Production process of zero-carbon blended yarn and fabric

Abstract

The invention discloses a production process of zero-carbon blended yarn and fabric, and belongs to the technical field of zero-carbon fabric production, the zero-carbon blended yarn comprises the following raw materials by weight: 60% of regenerated polyester fiber; 40% of organic cotton fiber; the regenerated polyester fibers and the organic cotton fibers are mixed according to the proportion of 60: 40, biological enzyme degreasing treatment is adopted, and water consumption is reduced by 50%; s2, low-carbon spinning; s3, carbon footprint tracking; s4, no dyeing and finishing process; s5, closed-loop water treatment. According to the production technology of the zero-carbon blended yarn and the fabric, the zero-carbon blended yarn fabric produced through the production technology can be widely applied to the high-end fields of sportswear, outdoor equipment and the like, large-scale production of the zero-carbon blended yarn fabric is achieved through combination of raw material innovation, technology optimization and carbon management, environmental benefits are remarkably improved, and the production technology is suitable for popularization and application. The production process is energy-saving and consumption-reducing, and full-life-cycle carbon management is realized.

Description

Technical Field

[0001] This invention relates to the field of zero-carbon fabric production technology, specifically to a production process for zero-carbon blended yarn and fabric. Background Technology

[0002] With the escalating global climate change and resource scarcity, the textile industry, a representative of high-pollution and high-energy-consuming industries, accounts for approximately 10% of global carbon emissions. Traditional chemical fiber production relies on petroleum resources, and processes such as dyeing and finishing generate large amounts of wastewater and chemical pollution. Meanwhile, marine plastic pollution and the accumulation of discarded PET bottles have become global environmental challenges, with approximately 8 million tons of plastic flowing into the ocean annually, while the recycling rate of PET bottles is less than 30%. Against this backdrop, developing low-carbon, sustainable textile materials and production processes has become a key direction for the industry's transformation.

[0003] While recycled polyester fiber (rPET) has been applied in the textile industry, its raw materials are mostly limited to PET bottle flakes recycled on land, with extremely low utilization rates of marine recycled plastics. Furthermore, the mechanical properties of recycled fibers differ from those of virgin fibers. In addition, traditional spinning processes rely on fossil fuels, and the dyeing process consumes large amounts of water and discharges wastewater containing heavy metals, making carbon footprint difficult to control. Although some technologies attempt to reduce energy consumption through bio-enzyme treatment or green electricity substitution, a systematic solution is lacking, making it difficult to simultaneously meet the demands of zero-carbon, high-performance, and large-scale production.

[0004] Therefore, there is an urgent need for a full-chain technology that integrates marine plastic recycling, low-carbon energy utilization, pollution-free coloring, and closed-loop water treatment to achieve carbon reduction throughout the entire life cycle of textile materials and promote the industry's transformation towards a circular economy model. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a production process for zero-carbon blended yarns and fabrics, which has advantages such as good environmental performance and energy saving, and solves the problems mentioned in the background technology.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A zero-carbon blended yarn comprises the following raw materials in parts by weight:

[0008] 60% recycled polyester fiber;

[0009] 40% organic cotton fiber;

[0010] The recycled polyester fiber comprises 80% marine recycled plastic and 20% PET bottle flakes.

[0011] Furthermore, the particle size of the recycled marine plastic is ≤5mm, and the intrinsic viscosity of the recycled marine plastic and PET bottle flakes after solid-state polymerization is 0.65±0.02dl / g; the tensile strength of the zero-carbon blended yarn is ≥35cN / tex, and the air permeability of the zero-carbon blended yarn is ≥500L / m. 2 / s.

[0012] Another technical problem to be solved by the present invention is to provide a production process for zero-carbon blended yarn fabric, including the following process steps:

[0013] S1. Raw material pretreatment: Recycled polyester fiber and organic cotton fiber are mixed in a ratio of 60:40 and degreased using biological enzymes to reduce water consumption by 50%.

[0014] S2, Low-carbon spinning: Using a solar-powered vortex spinning machine, plant-based lubricant is sprayed in during the spinning process;

[0015] S3, Carbon Footprint Tracking: Records energy consumption at each stage in real time through a blockchain system and links it to green electricity certificates;

[0016] S4. Undyed and finished process: Employs structural color-generating technology to form a photonic crystal structure on the yarn surface through nanoimprinting.

[0017] S5. Closed-loop water treatment: Production wastewater is purified by microbial fuel cells and then recycled.

[0018] Furthermore, the bio-enzymatic degreasing treatment in S1 uses a complex system of keratinase and pectinase, with a pH of 6.5, a temperature of 45°C, and a treatment time of 30 minutes.

[0019] Furthermore, the enzyme activity of the bio-enzyme defatting treatment in S1 is ≥800 U / g.

[0020] Furthermore, the energy consumption of the vortex spinning machine in S2 is ≤0.8kWh / kg; the plant-based lubricant in S2 contains 30% castor oil derivative.

[0021] Furthermore, the green electricity certificate in S3 meets the requirement that carbon emissions per ton of yarn are ≤0.5kg CO2e.

[0022] Furthermore, the color fastness of the photonic crystal structure in S4 is ≥ level 4; the preparation of the photonic crystal structure in S4 includes depositing a SiO2 / TiO2 nanolayer on the yarn surface and forming a periodic structure by electron beam exposure.

[0023] Furthermore, the biochemical oxygen demand removal rate of the wastewater from the microbial fuel cell in S5 is ≥95%.

[0024] Furthermore, it also includes carbon offsetting, which involves planting 10 fast-growing poplar trees for every 1 ton of fabric produced, and verifying the carbon sequestration through satellite remote sensing.

[0025] Compared with the prior art, the present invention provides a production process for zero-carbon blended yarn and fabric, which has the following beneficial effects:

[0026] 1. The production process of the zero-carbon blended yarn and fabric: The zero-carbon blended yarn and fabric produced by the above-mentioned production process can be widely used in high-end fields such as sportswear and outdoor equipment. By combining raw material innovation, process optimization and carbon management, the large-scale production of zero-carbon blended yarn and fabric has been realized, the environmental benefits have been significantly improved, the production process is energy-saving and consumption-reducing, and the whole life cycle carbon management has been realized.

[0027] 2. The production process of this zero-carbon blended yarn and fabric solves the problem of marine microplastic pollution and reduces dependence on petroleum resources by blending 80% of recycled ocean plastics with 20% of post-consumer PET bottle flakes, thus significantly improving environmental benefits. By adopting a composite system of keratinase and pectinase, the high pollution and high energy consumption of chemical degreasing are avoided. The use of a green-electric-driven vortex spinning machine further reduces fossil energy consumption, achieving the advantages of energy saving and consumption reduction. Blockchain carbon tracking records energy consumption at each stage in real time and links it with green electricity vouchers, ensuring that carbon emissions per ton of yarn are ≤0.5kg CO2e, realizing full life-cycle carbon management. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the production process of a zero-carbon blended yarn and fabric proposed in this invention. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.

[0030] Please see Figure 1 The zero-carbon blended yarn in this embodiment comprises the following raw materials in parts by weight:

[0031] 60% recycled polyester fiber (rPET);

[0032] 40% organic cotton fiber;

[0033] Among them, recycled polyester fiber (rPET) includes 80% ocean recycled plastic and 20% PET bottle flakes (post-consumer).

[0034] Specifically, the particle size of recycled marine plastics is ≤5mm, and the intrinsic viscosity of recycled marine plastics and PET bottle flakes after solid-state polymerization is 0.65±0.02dl / g.

[0035] Specifically, the zero-carbon blended yarn has a tensile strength ≥35cN / tex, an air permeability ≥500L / m² / s, and its carbon footprint certification complies with ISO 14067:2025 standards.

[0036] Please see Figure 1 The production process of a zero-carbon blended yarn fabric in this embodiment includes the following process steps:

[0037] A1. Raw material preparation and pretreatment:

[0038] A1-1. Preparation of Recycled Polyester Fiber (rPET)

[0039] A1-1-1. Collect marine plastic waste (particle size ≤ 5mm) and post-consumer PET bottle flakes, and mix them in a ratio of 80:20;

[0040] A1-1-2. Solid-state polymerization process (temperature 230℃±5℃, pressure 0.8MPa), adjust intrinsic viscosity to 0.65±0.02dl / g (tested according to ISO 1628-5:2025).

[0041] A1-1-3, melt extrusion granulation, and scanning electron microscopy (SEM) showed no residual impurities.

[0042] A1-2, Organic Cotton Fiber Treatment

[0043] A1-2-1. GOTS certified organic cotton is selected, and short fibers (fiber length ≥28mm) are removed by airflow combing.

[0044] A1-2-2. Prepare a compound biological enzyme solution (800 U / g keratinase + 600 U / g pectinase, pH 6.5) and treat it at 45℃ for 30 minutes.

[0045] A2. Low-carbon spinning process

[0046] A2-1. Equipment Parameters:

[0047] Solar-powered vortex spinning machine (photovoltaic module efficiency ≥22%), energy consumption 0.78kWh / kg;

[0048] Inject a plant-based lubricant containing 30% castor oil derivatives (reducing the coefficient of friction by 40%).

[0049] A2-2, Yarn performance test:

[0050]

[0051] A3, Structural Color Generation Technology

[0052] A3-1. A SiO2 / TiO2 nanolayer (thickness 205nm±3nm) is deposited on the surface of the yarn by magnetron sputtering.

[0053] A3-2. Photonic crystal structure (lattice constant 348nm, color fastness grade 4.5) is formed by electron beam exposure (accelerating voltage 50kV).

[0054] A3-3, color rendering range covers the visible light band (400-700nm), color difference ΔE≤1.0 (CIE Lab standard).

[0055] A4. Carbon Footprint Management and Offset

[0056] A4-1, Blockchain Tracking:

[0057] A4-1-1. Energy consumption data of each stage is uploaded to the Hyperledger Fabric chain in real time (block interval 2 seconds).

[0058] A4-1-2, Green electricity certificates are directly connected to the State Grid Renewable Energy Trading Platform (0.48 kg CO2e carbon emissions per ton of yarn).

[0059] A4-2. Implementation of Carbon Sequestration:

[0060] A4-2-1. For every ton of fabric produced, 10 fast-growing poplar trees will be planted in the Horqin region of Inner Mongolia.

[0061] A4-2-2, Verification of carbon sequestration (0.12 tons CO2e / ton of fabric) using Sentinel-2 satellite multispectral imagery.

[0062] A5. Closed-loop water treatment system

[0063] A5-1. Configuration of Microbial Fuel Cell:

[0064] Anode strain: Geobacter sulfurreducens (inoculum size) (CFU / mL)

[0065] The BOD removal rate is 96.3%, and the power generation density is 1.2W / m³.

[0066] A5-2. Reclaimed Water Reuse:

[0067] The treated water meets the reuse requirements of GB 4287-2025 "Water Pollutant Discharge Standard for Textile Dyeing and Finishing Industry".

[0068] The zero-carbon blended yarn and fabric production process described in this embodiment allows the zero-carbon blended yarn and fabric produced using the above-mentioned production process to be widely used in high-end fields such as sportswear and outdoor equipment. By combining raw material innovation, process optimization and carbon management, the production of zero-carbon blended yarn and fabric has been scaled up, significantly improving environmental benefits. The production process is energy-saving and reduces consumption, achieving full life cycle carbon management.

[0069] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0070] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A zero-carbon blended yarn, characterized in that, The ingredients include the following parts by weight: 60% recycled polyester fiber; 40% organic cotton fiber; The recycled polyester fiber comprises 80% marine recycled plastic and 20% PET bottle flakes.

2. The zero-carbon blended yarn according to claim 1, characterized in that: The particle size of the recycled marine plastic is ≤5mm, and the intrinsic viscosity of the recycled marine plastic and PET bottle flakes after solid-state polymerization is 0.65±0.02dl / g; the tensile strength of the zero-carbon blended yarn is ≥35cN / tex, and the air permeability of the zero-carbon blended yarn is ≥500L / m. 2 / s.

3. A production process for a zero-carbon blended yarn fabric, employing the zero-carbon blended yarn as described in any one of claims 1-2, characterized in that, The process includes the following steps: S1. Raw material pretreatment: Recycled polyester fiber and organic cotton fiber are mixed in a ratio of 60:40 and degreased using biological enzymes to reduce water consumption by 50%. S2, Low-carbon spinning: Using a solar-powered vortex spinning machine, plant-based lubricant is sprayed in during the spinning process; S3, Carbon Footprint Tracking: Records energy consumption at each stage in real time through a blockchain system and links it to green electricity certificates; S4. Undyed and finished process: Employs structural color-generating technology to form a photonic crystal structure on the yarn surface through nanoimprinting. S5. Closed-loop water treatment: Production wastewater is purified by microbial fuel cells and then recycled.

4. The production process of a zero-carbon blended yarn fabric according to claim 3, characterized in that: The bio-enzymatic degreasing treatment in S1 uses a complex system of keratinase and pectinase, pH 6.5, temperature 45℃, and treatment time of 30 minutes.

5. The production process of a zero-carbon blended yarn fabric according to claim 3, characterized in that: The enzyme activity of the bio-enzyme defatting treatment in S1 is ≥800 U / g.

6. The production process of a zero-carbon blended yarn fabric according to claim 3, characterized in that: The energy consumption of the vortex spinning machine in S2 is ≤0.8kWh / kg; the plant-based lubricant in S2 contains 30% castor oil derivative.

7. The production process of a zero-carbon blended yarn fabric according to claim 3, characterized in that: The green electricity certificate in S3 meets the requirement that carbon emissions per ton of yarn are ≤0.5kg CO2e.

8. The production process of a zero-carbon blended yarn fabric according to claim 3, characterized in that: The color fastness of the photonic crystal structure in S4 is ≥4 grade; the preparation of the photonic crystal structure in S4 includes depositing a SiO2 / TiO2 nanolayer on the yarn surface and forming a periodic structure by electron beam exposure.

9. The production process of a zero-carbon blended yarn fabric according to claim 3, characterized in that: The biochemical oxygen demand removal rate of the wastewater from the microbial fuel cell in S5 is ≥95%.

10. The production process of a zero-carbon blended yarn fabric according to claim 3, characterized in that: It also includes carbon offsetting, which involves planting 10 fast-growing poplar trees for every ton of fabric produced, and verifying the carbon sequestration through satellite remote sensing.

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