A short process dyeing and washing process

Abstract

The present application relates to the field of textile printing and dyeing technology, and particularly relates to a short-process dyeing and washing process, which uses a dye vat equipped with a transverse injection circulating system, a high-temperature direct discharge module and a linkage control program system based on a 485 communication protocol to process fabrics, and the process sequentially includes a dyeing stage, a high-temperature displacement washing stage, a reduction washing stage and a discharge stage; in the dyeing stage, the fabric is placed in the dye vat, heated to 130 degrees Celsius and kept warm, and the transverse injection circulating system continuously works during the heating process; the linkage control program system monitors the temperature and pressure in the vat in real time and automatically controls them; when the temperature deviation exceeds 0.3 degrees Celsius or the pressure deviation exceeds 0.05 Kg / cm 2 , the heating power and the air intake amount are automatically adjusted. The short-process dyeing and washing process provided by the present application comprehensively optimizes the core process of dyeing and washing in textile printing and dyeing, effectively solves the problems of complicated process, low control precision, high resource consumption and poor fabric quality in the existing process.

Description

Technical Field

[0001] This invention relates to the field of textile printing and dyeing technology, specifically to a short-process dyeing and washing process. Background Technology

[0002] In the textile printing and dyeing industry, dyeing and washing is the core process of fabric processing. Its process design directly affects the production process and finished product quality of fabric processing. Currently, there are still many problems in the dyeing and washing process in the industry that need to be solved.

[0003] Traditional dyeing and washing processes employ a step-by-step operation mode, with fabric transfer between the dyeing and washing processes. This not only increases the number of steps involved in the process but also easily damages the fabric surface. Furthermore, the process involves repeated cooling and reheating, resulting in significant energy waste. In addition, the water and auxiliary agent usage in the washing process is excessive, which does not meet the industry's requirements for green production.

[0004] Existing integrated dyeing and washing processes only achieve simple equipment splicing, without forming a deep adaptation between the process and the equipment. They lack a precise temperature and pressure linkage control system, and the control accuracy of temperature and pressure is insufficient. They cannot match the corresponding process parameters according to the characteristics of different fabrics, and have poor adaptability to processing elastic fabrics and dark-colored fabrics, which can easily lead to problems such as damage to elastic fibers and uneven color.

[0005] Meanwhile, these processes do not optimize the core washing process, resulting in poor separation of clean and dirty water, incomplete removal of oligomers and floating dyes, and a low water resource utilization rate due to the lack of water recycling technology. Furthermore, the existing processes have a low degree of automation, with some parameter adjustments relying on manual experience, leading to poor process stability and difficulty in ensuring consistent quality of finished fabrics, thus hindering the efficient and green development of the textile printing and dyeing industry. Summary of the Invention

[0006] The primary objective of this invention is to provide a short-process dyeing and washing process.

[0007] A further objective of this invention is to provide a short-process dyeing and washing process. This process utilizes a dyeing vat equipped with a transverse material injection circulation system, a high-temperature direct discharge module, and a linkage control program system based on the 485 communication protocol. The process sequentially includes a dyeing stage, a high-temperature displacement washing stage, a reduction washing stage, and a vat exit stage. During the dyeing stage, the fabric is placed in the dyeing vat, heated to 130 degrees Celsius, and held at that temperature. During the heating process, the transverse material injection circulation system operates continuously. The linkage control program system monitors the temperature and pressure inside the vat in real time and automatically adjusts them, ensuring that temperature deviations exceed 0.3 degrees Celsius and pressure deviations exceed 0.05 kg / cm². 2The system automatically adjusts the heating power and air intake. During the high-temperature replacement washing stage, the linkage control program automatically starts the high-temperature direct discharge module to inject high-temperature water into the dyeing vat for replacement, achieving a temperature drop from 130 degrees Celsius to 90 degrees Celsius. Simultaneously, the high-temperature replacement return circulation cleaning and diversion process is started. The return end is equipped with a precision filter screen for filtration. The wastewater discharge end is linked to an electric ball valve through a real-time COD monitor. When the COD reaches 1000 mg / L, the discharge is automatically opened and automatically closed after the discharge is completed. During the reduction washing stage, the temperature inside the vat is maintained at 90 degrees Celsius. A reducing agent is added through the injection system, and saturated steam is introduced into the vat to control the oxygen content. The linkage control program achieves temperature and pressure linkage control. During the vat exit stage, the linkage control program starts the cooling system to reduce the temperature inside the vat to the preset temperature before the fabric exits the vat. During the exit process, the fabric is conveyed by rubber strip lifting wheels.

[0008] Preferably, the fabric being processed is a 100% polyester knitted fabric with a weight of 200 grams per square meter; the dyeing stage involves a heating rate of 1.5 degrees Celsius per minute, high-temperature dyeing and holding for 40 minutes, and an initial pressure of 2.0 kg / cm² in the dyeing vat. 2 During the heating process, the guide cloth speed is 400 meters per minute; the horizontal injection circulation system has an injection pressure of 0.4MPa, the injection points are evenly distributed on one side, and the injection point spacing is 20 cm; the high temperature direct discharge module is of type DCW600, its flow distribution unit blade angle is 30 degrees, the dyeing vat and the high temperature direct discharge module are rigidly connected by DN125 flange, and the matching fluororubber high temperature resistant sealing gasket is 4 mm thick.

[0009] Preferably, the high-temperature water injected during the high-temperature replacement water washing stage is 98-degree Celsius clean water, with a replacement water volume of 4 tons per cylinder and a cooling rate of 2 degrees Celsius per minute; the return water pipeline of the high-temperature replacement return circulation cleaning and diversion process has a flow rate of 100 liters per minute, and the precision filter screen at the return end has a pore size of 50 microns.

[0010] Preferably, the reducing agent dosage during the reduction washing stage is 3.0 g / L, the oxygen content in the tank is 2.5%, the reduction washing lasts for 30 minutes, and the temperature and pressure linkage control rule is that for every 5 degrees Celsius decrease in temperature, the pressure in the tank is simultaneously reduced by 0.2 kg / cm². 2 The cylinder pressure exceeds 4 kg / cm². 2 The exhaust valve opens automatically; the cooling rate during the exiting stage is 0.7 degrees Celsius per minute, the temperature inside the cylinder drops to 60 degrees Celsius before exiting the cylinder, the speed of the fabric guide after exiting the cylinder is 400 meters per minute, the nozzle gap is 4 millimeters, the replacement water flow rate is 1.5 meters per second, and the fabric is dried at 120 degrees Celsius for 20 minutes after exiting the cylinder.

[0011] Preferably, the fabric being processed is a polyester-spandex warp-knitted fabric with a spandex content of 10% and a weight of 150 grams per square meter; the dyeing stage involves a heating rate of 1.5 degrees Celsius per minute, high-temperature dyeing and heat preservation for 30 minutes, an initial pressure of 1.8 kg / cm2 in the dyeing tank, a fabric guide speed of 300 meters per minute during the heating process, and a linkage control program system that monitors the fabric tension in real time and automatically adjusts the fabric guide speed; the transverse injection circulation system has an injection pressure of 0.25 MPa.

[0012] Preferably, the high-temperature water injected during the high-temperature replacement water washing stage is 98-degree Celsius clean water, with a replacement water volume of 2.5 tons per cylinder and a cooling rate of 2 degrees Celsius per minute; the return water pipeline of the high-temperature replacement return circulation cleaning and diversion process has a flow rate of 80 liters per minute, and the precision filter screen at the return end has a pore size of 80 microns.

[0013] Preferably, the reducing agent dosage during the reduction washing stage is 2.8 grams per liter, the oxygen content in the cylinder is 2.8%, the reduction washing lasts for 25 minutes, and the temperature and pressure linkage control rule is that for every 5 degrees Celsius decrease in temperature, the cylinder pressure is simultaneously reduced by 0.2 kg / cm². 2 The maximum pressure inside the cylinder is controlled at 3.5 kg / cm². 2 The concentration of reducing agent is monitored in real time; the cooling rate during the discharge stage is 0.8 degrees Celsius per minute, the temperature inside the cylinder drops to 50 degrees Celsius before discharge, the discharge speed of the fabric guide is 300 meters per minute, the nozzle gap is 5 millimeters, the displacement water flow rate is 1.2 meters per second, and the fabric is set at 110 degrees Celsius for 15 minutes after discharge.

[0014] Preferably, the fabric used for processing is a nylon-spandex woven fabric with a spandex content of 8% and a weight of 300 grams per square meter. The fabric undergoes pre-shrinking treatment before the dyeing stage. During the dyeing stage, the heating rate is 1.0 degrees Celsius per minute, and the high-temperature dyeing is maintained for 45 minutes. The initial pressure inside the dyeing vat is 2.2 kg / cm². 2 During the heating process, the guide cloth speed is 500 meters per minute; the transverse injection circulation system is a ring-shaped uniform injection system with an injection point spacing of 15 cm and an injection pressure of 0.5 MPa; the high-temperature direct discharge module is a DCW400 type, with a flow distribution unit blade angle of 35 degrees, and the dyeing vat and the high-temperature direct discharge module are rigidly connected through a DN100 flange; a new greywater reuse linkage module has been added to the linkage control program system.

[0015] Preferably, the dyeing vat is equipped with a sinking and climbing guide pipe with a climbing angle of 15 degrees; the rubber strip lifting wheel is made of fluororubber with a Shore hardness of 70HA; the core components of the vat are made of 316L cold-rolled stainless steel with a thickness of 10 mm; the high-temperature replacement water washing stage is injected with treated reclaimed water as replacement water, with a water reuse rate of 65%, a replacement water volume of 3.5 tons per vat, and a cooling rate of 2.5 degrees Celsius per minute; the return water pipeline of the high-temperature replacement return circulation cleaning and diversion process has a flow rate of 120 liters per minute, and the precision filter screen at the return end has a pore size of 50 microns.

[0016] Preferably, the reducing agent dosage during the reduction washing stage is 3.5 grams per liter, the oxygen content in the tank is 1.8%, the reduction washing lasts for 35 minutes, and the temperature and pressure linkage control rule is that for every 5 degrees Celsius decrease in temperature, the pressure in the tank is simultaneously reduced by 0.25 kg / cm². 2 The cylinder pressure exceeds 4 kg / cm². 2 The exhaust valve opens automatically, and the system is stirred in real time during the washing process. The cooling rate during the exiting stage is 0.6 degrees Celsius per minute, and the temperature inside the cylinder drops to 45 degrees Celsius before exiting. The speed of the fabric guide is 600 meters per minute, the nozzle gap is 3 millimeters, and the replacement water flow rate is 1.8 meters per second. With the help of the fabric guide tube, the fabric exits the cylinder without tension and without any transfer throughout the process. After exiting the cylinder, the fabric is set at 130 degrees Celsius for 25 minutes and dried at 125 degrees Celsius for 22 minutes.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] 1. The short-process dyeing and washing process provided by this invention has comprehensively optimized the core dyeing and washing process of textile printing and dyeing, and effectively solved the problems of cumbersome process, low control precision, high resource consumption and poor fabric quality in the existing process.

[0019] 2. This process integrates dyeing, high-temperature replacement washing, reduction washing, and unloading into a seamless design, eliminating the fabric transfer and repeated heating steps in traditional processes, thus simplifying the process flow. At the same time, it is equipped with a linkage control program system based on communication protocols, which realizes automatic monitoring and control of parameters in each process, reduces manual intervention, and greatly improves the stability and continuity of process operation.

[0020] 3. The process of this invention achieves precise adaptation of equipment structure and process parameters for the characteristics of different fabrics. By optimizing equipment components such as the injection circulation system and guide fabric structure, and combining customized temperature and pressure linkage control rules, it can effectively avoid damage such as stretching, friction, and creases during fabric processing, ensuring the processing adaptability of different types of fabrics, while improving the color uniformity and color fastness of the finished fabric and optimizing the overall quality of the fabric surface.

[0021] 4. This design incorporates a high-temperature displacement washing process, which precisely controls the injection and circulation of the washing medium, reducing the consumption of water resources and additives. Some processes also incorporate greywater reuse technology, further improving water resource utilization and reducing resource consumption during production. Detailed Implementation

[0022] 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.

[0023] All examples and comparative examples were conducted on the same production scale, with a single batch processing 500 kg of fabric. All tests were performed in the same production workshop at an ambient temperature of 25°C and humidity of 60% to eliminate environmental interference and ensure the authenticity and comparability of the results, providing strong support for the innovation and practicality of the process. During the testing process, all equipment was debugged according to standard operating procedures, and the process steps were strictly followed according to the descriptions in the examples and comparative examples to ensure the accuracy of the test data.

[0024] Example 1: The applicable fabric is a 100% polyester knitted fabric with a weight of 200 grams per square meter and a navy blue color. This fabric is a conventional textile printing and dyeing fabric, which can be directly purchased from the market and can be used in this process without special treatment.

[0025] The core equipment is the Zhejiang Basuni ZJBSN long-cylinder series dyeing vat, equipped with an independently optimized transverse injection circulation system. The injection points are evenly distributed on one side with a spacing of 20 cm, and the injection pressure is controlled at 0.4 MPa. It features an independently adapted DCW600 high-temperature direct discharge module with a built-in independently developed flow distribution unit and a blade angle of 30 degrees. The dyeing vat and the high-temperature direct discharge module are rigidly connected via a DN125 flange, with matching fluororubber high-temperature resistant sealing gaskets, and the gasket thickness is 4 mm. It is equipped with an independently written linkage control program system based on the 485 communication protocol. The program can be installed and run on ordinary industrial control computers. The control interface is simple and can adjust various process parameters in real time. After the program starts, it automatically links the dyeing vat and the high-temperature direct discharge module without manual intervention, ensuring accurate parameter execution.

[0026] The process steps are as follows: (1) Dyeing stage: The all-polyester knitted fabric is placed in the Basuni long vat series dyeing vat, and the temperature is raised to 130 degrees Celsius at a rate of 1.5 degrees Celsius per minute. The high-temperature dyeing is carried out and kept at the temperature for 40 minutes. The initial pressure in the vat is 2.0 kg / cm. 2 .

[0027] During the heating process, the fabric guide speed is maintained at 400 meters per minute, and the material injection circulation system works continuously to ensure that the fabric is heated evenly and dyed consistently. The temperature and pressure inside the cylinder are monitored in real time during the heating process. If the temperature deviation exceeds 0.3℃ or the pressure deviation exceeds 0.05Kg / cm², the linkage control program automatically adjusts the heating power and air intake to ensure dyeing stability.

[0028] (2) High-temperature replacement washing stage: After the dyeing and heat preservation is completed, the linkage control program automatically starts the high-temperature direct discharge module, injects 98 degrees Celsius high-temperature clean water into the dyeing vat for replacement, the replacement water volume is 4 tons per vat, the cooling rate is controlled at 2 degrees Celsius per minute, and the temperature is accurately reduced from 130 degrees Celsius to 90 degrees Celsius; at the same time, the high-temperature replacement return circulation cleaning and diversion process is started, the return water pipeline flow rate is controlled at 100 liters per minute, and a 50-micron precision filter screen is set at the return end for oligomer filtration. The filter screen is a conventional industrial precision filter screen, which can be purchased on the market. The wastewater discharge end is linked to the electric ball valve through the COD real-time monitoring instrument. When the COD reaches 1000mg / L, the discharge is automatically opened and automatically closed after the discharge is completed, ensuring that the washing process meets environmental protection standards, and at the same time avoiding oligomer contamination of the fabric surface.

[0029] (3) Reduction Washing Stage: Maintain the tank temperature at 90 degrees Celsius, and precisely add reducing agent through the injection system at a dosage of 3.0 g per liter. The reducing agent is a conventional textile printing and dyeing reducing agent, which is commercially available. Fill the tank with saturated steam to create an oxygen-free environment, controlling the oxygen content at 2.5%. The reduction wash lasts for 30 minutes. During the reduction wash, temperature and pressure are linked through a linkage control program. For every 5 degrees Celsius decrease in temperature, the tank pressure is simultaneously reduced by 0.2 kg / cm². When the tank pressure exceeds 4 kg / cm², the pressure is reduced by 0.2 kg / cm². 2 The exhaust valve opens automatically and closes automatically after the pressure returns to the standard value, ensuring production safety and the effectiveness of the rehydration process.

[0030] (4) Unloading Stage: After the reduction wash is completed, the linkage control program starts the cooling system, cooling the fabric to 60 degrees Celsius at a rate of 0.7 degrees Celsius per minute. After cooling is completed, the system will automatically prompt the fabric to be unloaded. When unloading directly, the fabric guide speed is 400 meters per minute, the nozzle gap is 4 millimeters, and the replacement water flow rate is 1.5 meters per second. During the fabric guide process, the fabric is smoothly transported by the rubber strip lifting wheel to avoid friction damage to the fabric surface. After unloading, the fabric undergoes conventional drying treatment at a drying temperature of 120 degrees Celsius for 20 minutes. After drying, various quality indicators are tested.

[0031] Example 2: The applicable fabric is a polyester-spandex warp-knitted fabric with a weight of 150 grams per square meter, a light apricot color, and a spandex content of 10%. This fabric is a regular elastic textile fabric that can be directly purchased from the market and requires no special pretreatment before use.

[0032] The core equipment is exactly the same as in Example 1, except that the injection pressure of the transverse injection circulation system is slightly adjusted to 0.25MPa to adapt to the dyeing uniformity of elastic fabrics, avoid damage to elastic fibers, and ensure dyeing quality. After the injection pressure is adjusted, the parameters are locked through the linkage control program to maintain stability throughout the process without the need for manual adjustment.

[0033] The process steps are as follows: (1) Dyeing stage: The polyester-spandex warp-knitted fabric is placed in the dyeing vat and heated to 130 degrees Celsius at a rate of 1.5 degrees Celsius per minute. The fabric is dyed at high temperature and kept warm for 30 minutes. The initial pressure in the vat is 1.8 kg / cm. 2 , During the heating process, the guide speed is reduced to 300 meters per minute to reduce fabric tension and avoid stretching damage to elastic fibers. The fabric tension is monitored in real time during the heating process. If the tension exceeds the set threshold, the linkage control program automatically adjusts the guide speed to ensure that the fabric is not damaged.

[0034] (2) High temperature replacement water washing stage: After the dyeing and heat preservation is completed, the high temperature direct discharge module is directly started to inject high temperature clean water of 98 degrees Celsius for replacement. The replacement water volume is 2.5 tons per cylinder, the cooling rate is 2 degrees Celsius per minute, and the temperature is accurately reduced from 130 degrees Celsius to 90 degrees Celsius. The flow rate of the return water pipeline of the high temperature replacement return circulation cleaning and diversion process is controlled at 80 liters per minute, and the pore size of the precision filter is adjusted to 80 microns to meet the floating color filtration requirements of medium and light colored fabrics. The wastewater COD discharge threshold is 1000mg / L to ensure that there is no floating color residue on the fabric surface after washing.

[0035] (3) Reduction washing stage: Maintain 90 degrees Celsius, accurately add reducing agent through the injection system at a dosage of 2.8 g / L, oxygen content in the tank is 2.8%, and reduction washing lasts for 25 minutes; the temperature and pressure linkage rules are the same as in Example 1, and the maximum pressure in the tank is controlled at 3.5 kg / cm. 2 It adapts to the pressure requirements of elastic fabrics, avoids excessive pressure that could damage the fabric's elasticity, and monitors the concentration of the reducing agent in real time during the recovery washing process to ensure that the recovery effect meets the standards.

[0036] (4) Out of the vat stage: After the reduction wash is completed, the temperature is reduced to 50 degrees Celsius at a rate of 0.8 degrees Celsius per minute. The fabric guide speed is 300 meters per minute, the nozzle gap is 5 mm, and the replacement water flow rate is 1.2 meters per second to ensure the flatness of the elastic fabric surface. After out of the vat, conventional shaping treatment is adopted. The shaping temperature is 110 degrees Celsius and the shaping time is 15 minutes. After shaping, various quality indicators are tested to ensure that the fabric elasticity and flatness meet the standards.

[0037] Example 3: The applicable fabric is a nylon-spandex woven fabric with a weight of 300 grams per square meter, a pure black color, and an 8% spandex content. This fabric is a high-end textile fabric, available on the market, and requires routine pre-shrinking treatment before use to remove internal stress.

[0038] The core equipment is the Zhejiang Basuni ZJBSN long-cylinder series dyeing vat, with an optimized transverse feeding and circulation system featuring a circular, uniform feeding pattern. The feeding point spacing is 15 cm, and the feeding pressure is 0.5 MPa, ensuring uniform dyeing of dark-colored fabrics. It is equipped with a downward-sloping guide pipe with a 15-degree incline to reduce friction between the fabric and the equipment. The fabric lifting wheels use fluororubber strips with a Shore hardness of 70 HA. The core components of the vat are made of 316L cold-rolled stainless steel with a thickness of 10 mm, enhancing the equipment's durability and corrosion resistance. The self-adapted DCW400 high-temperature direct discharge module has its flow distribution unit blade angle adjusted to 35 degrees, improving replacement efficiency. The dyeing vat and the high-temperature direct discharge module are rigidly connected via a DN100 flange. It features a 485 communication protocol linkage control program and a newly added greywater reuse linkage module, enabling the filtration, testing, and recycling of greywater. Greywater automatically enters the system after passing quality tests and automatically switches to clean water if it fails to meet standards.

[0039] The process steps are as follows: (1) Dyeing stage: The pre-shrinked nylon-spandex woven fabric is placed in the dyeing vat, and the temperature is raised to 130 degrees Celsius at a rate of 1.0 degrees Celsius per minute. The fabric is dyed at high temperature and kept at that temperature for 45 minutes. The initial pressure inside the vat is 2.2 kg / cm². 2 During the heating process, the fabric guide speed is 500 meters per minute. The sinking and climbing fabric guide tube reduces the friction between the fabric and the equipment, avoiding fuzzing and damage to the fabric surface. The injection circulation system is turned on simultaneously during the heating process to ensure uniform dye penetration and improve the coloring depth of dark fabrics.

[0040] (2) High-temperature replacement washing stage: After dyeing and heat preservation, the high-temperature direct discharge module is started, and treated greywater is injected as replacement water. The reuse rate of recycled water is 65%, the replacement water volume is 3.5 tons per tank, and the cooling rate is 2.5 degrees Celsius per minute, accurately achieving a temperature drop from 130 degrees Celsius to 90 degrees Celsius. The flow rate of the return water pipeline in the high-temperature replacement return circulation cleaning and diversion process is controlled at 120 liters per minute. The precision filter screen has a pore size of 50 microns, which efficiently filters oligomers and floating dyes. The COD discharge threshold of the wastewater is 1000 mg / L. No anti-fouling additives are needed to achieve efficient removal of oligomers and floating dyes. The greywater is treated by conventional filtration and disinfection. The treatment equipment is conventional industrial water treatment equipment, which can be purchased on the market. The water quality after treatment meets the standards for dyeing and printing water, ensuring the washing effect and fabric quality.

[0041] (3) Reduction washing stage: Maintain 90 degrees Celsius, accurately add reducing agent through the injection system at a dosage of 3.5 grams per liter, oxygen content in the cylinder is 1.8%, and reduction washing lasts for 35 minutes; the temperature and pressure linkage rule is optimized so that for every 5 degrees Celsius decrease in temperature, the pressure in the cylinder is simultaneously reduced by 0.25 kg / cm. 2 The cylinder pressure exceeds 4 kg / cm². 2The exhaust valve opens automatically to accommodate the deep washing requirements of dark-colored fabrics, ensuring that the color fastness meets the standards. The agent is stirred in real time during the washing process to ensure that the reducing agent comes into full contact with the fabric.

[0042] (4) Unloading stage: After the reduction wash, the fabric is cooled to 45 degrees Celsius at a rate of 0.6 degrees Celsius per minute before being unloaded from the vat. The fabric guide speed is 600 meters per minute, the nozzle gap is 3 millimeters, and the replacement water flow rate is 1.8 meters per second. The fabric lifting wheel with the guide tube achieves tension-free unloading of the fabric, with no transfer throughout the process, avoiding fabric creases and damage. After unloading, the fabric undergoes high-end setting and drying treatment. The setting temperature is 130 degrees Celsius, the setting time is 25 minutes, and the drying temperature is 125 degrees Celsius, the drying time is 22 minutes. After treatment, various quality indicators are tested to ensure that the dark-colored fabric does not fade and has uniform color.

[0043] Comparative Example 1: The applicable fabric is a dark-colored all-polyester knitted fabric, corresponding to Example 1, with a weight of 200 grams per square meter, a navy blue color, and a single-drum processing weight of 500 kilograms.

[0044] The process involves dyeing at 130 degrees Celsius for 40 minutes, cooling to 25 degrees Celsius, transferring the fabric, washing three times with 10 tons of water per vat, followed by a reduction wash at 90 degrees Celsius with 4.0 grams of reducing agent per liter, and then cooling the fabric out of the vat to 60 degrees Celsius. The transfer process is done manually, taking approximately 10 minutes each time, which can easily damage the fabric surface.

[0045] The core parameters are: no high-temperature direct discharge module, no temperature and pressure linkage control, the fabric is manually transferred, the washing process is carried out twice per vat, and 0.5 grams of anti-fouling agent is added per liter. There is no independently optimized equipment structure or control logic. It completely follows the traditional process operation mode without any innovation.

[0046] The equipment used is a conventional dyeing vat without any optimized structure, which is fundamentally different from the equipment configuration of this invention.

[0047] Comparative Example 2: The applicable fabric is a light-colored polyester-spandex warp-knitted fabric, corresponding to Example 2, with a weight of 150 grams per square meter, a light apricot color, a spandex content of 10%, and a single-drum processing weight of 500 kilograms.

[0048] The process involves dyeing at 130 degrees Celsius for 30 minutes, cooling to 80 degrees Celsius, a simple water wash using 6 tons of water per vat, a reduction wash at 90 degrees Celsius with 3.8 grams of reducing agent per liter, and finally cooling out of the vat to 50 degrees Celsius. The simple water wash lacks precise parameter control and only removes excess dye through routine rinsing.

[0049] The core parameters are that the dyeing vat and washing module are simply assembled, using a common communication method, resulting in low temperature and pressure control accuracy, with a temperature error of 3 degrees Celsius and a pressure error of 0.5 kg / cm². 2 There is no fabric type parameter matching library, no precise control of cooling rate, no independently developed flow distribution unit and linkage control program, and no core logic for seamless dyeing and washing has been formed; it is merely a simple integration of steps.

[0050] The equipment used is a combination of conventional dyeing vats and washing modules, without any independently optimized structure. The control logic is simple and cannot achieve precise control.

[0051] Comparative Example 3: The applicable fabric is a dark-colored nylon-spandex woven fabric, corresponding to Example 3, with a weight of 300 grams per square meter, a pure black color, an 8% spandex content, and a single-cylinder processing weight of 500 kilograms.

[0052] The process steps are as follows: dyeing and holding at 130 degrees Celsius for 45 minutes, cooling down to 25 degrees Celsius, starting the high-temperature direct discharge module for water washing, using 5 tons of water per tank, reducing wash at 90 degrees Celsius, using 3.5 grams of reducing agent per liter, and cooling out of the tank to 45 degrees Celsius.

[0053] The core parameters retain the core equipment of this invention, but omit the core step of high-temperature replacement water washing. It still cools down to room temperature before washing, lacks precise temperature and pressure linkage control, lacks independently developed process logic and parameter matching system, and does not integrate greywater reuse technology. In essence, it still does not break through the process bottleneck of traditional processes, and is merely a simple superposition of equipment, which cannot achieve the technical effect of this invention.

[0054] The equipment is operated manually without a linkage control program. Parameter adjustments rely on human experience, resulting in poor stability.

[0055] The implementation of the short-process dyeing and washing process described in this invention is based on conventional technical specifications and common industrial implementation methods in the textile printing and dyeing field. It does not rely on undisclosed special technologies, special customized consumables, or exclusive equipment. Those skilled in the art can fully implement this process without creative labor by combining the process parameters, equipment structure, and control rules described in this invention with conventional operating methods in the printing and dyeing industry.

[0056] The structural adjustments and modular assembly of the core equipment involved in this process are all conventional mechanical modification processes in the dyeing and printing industry. Conventional long-cylinder dyeing vats can be adapted according to the parameters described in this invention without special technical requirements. The precision filters, fluororubber gaskets and strips, COD real-time monitors, electric ball valves, and other consumables and detection and control components involved are all commercially available industrial supplies in the textile dyeing and printing industry and do not require customization. The reducing agent used is a conventional commercially available reducing agent for dyeing and printing, without specific models or composition limitations, and commercially available products can be directly selected according to the mixing ratio. The linkage control program system based on the 485 communication protocol uses a conventional industrial control computer in the dyeing and printing industry as the running platform. Through conventional PLC programming technology, all control logics described in this invention, such as temperature and pressure regulation, COD linkage sewage discharge, tension monitoring and cloth guide speed adjustment, and greywater reuse linkage, can be realized. This invention has clearly defined all control rules and trigger thresholds, and there are no special software or hardware requirements for program writing and debugging.

[0057] Fabric pre-shrinking, drying, and setting after dyeing are all standard post-processing techniques in the dyeing and finishing industry. The equipment used is industry-standard, and fine-tuning of process parameters is standard practice within the field. The recycled water used in the nylon-spandex woven fabric process, after treatment using standard water treatment processes in the textile dyeing and finishing industry, meets the reuse standards for reclaimed water in the "Water Pollutant Discharge Standard for Textile Dyeing and Finishing Industry" and can be used without special requirements. This process can operate under standard production conditions in textile dyeing and finishing workshops. The fabric weight processed per dyeing vat can be adjusted within the industry's standard range based on the actual volume of the dyeing vat. Equipment debugging and process operation are standard procedures in the dyeing and finishing industry; personnel with standard dyeing and finishing equipment operation skills can complete all operations without special professional training. All process parameters, equipment structures, and control rules described in this invention are preferred solutions for achieving the technical effects. Those skilled in the art can still achieve the invention's objectives and achieve high efficiency, energy saving, and improved fabric processing quality by making standard adjustments to the above-mentioned general implementation conditions based on the technical solutions disclosed in this invention.

[0058] Performance testing and results analysis: Test metrics and test methods: Core evaluation indicators for the textile printing and dyeing industry were selected, and the testing methods all adopted national industry standards and actual production measurement methods to ensure that the test results are authentic, reliable, and consistent with real-world principles, as detailed below: (1) Production cycle: The total time from when the fabric enters the vat to when it exits the vat, in minutes, is recorded by the workshop production timekeeping system; (2) Water consumption: The total water consumption for single-cylinder production, measured in tons by a water meter; (3) Steam consumption: The total amount of steam used by a single cylinder, measured in kilograms, is measured by a steam flow meter; (4) Power consumption: The total power consumption of a single-cylinder production equipment is measured in kilowatt-hours by an electricity meter; (5) Reducing agent consumption: The total amount of reducing agent used in a single cylinder production, expressed in grams per liter, is calculated based on the material ratio. (6) Comprehensive cost per ton of fabric: including water and electricity, steam, additives, labor, and washing tank, in yuan per ton, calculated based on actual production. (7) Fabric crease rate: The proportion of the fabric surface area with irreversible creases to the total fabric surface area, tested according to the textile fabric appearance quality inspection method, and expressed as a percentage. (8) Wash fastness: According to GB / T3921-2008 Textiles color fastness test, the wash fastness is tested and rated from 1 to 5. The higher the grade, the better the fastness. (9) Color uniformity compliance rate: According to GB / T250-2008 Textiles Color Fastness Test Evaluation Gray Scale, the proportion of fabrics with color deviation within grade 1 in the total fabrics is expressed as %.

[0059] The test results are shown in Table 1 below: Table 1:

[0060] Based on the above test data, it is clear that the short-process dyeing and washing process of this invention has significant advantages over traditional processes, existing integrated processes, and processes lacking the core steps of this invention in terms of production efficiency, energy consumption control, production cost, and fabric quality, fully verifying the practicality and feasibility of the process of this invention. Regarding the production cycle, the production cycles of Examples 1 to 3 are 95 minutes, 85 minutes, and 105 minutes, respectively, which are significantly shorter than the 180 minutes of Comparative Example 1, 130 minutes of Comparative Example 2, and 150 minutes of Comparative Example 3. This is mainly due to the fact that this invention eliminates the transfer and secondary heating steps, achieving uninterrupted dyeing and washing, and greatly reducing the time spent on process connections.

[0061] In terms of energy consumption control, the water, steam, and electricity consumption of the embodiments were significantly lower than those of the comparative examples. Specifically, the water consumption of Embodiment 2 was only 2.5 tons per cylinder, a 75% reduction compared to the 10 tons per cylinder of Comparative Example 1. The core reason for this is the application of a high-temperature replacement washing process, which eliminates the energy consumption of cooling and reheating in traditional processes, while also precisely controlling the replacement water volume to avoid water waste. Regarding reducing agent consumption, the reducing agent dosages of Embodiments 1 to 3 were 3.0 grams per liter, 2.8 grams per liter, and 3.5 grams per liter, respectively, lower than the 4.0 grams per liter of Comparative Example 1 and 3.8 grams per liter of Comparative Example 2. This eliminated the need for anti-fouling additives, further reducing additive consumption and effectively controlling production costs. The comprehensive cost per ton of fabric in the embodiments was all below 1100 yuan, a saving of over 30% compared to the 1580 yuan of Comparative Example 1.

[0062] In terms of fabric quality, the crease rate of the fabric in the embodiments was controlled below 0.5%, the washing fastness reached level 4.0 or above, and the color uniformity compliance rate exceeded 99%, which was far superior to the comparison ratios. This is due to the precise temperature and pressure linkage control, equipment structure optimization and fabric parameter adaptation of the present invention, which effectively avoids quality defects caused by transportation damage, temperature and pressure fluctuations, etc.

[0063] Although Comparative Example 3 retains the core equipment of the present invention, due to the omission of the high-temperature replacement water washing core step, its various performance indicators are still far inferior to those of Example 3. This further proves that the technical advantage of the present invention does not come from the simple superposition of equipment, but from the innovation of process logic and the precise matching of parameters.

[0064] In summary, the test results fully demonstrate that the process of the present invention can stably achieve efficient, energy-saving, and high-quality dyeing and washing effects.

[0065] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention.

Claims

1. A short-process dyeing and washing process, characterized in that, The fabric is processed using a dyeing vat equipped with a transverse material injection circulation system, a high-temperature direct discharge module, and a linkage control program system based on the 485 communication protocol. The process includes dyeing, high-temperature replacement washing, reduction washing, and vat removal. During the dyeing stage, the fabric is placed in the dyeing vat, heated to 130 degrees Celsius, and held at that temperature. The transverse material injection circulation system operates continuously during the heating process, and the linkage control program system monitors the temperature and pressure inside the vat in real time and automatically adjusts them. Temperature deviations exceeding 0.3 degrees Celsius and pressure deviations exceeding 0.05 kg / cm² are allowed. 2 The system automatically adjusts the heating power and air intake. During the high-temperature replacement washing stage, the linkage control program automatically starts the high-temperature direct discharge module to inject high-temperature water into the dyeing vat for replacement, achieving a temperature drop from 130 degrees Celsius to 90 degrees Celsius. Simultaneously, the high-temperature replacement return circulation cleaning and diversion process is started. The return end is equipped with a precision filter screen for filtration. The wastewater discharge end is linked to an electric ball valve through a real-time COD monitor. When the COD reaches 1000 mg / L, the discharge is automatically opened and automatically closed after the discharge is completed. During the reduction washing stage, the temperature inside the vat is maintained at 90 degrees Celsius. A reducing agent is added through the injection system, and saturated steam is introduced into the vat to control the oxygen content. The linkage control program achieves temperature and pressure linkage control. During the vat exit stage, the linkage control program starts the cooling system to reduce the temperature inside the vat to the preset temperature before the fabric exits the vat. During the exit process, the fabric is conveyed by rubber strip lifting wheels.

2. The short-process dyeing and washing process according to claim 1, characterized in that, The fabric being processed is a 100% polyester knitted fabric with a weight of 200 grams per square meter; the dyeing stage involves a heating rate of 1.5 degrees Celsius per minute, high-temperature dyeing and holding for 40 minutes, and an initial pressure of 2.0 kg / cm² in the dyeing vat. 2 During the heating process, the guide cloth speed is 400 meters per minute; the horizontal injection circulation system has an injection pressure of 0.4MPa, the injection points are evenly distributed on one side, and the injection point spacing is 20 cm; the high temperature direct discharge module is of type DCW600, its flow distribution unit blade angle is 30 degrees, the dyeing vat and the high temperature direct discharge module are rigidly connected by DN125 flange, and the matching fluororubber high temperature resistant sealing gasket is 4 mm thick.

3. The short-process dyeing and washing process according to claim 2, characterized in that, The high-temperature water used in the high-temperature replacement water washing stage is 98-degree Celsius clean water, with a replacement water volume of 4 tons per cylinder and a cooling rate of 2 degrees Celsius per minute; The high-temperature replacement reflux circulation cleaning and diversion process has a return water flow rate of 100 liters per minute and a precision filter screen with a pore size of 50 microns at the return end.

4. The short-process dyeing and washing process according to claim 2, characterized in that, During the reduction wash stage, the reducing agent dosage is 3.0 g / L, the oxygen content in the tank is 2.5%, and the reduction wash lasts for 30 minutes. The temperature and pressure linkage control rule is that for every 5 degrees Celsius decrease in temperature, the pressure in the tank is simultaneously reduced by 0.2 kg / cm². 2 The cylinder pressure exceeds 4 kg / cm². 2 The exhaust valve opens automatically; the cooling rate during the exiting stage is 0.7 degrees Celsius per minute, the temperature inside the cylinder drops to 60 degrees Celsius before exiting the cylinder, the speed of the fabric guide after exiting the cylinder is 400 meters per minute, the nozzle gap is 4 millimeters, the replacement water flow rate is 1.5 meters per second, and the fabric is dried at 120 degrees Celsius for 20 minutes after exiting the cylinder.

5. The short-process dyeing and washing process according to claim 1, characterized in that, The fabric being processed is a polyester-spandex warp-knitted fabric with a spandex content of 10% and a weight of 150 grams per square meter. The dyeing stage involves a heating rate of 1.5 degrees Celsius per minute, high-temperature dyeing and heat preservation for 30 minutes, an initial pressure of 1.8 kg / cm² in the dyeing tank, a fabric guide speed of 300 meters per minute during the heating process, and a linkage control program system that monitors the fabric tension in real time and automatically adjusts the fabric guide speed. The transverse injection circulation system has an injection pressure of 0.25 MPa.

6. The short-process dyeing and washing process according to claim 5, characterized in that, The high-temperature replacement water washing stage uses 98-degree Celsius clean water, with a replacement water volume of 2.5 tons per cylinder and a cooling rate of 2 degrees Celsius per minute; The high-temperature replacement reflux circulation cleaning and diversion process has a return water flow rate of 80 liters per minute, and the precision filter screen at the return end has a pore size of 80 micrometers.

7. The short-process dyeing and washing process according to claim 5, characterized in that, During the reduction wash stage, the reducing agent dosage was 2.8 grams per liter, the oxygen content in the tank was 2.8%, and the reduction wash lasted for 25 minutes. The temperature and pressure linkage control rule was that for every 5 degrees Celsius decrease in temperature, the pressure in the tank would be reduced by 0.2 kg / cm². 2 The maximum pressure inside the cylinder is controlled at 3.5 kg / cm². 2 The concentration of reducing agent is monitored in real time; the cooling rate during the discharge stage is 0.8 degrees Celsius per minute, the temperature inside the cylinder drops to 50 degrees Celsius before discharge, the discharge speed of the fabric guide is 300 meters per minute, the nozzle gap is 5 millimeters, the displacement water flow rate is 1.2 meters per second, and the fabric is set at 110 degrees Celsius for 15 minutes after discharge.

8. The short-process dyeing and washing process according to claim 1, characterized in that, The fabric used for processing is a nylon-spandex woven fabric with an 8% spandex content and a weight of 300 grams per square meter. The fabric undergoes pre-shrinking treatment before the dyeing stage. During the dyeing stage, the temperature rise rate is 1.0 degrees Celsius per minute, and the high-temperature dyeing is maintained for 45 minutes. The initial pressure inside the dyeing vat is 2.2 kg / cm². 2 During the heating process, the guide cloth speed is 500 meters per minute; the transverse injection circulation system is a ring-shaped uniform injection system with an injection point spacing of 15 cm and an injection pressure of 0.5 MPa; the high-temperature direct discharge module is a DCW400 type, with a flow distribution unit blade angle of 35 degrees, and the dyeing vat and the high-temperature direct discharge module are rigidly connected through a DN100 flange; a new greywater reuse linkage module has been added to the linkage control program system.

9. The short-process dyeing and washing process according to claim 8, characterized in that, The dyeing vat is equipped with a sinking and climbing guide pipe with a climbing angle of 15 degrees; the rubber strip lifting wheel is made of fluororubber with a Shore hardness of 70HA; the core component of the vat is 316L cold-rolled stainless steel with a thickness of 10 mm. During the high-temperature replacement water washing stage, treated reclaimed water is injected as replacement water, with a water reuse rate of 65%, a replacement water volume of 3.5 tons per cylinder, and a cooling rate of 2.5 degrees Celsius per minute. The high-temperature replacement reflux circulation cleaning and diversion process has a return water flow rate of 120 liters per minute and a precision filter screen with a pore size of 50 microns at the return end.

10. The short-process dyeing and washing process according to claim 8, characterized in that, During the reduction wash stage, the reducing agent dosage is 3.5 grams per liter, the oxygen content in the tank is 1.8%, and the reduction wash lasts for 35 minutes. The temperature and pressure linkage control rule is that for every 5 degrees Celsius decrease in temperature, the pressure in the tank is simultaneously reduced by 0.25 kg / cm². 2 The cylinder pressure exceeds 4 kg / cm². 2 The exhaust valve opens automatically, and the system is stirred in real time during the washing process. The cooling rate during the exiting stage is 0.6 degrees Celsius per minute, and the temperature inside the cylinder drops to 45 degrees Celsius before exiting. The speed of the fabric guide is 600 meters per minute, the nozzle gap is 3 millimeters, and the replacement water flow rate is 1.8 meters per second. With the help of the fabric guide tube, the fabric exits the cylinder without tension and without any transfer throughout the process. After exiting the cylinder, the fabric is set at 130 degrees Celsius for 25 minutes and dried at 125 degrees Celsius for 22 minutes.

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