Description:The R.E.G.A.L technology, is an abbreviation for ‘Free Radical Enhancement using Gas Assisted Liquid Dispersion’. There are essentially 3 component or facets to the R.E.G.A.L. technology.
The first process, is the Generation of a mixture of Micro-Nano Bubbles using, but not limited to, shear/hydrodynamic cavitation/solvent mixing methods, with higher weightage on Nanobubbles of various gases (air, oxygen, ozone, nitrogen, etc). Micro-bubbles vary from macro bubbles based on their diameter, which ranges in micron scale, as opposed to macro-bubbles, the diameter for which ranges in the milli-meter range. Nanobubbles are defined as gas bubbles having a diameter of less than 1 micron, in the Nano-meter range. Nanobubbles have various characteristics that cause them to behave very differently from macro-bubbles. Some of these properties include, they are stable in water for months. This is because they are homogenously negatively charged, meaning they will repel each other and remain equally distributed in the liquid media (A), they follow Brownian motion meaning they cannot float the surface of the liquid and escape the water column (B), their concentration per ml of water is dynamic and can be customized from 50 Million to 1 Billion bubbles/ml (C). Micro-nanobubble generation already exists and is being applied in various applications across the world, however, not in textiles or laundry washing.
The second process, is the generation of high frequency ultrasound in the R.E.G.A.L system. The internal pressure of a nanobubble and even microbubbles is extremely high as estimated by scientists using the Young-Laplace equation. Ultrasound waves, induce systemic disturbance/entropy by creating these waves to (A) collapse nanobubbles, (b) to break down hydrogen bonds and reduce the surface tension of water. When a nanobubble collapses, an extremely high number of free radicals^ (4) are generated, which significantly increase the cleaning capacity of water. Free Radicals are unstable molecules with Unpaired electrons, which make them unstable and highly reactive due to their high REDOX potential.” The R.E.G.A.L. process is combination of generation of micro-nanobubbles and systematically imploding them using Ultra sound, under a controlled environment to generate processed liquids/water having a combination of micro-nano bubbles and free radicals of different compositions, which enhance the process efficiency and yields of industrial and other processes at optimum level.
This is why Free Radicals are the cornerstone of R.E.G.A.L. technology, as they significantly enhance the Oxidation and cleaning of water, which ultimately serves various textile applications such as cleaning of the cloth, penetration of chemicals into fibers and the ones enlisted in the patent.

LYE FOR MERCERIZER MAKING PROCESS
Two tanks are available at our facility. T1 (Caustic Lye tank), T2 (spent liquor tank). The goal is to have a Twaddell of about 50 in our mercerizers’ impregnator tank. However, pure caustic lye (48%) has a higher Twaddell of about 80-90. Therefore, it is diluted. The spent liquor from STEP 2 and 3 above is introduced from T2, into T1, where a pump brings in fresh caustic lye. Therefore, about 1100 Kilos of Caustic is diluted using 700-800 liters of Spent Liquor to prepare about 1800-1900 liters of Caustic for our Mercerize, which helps us mercerize on average about 25-30000 Meters of cotton.
THE REGAL Addition: Here, by Gas Enhancing the water using the REGAL technology in the fresh water of STEP 2/3, which is then pumped up to the Spent Liquor tank, we have noted that we can achieve the 50 Twaddell Concentration using Lesser Caustic (15% less, 900-950 Liters of Caustic Lye needed now, resulting in significant cost and environmental savings).

Using R.E.G.A.L. in Viscose Pre-Processing:

Using R.E.G.A.L activated water instead of conventional ground/surface/RO water, there are various advantages. The bleaching (RFP) part of Rayon (A viscose variant) is done in U-Jet machines at ~90 Degrees Celsius, starting with desizing under acid conditions, followed by h202 assisted bleaching. Using the R.E.G.A.L technology, the process remains the same, however, there is a flat reduction of 12-15% in the chemicals used:
• Amylase enzyme using REGAL: 0.6% Weight of fabric (W.o.f) vs 0.7% (W.o.f) under conventional water
• Wetting agent: 0.25% W.o.F (REGAL) vs 0.3 % W.o.F, using conventional water
• The same methodology applies to all the remaining chemicals detailed in the following flow chart.

Examples

During experimental studies following applications for nanobubble technologies were identified:
15% reduction in caustic lye/flakes, in Rotary Drum washing/U-jet Applications, and up-to 20% reduction in speciality chemicals used for dyeing processes like, Weight Reduction, Desizing, Scouring, Bleaching and Optical Brightening.

1. Superior Wetting Ability: Nanobubbles plus Ultrasonic activation significantly improve the wetting properties of water, creating gas clusters on the inside due to extreme pressure dynamics. A better wetting capacity enhances the efficiency of both caustic and specialty chemicals, meaning less is required to achieve the same effects in processes like scouring, desizing, and bleaching.
2. Enhanced Penetration: The small size of nanobubbles enables them to infiltrate the fiber matrix more deeply. This allows for improved removal of impurities and better adhesion of dyes and other treatments, reducing the need for excessive amounts of chemicals.
3. Sonochemical Effects: The implosion of nanobubbles under ultrasonic influence generates localized high temperatures and pressures. This phenomenon, known as cavitation, boosts the rate of chemical reactions, allowing for lesser quantities of caustic and specialty chemicals to achieve the same level of processing.
4. High Surface Area-to-Volume Ratio: The increased surface area enables higher solute (chemical) loading capacity, optimizing the dispersion of caustic lye and specialty chemicals, thereby reducing the actual quantity needed for similar or better efficacy.
5. Electrostatic Repulsion: The zeta potential of nanobubbles facilitates better electrostatic dispersion of chemicals across the fabric surface and within the drum, leading to more uniform treatment and less waste of chemicals.
6. Localized Alkalinity: Nanobubbles can be engineered to create localized high-pH microenvironments, thereby maximizing the effectiveness of the caustic lye and reducing the quantity needed for processes like desizing and scouring.
7. Chemical Synergy: By reducing the amount of one chemical, there’s often a knock-on effect of reducing others. For instance, a lesser amount of caustic may lead to lower neutralizing agent requirements.
8. Environmental Conditions: Nanobubbles can be stabilized to withstand different temperature and pressure conditions in rotary drums and U-jets, making them more compatible and effective with existing chemical treatments, thereby reducing overall chemical needs.
9. Free Radical Production: Nanobubbles produce hydroxyl radicals upon collapse, aiding in the breakdown of unwanted residues and impurities. This can reduce the need for specialized chemicals in the processes of weight reduction, desizing, and bleaching.
Upto 25 % reduction in Discharging Agent used, such as zinc sulphox-ylate formaldehyde, in discharge printing applications of Polyester and Cotton fabrics.

1. Accelerated Redox Reactions: Nanobubbles can enhance mass transfer and reaction kinetics. In the case of discharge printing, the redox reactions involving zinc sulfoxylate formaldehyde become more efficient, thus reducing the amount required to bleach or discharge the dye. Nanobubbles also increase the ORP of water as measured in mV, meaning they are better oxidizing agents than normal water.
2. Localized Thermal Gradients: The collapse of nanobubbles and the addition of Ultrasound activation, can create localized thermal gradients that can accelerate the kinetics of the discharging reaction, allowing for less agent to be used.
3. Dynamic Surface Tension Reduction: Nanobubbles significantly reduce the dynamic surface tension of water, which can influence the mobility and spread ability of the discharging agent across the fabric. Improved spread ability can lead to less agent being needed for uniform discharging.
4. Mechanochemical Effects: The combination of ultrasound with nanobubbles can amplify mechanochemical effects, such as cavitation and sonochemistry. This will accelerate the bleaching and discharging reactions, making zinc sulfoxylate formaldehyde more efficient, thus requiring less quantity.
5. Electrostatic Repulsion: The negative zeta potential of nanobubbles helps in better dispersion of negatively charged discharging agents, increasing their surface interaction with the fabric. This reduces agglomeration and wastage, thereby reducing the amount required. Coupled with Free Radical production, this increases the discharging capacity of print paste due to great Oxidation Potential.

Upto 30% reduction in chemicals used in Washing of the Polyester and Cotton based fabrics.
1. Amplified Detergent Efficiency: The Ultrasound-Nanobubble combination can cause a micro-turbulence that enhances the distribution and penetration of detergents into the fabric, making them more effective at breaking down dirt and oils, thus reducing the amount required.
2. Enhanced Surfactant Activity: Nanobubbles can reduce surface tension of water and encapsulate surfactant molecules, while ultrasound ensures their better dispersion. This maximizes surface area contact due to massive nanobubble surface area, thereby reducing the surfactant amount needed.
3. High-Efficiency Micro-Emulsification: Both ultrasound and nanobubbles facilitate the formation of micro-emulsions, which can lift off and encapsulate soil particles more efficiently, thus reducing the amount of emulsifying agents required.
4. Catalytic Hydrolysis: Ultrasound-induced cavitation generates localized hot spots with high pressure. When these collide with nanobubbles, it can catalyze the hydrolysis of organic compounds and dyes, thus reducing the amount of chemical catalysts needed in washing.

20% increase in the Colour Yield of disperse ink based digital printing of Polyester based and cotton fabrics, when NB+ Ultrasound activated water is used in the coating paste before digital printing.
1. Enhanced Ink Penetration: The nanobubble and ultrasound combination creates micro-cavities and turbulence that can facilitate deeper penetration of the ink into the fabric fibers. This would make the color appear more vivid and result in a higher color yield.
2. Ink Particle Dispersion: Ultrasonic agitation can lead to better dispersion of ink particles. This, coupled with the stabilizing effect of nanobubbles, ensures that the ink spreads more uniformly, thereby increasing color yield.
3. Optimized Coating Viscosity: The combined technology can modulate the rheological properties of the coating paste, aiding in more uniform and thinner layers, which enhances the effectiveness of the ink and results in a higher color yield.
4. Improved Wettability: The presence of nanobubbles can reduce the surface tension of the coating paste, and ultrasound ensures that this low-tension layer spreads uniformly. Improved wettability allows for more effective color uptake.
5. Enhanced Capillarity: The Nanobubble+Ultrasound activated water can modify the wettability of polyester and Cellulosic fibers, thereby improving the capillary action of the fabric. This allows for more even distribution of ink, contributing to an increase in color yield.

Reduction of Urea in Printing Paste by up to 35%.
1. Enhanced Mass Transfer: Nanobubbles, given their size (50-200 nm), exhibit an extremely high surface-to-volume ratio, thereby accelerating mass transfer rates. In textile processing, the mass transfer of solutes (like urea) from the paste to the fabric can be a rate-limiting step. Faster mass transfer implies that lesser urea would be required to achieve the same rate of solute uptake.
2. Zeta Potential: Nanobubbles exhibit a negative zeta potential, leading to electrostatic repulsion between the bubbles and the negatively charged fabric surface. This repulsion facilitates the dispersion of urea, enhancing its effectiveness and thereby requiring less quantity for similar performance.
3. Increased Penetration: The small size of nanobubbles enables deeper penetration into the fabric matrix. This, in combination with ultrasonic waves, can disaggregate clusters of urea, spreading it more uniformly on a micro-level. Therefore, a lower concentration can achieve the same dyeing or printing effect.
4. Oxidative Degradation of Excess Urea: The collapse of nanobubbles generates localized hotspots and produces hydroxyl radicals. These radicals can degrade excess urea, reducing the amount required for the process.
Reduction of Caustic Lye in Mercerizing Process by 20-25%
1. Increased Homogeneity: The nanobubbles and ultrasound together ensure a more homogeneous caustic lye solution due to better dispersion. This uniformity facilitates even mercerization across the fabric, allowing for less alkali consumption.
2. Optimized Alkali Penetration: The introduction of nanobubbles into the caustic lye solution, augmented by ultrasound, can enhance the penetration of alkali into the fabric. This higher efficiency could reduce the overall requirement for caustic lye.
3. Enhanced Swelling Effect: Ultrasound waves can temporarily alter the fabric's structure, aiding the swelling action of caustic lye in the mercerizing process. This leads to quicker and more effective mercerization, thereby requiring less alkali.
4. High-Frequency Impulse Waves: Ultrasound can generate impulse waves that disrupt the fabric structure at a microscopic level, making it more receptive to the mercerizing agent and hence requiring less caustic lye.

Much Better Textile Processing Effluent, improving treatability for ETPs and saving significant Carbon/GHG in the Textile Value Chain.

1. Reduced Chemical Manufacturing: Lesser chemical usage in textile processing would mean that fewer chemicals need to be produced, reducing carbon emissions at the manufacturing level.
2. Transportation Savings: Fewer chemicals to transport would reduce the carbon emissions associated with moving these substances from manufacturing to usage points.
3. Energy Savings in Operations: The usage, handling, and processing of chemicals in textile operations often require energy. Fewer chemicals would mean lesser energy and, consequently, fewer carbon emissions.
4. Reduced Load on Wastewater Treatment: Fewer chemicals in the effluent imply less energy-intensive treatment processes, reducing the carbon footprint of the wastewater treatment stage.
5. Increased Efficiency of CETPs: Multi-level adoption of this technology would mean both cost savings and augmented performance of Industrial CETPs
6. Reduced Sludge Formation: The combination of nanobubbles and ultrasound can break down complex organic matter into simpler forms, reducing the volume of sludge produced during wastewater treatment.
Potential Environmental Value Chain Impact:
1. Raw Material Savings: A 20% reduction in chemical usage can lead to significant cost savings and a reduced need for chemical production.
2. Energy Efficiency: Lesser chemical usage also means less energy consumed in manufacturing, mixing, and application of these chemicals.
3. Waste Minimization: Reduced chemical usage would directly lead to less waste generated and, subsequently, less energy-intensive waste treatment processes.
4. Reduced Emissions: Every stage—from chemical production to disposal—that sees reduced chemical usage will also see a proportionate decrease in carbon emissions.

Reduction of Pre-Treatment Dyeing chemicals by up to 20% in Pre-Treatment of Cellulosic Fabrics.

Enhanced Wetting and Penetration: Nanobubbles have a high specific surface area, which can significantly improve the wettability and penetration of chemical solutions into cellulosic fabrics. Ultrasound cavitation further improves this by breaking up clusters of fibers, allowing chemicals to penetrate more efficiently. As a result, fewer chemicals are required for pre-treatment processes like desizing, scouring, and bleaching.
1. Synergistic Cleaning Action: Ultrasound generates micro-jets and shock waves during the cavitation collapse. These micro-jets can physically remove impurities from the fiber surface. Nanobubbles, due to their high internal pressure and surface energy, can also break down impurities. The combined cleaning action of NB+US technology can dislodge and remove natural waxes, pectin, and other non-cellulosic materials more efficiently, thus reducing the need for harsh chemicals.
Reduction of 8-10% in Steam Boiler fuel consumption due using Nanobubble+US technology

1. Improved Heat Transfer Efficiency: Nanobubbles increase the thermal conductivity of water, enhancing the boiler's heat transfer efficiency. Ultrasound cavitation also disrupts boundary layers, facilitating better heat exchange.
2. Reduced Scaling: NB+US technology helps in the dispersion of mineral ions, reducing scale formation on heat exchange surfaces. Reduced scaling improves heat transfer and, consequently, fuel efficiency.
3. Optimized Combustion: The high surface area of nanobubbles can facilitate more efficient oxygen transfer for boiler combustion processes, resulting in more complete combustion and reduced fuel needs.
4. Cold Gum Preferences: Respecting the nanobubble thermodynamic stability range between, 5-85 Degrees Celsius, the thickener used, in Polyester printing, is Cold Temperature Gum. Conventional gums like Tamarind/Guar Gum have to be heated using steam, whilst cold gum does not have to be. Therefore, this saves energy in color kitchen operations.
5. Optimized Process Efficiency: Given the catalytic application of free radicals in the Nanobubble life cycle, processes are catalyzed, reducing processing and cycle time, improving productivity, thereby reducing steam consumption during hot cycles, especially in dyeing applications.
Reduction of 20% use of dyes and chemicals in Printing Paste of Polyester and Cotton fabric:
1. Enhanced Penetration: The high surface area and charge stability of nanobubbles facilitate deeper and more uniform penetration of dyes into fabric fibers. Ultrasound further accelerates this by agitating the fiber surface, making it more permeable to dyes.
2. Improved Dispersion: Ultrasound technology aids in the fine dispersion of dye particles in the printing paste, thereby improving color strength and uniformity. Well-dispersed dye particles also bind more effectively, reducing the amount of dye needed for desired color depth.
3. Accelerated Dye-Fiber Affinity: The nanobubbles' high internal pressure and surface energy can increase the chemical affinity between dyes and fabric fibers. This enables a higher percentage of dye uptake, which in turn reduces the amount of dye needed for a given level of coloration.
4. Viscosity Play: High viscosity paste can easily print with no leveling issues using Nanobubble+US technology, as it can penetrate deep in higher mesh construction-based screen-printing bolting cloth, this causes lower consumption of printing paste.

Reduction of 5-6% in Electricity Consumption.

• Viscosity Impacts: High viscosity paste application of fabric shall decrease moisture removal load on Printing dryers due to less amount of penetration.
• Cycle time: Reduced cycle time in dyeing can improve units consumed in kWh, reducing units, and the amount of water consumed.

50% reduction in Detergent in Laundry Garment Washing applications and reduced bacterial load in Commercial Laundries of different applications

• Improved Dispersion: Ultrasound technology plus Nanobubbles aid in the fine dispersion of chemicals particles in the laundry bath, thereby improving cleaning efficiency.
• ORP Increase: R.E.G.A.L processed water is consistently able to achieve higher ORP due to the presence of free radicals, meaning that it is superior at oxidizing bacteria/stains when compared to normal water.
• Surface Tension: R.E.G.A.L processed water, specifically ultra-sound shock waves, collapse hydrogen bonds in water, meaning this would significantly reduce the surface tension, which is the primary role of detergents. By mechanically modifying surface chemistry, 50% less detergents and soaps are required to achieve comparable results.
, C , Claims:1. A Method and process for forming Nano bubbles and ultra sound for
application in textile processes space including dyeing, printing, washing, finishing of textile fabrics and yarns, also, industrial boiler applications in
Textile Processing and a mechanism for free radical enhancement using
gas assisted liquid dispersion.
2. As claimed in claim 1 above, a process for free radical enhancement using gas assisted liquid dispersion wherein micro nano bubbles with a diameter of 1 micron and in combination of ultra sound which creates high
frequency enabling the cleaning capacity of water
3. As claimed in claim 1 and 2 above, a process for free radical enhancement using gas assisted liquid dispersion wherein the combination of micro nano bubbles enables systematically imploding them using ultra sound under a controlled environment.
4. As claimed in claim 1 to 3 above, and a process whereby there is 15% reduction in caustic lye/flakes, in Rotary Drum washing/U-jet Applications, and up-to 20% reduction in specialty chemicals used for
dyeing processes like, Weight Reduction, Desizing, Scouring, Bleaching
and Optical Brightening.
As claimed in claim 1 to 4 above, and a process whereby there is Up to 25% reduction in Discharging Agent used, such as zinc sulphox-ylate
formaldehyde, in discharge printing applications of Polyester and Cotton
fabrics.
As claimed in claim 1 to 5 above, and a process whereby there is Up to
30% reduction in chemicals used in Washing of the Polyester and Cotton based fabrics.
As claimed in claim 1 to 6 above, and a process whereby there is Reduction of Urea in Printing Paste by up to 35%.
As claimed in claim 1 to 7 above, and a process whereby there is Reduction
of Caustic Lye in Mercerizing Process by 20-25%
As claimed in claim 1 to 8 above, and a process whereby there is Much
Better Textile Processing Effluent, improving treatability for ETPs and
saving significant Carbon/GHG in the Textile Value Chain.
10. As claimed in claim 1 to 9 above, and a process whereby there is Reduction
of Pre-Treatment Dyeing chemicals by up to 20% in Pretreatment of
Cellulosic Fabrics
11. As claimed in claim 1 to 10 above, and a process whereby there is
Reduction of 20% use of dyes and chemicals in Printing Paste of Polyester and Cotton fabric.
12. As claimed in claim 1 to 11 above, and a process whereby there is
Reduction of 5-6% in Electricity Consumption.
13. As claimed in claim 1 to 12 above, 20% increase in the Color Yield of
disperse ink based digital printing of Polyester based and cotton fabrics,
when NB+ Ultrasound activated water is used in the coating paste before digital printing.