Experimental studies on energy recovery from plasma-treated textile sludge

Textile sludge is the solid residue remaining after the effluent treatment process. The treatment and disposal of textile sludge is a major challenge. In this research, an attempt has been made to study the characteristics of plasma-treated textile sludge. A plasma-firing gun is operated inside a closed chamber for plasma treatment. Vitrified slag is obtained as a result of this plasma treatment and the gaseous output is studied under the influence of various established thermal process concepts. Since plasma treatment is a thermal transfer process, the energy consumption and its recovery are studied. Thermodynamic efficiency as per calculations is 49%. The exhaust gas contains CO, CO₂, and hydrogen at high temperatures (above 100 °C) and can be utilized for thermal energy recovery. The exhaust gas can be further reformed to improve its calorific value by adding steam, CO₂ and oxygen. Efficiency reaches 73% in CO₂ reformation, and it is 59% and 58% for oxygen and steam reformation, respectively, based on experimental observations. A weight reduction of 55–62% and a volume reduction of 42% are observed. The quality of syngas evaluation through equivalence ratio evaluation proves that higher efficiencies are achievable through steam reformation. Textile sludge generation of Tamilnadu state of India data is considered and cost and payback period are estimated around 8 years. Cost reducing suggestions in Indian context is explained.