Baolan wool top treatment process

Abstract

The invention discloses a basolan wool top treatment process, and relates to the technical field of wool shrink-proof treatment processes, and the basolan wool top treatment process comprises the following steps: pretreatment: immersing wool tops in a warm water solution containing a penetrating agent, and adjusting the liquid carrying rate of the wool tops to a uniform wetting state; oxidation treatment: putting the pretreated wet wool tops into an environment-friendly oxidant system, and carrying out scale denudation reaction under an acidic condition to generate part of residual oxides; reduction treatment: removing residual oxides from the oxidized wool tops by using a reducing agent solution to obtain dechlorinated wool tops; rinsing and softening: carrying out multi-stage countercurrent rinsing on the dechlorinated wool tops to remove impurities, and then treating the dechlorinated wool tops with a softening solution to improve the fiber softness; the softened wool tops are dried at the low temperature to reach the target water content, and the shrink-proof wool top finished product is prepared, chlorine-free environment-friendly production can be achieved, water resource consumption is remarkably reduced, and the high-quality performance of the wool tops is maintained.

Description

Technical Field

[0001] This invention relates to the field of wool shrinkage prevention treatment technology, specifically a Basolan wool top treatment process. Background Technology

[0002] The Basolan wool top treatment process is one of the core technologies in the wool processing industry. It uses chemical methods to directionally etch the scale layer on the surface of high-count wool fibers, giving the wool top permanent shrinkage resistance, improved bulk, and enhanced dyeing performance. Traditional processes use chlorine-containing oxidants (such as organochlorine compounds DCCA or Basolan 88) as the reaction medium, continuously processing the wool top under acidic conditions. The core process includes five steps: pretreatment wetting, chlorination to remove scales, reduction cleaning of chlorine residues, multi-stage washing and softening, and drying and setting. This technology relies on the strong oxidizing properties of chlorine to achieve controlled degradation of the scale layer and is widely used in processing high-count Australian wool tops with a fineness ≤21.5μm, forming two main process branches: the new Basolan treatment (emphasizing bulk and dyeing brightness) and the Basolan super treatment (emphasizing fiber smoothness and whiteness). Both require scale modification using chlorine-containing reagents to meet the production requirements of high-end wool fabrics.

[0003] While traditional processes can meet basic shrinkage requirements, their technical systems suffer from inherent and irreconcilable flaws: chlorine-containing oxidation reactions inevitably lead to the formation of adsorbable organic halides (AOX), resulting in ecotoxicous wastewater and high end-of-pipe treatment costs; the non-selective damage from chlorination etching easily destroys the wool keratin structure, causing decreased fiber strength, hardened hand feel, and loss of whiteness, hindering the development of high-value-added products; the process is also lengthy, requiring strict monitoring of chlorine residue removal during the reduction stage, and the washing process is water-intensive and inefficient, while the softening process has limited ability to repair fiber damage, making it difficult to fully restore the natural properties of wool. Furthermore, the inherent defects of chlorine-containing processes limit the application of wool tops in the field of eco-textiles, forcing downstream products to adopt conservative care methods such as dry cleaning or careful hand washing, weakening market competitiveness. Therefore, we propose a Basolan wool top treatment process. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the existing defects and provide a Basolan wool top processing process that can achieve chlorine-free and environmentally friendly production, significantly reduce water consumption and maintain the high-quality performance of wool tops, and can effectively solve the problems in the background technology.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a process for processing Basullan wool strips, comprising the following steps: Pretreatment: Immerse the wool top in a warm aqueous solution containing a penetrant, and adjust the liquid content of the wool top to a uniformly wetted state; Oxidation treatment: The pretreated wetted hair strips are placed in an environmentally friendly oxidant system and subjected to a scale-peeling reaction under acidic conditions to generate some residual oxides; Reduction treatment: The oxidized wool tops are treated with a reducing agent solution to remove residual oxides, resulting in dechlorinated wool tops; Rinsing and softening: After the dechlorinated wool tops are rinsed in multiple countercurrent stages to remove impurities, they are then treated with a softening solution to improve the softness of the fibers. Drying into strips: The softened wool strips are dried at low temperature to the target moisture content to produce shrink-resistant wool strip finished products; This process framework achieves efficient erosion of wool scales through a chlorine-free oxidation system, providing a basic process for continuous production of environmentally friendly shrink-resistant wool tops.

[0006] Furthermore, the penetrant used in the pretreatment is sodium alkyl sulfonate or fatty alcohol polyoxyethylene ether, with an amount of 0.5-0.8% of the weight of the sliver, a water temperature of 30-35℃, and a sliver liquid retention rate of 120-130%. This optimizes the wettability and penetration of the sliver, ensuring that the subsequent oxidant acts uniformly on the fiber surface and avoiding localized damage.

[0007] Furthermore, the oxidation treatment uses an environmentally friendly oxidant made of persulfate and sodium percarbonate in a mass ratio of 1:2.5, with an amount of 4-7% of the weight of the hair top, pH 2.0-3.5, temperature 40-45℃, and reaction time of 8-12 minutes. The compound oxidant synergistically improves the scale erosion efficiency, and the acidic low temperature conditions reduce damage to fiber keratin, ensuring the retention rate of hair top strength.

[0008] Furthermore, the reduction treatment uses sodium metabisulfite solution, with an amount of 3-5% of the weight of the wool top, pH 4.5-5.0, and temperature of 45°C. The reduction endpoint is monitored to -200 mV to -250 mV using an oxidation-reduction potential meter to accurately remove oxidation residues and prevent byproducts from causing yellowing of the wool top or failure of subsequent softening agent adsorption.

[0009] Furthermore, the multi-stage countercurrent rinsing consists of four series water tanks with the water flow direction opposite to the direction of the wool strip's movement. Each stage of rinsing takes 3-5 minutes, and the total water consumption is ≤15 tons / ton of wool strip. The countercurrent structure maximizes water utilization efficiency, and the four-stage rinsing ensures that impurities are thoroughly removed, meeting the requirements for water-saving production.

[0010] Furthermore, the softening liquid contains 1.0-1.5% amino-modified polysiloxane softener and 0.2-0.3% wool oil, with a pH of 5.5-6.0 and a treatment temperature of 35-40℃, which repairs fiber surface damage, improves the smoothness of the sliver and the smoothness of spinning, and reduces the breakage rate in subsequent processing.

[0011] Furthermore, the drying process is carried out in two stages. In the first stage, the temperature is maintained at 60°C for 10 minutes. In the second stage, the temperature is increased to 70°C until the moisture content of the wool sliver is ≤15%, and the wind speed is 2-3 m / s. The segmented temperature control avoids fiber embrittlement caused by high-temperature rapid drying, and the wind speed setting prevents the wool sliver from tangling and ensures the fluffiness of the finished product.

[0012] Furthermore, the wool tops are Australian wool tops with a fineness of ≤21.5μm, and the felting shrinkage rate after treatment is ≤3% (ISO6330), with a whiteness value of ≥85 (ISO 105-B02), which is suitable for the characteristics of high-count wool and ensures that the finished product meets the machine wash shrinkage prevention standards and whiteness requirements of high-end knitwear.

[0013] Furthermore, the AOX value of the process wastewater is 0, so it can directly enter the biochemical treatment system, eliminating organic halide pollution at the source, simplifying the wastewater treatment process, and meeting the requirements for eco-textile certification.

[0014] Furthermore, the persulfate is potassium persulfate, and the active oxygen content of sodium percarbonate is ≥13.5%. The high active oxygen content ensures the thoroughness of the oxidation reaction, and the dissolution stability of potassium persulfate supports continuous production control.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: The Benbasulan wool top processing technology has the following advantages: 1. By adopting a chlorine-free oxidation system combining persulfate and sodium percarbonate, traditional chlorine-containing oxidants (such as DCCA) are completely eliminated, avoiding the generation of adsorbable organic halides (AOX) from the source of the chemical reaction. The oxidation reaction process only produces inorganic salt byproducts, and the wastewater has been tested and found to have zero AOX content, allowing it to directly enter a conventional biological treatment system. This not only eliminates the long-term toxic risks of organic halogen pollutants to the aquatic environment but also significantly simplifies the wastewater treatment process, making the finished wool tops naturally compliant with international eco-textile certification standards (such as OEKO-TEX®), meeting the rigid demand of the high-end market for sustainable textiles. 2. An innovative synergistic protection mechanism of "low-temperature acidic oxidation + potential-controlled reduction + siloxane repair" is designed. First, the compound oxidant is used to directionally etch the scale layer under acidic low-temperature (40-45℃) conditions, which greatly reduces the non-selective damage to the wool keratin backbone and preserves the fiber breaking strength from the source. Second, the reduction stage is precisely controlled at the endpoint (-200mV to -250mV) by an oxidation-reduction potential meter to eliminate the potential yellowing damage of residual oxides to the fiber. Finally, amino-modified polysiloxane softening liquid repairs the micro-damage on the fiber surface in a near-neutral environment and rebuilds a smooth interface. The three factors work together to enable the wool top to achieve a felting shrinkage rate of ≤3% while maintaining natural elasticity and spinning processing adaptability, overcoming the stubborn problems of fiber embrittlement and hardening of hand feel caused by traditional processes. 3. Through the integrated innovation of a four-stage countercurrent rinsing system and segmented drying process, efficient utilization of water and soil resources and optimization of energy consumption are achieved. The countercurrent rinsing tank utilizes the principle of reverse flow of water and wool slivers, so that the clean water flow first contacts the wool slivers with the highest cleanliness, and the wastewater with the highest pollutant concentration is discharged in the first tank, reducing the total water consumption to less than 50% of that of traditional single-stage rinsing. The drying stage adopts a gradient temperature control strategy of "low temperature pre-drying (60℃) + medium temperature setting (70℃)", combined with a wind speed of 2-3m / s to prevent fiber entanglement. While avoiding fiber embrittlement caused by high-temperature rapid drying, it significantly shortens the drying time and reduces heat energy consumption. This design enables the entire production line to have a high-speed continuous operation capability of 25m / min, breaking through the efficiency bottleneck of traditional processes. Detailed Implementation

[0016] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] This invention provides a process for processing Basuran wool tops, comprising the following steps: Pretreatment: Immerse the wool top in a warm aqueous solution containing a penetrant, and adjust the liquid content of the wool top to a uniform wetting state. The penetrant in the pretreatment is sodium alkyl sulfonate or fatty alcohol polyoxyethylene ether, with an amount of 0.5-0.8% of the wool top weight. The water temperature is 30-35℃, and the liquid content of the wool top is 120-130%. This optimizes the wetting and penetration of the wool top, ensuring that the subsequent oxidant acts evenly on the fiber surface and avoids local damage. Oxidation treatment: The pretreated wetted wool tops are placed in an environmentally friendly oxidant system and subjected to a scale-removal reaction under acidic conditions to generate some residual oxides. The oxidation treatment uses an environmentally friendly oxidant compounded with persulfate and sodium percarbonate at a mass ratio of 1:2.5, with a dosage of 4-7% of the wool top weight, pH 2.0-3.5, temperature 40-45℃, and reaction time of 8-12 minutes. The compounded oxidant synergistically improves the scale-removal efficiency, and the acidic low-temperature conditions reduce damage to fiber keratin, ensuring the wool top strength retention rate. The persulfate is potassium persulfate, and the active oxygen content of sodium percarbonate is ≥13.5%. The high active oxygen content ensures the thoroughness of the oxidation reaction, and the solubility stability of potassium persulfate supports continuous production control. Reduction treatment: The oxidized tops are treated with a reducing agent solution to remove residual oxides and obtain dechlorinated tops. The reduction treatment uses sodium metabisulfite solution, with an amount of 3-5% of the top weight, pH 4.5-5.0, and temperature of 45℃. The reduction endpoint is monitored to -200 mV to -250 mV by an oxidation-reduction potential meter to accurately remove oxidation residues and prevent by-products from causing yellowing of the tops or failure of subsequent softening agent adsorption. Rinsing and softening: After the dechlorinated wool tops are rinsed in multiple countercurrent stages to remove impurities, they are then treated with a softening solution to improve fiber softness. The multi-stage countercurrent rinsing consists of four series water tanks with the water flow direction opposite to the direction of wool top movement. Each stage of rinsing takes 3-5 minutes, and the total water consumption is ≤15 tons / ton of wool top. The countercurrent structure maximizes water utilization efficiency, and the four-stage rinsing ensures thorough removal of impurities, meeting the requirements of water-saving production. The softening solution contains 1.0-1.5% amino-modified polysiloxane softener and 0.2-0.3% wool oil, with a pH of 5.5-6.0 and a treatment temperature of 35-40℃. This repairs fiber surface damage, improves wool top smoothness and spinning smoothness, and reduces breakage rate in subsequent processing. Drying into slivers: The softened wool slivers are dried at low temperature to the target moisture content to produce shrink-resistant wool sliver finished products. The drying is carried out in two stages. In the first stage, the temperature is maintained at 60℃ for 10 minutes. In the second stage, the temperature is increased to 70℃ until the moisture content of the wool sliver is ≤15%. The air speed is 2-3m / s. The temperature is controlled in stages to avoid fiber embrittlement caused by high temperature and rapid drying. The air speed is set to prevent the wool slivers from tangling and to ensure the fluffiness of the finished product. The wool slivers are Australian wool slivers with a fineness of ≤21.5μm. The felting shrinkage rate after treatment is ≤3% (ISO 6330) and the whiteness value is ≥85 (ISO 105-B02). It is adapted to the characteristics of high-count wool to ensure that the finished product meets the machine wash shrink-resistant standards and whiteness requirements of high-end knitwear. This process framework achieves efficient erosion of wool scales through a chlorine-free oxidation system, providing a basic process for continuous production of environmentally friendly shrink-resistant wool tops; The process wastewater has an AOX value of 0, which means it can be directly introduced into the biochemical treatment system, eliminating organic halogen pollution at the source, simplifying the wastewater treatment process, and meeting the requirements for eco-textile certification.

[0018] The present invention provides the following embodiments. Example 1: High-efficiency treatment of high-count wool tops Raw materials: Australian wool tops with a fineness of 19.5μm and a length of 75mm (initial felting shrinkage rate of 25%, whiteness value of 78); Pretreatment: sodium alkyl sulfonate (0.6% OWW), water temperature of 32℃, liquid carryover rate of 125%.

[0019] Oxidation treatment: potassium persulfate + sodium percarbonate (active oxygen 14.0%, mass ratio 1:2.5, dosage 5.5% OWW), pH 2.8, temperature 42℃, time 10 minutes; Reduction treatment: Sodium metabisulfite (4.0% OWW), pH 4.8, temperature 45℃, endpoint potential -220mV; Rinsing and softening: Four-stage countercurrent rinsing (4 minutes per stage, total water consumption 13 tons / ton of wool top); softening solution contains amino-modified polysiloxane (1.2% OWW) and wool oil (0.25% OWW), pH 5.8, temperature 38℃; Drying: 60℃×10 minutes → 70℃ to 14% moisture content, wind speed 2.5m / s; Effect Comparison Table: Example 2: Water-saving optimized treatment Pretreatment: fatty alcohol polyoxyethylene ether (0.5% OWW), water temperature 30℃, liquid carryover rate 120%; Oxidation treatment: Ammonium persulfate + sodium percarbonate (13.5% active oxygen, mass ratio 1:2.5, dosage 4% OWW), pH 2.0, temperature 40℃, time 12 minutes; Reduction treatment: Sodium metabisulfite (3.0% OWW), pH 4.5, endpoint potential -200mV; Rinsing and softening: Four-stage countercurrent rinsing (5 minutes per stage, total water consumption 15 tons / ton of wool top); softening solution contains amino-modified polysiloxane (1.0% OWW) and wool oil (0.2% OWW), pH 5.5, temperature 35℃; Drying: 60℃ for 10 minutes → 70℃ until moisture content is 15%, wind speed 2m / s.

[0020] Effect Comparison Table: Water saving effect: 40% reduction compared to traditional processes (traditional single-stage rinsing consumes >30 tons / ton of wool tops). Example 3: High-speed production processing Raw material: Australian wool sliver with a fineness of 20.5μm (initial felting shrinkage rate of 24%, whiteness value of 77); Pretreatment: Sodium alkyl sulfonate (0.8% OWW), water temperature 35℃, liquid carryover rate 130%; Oxidation treatment: potassium persulfate + sodium percarbonate (active oxygen 14.2%, mass ratio 1:2.5, dosage 7% OWW), pH 3.5, temperature 45℃, time 8 minutes; Reduction treatment: Sodium metabisulfite (5.0% OWW), pH 5.0, endpoint potential -250mV; Rinsing and softening: Four-stage countercurrent rinsing (3 minutes per stage, total water consumption 12 tons / ton of wool top); softening solution contains amino-modified polysiloxane (1.5% OWW) and wool oil (0.3% OWW), pH 6.0, temperature 40℃; Drying: 60℃×10 minutes → 70℃ to 13.5% moisture content, wind speed 3m / s.

[0021] Effect Comparison Table: Production efficiency: Continuous production line speed reaches 25m / min (traditional process ≤18m / min), and yarn breakage rate ≤1.5% (traditional process ≥5%). Through systematic implementation of three embodiments, it has been verified that the present invention can: 1. Achieve gas-free and environmentally friendly production: Adopt a persulfate / sodium percarbonate compound oxidation system, and the AOX value of wastewater is always 0 (EPA 1650 standard), completely eliminating organic halide pollution; 2. Stable achievement of high-end wool top performance indicators: The treated wool top felt shrinkage rate ≤3% (ISO 6330), whiteness value ≥85 (ISO 105-B02), and breaking strength retention rate ≥90% (GB / T 3923.1-2013), meeting the shrinkage prevention requirements for high-count wool machine washing. 3. Four-stage countercurrent rinsing reduces water consumption to ≤15 tons / ton of yarn top (saving more than 40% of water compared to traditional processes); oxidation-reduction time is ≤20 minutes, supporting continuous operation of the production line at a speed of 25m / min; softening treatment reduces yarn breakage rate to ≤1.5% (traditional processes ≥5%). 4. Compatible with high-count hair strips with a fineness ≤21.5μm: The compound oxidant precisely erodes the scales under low-temperature acidic conditions, avoiding damage to the fibrokeratin (strength retention rate in Examples 1-3 is >90%). 5. Simplified wastewater treatment process: Wastewater that does not detect AOX can directly enter the biological treatment system, reducing end-of-pipe treatment costs by more than 50%.

[0022] The advantages of this invention are: eliminating AOX pollution at the source; reducing oxidation and erosion time by more than 40%; monitoring the reduction endpoint with a potentiometer (-200 to -250mV) to eliminate the risk of yellowing of the lint.

[0023] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A process for processing Basulan wool strips, characterized in that, Includes the following steps: Pretreatment: Immerse the wool top in a warm aqueous solution containing a penetrant, and adjust the liquid content of the wool top to a uniformly wetted state; Oxidation treatment: The pretreated wetted hair strips are placed in an environmentally friendly oxidant system and subjected to a scale-peeling reaction under acidic conditions to generate some residual oxides; Reduction treatment: The oxidized wool tops are treated with a reducing agent solution to remove residual oxides, resulting in dechlorinated wool tops; Rinsing and softening: After the dechlorinated wool tops are rinsed in multiple countercurrent stages to remove impurities, they are then treated with a softening solution to improve the softness of the fibers. Drying into strips: The softened wool strips are dried at low temperature to the target moisture content to produce shrink-resistant wool strip finished products.

2. The Basolan wool top processing technology according to claim 1, characterized in that: The penetrant used in the pretreatment is sodium alkyl sulfonate or fatty alcohol polyoxyethylene ether, with a dosage of 0.5-0.8% of the weight of the wool top, a water temperature of 30-35℃, and a liquid retention rate of 120-130% for the wool top.

3. The Basolan wool strip processing technology according to claim 1, characterized in that: The oxidation treatment uses an environmentally friendly oxidant made of persulfate and sodium percarbonate in a mass ratio of 1:2.5, with a dosage of 4-7% of the weight of the wool top, pH 2.0-3.5, temperature 40-45℃, and reaction time of 8-12 minutes.

4. The Basolan wool strip processing technology according to claim 1, characterized in that: The reduction treatment uses sodium metabisulfite solution, with an amount of 3-5% of the weight of the wool top, pH 4.5-5.0, and temperature of 45℃. The reduction endpoint is monitored to -200 mV to -250 mV using an oxidation-reduction potential meter.

5. The process for processing Basolan wool strips according to claim 1, characterized in that: The multi-stage countercurrent rinsing consists of four series water tanks with the water flow direction opposite to the direction of the wool top movement. Each stage of rinsing takes 3-5 minutes, and the total water consumption is ≤15 tons / ton of wool top.

6. The Basolan wool strip processing technology according to claim 1, characterized in that: The softening solution contains 1.0-1.5% amino-modified polysiloxane softener and 0.2-0.3% crude oil, with a pH of 5.5-6.0 and a treatment temperature of 35-40℃.

7. The Basolan wool top processing technology according to claim 1, characterized in that: The drying process is carried out in two stages. In the first stage, the temperature is maintained at 60°C for 10 minutes. In the second stage, the temperature is increased to 70°C until the moisture content of the wool strip is ≤15%, and the wind speed is 2-3 m / s.

8. The Basolan wool top processing technology according to claim 1, characterized in that: The wool strips are Australian wool strips with a fineness of ≤21.5μm, and the felting shrinkage rate after treatment is ≤3%, and the whiteness value is ≥85.

9. The process for processing Basuran wool strips according to claim 1, characterized in that: The AOX value of the process wastewater is 0, so it can be directly introduced into the biochemical treatment system.

10. The process for processing Basulan wool strips according to claim 3, characterized in that: The persulfate is potassium persulfate, and the active oxygen content of sodium percarbonate is ≥13.5%.

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