Environment-friendly soaping-free dyeing process

Abstract

The invention provides an environment-friendly soaping-free dyeing process, and relates to the technical field of soaping dyeing, and the environment-friendly soaping-free dyeing process avoids the use of a large amount of chemical detergent in the traditional soaping process, thereby significantly reducing sewage discharge. Therefore, the pollution pressure on the water environment is reduced, the ecological balance is protected, the accumulation of chemical substances in the water body is reduced, and the living environment of aquatic organisms is maintained. Meanwhile, resource and cost input needed by sewage treatment is reduced, the requirement of sustainable development is met, powerful support is provided for green transformation of the textile industry, the whole industry is promoted to develop in the more environment-friendly and sustainable direction, and by reducing water resource consumption, the situation of water resource shortage is relieved, and the environment-friendly and sustainable development of the textile industry is facilitated. The soaping-free dyeing process provided by the invention has the advantages that the process is simplified, the whole dyeing period is shortened, and the energy demand is correspondingly reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of soaping and dyeing, and more specifically, particularly relates to an environmentally friendly soap-free dyeing process. Background Art

[0002] In the modern textile industry, dyeing technology is the key link to give fabrics rich colors and unique appearance. However, the traditional dyeing process has gradually exposed a series of problems that need to be solved in practice.

[0003] The traditional dyeing process usually includes pretreatment, dyeing, soaping and fixing. Among them, soaping was considered an important step to remove unfixed dyes and impurities and improve color fastness in the past. However, its drawbacks have become increasingly prominent over time.

[0004] First, from an environmental perspective, a large amount of chemical detergents are required in the soap washing process, which will be discharged into the environment with wastewater after use. Since it contains a large amount of pollutants such as organic matter, inorganic salts and surfactants, it puts tremendous pressure on sewage treatment. Not only that, the discharge of wastewater without effective treatment will also cause serious damage to the soil, water bodies and ecosystems, threatening the ecological balance and biodiversity.

[0005] Secondly, in terms of resource utilization, the traditional dyeing process has serious waste. The soap washing process consumes a lot of water resources, and this problem is particularly prominent in some areas where water resources are scarce. At the same time, the high temperature conditions and long processing time during the dyeing and soap washing process also lead to a large amount of energy consumption, increasing the production costs and environmental burden of enterprises.

[0006] Furthermore, from the perspective of production efficiency and cost, the traditional process has complicated steps and a long production cycle, which reduces the utilization rate of equipment and production efficiency. In addition, the consumption of a large amount of chemical reagents, water and energy makes the production cost high, limiting the profit margin and market competitiveness of enterprises.

[0007] Moreover, traditional dyeing processes also face challenges in ensuring dyeing quality and color fastness. Due to the difficulty in controlling process parameters, uneven dyeing and substandard color fastness are prone to occur, affecting product quality and market value.

[0008] As consumers' requirements for textile quality and environmental protection continue to increase, and environmental regulations become increasingly stringent, the textile industry urgently needs a new dyeing process that is more environmentally friendly, efficient, energy-saving, and can guarantee dyeing quality. In this context, the development of an environmentally friendly soap-free dyeing process has become an inevitable trend in the development of the industry, aiming to solve many problems existing in traditional processes and promote the transformation and upgrading of the textile industry towards a green and sustainable direction. Summary of the invention

[0009] In order to solve the above technical problems, the present invention provides an environmentally friendly soap-free dyeing process to solve the above problems.

[0010] An environmentally friendly soap-free dyeing process comprises the following steps:

[0011] Pretreatment: Soak the fabric to be dyed in a pretreatment solution at a temperature of 40°C for 20 minutes, wherein the pretreatment solution contains component A at a concentration of 10 g / L and component B at a concentration of 5 g / L;

[0012] Dyeing: The pretreated fabric is placed in a dye solution and dyed at a temperature of 60° C. for 40 minutes. The dye solution contains a dye concentration of 8 g / L and an auxiliary concentration of 3 g / L.

[0013] Color fixing: the dyed fabric is placed in a color fixing solution at a temperature of 80°C for 25 minutes, wherein the color fixing solution contains a color fixing agent at a concentration of 6 g / L;

[0014] Among them, the pretreatment liquid temperature T1, the immersion time M1, the component A concentration C1, the component B concentration C2, the dye solution temperature T2, the dyeing time M2, the dye concentration C3, the auxiliary agent concentration C4, the fixing liquid temperature T3, the fixing time M3 and the fixing agent concentration C5 satisfy the following relationship:

[0015] T1=0.8×M1+35;

[0016] C1=0.2×C3+8;

[0017] C2=0.3×C4+5.

[0018] Preferably, component A in the pretreatment solution is sodium carbonate, and component B is penetrant JFC.

[0019] Preferably, the auxiliary agent is a leveling agent, and the fixing agent is an aldehyde-free fixing agent.

[0020] Preferably, T2=1.2×M2+55.

[0021] Preferably, M2=6×C3+15.

[0022] Preferably, T3=1.5×M3+65.

[0023] Preferably, M3=5×C5+8.

[0024] Preferably, C3, C4 and C5 satisfy the following relationship: C5=0.1×(C3+C4)+2.

[0025] Preferably, the fabric to be dyed is made of pure cotton, weighs 500 grams, and satisfies the relationship: C3=0.003×500+2=3.5 g / L.

[0026] Preferably, the bath ratio in the dyeing process is 1:15.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] 1. Significant environmental benefits: The environmentally friendly soap-free dyeing process of the present invention avoids the use of a large amount of chemical detergents in the traditional soaping process, thereby significantly reducing sewage discharge. This not only reduces the pollution pressure on the water environment, but also helps to protect the ecological balance, reduce the accumulation of chemical substances in the water body, and maintain the living environment of aquatic organisms. At the same time, it reduces the resources and cost investment required for sewage treatment, meets the requirements of sustainable development, provides strong support for the green transformation of the textile industry, and promotes the entire industry to develop in a more environmentally friendly and sustainable direction.

[0029] 2. Water conservation and sustainable utilization: In traditional dyeing processes, soap washing usually consumes a lot of water to clean the unfixed dyes and auxiliaries on the fabric. The soap-free washing process of the present invention directly eliminates this step, greatly reducing the amount of water used in the dyeing process. By reducing the consumption of water resources, it not only helps to alleviate the situation of water shortage, but also reduces the water cost of enterprises. This is particularly important for textile enterprises in water-scarce areas, so that more production activities can be carried out under limited water resources, promoting the sustainable utilization of water resources.

[0030] 3. Reduced energy consumption and energy conservation and emission reduction: Dyeing and soaping processes usually consume a lot of heat and electricity. The soap-free dyeing process of the present invention simplifies the process and shortens the entire dyeing cycle, which reduces the demand for energy accordingly. This means that the use of energy such as steam and electricity can be reduced during the production process, thereby reducing greenhouse gas emissions and energy costs. This energy-saving and emission-reduction effect not only helps to cope with global climate change, but also meets the requirements of countries and regions for enterprises to reduce energy consumption and achieve green production, and enhances the social image and market competitiveness of enterprises.

[0031] 4. Improve production efficiency and shorten production cycle: Traditional dyeing process often takes a long time to complete the entire dyeing process due to the complex soap washing step. The soap-free process of the present invention simplifies the operation process and reduces unnecessary intermediate links, thereby significantly shortening the production cycle. This enables enterprises to complete more batches of dyeing tasks in the same time, improves equipment utilization and production efficiency. Faster production speed helps enterprises respond to market demand in a timely manner, flexibly adjust production plans, reduce inventory backlogs, and enhance enterprises' adaptability and competitiveness in the market.

[0032] 5. Ensure dyeing quality and color fastness: The process of the present invention can ensure that the dye fully penetrates and firmly adheres to the fabric fiber by optimizing key steps such as pretreatment, dyeing and color fixation, thereby obtaining a color depth and color fastness that is equivalent to or even better than that of the traditional soaping process. This means that the dyed fabric is not easy to fade during use, maintains a good appearance and quality, and meets consumers' requirements for high quality of textiles. Stable and excellent dyeing quality helps to enhance the added value and market recognition of the product, establish a good brand image for the company, and expand market share.

[0033] 6. Reduce production costs and improve economic benefits: Eliminating the soap washing process not only reduces the use of chemical reagents and water resources, but also reduces energy consumption and equipment operation time, thereby significantly reducing raw material costs, energy costs and equipment maintenance costs. At the same time, due to the shortened production cycle, enterprises can produce more products per unit time, further improving production efficiency and economic benefits. The reduction in costs gives enterprises more price advantages in market competition, enables flexible pricing, increases product profit margins, and provides strong financial support for the sustainable development and expanded reproduction of enterprises.

[0034] 7. Enhance fabric performance and feel: During the dyeing process, the process conditions of the present invention are carefully designed and optimized to reduce damage to fabric fibers. Compared with traditional processes, the treated fabric fibers maintain good physical properties, such as strength and elongation. At the same time, due to the avoidance of excessive chemical treatment and mechanical friction, the fabric feels softer and more comfortable, which improves the consumer experience. This advantage of improving fabric performance without affecting the dyeing effect makes the product more competitive in the market and suitable for a variety of high-end and sensitive textiles.

[0035] 8. Wide applicability and market prospects: The environmentally friendly soap-free dyeing process of the present invention is not only applicable to common fabric materials such as pure cotton, polyester-cotton, and pure linen, but can also be applied to various types of dyes, such as reactive dyes, disperse dyes, and direct dyes. This wide applicability enables the process to meet the needs of different textile companies and products, and has huge market promotion potential. With the increasing demand of consumers for environmentally friendly products and increasingly stringent environmental regulations, the process of the present invention with significant environmental advantages is expected to be widely used in the textile industry, leading the development trend of the industry and bringing new business opportunities and development opportunities to enterprises.

[0036] 9. Promote technological innovation and industry upgrading: The emergence of this invention has brought new technical ideas and methods to the field of textile dyeing, and stimulated the vitality of technological innovation in the industry. Other enterprises and research institutions may further conduct research and improvements on this basis to promote the continuous improvement of the technical level of the entire industry. This chain reaction of technological innovation will help break the limitations of traditional technology, accelerate the upgrading of the industry, and improve the competitiveness of my country's textile industry in the international market. At the same time, it also provides an opportunity for the coordinated development of related industries, such as promoting innovation in the fields of auxiliary agent research and development, equipment manufacturing, etc., and forming a complete industrial chain innovation system.

[0037] 10. Easy operation and high stability: The process of the present invention is easier to operate than the traditional process, reduces the complicated soaping operation and parameter control, and reduces the technical requirements for the operator. This helps to reduce human operating errors and improve the stability and controllability of the production process. A stable and reliable production process can ensure the consistency of product quality, reduce the defective rate, and further save production costs. At the same time, the simple operation process is also conducive to the company's rapid training of new employees, improving production efficiency, and adapting to the rapid changes in market demand. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a schematic diagram of the process of the present invention. DETAILED DESCRIPTION

[0039] The following embodiments of the present invention are described in further detail in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0040] With the continuous improvement of environmental protection requirements and people's pursuit of textile quality, the traditional dyeing process faces many challenges. Among them, the soap washing process after dyeing not only consumes a lot of water resources, but also produces a lot of sewage discharge, which puts great pressure on the environment. Therefore, it is of great practical significance to develop an environmentally friendly soap-free dyeing process.

[0041] The environmentally friendly soap-free dyeing process of the present invention can achieve good dyeing effect and color fastness without using soaping agent by optimizing the steps of pretreatment, dyeing and color fixing, while reducing water resource consumption and sewage discharge. The process and effect of the present invention will be described in detail through multiple specific embodiments.

[0042] Materials and equipment:

[0043] Material:

[0044] Fabrics to be dyed: Select fabrics of different materials such as pure cotton, polyester-cotton, pure linen, etc. Prepare several batches of each material, and the weight of each batch is [X] grams.

[0045] Dyes: Choose common dyes such as reactive dyes, disperse dyes, direct dyes, etc., and prepare different colors and concentrations for each dye.

[0046] Auxiliary agents: including leveling agent, penetrant, fixing agent, etc.

[0047] Raw materials for pretreatment solution and fixing solution: such as sodium carbonate, sodium phosphate, sodium chloride, etc.

[0048] equipment:

[0049] Dyeing machine: high temperature and high pressure dyeing machine, normal temperature and normal pressure dyeing machine, etc.

[0050] Testing instruments: spectrophotometer, color fastness tester, fabric strength tester, etc.

[0051] Embodiment 1: reactive dyeing of pure cotton fabric:

[0052] Preprocessing:

[0053] Pretreatment liquid formula: sodium carbonate 10g / L, penetrant JFC 5g / L.

[0054] Treatment conditions: temperature 40°C, time 20 minutes, bath ratio 1:15.

[0055] dyeing:

[0056] Dye solution formula: reactive red dye 8g / L, leveling agent 3g / L.

[0057] Dyeing conditions: temperature 60°C, time 40 minutes, bath ratio 1:15.

[0058] Color fixation:

[0059] Fixing solution formula: formaldehyde-free fixing agent 6g / L.

[0060] Fixing conditions: temperature 80°C, time 25 minutes, bath ratio 1:15.

[0061] Embodiment 2: disperse dyeing of polyester-cotton fabric:

[0062] Preprocessing:

[0063] Pretreatment liquid formula: sodium phosphate 8g / L, penetrant JFC4g / L. Treatment conditions: temperature 35℃, time 15 minutes, bath ratio 1:20. Dyeing:

[0064] Dye solution formula: disperse blue dye 6g / L, leveling agent 2g / L.

[0065] Dyeing conditions: temperature 130℃, time 60 minutes, bath ratio 1:20. Fixation:

[0066] Fixing solution formula: formaldehyde-free fixing agent 5g / L.

[0067] Fixing conditions: temperature 100°C, time 20 minutes, bath ratio 1:20.

[0068] Embodiment 3: direct dyeing of pure linen fabric:

[0069] Preprocessing:

[0070] Pretreatment liquid formula: sodium carbonate 8g / L, penetrant JFC 3g / L. Treatment conditions: temperature 45℃, time 18 minutes, bath ratio 1:18. Dyeing:

[0071] Dyeing liquid formula: direct yellow dye 7g / L, leveling agent 2.5g / L. Dyeing conditions: temperature 90℃, time 50 minutes, bath ratio 1:18. Color fixation:

[0072] Fixing solution formula: 4.5g / L formaldehyde-free fixing agent.

[0073] Fixing conditions: temperature 70°C, time 22 minutes, bath ratio 1:18.

[0074] The color depth (K / S value) of the dyed fabric was measured using a spectrophotometer. Five different locations were selected for measurement in each example, and the average value was taken. The results are shown in the following table:

[0075] Example K / S value 1 13.2 2 11.5 3 10.8

[0076] The dyed fabric of each example was tested for color fastness to washing, color fastness to rubbing and color fastness to sunlight, and rated according to relevant standards. The test results are shown in the following table:

[0077]

[0078] The total water consumption of each example during the dyeing process, including pretreatment, dyeing and fixation steps, was recorded. The results were compared with the traditional soaping dyeing process, as shown in the following table:

[0079]

[0080]

[0081] The energy consumption (such as steam, electricity, etc.) of each embodiment during the dyeing process was measured and compared with the traditional process. The results are shown in the following table:

[0082]

[0083] The cost of raw materials such as dyes, auxiliaries, pretreatment liquid and fixing liquid used in each example was calculated and compared with the traditional process. The results are shown in the following table:

[0084]

[0085]

[0086] Firstly, the material and equipment preparation of this process is explained, including fabrics of different materials to be dyed, various types of dyes and auxiliaries, and corresponding dyeing and testing instruments, laying the foundation for subsequent experimental operations.

[0087] Then, the application of the process on different fabric materials and dye types is demonstrated through a number of specific examples. For example, in the reactive dyeing of pure cotton fabric, the detailed conditions and formulas of the pretreatment, dyeing and fixation stages are clarified. Similarly, the specific steps and parameters for disperse dyeing of polyester-cotton fabric and direct dyeing of pure linen fabric are also given.

[0088] In the data statistics and analysis phase, the three main aspects were carried out: dyeing effect evaluation, resource consumption comparison and cost analysis. In the dyeing effect evaluation, the effectiveness of the new process in ensuring dyeing quality was proved by measuring the color depth (K / S value) and conducting color fastness tests. In terms of resource consumption comparison, water consumption and energy consumption data were recorded. The results showed that the new process has significant advantages over traditional processes in terms of water and energy saving, and the saving ratio is relatively high. The cost analysis covers the cost of raw materials and equipment maintenance costs. The data shows that the new process can reduce production costs, and the saving ratio of total production costs is considerable.

[0089] The data was then discussed in depth. In terms of the impact of process parameters on dyeing effects, the possible results of changes in parameters such as temperature and time for pretreatment, dyeing and fixation were analyzed. In terms of the applicability of fabrics of different materials, the need for process adjustment due to differences in fabric characteristics was discussed. In terms of the comparative advantages with traditional processes, combined with the data, the outstanding performance of the new process in terms of environmental protection and cost was emphasized again when the dyeing effect was equivalent.

[0090] Finally, it is concluded that multiple embodiments have verified the good effect and color fastness of the environmentally friendly soap-free dyeing process on different fabrics. Compared with the traditional soap-washing dyeing process, it has significant environmental advantages, can greatly reduce water resource consumption and sewage discharge, and reduce energy consumption. At the same time, it also has obvious advantages in terms of cost, including the reduction of raw material costs and equipment maintenance costs, thereby improving production efficiency and competitiveness. In actual production, the process parameters can be flexibly adjusted according to the fabric material and dyeing requirements to achieve the best dyeing effect and economic benefits.

[0091] In summary, this environmentally friendly soap-free dyeing process provides an innovative, efficient and sustainable solution for the field of textile dyeing.

[0092] The embodiments of the present invention are given for the purpose of illustration and description, and are not intended to be exhaustive or to limit the invention to the disclosed forms. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments are selected and described in order to better illustrate the principles and practical applications of the present invention and to enable those of ordinary skill in the art to understand the present invention and thereby design various embodiments with various modifications suitable for specific uses.

Claims

1. An environmentally friendly soap-free dyeing process, characterized in that: The following steps are involved: Pretreatment: Soak the fabric to be dyed in a pretreatment solution at a temperature of 40°C for 20 minutes, wherein the pretreatment solution contains component A at a concentration of 10 g / L and component B at a concentration of 5 g / L; Dyeing: The pretreated fabric is placed in a dye solution and dyed at a temperature of 60° C. for 40 minutes. The dye solution contains a dye concentration of 8 g / L and an auxiliary concentration of 3 g / L. Color fixing: the dyed fabric is placed in a color fixing solution at a temperature of 80°C for 25 minutes, wherein the color fixing solution contains a color fixing agent at a concentration of 6 g / L; Among them, the pretreatment liquid temperature T1, the immersion time M1, the component A concentration C1, the component B concentration C2, the dye solution temperature T2, the dyeing time M2, the dye concentration C3, the auxiliary agent concentration C4, the fixing liquid temperature T3, the fixing time M3 and the fixing agent concentration C5 satisfy the following relationship: T1=0.8×M1+35; C1=0.2×C3+8; C2=0.3×C4+5.

2. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: Component A in the pretreatment solution is sodium carbonate, and component B is penetrant JFC.

3. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: The auxiliary agent is a leveling agent, and the fixing agent is an aldehyde-free fixing agent.

4. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: T2=1.2×M2+55.

5. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: M2=6×C3+15.

6. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: T3=1.5×M3+65.

7. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: M3=5×C5+8.

8. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: C3, C4 and C5 satisfy the following relationship: C5=0.1×(C3+C4)+2.

9. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: The fabric to be dyed is made of pure cotton, weighs 500 grams, and satisfies the relationship: C3=0.003×500+2=3.5 g / L.

10. An environmentally friendly soap-free dyeing process as claimed in claim 1, characterized in that: The bath ratio in the dyeing process is 1:15.

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