like to thank from the core of our
heart to express our deepest appreciation and sincerest gratitude to our respected supervisor,
Md. Mahbubur Rahman, Assistant Professor, Department of Textile Engineering, Green
University of Bangladesh, for their valuable guidance, suggestion, encouragement, inspiration
and constructive criticism throughout this project work period. We will always be thankful for
their extraordinary reinforcement.

We would like to specially thanks to respected honorable Dr. Nitai Chandra Sutradhar,
Distinguished Professor and chairperson, Department of Textile Engineering, Green
University of Bangladesh for giving us the courage to carry out this project work in the
industry. Special thanks go to all of our teachers of the department.

We would like to show our sincere gratitude to Dr. Md. Shariful Alam, Associate Professor,
Md. Sherazul Islam, Lecturer, Department of Textile Engineering, Mr. Tariqul Islam,
Lecturer, Department of EEE, Green University of Bangladesh, for their valuable suggestion,
encouragement, inspiration. Without their co-operation, it would not be possible for us to
complete our task. Thanks for their friendly behavior & supportiveness. We are also grateful
to the supervisors, technicians, operators and all other staffs of GIANT Textile Ltd who were
most cordial and helpful to us during our project work. Finally, we would like to express a
sense of gratitude to our beloved parents and friends for their mental support, strength and
assistance throughout the working days and writing the project work report.

ii
 ABSTRACT
The continuous growth in the global population and the corresponding improvement in living
standards have led to a noticeable surge in fiber consumption worldwide in recent decades.
Consequently, this increase has also resulted in a substantial rise in post-industrial and
postconsumer fiber waste. To address this mounting waste issue and promote sustainable
recycling practices, a rigorous effort was undertaken to complete this research, which places a
strong emphasis on the development of modified conducting bars capable of exhibiting both
thermal and electrical conductivity. Throughout the course of this study, we delve into the
value of textile waste, the outcomes of recycling such waste, and the wide-ranging
applications of these recycled materials. The resulting conductive bars underwent extensive
testing for their electrical and thermal performance, and the results consistently demonstrate
the efficacy of bars produced from recycled waste materials for electro thermal conductivity.

iii
 Contents
Certification...............................................................................................................................i
Acknowledgment......................................................................................................................ii
ABSTRACT............................................................................................................................iii
List of Figures..........................................................................................................................vi
List of Tables..........................................................................................................................vii
List of Symbols......................................................................................................................viii
List of Acronyms.....................................................................................................................ix

Chapter-1: Introduction ..........................................................................................................

1
1.1 Introduction ..........................................................................................................................
2
1.2 Background of the Study ......................................................................................................
5
1.3 Research Questions ..............................................................................................................
5
1.4 Objective ..............................................................................................................................
6
1.5 Purpose of the Study ............................................................................................................ 6
1.6 Statement of the Problem .....................................................................................................
7 Chapter-2: Literature
Review ................................................................................................. 8
2.1 Background of the study ...................................................................................................... 9
2.2 Theoretical Aspects ............................................................................................................
11
2.2.1 Insulator .......................................................................................................................
11
2.2.2 Use of Insulator ...........................................................................................................
11
2.2.3 The Common Uses of Electrical Insulators Are Given Below: ..................................
11

iv
 2.2.4 Application of Electric Insulator .................................................................................
12
2.3 The Functions of the chemicals: ........................................................................................ 12
Chapter-3: Materials and Methods ......................................................................................
17
3.1 Raw material, chemicals & machineries ............................................................................
18
3.1.1 Raw material ................................................................................................................
18
3.1.2 Chemicals ....................................................................................................................
18
3.1.3 Machineries .................................................................................................................
19
3.2 Working Procedure ............................................................................................................ 20
3.4 Assessment Methods and Procedures ................................................................................ 22
3.4.1 Electrical insulating check ...........................................................................................
22
3.4.2 Physical representation check ..................................................................................... 23
3.4.3 Thermal stability test ................................................................................................... 23
3.4.4 Water regain test .......................................................................................................... 24
3.4.5 Water absorption test ...................................................................................................
24 Chapter-4: Result &
Discussion ............................................................................................ 25
4.1 Stenter Machine Waste: Daily Impact ............................................................................... 26
4.2 Electrical insulating assessment .........................................................................................
26
4.3 Physical representation assessment ....................................................................................
27
4.4 Thermal stability test ..........................................................................................................
28
4.5 Water regain test ................................................................................................................ 28
4.6 Water absorption test.......................................................................................................... 29
4.7 Acid test ............................................................................................................................. 30

v
4.8 Alkali test ...........................................................................................................................
31 Chapter-5:
Conclusion ........................................................................................................... 32
5.1 Concluding Remarks ..........................................................................................................
33
5.2 Limitations ......................................................................................................................... 33
5.3 Scope of future study ......................................................................................................... 34
References ...............................................................................................................................
35

List of Figures
Fig 2.1 Chemical structure of epoxy resin……………………………..……….………..…..11

Fig 2.2 Chemical structure of Polyvinyl Acetate……………………..……………………...12

Fig 2.3 Chemical structure of PEG…………………………..…………..……………..……12

Fig 2.4 Chemical structure of Hardener………………………….......……..……………..…13

Fig 2.5 Chemical structure of TiO2…………………………….....……………..……..……14

Fig. 3.1. Treatment procedure of dyed waste & sample preparation………………….……..19
Fig. 3.2. Electrical conductivity checking using HV insulation tester……………………….20
Fig. 3.3. Physical representation checking using battery and light…………………….…….21
Fig. 3.4. Thermal stability test using preheated oven……………………………….….…....21

Fig. 4.1. Graphical representation of sample resistance………………….…………….…….24

vi
 List of Tables
Table 3.1: Different chemicals, machineries, equipment………………………….………….12

Table 4.1 HVI reading of the samples………………………………...………………………27

Table 4.2 Thermal stability test result of samples…………………………………………….29

Table 4.3 water regain test result of samples……………………………………………...….29

Table 4.4 water absorption test result of samples…………………………………………….30

Table 4.5 Acid test result of samples………………….……………………………………...31

Table 4.6 Alkali test result of samples………………………………………………………..31

vii
 List of Symbols
% Percentage

Ω ohm

MΩ Megaohm

: Colon, ratio sign

[] Square brackets

viii
 List of Acronyms
SWM Solid Waste Management
DMSO Dimethyl Sulfoxide
MSW Municipal solid waste

ix
 Chapter-1: Introduction
1.1 Introduction
The accumulation of solid waste presents a critical concern for both public health and the
environment. This underscores the urgency of implementing a comprehensive Solid Waste
Management (SWM) policy to combat waste accumulation in our external surroundings.
Addressing the considerable expenses associated with SWM can be achieved by identifying
economically viable methods to repurpose textile waste. Recent studies indicate a rising
public interest in recycled textile products, as people grow more aware of the environmental
risks posed by textile waste [1]. The textile knit dyeing industry is responsible for the
generation of large quantities of waste, which often cannot be effectively recycled or
repurposed using conventional techniques. In certain instances, this waste is haphazardly
discarded in the environment without undergoing any form of treatment. A noteworthy
portion of fabric loss occurs during the stenter machine process, specifically when fabric is
guided through the padder. The resulting fiber dust comprises extremely short staple-length
fibers that lack usability in any application [3]. As a result, this waste is directly relegated to

1
landfills, resulting in substantial environmental pollution. The fiber dust collected from the
stenter machine displays minimal electro thermal conductivity and primarily serves as an
insulator within the electrical sector. To address this limitation, research efforts focused on
enhancing the fiber's insulating properties by subjecting it to various chemical treatments.
These treatments not only increased insulating properties but also improved the cohesion
between individual fibers [3]. According to our research, the stenter machine at Giant Textile
Ltd. produces 7-8 kg of waste cotton dyed fiber waste each day from 32 tons of cloth.
An electro thermally insulating bar was created using the cotton dust that had been treated.
This bar may be used in homes, streets, and offices. This insulator is used in different types of
devices and equipment where no flow of electricity is required. If human skin comes into
contact with an active naked wire, it will conduct electrical charges and a current will be felt.
Hence, insulators are used on bare wires which prevent the flow of electric charges. When left
untreated, the bar's resistance is lower than that of typical electrical wire insulator material.
Thus, the bar can be utilized as an affordable substitute material for electrical wire. The bar
has the ability to conduct thermal energy in addition to electrical energy [4]. Fibrous waste is
generated at every step of the fabric processing process. Since no viable method for recycling
their waste has yet been developed, the textile industry typically disposes of their waste in
landfills. It is a contentious matter concerning the textile industry's present objective, which is
to minimize waste in order to attain sustainability. Even though a lot of research has been
done, waste minimization is still a very active area of study. Because of its exceptional
insulating property, the production of wearable textiles has grown more and more
commonplace these days [5]. Wearable textile materials might definitely use insulating bar as
an integrated component if it can be made from these fibrous waste materials. Fibrous cotton,
a kind of textile solid waste, offers a number of possible applications. One possibility is using
a mixture of pulp to produce paper. Paper is made at a ratio of 1: 0.25–3 of paper to solid
cotton waste. Using cotton cutting and knitting waste, biogas may also be produced. 300
grams of trash are processed by the anaerobic digestion process of bacteria, which yields
enough biogas to light a gas burner. One method of producing non-woven materials is to
gather solid debris and pierce the material with a needle. The created non-woven exhibits
superior insulating properties in the 0.03476–0.04877 range. The characteristics suggest that
these non-woven materials are perfect for insulation and have a wide range of applications.
Global IT firms have determined that wearable, flexible materials represent the next frontier

2
in technology. Flexible sensor sheet for human interaction that is created by combining two
textile sheets with Ag thread. Two textile sheets are placed in front of a cotton mesh spacer.
These basic textile-based sensor sheets are capable of tracking a number of bodily parameters,
including breathing rate and foot pressure [8].

Recycling cotton waste might provide a new supply of cotton fiber despite the lack of
arable land, the growing demand for raw cotton for the textile sector, and the possibility of
rising cotton bell prices. Three stages of recycling have been completed. a) Nitric acid is used
to leach textile dye; b) Dimethyl Sulfoxide (DMSO) is used to dissolve the dye; and c)
bleaching is performed [6]. Fabrics go through a variety of processes, starting with the most
basic step of fiber production and ending with knitting or weaving. As a result, waste is
produced during the entire process at various points. The growing global population is causing
a daily increase in the consumption of fabrics [7]. Recycling these wastes is therefore deemed
necessary in order to provide a more practical and sustainable environment. Three key phases
are needed to move raw cotton from its initial stage to the later finishing stages: desizing,
scouring, and bleaching. The primary goal of the scouring stage is to make the gray cloth
hydrophilic. Because of the coating of oil, wax, pectin, and lipids, the gray materials initially
retain their hydrophobic properties. By clearing the surface of the fabric of these non-
cellulosic natural materials, scouring attempts to improve the fabric's absorbency as well as its
whiteness. These substances—wax, pectin, oil, and fat—represent raw cotton's hydrophobic
quality. As we go on to the subsequent processes of bleaching, dying, mercerizing, and
finishing, the effectiveness of the scouring process is crucial [9].
Boiling is used to assist carry out this entire process in an alkaline media. The rate at
which alkali is used rises when alkaline is used. It removes dangerous substances during the
rinse process. However, cellulose is susceptible to the harm caused by oxidation. Following
this, several chemicals are used to carry out the bleaching process. The most commonly
utilized ones include hydrogen peroxide, soda ash, etc. In this regard, bio-finishing can be
applied in a beneficial manner. These days, wastes are produced either directly or indirectly
by every plant or project. There are three main approaches to reduce these wastes. The first is
the introduction of a new manufacturing medium or technology that reduces waste. The
second is to properly treat the effluent so that the desired outcome is achieved. The final
option, which is seen as the best, is to recycle waste to create something useful or, at the very
least, to ensure that it won't hurt anyone after being dumped [3] [5]. There might be a few

3
things that happen to justify this enormous hazard. The most common factors that call for
action to be taken to reduce this risk include rising prices associated with raw material
procurement, rising consumption, etc. The "Cut & Sew" approach produces a vast amount of
clippings and scraps during the garmentmaking process. They are discarded into the soil
unless they are brought to a recycling facility. However, the prospects of recycling or non-
woven matting become questionable because of the little market potential. Thus, it is
imperative that we take some real action for our own benefit. About 11.9 million tons of
textile trash, 4.7% of municipal solid waste (MSW), and 15.9% of garbage were recycled
were produced in the United States in 2007 [1].

The thesis work's primary goal, which is to remove dyed fiber wastes from the
processing of cotton knit fabric so they can be recycled once more and turned into something
worthwhile. Additionally, this endeavor aims to create conductive materials from these wastes
while also considering their potential end uses. This project of making conductive bars can be
applied in other ways in order to achieve this fundamental goal [8].

1.2 Background of the Study

A substantial quantity of trash, including waste from colored fibers, is produced by the textile
industry. Due to its frequent disposal in landfills, where it pollutes the environment and takes
up precious space, this garbage presents a serious environmental concern. Historically, the
inclusion of chemicals and dyes has limited the reuse options for waste colored fiber.
Nonetheless, current research initiatives are concentrated on creating strategies for
repurposing waste colored fiber into useful goods.

The purpose of this study is to explicitly explore the possibility of producing insulating
materials for electrical applications utilizing discarded colored fiber. The following are the
main justifications for the significance of this study:
1. Benefits to the environment: Recycling discarded colored fiber lessens the load on
landfills and encourages a more environmentally friendly textile sector.
2. Resource recovery: It makes it possible to use priceless materials that are incorporated
in the fibers to create new goods.

4
3. Innovative applications: Finding new uses for waste colored fiber can lead to the
creation of creative and environmentally friendly goods.

This project intends to contribute to a more sustainable future for the textile and electrical
sectors by investigating the viability of recovering colored fiber waste for electrical insulation.

1.3 Research Questions

1. Which dyed fiber waste processing and preparation techniques are the most effective
and environmentally friendly for use in electrical insulation?

2. Is it possible to properly treat and clean waste colored fiber to satisfy the standards for
electrical insulation?

1.4 Objective
1. To clean and treat waste colored fiber to fulfill the demands of electrical insulation,
including those related to thermal stability and dielectric strength.

2. Examine the created recycled fiber insulation's insulating qualities and contrast them
with those of traditional electrical insulation materials.

3. Determine and enhance environmentally friendly techniques for handling and getting
ready waste colored fibers for use in electrical insulation applications.

4. Determine possible electrical applications where the generated recycled fiber

insulation can be used to good effect.

1.5 Purpose of the Study

The goal of this project is to create a process for recycling waste colored fiber into useful
products like electrical insulation, in an effort to mitigate the environmental impact of this
waste. This lessens the amount of textile waste that ends up in landfills and encourages
resource recovery.

5
The study investigates dyed fiber waste's potential as a cutting-edge material for electrical
applications. This research lessens dependency on virgin resources while promoting
innovation in the electrical sector by effectively producing useful insulating materials from
recycled garbage.

Essentially, the goal of this study is to present a novel and perhaps affordable electrical
insulation alternative while also looking for a sustainable way to manage waste in the textile
business.

1.6 Statement of the Problem

There is a large amount of waste colored fiber produced by the textile industry. This waste
gives rise to two issues:
1. Impact on the Environment: Waste colored fiber that is discarded frequently finds up
in landfills, where it causes pollution and takes up precious space. In the long run, traditional
disposal techniques are not sustainable.

2. Depletion of Resources: The fibers that are thrown away indicate the loss of important
resources used in their creation. Furthermore, additional resource extraction is needed for the
virgin materials used in conventional electrical insulation.

The purpose of this study is to investigate the possibility of recycling waste colored fiber into
electrical insulation materials in order to address this issue. If this strategy is developed
correctly, we can accomplish:

1. Lessening of the impact on the environment by diverting garbage from landfills.

2. Resource recovery through the development of a useful new use for waste fibers.
3. The electrical sector may be able to save costs by insulating using recycled materials.
4. Encouragement of a circular economy in the electrical and textile sectors.

6
Thus, the primary issue that this research aims to address is the absence of a resource-efficient
and sustainable method for handling waste colored fiber. We can achieve a win-win situation
for industrial innovation and environmental sustainability by devising a way to convert this
trash into useful electrical insulation.

Chapter-2: Literature Review

7
2.1 Background of the study
From this journal paper we observe that the author of this paper are using some solid wastage
or Fiber dust collected from stenter machine has very low electro thermal conductivity. Their
experiment has been done to bring moderate conductive property into the fiber by the
modification of fiber dust by treating it with various chemicals. And the chemicals are
Polyethylene, Polyvinyl acetate, Ti02, Polyethylene Glycol, Non-ionic resin, Iodine solution,
Hardener. After treating the chemicals with the solid wastage they get the electro thermal
conductivity in a negligible amount [1].

From this journal paper we observe that the author of this paper are using some solid wastage
or Fiber dust collected from brushing and Sueding machines (from finishing section), and also
from the backside of the factory where this waste was dumped in open atmosphere and near
the water body. In their experiment made to recycle this solid wastage in the production of
paper, they use newspaper, used A4 sized paper, poster, small amount of paper glue and water
[2].

Textile waste poses a serious threat to the environment and has detrimental effects. By
investigating a way to recycle waste colored fiber, our study directly addresses this problem
by keeping it out of landfills and encouraging a more sustainable textile sector. Through the
process of turning garbage into insulating materials, the study encourages the electrical
applications industry to adopt a circular economy. Waste colored fiber may hold the key to
developing novel insulating materials with distinct characteristics. This study investigates this
possibility, which could result in new materials with particular benefits (such being flexible
and lightweight) for a range of electrical applications [3].

The concept is more appealing for widespread adoption because of the emphasis on creating
an affordable recycling method. This could have a major effect on the insulating materials'
overall cost structure and encourage the usage of sustainable alternatives more widely. The
goal of the project is to make a connection between the problem of textile waste and the
increasing need for insulating materials in electrical applications. By meeting the needs of a
different industry and providing a lasting solution, this forges a useful connection [4].

8
The market for repurposed cotton seems to be expanding, but the primary barrier to cotton
recycling is the inferior quality of the items that are produced as a consequence. Thus, it is
crucial to thoroughly examine all aspects of recycled cotton processing, from separation and
shredding to finishing. This contribution illustrates how the kind of textile wastes derived
from cotton affects the qualities of recovered fibers after shredding. To achieve this, pre-
consumer wastes from knitted cotton textiles were systematically gathered and categorized
based on the kind of fabric (loose/single-jersey and tight/interlock), as well as the type of
finishing treatment (untreated greige cotton fabrics and colored cotton fabrics). Additionally,
the impact of the size of the waste fabric pieces fed into the shredding process was examined
[13].

The path toward a circular economy for sustainability is paved by the recycling and
transformation of textile waste into products with additional value and improved functional
qualities. This study explores the production of high-performance thermal barrier materials
using recycled cotton fiber from waste clothing cutting. Because cotton waste is recycled, the
created textiles' physical characteristics showed a regular fiber arrangement and, as a result, a
consistent thickness without any distortion on the fiber surfaces. Comparing the produced
materials to commercial fabrics of similar thickness, they also showed low average bending
stiffness and compression and high softness index. As the percentage of recycled cotton fiber
in the textiles increased, the heat protection performance showed an improvement in the
conductive and radiative heat resistance of the fabric [14].

In our thesis paper we will try to increase insulating properties by varying the amount and
volume of chemicals and observe the conditions of electric insulating property in solid
wastages [1]. In our thesis paper we will try to make electro insulating bar by the use of solid
wastage which are from stenter machine (also from finishing section) [2].

2.2 Theoretical Aspects

2.2.1 Insulator
Insulators are materials that prevent the flow of electricity through them. Air is one of these
materials, along with rubber, plastic, wood, and glass. Glass, rubber, ceramic, and plastic are
9
examples of materials that show electrical insulators, which have a resistance that either
partially or totally stops electricity from moving.

To keep them safe, insulators are used in the construction of most electrical devices. For
instance, plugs come in plastic containers. Plastic is used to wrap electrical lines because it is
both flexible and insulating. Plastic coating is applied to copper wires in electrical circuits to
stop electricity from spilling.

2.2.2 Use of Insulator

The majority of places to find electrical insulators are buildings, roadways, and workplaces.
Electrical insulators are utilized in many equipment and device kinds where an electrical
current is not necessary. Using electrical insulators is common.

Electrical insulators stop high voltage from being produced by electrical devices. Human skin
will transmit electrical charges and feel a current if it comes into touch with an active bare
wire. As a result, insulators are put on exposed wires to stop electric charges from flowing.
Numerous locations employ insulators.

2.2.3 The Common Uses of Electrical Insulators Are Given Below:

 Prevents the production of high voltage in the electrical circuit.

 Controlling the emission of pollutants.

 Improves process performance.

 Prevents electric shock.

2.2.4 Application of Electric Insulator

Some of the major applications of electric insulators are given below:

 Electrical Wiring Coating

 The Coating on Electric Poles on Roads

10
  Circuit Board

 Coating of Cables

 High Voltage Equipment

2.3 The Functions of the chemicals:

1. Resin:
Resins can potentially improve the insulating properties of cotton dyed fiber waste in a few
ways:
The formation of air pockets: Resins have the ability to bind cotton fibers together
loosely. Air pockets are formed in the material as a result. Since air is a poor heat
conductor, the sample's capacity to withstand heat is enhanced by these trapped air
pockets.

There are several ways that polyurethane resin might enhance the insulating qualities of
discarded cotton-dyed fiber waste:

Air Gaps: Air is a strong insulator and is naturally trapped by cotton strands. The spaces
between the fibers can be filled up with polyurethane resin to provide an insulating layer that
is more continuous. As a result, there is less heat transmission and air restriction.

Material Properties: The insulating qualities of polyurethane are good in and of itself. It
increases the total insulation value by adding a second, low-thermal-conductive layer of
insulation when it covers the cotton fibers.

11
 Fig 2.1 Chemical structure of polyurethane resin

2. Polyvinyl acetate:

The most popular use of PVAc is in adhesives. It may be referred to as carpenter's glue, wood
glue, or white glue. It is an excellent adhesive for porous materials such as fabric, paper, and
wood.

Formation of Polyvinyl Acetate:

 PVAc is a synthetic polymer, which means that several smaller molecules are joined
to produce one giant molecule.
 Vinyl acetate monomer is the starting ingredient in the PVAc instance.
 These monomers combine in chains through a process known as polymerization to
create PVAc.
.

Fig 2.2 Chemical structure of Polyvinyl

Acetate

3. Polyethylene Glycol
Functions: Because of its qualities, PEG is used in many different sectors. Here are few
instances:
 solubilizer: A solubilizer is a substance that aids in the dissolution of other materials
and medications in water.
 Lubricant: PEG has the ability to lessen surface friction.

12
  Coating agent: It can be used to coat implants, capsules, and tablets to stabilize or
regulate their release.
 Moisturizer: PEG draws water to the skin to maintain its moisture content.
How it works: Depending on its molecular weight and the intended outcome, PEG behaves
differently in these applications. For instance, PEG acts as a lubricant and creates a slick
coating that lowers friction. It forms a thin layer around a substance in its capacity as a
coating agent.

Fig 2.3 Chemical structure of PEG

4. Hardener:
Chemical reactions can be started by hardeners by adding reactive molecules, which cause the
base material to begin curing. Cross-linking: Certain hardeners encourage the material's
polymer chains to create cross-links. By serving as small bridges between the chains, these
cross-links strengthen and stiffen the material. This is typical of curing procedures such as
rubber vulcanization. Reducing water content: Hardeners may be able to assist in part of the
material's water removal process, which is required for adequate curing. Concrete hardeners,
for instance, may contain chemicals that, when combined with water, react and create vapor,
hastening the drying process and accelerating the concrete's ability to harden.

13
 Fig 2.4 Chemical structure of Hardener

5. Wetting agent:

Chemical additions known as "wetting agents" lower a liquid's surface tension. A liquid's
ability to resist spreading by making its molecules pull inward is known as surface tension.
Wetting agents help liquids spread more readily and establish better contact with solid
surfaces by reducing surface tension.
Here are some of the key functions of wetting agents:
 Improving wetting and spreading
 Lowering surface tension
 Enhancing detergency

Fig 2.5 Chemical structure of wetting agent

6. TiO2:

14
TiO2 is used as a photocatalyst for dye degradation, which breaks down the pigments in the
fibers. Under UV light, TiO2 functions as a photocatalyst, producing reactive oxygen species
that have the ability to break down organic materials. This may be a method of pre-treating
the colored fibers prior to their recycling into materials for insulation. Improving Material
Properties: To increase the recycled fiber material's insulating capabilities, TiO 2 is integrated
into it. TiO2 may store electrical energy in a regulated manner because of its high dielectric
qualities. This could be advantageous for materials used in electrical insulation.

Fig 2.6 Chemical structure of TiO2

15
 Chapter-3: Materials and Methods

3.1 Raw material, chemicals & machineries

Table 3.1: Different chemicals, machineries, equipment were used. Only single raw material
was used which is regarded as dyed cotton waste.
Raw material Chemicals Machineries Equipment

Polyurethane Resin Dryer Glass plates

Wetting agent High Voltage Hard poly paper
insulation

16
 tester
Dyed Cotton waste collected Ti02 Pre-heated Tape
from Knit Dyeing-Finishing Oven
section Polyethylene Glycol Dead weight for
pressure application
Hardener Spray machine

Polyvinyl acetate

3.1.1 Raw material

1. Dyed Cotton waste
From: Collected from Knit Dyeing-Finishing section, Stenter machine in GIANT Textile Ltd

3.1.2 Chemicals
a. Resin specification
 Band: ZDS
 Origin: China
 Drying time: 12-48 hours

b. Wetting agent specification

 Collected from GIANT Textile Ltd

c. TiO2 specification

 Titanium Dioxide
 Type: Fine Powder
 Chemical Formula: TiO2
 Pack Size: 1kg Loose Pack  Made in Korea

d. Polyethylene Glycol specification

 Product name: Polyethylene Glycol
 Alias: PEG
 CAS No:25322-68-3
 Type: Nonionic / Anionic Surfactants
 Molecular formula:C18H30O3S

17
  Appearance: waxy solid
 Application: Used as PVC lubricant, color master-batch additive, textile softener,
pigment dispersant, etc.

e. Hardener specification
 Collected from GIANT Textile Ltd

d. Polyvinyl acetate specification

 Cat. No.: 01213
 Polyvinyl acetate (granulars)
 Batch no: 1213290318
 Amount 500g

3.1.3 Machineries
a. Dryer
 We use dryer from GIANT Textile Ltd.
b. HVI tester
 We use HVI tester from EEE lab room in Green University of Bangladesh. c. Pre-
heated Oven
 We use Pre-Heated Oven from textile wet processing lab room in Green University of
Bangladesh.

3.2 Working Procedure

The knit dyeing finishing facility was the source of the colored waste, which was entirely
composed of cotton fiber. In essence, these colored waste fibers were the fabric that was lost
during the dying process and were gathered when the dyed textiles were run through the
Stenter machine's padder. The waste fibers were freed from the cloth when it passed past the
Stenter Padder's nip point. In textile finishing, stabilizer machines are used to enhance the
form and dimension of the cloth. The waste fibers were dried in a dryer after being collected.
After then, the substance was physically cleansed with try-contained holes. Since softeners
could be added to colored cloth while it was being processed in a dyeing machine, fibers had
low absorbency properties in their initial form. The initial effort was boosting the absorbency

18
to facilitate the 7777777777777777777777777777easy penetration of chemicals into the fiber.
First, a wetting agent was added to the fiber.

The sample was then heated to 80 degrees Celsius for ten minutes in order to completely dry it
out. The sample was dried and then allowed to properly condition at room temperature until it
reached the relaxed state. Subsequently, Ti02 was sprayed upon the sample. It was totally
soluble in water and has the ability to cleanse itself of undesired trash. The sample was
conditioned once more at ambient temperature before being immersed in polyethylene glycol.
Polyurethane resin was then applied to the sample at room temperature. The goal was to
improve the insulating quality. The cotton that had been chemically altered was dried in a
dryer using hot air after all the chemicals had been added. Chemicals were absorbed into dyed
waste fibers. It was therefore not qualified to manufacture bar in wet form. Thus, waste fiber
that had been colored chemically was dried in an oven. Bars were made by applying hardener
and Polyvinyl acetate to both treated and untreated fiber waste. In order to prevent the sample
from stumbling at the ideal pressure, it was utilized to harden it just enough. Using tape, a
frame was created to ensure that the bar was properly shaped. Over a glass plate, the frame
was ready. Samples prepared with a hardener mixture were put within the frame. The
processed and dyed garbage was laid by hand into the frame. For covering, a second glass
plate was employed, and the frame was subjected to outside pressure. After a full day of
careful study, each frame was examined.
Samples wt. (5—6) gram each.

19
 Fig. 3.1. Treatment procedure of dyed waste & sample preparation

Untreated sample Treated sample

20
 3.4 Assessment Methods and Procedures
3.4.1 Electrical insulating check
Every sample was examined for electrical resistance. For this, a High Voltage Insulation
(HVI) tester was employed. First, the bar made from colored fiber waste that hadn't been
treated was tested for resistance. The HVI tester electrode was then positioned at the tested
bar sample's other two edges. To assess the resistance of the other bars made from treated
trash, a similar approach was used.

a) Measurement of insulation b) Measurement of insulation

resistance of untreated sample resistance of sample with
cotton

c) Measurement of insulation d) Measurement of insulation

resistance of sample with denim resistance of sample with
polyester

e) Measurement of insulation resistance of raw treated sample

Fig. 3.2. Electrical conductivity checking using HV insulation tester.

21
3.4.2 Physical representation check
We first take a 9-volt battery, and a light. We turn on the light with a 9-volt battery. Then put
our test sample in the middle and try to turn on the light with the help of battery. This way we
can see if our test sample actually works.

Fig. 3.3. Physical representation checking using battery and light.

3.4.3 Thermal stability test

This test evaluates the degree to which our sample retains its insulating qualities at high
temperatures. A basic procedure entails:

1. Heating our sample to a temperature appropriate for our use, such as 100°C or 200°C,
in an oven that has been preheated. Keep an eye out for any indications of bending, melting,
or deterioration in the sample.
2. Take out the sample after a certain amount of time (such as thirty minutes) and note
any alterations to its structure or appearance.

These easy experiments shed light on our insulator's physical properties and possible behavior
in various scenarios. They provide important hints regarding the efficiency of our cotton
colored fiber waste as an insulator, even though they are not as quantitative as evaluating
conductivity or density.

22
 Fig. 3.4. Thermal stability test using preheated oven

3.4.4 Water regain test

This test calculates the water absorption capacity of our sample. Moisture has a big effect on
how well insulation works. Here's a basic technique:
1. Accurately weigh our dry sample.
2. For a predetermined amount of time, fully submerge the sample in water (e.g., 24 hours).
3. Take out the sample, gently dry any moisture on its surface, and weigh it once again.
4. Divide the weight increase by the starting dry weight and multiply the result by 100 to
determine the percentage of water absorbed.
A greater proportion of water absorption suggests that the material may become less efficient
as an insulator when wet.

3.4.5 Water absorption test

Using a dropper, we first applied a few drops of water to the sample in this test. Next, we
watch to see how long it takes for the sample to absorb the water droplets.

23
Chapter-4: Result & Discussion

24
4.1 Stenter Machine Waste: Daily Impact
We research in the Giant Textile Ltd, and we found that, according to our research, the stenter
machine at Giant Textile Ltd. produces 7-8 kg of waste cotton dyed fiber waste each day from
32 tons of cloth.

[References: ETP Section Database, Giant Textile Ltd]

4.2 Electrical insulating assessment

The process of determining the efficacy of electrical insulation is called an electrical
insulating check, often referred to as insulation resistance testing. The substance that envelops
wires and other electrical components to stop current from flowing in the wrong directions is
called insulation.

Resistance MΩ

84.9
90
80 68.3
70
60 51.8

50
35.62
40
30
15.73
20
10
0
Untreated Sample with Sample with Sample with Raw treated
sample cotton denim Polyester sample

Series1

Fig. 4.1. Graphical representation of sample resistance.

Sample Resistance

25
 Treated dyed waste bar with cotton 84.9 MΩ
Treated dyed waste bar with denim 68.3 MΩ
Treated dyed waste bar with polyester 51.3 MΩ
Untreated dyed waste bar 15.73 MΩ
Raw treated sample 35.62 MΩ
Table 4.1 HVI reading of the samples

From the result, it can be seen that electrical resistance of the bar prepared with untreated
dyed fiber waste was 15.73 MΩ. On the other hand, resistance was much higher for other bars
made with treated waste. For instance, the first sample bar with cotton (made with treated
waste), the electrical resistance was increased to 84.9 MΩ, second sample bar with denim
reading was 68.3 MΩ, third sample bar with polyester reading was 51.8 MΩ, and
raw treated sample was 35.62 MΩ.

Resistance range of the bars prepared with treated dyed waste was 50-90 MΩ. This can be
illustrated from the readings of all the samples that electrical resistance was increased for the
bars prepared with treated waste fiber.

4.3 Physical representation assessment

From the result, it can be seen that We first take a 9-volt battery, and a light. We turn on the
light with a 9-volt battery. Then put our test sample in the middle and try to turn on the light
with the help of battery. As there is no resistance, the light burns very easily. But when we put
our sample between the positive and negative ends, we can see that the light doesn't light up
anymore, or sometimes just dims. As the sample has insulating properties, it prevents the flow
of current, and prevents lights from lightning.

26
4.4 Thermal stability test
A test for thermal stability evaluates a material's behavior at high temperatures. In essence, it
gauges a material's ability to withstand heat-induced deterioration. For safe handling and
storage of a material, knowledge of its thermal stability is essential. It aids in preventing
potentially dangerous uncontrollable heat-induced processes including combustion and
breakdown. A lot of materials are heated during production or are subjected to high
temperatures when in use. Tests for thermal stability make that the material can survive these
circumstances without compromising its intended characteristics or functioning.
Temperature Color changes time Degradation or burning time

100°C 12 min 17 min

Table 4.2 Thermal stability test result of samples

From the result, it can be seen that we heat our sample to a temperature such as 100°C, in an
oven that has been preheated. we Keep our eye out for any indications of bending, melting, or
deterioration in the sample. Then we take out the sample after a thirty minutes. We can see
that after 12 min color changes occur of the sample, then after 17 min it was degrade and it
was burn.

4.5 Water regain test

The process of determining how much water a substance can absorb is called a water regain
test. It is utilized for a variety of purposes across sectors, but generally speaking, it is done to
determine whether a material is appropriate for a given application. The rationale behind its
completion: Material performance: A material's performance in usage may be predicted based

27
on how much water it absorbs. For instance, when bricks are exposed to the elements, a
significant water absorption might compromise their strength and longevity.

Dry sample weight Sample weight after water gaining Water regain in %

5.00 gm 4.410 gm 88.2

Table 4.3 water regain test result of samples

1. Our dry sample weight = 5.00 gm

2. Take out the sample, gently dry any moisture on its surface, and then sample weight =
4.410
gm
3. Then we calculate Water regain in % = 4.410 / 5 * 100 = 88.2%

In this test we can see there is less proportion of water absorption occur and we can say that
the material may become more efficient as an insulator when wet.

4.6 Water absorption test

The process of determining how much water a substance can absorb is called a water
absorption test. It is utilized for a variety of purposes across sectors, but generally speaking, it
is done to determine whether a material is appropriate for a given application. The rationale
behind its completion: Material performance: A material's performance in usage may be
predicted based on how much water it absorbs. For instance, when bricks are exposed to the
elements, a significant water absorption might compromise their strength and longevity.

Sample Water absorption time

Untreated sample 30.45 sec

Treated sample 59.52 sec

Table 4.4 water absorption test result of samples

28
In this test we can see when we first applied a few drops of water to the untreated sample then
it absorbs water in 30.45 sec and then when we first applied a few drops of water to the
treated sample then it absorbs water in 59.52 sec. From this result we can say that insulation
properties in the treated sample is more than the untreated sample.

4.7 Acid test

Sulfuric acid test:
The behavior of dyed cotton fiber waste in a sulfuric acid solution which is even dilute
sulfuric acid will start to decompose the cotton fibers through dehydration. Higher
concentrations will do so much faster and more aggressively. Sulfuric acid will begin to break
down the cellulose structure of the cotton fibers, regardless of the dye. This weakens the fibers
and eventually leads to their disintegration. Sulfuric acid works by dehydrating the cotton
fibers. This dehydration process weakens the structure of the cotton and breaks down the
cellulose molecules that make it up.

Hydrochloric acid test:

Since cotton is mostly made of cellulose, it will decompose when exposed to hydrochloric
acid (HCl). In general, breakdown will proceed more quickly and thoroughly at higher HCl
concentrations. Studies have employed 2.5% to 15% hydrochloric acid solutions to hydrolyze
cellulose. The warmth also accelerates the pace of breakdown.

Acetic acid Test:

The behavior of dyed cotton fiber waste in an acetic acid solution depends on several factors,
including: Low Concentration (Weak Solution) there are Minimal impact on the cotton fibers
themselves. Secondly High Concentration (Strong Solution) there are Might cause slight
swelling of the cotton fibers due to their cellulosic nature (acetic acid is a weak acid that can
cause some swelling in cellulose) and Potentially lead to some dye bleeding or leaching,
especially for dyes with poor acid resistance.

29
 Acid Name Concentration of Sulfuric acid Cotton dyed fiber waste
behavior
Sulfuric acid 5 % dilute solution The decomposition process is
very slow. It takes 1 hour 53
minutes to see cotton fiber
decomposition.

The decomposition rate

Sulfuric acid 10% medium concentration
becomes faster. It takes 42
minutes to see cotton fibers
decomposition.

Hydrochloric acid 10% concentration It takes 2 hours to see cotton

fiber decomposition.

Acetic acid 30% concentration It cause slight swelling of the

cotton fibers after 30 min
Table 4.5 Acid test result of samples

4.8 Alkali test

Due to its strong alkali properties, caustic soda (sodium hydroxide) solution will react with
cotton colored fiber waste. At high concentrations and over extended periods of contact,
caustic soda can break down the cellulose fibers themselves. This weakens the cotton and may
cause breaking of the fibers. Significant fiber destruction is thought to be quite likely at
concentrations exceeding 20% NaOH, especially during prolonged exposure periods.

Concentration of Sodium Hydroxide Cotton dyed fiber waste behavior

15% Sodium Hydroxide There is no degradation in cotton fiber

20% Sodium Hydroxide It takes 3 hours 15 min to see cotton fiber

degradation.

Table 4.6 Alkali test result of samples

30
Chapter-5: Conclusion

31
 5.1 Concluding Remarks
Although the waste from colored fibers, a byproduct of dying knitted fabric, is not useful for
commercial purposes, studies have demonstrated that it may be altered to produce valuable
insulating bars. In order to produce insulating bars, waste can be chemically altered to
enhance its insulating qualities. A research using an experimental setup revealed that the
treated dyed waste bars' conductivity rating ranged from 50 to 90 MΩ. On the other hand, the
resistance measurement of the untreated sample was modest, at 10-17 MΩ.

By varying the volume and amount of chemicals employed, attempts may be made to enhance
the insulating property even higher, even if the treated bar's quality is not particularly good. It
will be important for them to accept the lessons learnt from this study and establish a
specialized division for the manufacturing of insulating bars using this approach, should the
textile industry be considered in the improbable case that it is ten or fifteen years from now. It
will reduce waste load and increase profit margin.

5.2 Limitations
Although it has certain drawbacks, recycling discarded colored fiber into electrical insulating
materials is a viable sustainable strategy:

1. Chemicals that are used for this research or thesis work are less available in
Bangladesh market.
2. The introduction of conductive routes by dyes may increase leakage current and
decrease the material's overall insulating performance.
3. Uneven coloration can be produced by combining colored waste from various sources,
which could have an effect on the material's qualities and attractiveness.
4. Recycled fiber-based insulation may not have the same electrical qualities as
traditional materials, which would limit its usage in high-voltage or crucial applications.

32
 5.3 Scope of future study
Here are a few particular topics for further research:
Overcoming the issues of dyeing: The insulating qualities of the recycled fibers may be
impacted by the presence of colors. It will take research to determine how various colors
affect the insulating process and to provide countermeasures for any unfavorable impacts.
Investigating ways to alter recycled fibers (via treatments or mixing) in order to get the
required electrical insulating qualities, such as breakdown strength and dielectric constant, is
known as tailoring characteristics.
Economy of scale: To make this strategy economically feasible, cost-competitive recycling
and manufacturing techniques must be developed.
Safety aspects to consider: guaranteeing the recycled materials' safety for use in electrical
applications, taking into account any problems with electrical conductivity and fire safety.

Research in this area may result in the creation of novel, affordable, and environmentally
friendly insulating materials for the electrical industry.

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