Polyester fiber production method capable of reducing carbon emission in dyeing and finishing process

Abstract

The invention relates to the technical field of textile, and discloses a polyester fiber production method capable of reducing carbon emission in the dyeing and finishing process, the polyester fiber production method comprises the following steps: S1, a preparation stage: preparing a polyester material, a catalyst, an environment-friendly cleaning agent and a temperature-sensitive dye; s2, collection and pretreatment: waste PET bottles in urban recycle bin and industrial waste are collected, high-pressure water flow and an environment-friendly cleaning agent are used for cleaning the recycled PET bottles so as to remove stains and labels on bottle bodies, then an infrared recognition machine is used for distinguishing the PET bottles from other types of plastic waste, and the PET bottles and other types of plastic waste are subjected to pretreatment; and finally, crushing the cleaned PET bottle into small pieces by using an industrial-grade crusher to obtain the crushed polyester material. The recycled PET bottles are used as raw materials, the temperature-sensitive dye is combined with the ultrasonic technology, the use of water and chemicals is reduced, the pressure on the environment in the production process is relieved, and in addition, the overall environmental protection effect is improved by reducing the discharge of waste water and chemical waste materials.

Description

Technical Field

[0001] The invention relates to the technical field of textiles, in particular to a polyester fiber production method capable of reducing carbon emissions in a dyeing and finishing process. Background Art

[0002] Polyester is a widely used synthetic fiber made primarily from polyethylene terephthalate (PET). The fiber is popular for its durability, wrinkle resistance, and elasticity, and is widely used in clothing, home textiles, filling materials (such as quilts and pillows), automotive interiors, and industrial products. Polyester fibers are highly resistant to wear and tear. They do not wrinkle easily and can be machine washed and dry cleaned, making them ideal for everyday wear. Polyester clothing retains its shape and does not require frequent ironing. The fiber has low water absorption and dries quickly, making it suitable for sportswear and outdoor clothing. Polyester can be recycled and made into new fibers or other products, which has the potential to be environmentally friendly. Due to these properties, polyester fibers play an important role in modern textiles, not only because of their functionality, but also because of their relatively low cost and energy requirements during production.

[0003] However, the existing polyester fiber production methods, although the technology has made certain progress, still have some important problems in terms of environment, energy efficiency and cost control;

[0004] First, the production process of polyester fiber usually involves long-term high-temperature operation, which leads to extremely high energy consumption. Due to the large-scale use of fossil fuel energy, this high energy consumption directly leads to an increase in carbon emissions in the production process, which not only increases production costs, but also has a significant negative impact on the environment;

[0005] Secondly, the current production of polyester fibers mostly relies on new chemical raw materials, especially newly made PET. This high dependence on new raw materials not only consumes a large amount of non-renewable resources, but also increases resource consumption and environmental burden in the production process, limiting the sustainable development of the industry;

[0006] Finally, polyester fibers require a large amount of chemical dyes and water resources during the dyeing and finishing process. This not only puts tremendous pressure on water resources, but also, due to the use of dyes and other chemical treatment agents, the wastewater generated during the production process contains a variety of harmful substances, causing long-term pollution to the environment. In addition, the wastewater treatment process is complex, the treatment cost is high, and the efficiency is low, which further increases the operating costs and environmental risks of enterprises;

[0007] These issues highlight the shortcomings of existing polyester fiber production methods in terms of environmental protection, resource utilization and cost-effectiveness, so more advanced and sustainable production strategies are now needed. Summary of the invention

[0008] In view of the deficiencies of the prior art, the present invention provides a polyester fiber production method that reduces carbon emissions during the dyeing and finishing process, thereby solving the problem of excessive environmental pollution caused by traditional production methods.

[0009] To achieve the above objectives, the present invention is implemented by the following technical scheme: A polyester fiber production method for reducing carbon emissions during dyeing and finishing, comprising the following steps:

[0010] S1, preparation stage: polyester materials, catalysts, environmentally friendly cleaning agents, temperature-sensitive dyes;

[0011] S2. Collection and pretreatment: Collect discarded PET bottles from urban recycling stations and industrial waste, use high-pressure water and environmentally friendly cleaning agents to clean the recycled PET bottles to remove stains and labels on the bottle body, then use infrared recognition machines to distinguish PET bottles from other types of plastic waste, and finally use industrial-grade crushers to crush the cleaned PET bottles into small pieces to obtain crushed polyester materials;

[0012] S3, heating decomposition: the crushed polyester material and the pre-prepared catalyst are fully mixed in a mixer, and the mixed material is then transported to a chemical reactor, and the heating system is controlled to adjust the temperature to obtain terephthalic acid and ethylene glycol;

[0013] S4, polymerization reaction: terephthalic acid, ethylene glycol and a catalyst are placed in a reactor for preliminary mixing, and then a heating system is started to heat the mixture to a polymerization reaction temperature, thereby polymerizing to obtain the desired polyester fiber;

[0014] S5. Dyeing treatment: Put the polyester fiber and the temperature-sensitive dye into the dyeing machine, adjust the temperature of the dyeing machine, and use an ultrasonic machine to strengthen the treatment.

[0015] Preferably, in the step S1, the polyester material is recycled PET bottles; the catalyst is tin diacetic acid; and the environmentally friendly cleaning agent is citric acid solvent.

[0016] Preferably, in step S1, the temperature-sensitive dye is a liquid crystal thermochromic dye comprising a liquid crystal compound.

[0017] Preferably, in the step S2, the pressure of the high-pressure water flow for flushing is set to 100 bar; and the wavelength range of the infrared recognition machine is set to 940 nm to 1020 nm.

[0018] Preferably, in step S2, the rotation speed of the industrial-grade pulverizer is set to 3500rpm-4987rpm, and the particle size of the industrial-grade pulverizer is set to 1mm-5mm.

[0019] Preferably, in the step S3, the rotation speed of the stirrer is set to 150 rpm to 200 rpm; and the temperature of the chemical reactor is set to 250°C.

[0020] Preferably, in the step S3, the chemical reaction formula for decomposing the PET bottle into terephthalic acid and ethylene glycol is:

[0021] PET+H2O→C6H4(COOH)2+C2H6O2

[0022] Among them, PET represents recycled PET bottles, C6H4(COOH)2 represents terephthalic acid, and C2H6O2 represents ethylene glycol.

[0023] Preferably, in the step S4, the temperature of the reactor is set at 260° C. to 280° C., and the pressure of the reactor is set at 1.5 atm.

[0024] Preferably, in the step S4, the chemical reaction formula for polymerizing terephthalic acid and ethylene glycol is:

[0025] n C6H4(COOH)2+n C2H6O2→[-COC(C6H4COO)2C2H4O-] n +nH2O

[0026] Where nC6H4(COOH)2 represents terephthalic acid, nC2H6O2 represents ethylene glycol, [-COC(C6H4COO)2C2H4O-] n Stands for polyethylene terephthalate.

[0027] Preferably, in the step S5, the temperature of the dyeing machine is set to 130° C., and the frequency used by the ultrasonic machine is 40 KHZ.

[0028] The present invention provides a polyester fiber production method that reduces carbon emissions during dyeing and finishing.

[0029] Beneficial effects:

[0030] 1. The present invention uses recycled PET bottles as raw materials and adopts temperature-sensitive dyes combined with ultrasonic technology. The present invention greatly reduces the use of water and chemicals, alleviates the pressure of the production process on the environment, and improves the overall environmental protection effect by reducing the discharge of wastewater and chemical waste.

[0031] 2. The present invention adopts efficient production technology and equipment, which not only shortens the production time but also increases the output. This efficiency improvement makes the production cycle shorter and responds to market demand more quickly.

[0032] 3. The present invention uses an optimized catalyst and heating system, which significantly reduces energy consumption while ensuring production efficiency. Compared with traditional methods, energy consumption is reduced by 33%, which directly reduces energy costs and environmental impacts in the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a flow chart of the present invention. DETAILED DESCRIPTION

[0034] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0035] Example 1: Basic version

[0036] step:

[0037] S1, preparation stage: using 100% recycled PET bottles, using tin diacetic acid as a catalyst, citric acid solvent as an environmentally friendly cleaning agent, and liquid crystal type thermochromic dyes;

[0038] S2, collection and pretreatment: use 100 bar high-pressure water flow and infrared recognition machine (wavelength 940nm to 1020nm) to classify and crush PET bottles (particle size is set to 3mm);

[0039] S3, thermal decomposition: PET bottles are treated in a mixer (rotation speed 175 rpm) and a chemical reactor (temperature 250° C.) to obtain terephthalic acid and ethylene glycol;

[0040] S4, polymerization reaction: polymerization is carried out in a reactor (temperature 270° C., pressure 1.5 atm) to produce polyester fibers;

[0041] S5. Dyeing treatment: Dyeing treatment is performed in a dyeing machine (temperature 130° C.) and an ultrasonic machine (40 kHz).

[0042] Summarize:

[0043] This embodiment provides a basic production process utilizing fully recycled materials and environmentally friendly technologies, aiming to minimize environmental impact while maintaining product quality.

[0044] Example 2: Enhanced decomposition efficiency version

[0045] step:

[0046] S1, preparation stage: same as in Example 1;

[0047] S2. Collection and pretreatment: using an automated classification system, advanced infrared technology and a crusher with automatic particle size adjustment (particle size adjusted to 1 mm);

[0048] S3, thermal decomposition: using a continuous fluidized bed reactor to improve decomposition efficiency, the temperature and stirring speed remain unchanged;

[0049] S4. Polymerization reaction: Use microwave-assisted polymerization technology to accelerate the reaction speed and increase the polymerization rate;

[0050] S5. Dyeing treatment: Use nanotechnology to enhance the permeability and color fixation of dyes.

[0051] Summarize:

[0052] This embodiment greatly improves production efficiency and polymerization rate by introducing efficient technical equipment and methods, so that the performance and quality of the product are further improved.

[0053] Example 3: Low energy version

[0054] step:

[0055] S1, Preparation stage: Use low-temperature catalyst and low-energy consumption environmentally friendly cleaning agent;

[0056] S2, collection and pretreatment: PET bottles are processed using low-pressure water flow (50 bar) and low-energy infrared technology;

[0057] S3, thermal decomposition: carried out in an energy-saving chemical reactor, the temperature dropped to 230°C;

[0058] S4, polymerization reaction: polymerization reaction is carried out at low temperature (temperature 255°C) to reduce energy consumption;

[0059] S5. Dyeing treatment: Use environmentally friendly dyes and energy-saving ultrasonic equipment (35kHz).

[0060] Summarize:

[0061] This embodiment focuses on minimizing energy consumption and effectively reduces production costs and environmental impact by adopting energy-saving technologies and equipment.

[0062] Example 4: Fully automated version

[0063] step:

[0064] S1. Preparation stage: Automated batching and mixing system to ensure the accuracy of material proportion and processing;

[0065] S2. Collection and pretreatment: fully automated high-precision classification and crushing system, with particle size adjustable to 2 mm;

[0066] S3, thermal decomposition: using a computer-controlled reactor to automatically adjust the temperature and pressure;

[0067] S4, Polymerization reaction: Fully automatic control system to ensure optimal reaction conditions;

[0068] S5. Dyeing process: Intelligent dyeing system, automatically adjusts dye and temperature according to fiber type.

[0069] Summarize:

[0070] Through a fully automated production line, this embodiment significantly improves operational efficiency and product consistency, and reduces labor costs and error rates.

[0071] Example 5: Environmentally friendly advanced version

[0072] step:

[0073] S1. Preparation stage: using PET bottles recycled from marine plastic waste;

[0074] S2, collection and pretreatment: using environmentally friendly bio-enzyme cleaning technology, without high-pressure water flow;

[0075] S3, thermal decomposition: using solar heating system and renewable energy;

[0076] S4, Polymerization reaction: Add bio-based catalysts to reduce energy consumption and the need for chemical additives;

[0077] S5. Dyeing process: Use plant-based dyes and low-temperature fixing technology.

[0078] Summarize:

[0079] This embodiment is committed to promoting the concept of sustainable development. Environmentally friendly technologies are used in every link from raw material acquisition to production process, which significantly reduces the carbon footprint of the entire production process.

[0080] Summary:

[0081] These five examples demonstrate the possibilities of different technologies and methods to reduce carbon emissions in the polyester fiber production process. From basic technology applications to advanced full automation and environmental protection technologies, each implementation provides unique solutions for improving efficiency, energy conservation, emission reduction and environmental protection. These examples not only optimize the production process, but also enhance the market competitiveness of the products, while responding to the global call for sustainable development and environmental protection.

[0082] Test experiment 1: basic version

[0083] Test content: Evaluate the uniformity and mechanical properties of polyester fibers.

[0084] Testing process:

[0085] 1. Randomly select samples from each batch of fiber produced;

[0086] 2. Use a universal material testing machine to perform a tensile test and record the breaking strength and elongation;

[0087] 3. Use a microscope to evaluate the uniformity of fiber diameter.

[0088] Test data:

[0089] Tensile strength: average value is 500MPa;

[0090] Elongation: average value is 15%;

[0091] Fiber diameter uniformity: diameter deviation is within ±5%.

[0092] Test experiment 2: Enhanced decomposition efficiency version

[0093] Test content: Evaluate production efficiency and energy consumption.

[0094] Testing process:

[0095] 1. Record the total time required to process the same amount of PET;

[0096] 2. Measure the energy consumption of the entire process, including electricity consumption;

[0097] 3. Compare the efficiency and energy consumption with the basic version.

[0098] Test data:

[0099] Processing time: The processing time for each batch of PET is reduced by 20%, from 1 hour to 48 minutes;

[0100] Energy consumption: Compared with the basic version, energy consumption has been reduced by 15%, from 100kWh per batch to 85kWh.

[0101] Test experiment 3: Low energy version

[0102] Test content: Evaluate carbon emissions and overall environmental impact.

[0103] Testing process:

[0104] 1. Calculate the carbon emissions from the entire process from raw material collection to product completion;

[0105] 2. Use the life cycle assessment (LCA) method to conduct environmental impact assessment;

[0106] 3. Compare the environmental impacts of different implementation examples.

[0107] Test data:

[0108] Carbon emissions: Carbon emissions per ton of polyester fiber produced have been reduced by 25%, from 4 tons of CO2 to 3 tons of CO2;

[0109] Environmental Impact Assessment: Improved environmental impact score by 30% through life cycle assessment.

[0110] Test experiment 4: fully automated version

[0111] Test content: Evaluate operational error rate and production continuity.

[0112] Testing process:

[0113] 1. Record the number and reasons of production interruptions within a certain period;

[0114] 2. Conduct long-term operation tests to observe the stability and failure rate of the equipment;

[0115] 3. Analyze the ease of operation and degree of automation.

[0116] Test data:

[0117] Number of production interruptions: The number of interruptions per 1,000 hours of operation was reduced from 10 to 2;

[0118] Failure rate: Annual failure rate reduced from 5% to 1%;

[0119] Operational ease score: Improved from 7 / 10 to 9 / 10.

[0120] Test experiment 5: Environmentally friendly advanced version

[0121] Test content: Evaluate product sustainability and market feedback.

[0122] Testing process:

[0123] 1. Conduct eco-label assessment on the final product;

[0124] 2. Collect feedback from consumers and customers through market research;

[0125] 3. Analyze the product’s acceptance and preference in the market.

[0126] Test data:

[0127] Eco-label score: A+ eco-label, indicating extremely low environmental impact; Consumer satisfaction: Satisfaction increased from 85% to 95%;

[0128] Market acceptance: Acceptance in the target market increased from 60% to 85%.

[0129] Existing technical solutions:

[0130] 1. Use non-recycled PET as raw material;

[0131] 2. Standard thermal decomposition technology, usually set at 280°C;

[0132] 3. Traditional energy consumption management.

[0133] Technical solution of the present invention:

[0134] 1. Use 100% recycled PET;

[0135] 2. Optimized catalyst and heating system, temperature adjusted to 250°C;

[0136] 3. High-efficiency energy management system.

[0137] Comparative experiment 1: Comparison of energy efficiency and production efficiency

[0138] Comparative experimental process:

[0139] 1. Raw material preparation: the same amount of non-recycled and recycled PET;

[0140] 2. Heating decomposition: record the actual energy consumption and time of the two methods;

[0141] 3. Polymerization process: Compare the time and energy consumption of the two methods;

[0142] 4. Data recording: total energy consumption, production time, and output.

[0143] Data table:

[0144]

[0145]

[0146] Comparative Experiment 2: Environmental Impact Assessment

[0147] Existing technical solutions:

[0148] 1. Use traditional chemical dyes;

[0149] 2. Standard dyeing process.

[0150] Technical solution of the present invention:

[0151] 1. Use temperature-sensitive dyes;

[0152] 2. Ultrasonic technology assists dyeing, reducing the use of water and chemicals.

[0153] Comparative experimental process:

[0154] 1. Dye and water preparation: record the water and chemical consumption during the two dyeing processes;

[0155] 2. Dyeing process: compare dyeing efficiency and time required;

[0156] 3. Data recording: water and chemical consumption, dyeing time.

[0157] Data table:

[0158]

[0159] Comparative experiment 3: production cost analysis

[0160] Existing technical solutions:

[0161] 1. High energy consumption and raw material costs;

[0162] 2. Dependence on new PET materials.

[0163] Technical solution of the present invention:

[0164] 1. Reduce energy consumption and optimize the use of raw materials;

[0165] 2. Complete reliance on recycled PET.

[0166] Comparative experimental process:

[0167] 1. Raw material cost: compare the raw material cost under the two methods;

[0168] 2. Energy consumption cost: record and compare the cost corresponding to energy consumption;

[0169] 3. Data records: raw material cost, energy consumption cost.

[0170] Data table:

[0171]

[0172] Through comparative tests, it can be clearly seen that the polyester fiber production method that reduces carbon emissions in the dyeing and finishing process has significant advantages in energy efficiency, environmental protection and cost control compared to existing technologies. This method not only meets the current pursuit of sustainability in industrial production, but also helps companies stay ahead in increasingly stringent environmental regulations and market competition. By implementing this technology, companies can achieve improved production efficiency and significant cost reductions while reducing the impact on the environment, thereby enhancing economic benefits while promoting the realization of environmental responsibility.

[0173] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A polyester fiber production method for reducing carbon emissions during dyeing and finishing, characterized in that: The following steps are involved: S1, preparation stage: polyester materials, catalysts, environmentally friendly cleaning agents, temperature-sensitive dyes; S2. Collection and pretreatment: Collect discarded PET bottles from urban recycling stations and industrial waste, use high-pressure water and environmentally friendly cleaning agents to clean the recycled PET bottles to remove stains and labels on the bottle body, then use infrared recognition machines to distinguish PET bottles from other types of plastic waste, and finally use industrial-grade crushers to crush the cleaned PET bottles into small pieces to obtain crushed polyester materials; S3, heating decomposition: the crushed polyester material and the pre-prepared catalyst are fully mixed in a mixer, and the mixed material is then transported to a chemical reactor, and the heating system is controlled to adjust the temperature to obtain terephthalic acid and ethylene glycol; S4, polymerization reaction: terephthalic acid, ethylene glycol and a catalyst are placed in a reactor for preliminary mixing, and then a heating system is started to heat the mixture to a polymerization reaction temperature, thereby polymerizing to obtain the desired polyester fiber; S5. Dyeing treatment: Put the polyester fiber and the temperature-sensitive dye into the dyeing machine, adjust the temperature of the dyeing machine, and use an ultrasonic machine to strengthen the treatment.

2. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S1, the polyester material is recycled PET bottles; the catalyst is tin diacetic acid; and the environmentally friendly cleaning agent is citric acid solvent.

3. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S1, the temperature-sensitive dye is a liquid crystal thermochromic dye, which includes a liquid crystal compound.

4. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S2, the pressure of the high-pressure water flow for flushing is set to 100 bar; and the wavelength range of the infrared recognition machine is set to 940nm to 1020nm.

5. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S2, the rotation speed of the industrial-grade pulverizer is set to 3500 rpm to 4987 rpm, and the particle size of the industrial-grade pulverizer is set to 1 mm to 5 mm.

6. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S3, the rotation speed of the stirrer is set to 150 rpm to 200 rpm; and the temperature of the chemical reactor is set to 250°C.

7. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S3, the chemical reaction formula for decomposing the PET bottle into terephthalic acid and ethylene glycol is: PET+H2O→C6H4(COOH)2+C2H6O2 Among them, PET represents recycled PET bottles, C6H4(COOH)2 represents terephthalic acid, and C2H6O2 represents ethylene glycol.

8. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S4, the temperature of the reactor is set at 260° C. to 280° C., and the pressure of the reactor is set at 1.5 atm.

9. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S4, the chemical reaction formula for polymerizing terephthalic acid and ethylene glycol is: nC6H4(COOH)2+nC2H6O2→[-COC(C6H4COO)2C2H4O-] n +nH2O Where nC6H4(COOH)2 represents terephthalic acid, nC2H6O2 represents ethylene glycol, -COC(C6H4COO)2C2H4O-] n Stands for polyethylene terephthalate.

10. The polyester fiber production method for reducing carbon emissions during dyeing and finishing according to claim 1, characterized in that: In the step S5, the temperature of the dyeing machine is set to 130° C., and the frequency of the ultrasonic machine is 40 KHZ.

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