Salt Mixture Electrolyte for Low-TDS Reactive Dyeing of Cellulose
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Solution Overview
Problem
The textile dyeing industry faces environmental issues due to high consumption of salts and alkalis, leading to excessive water usage, energy consumption, and pollution from colored effluents, as well as inadequate dye exhaustion and fixation on cellulose materials.
Innovation Solution
A method of reactive dyeing using a salt mixture as an electrolyte with 0.5-5 g/L of sodium chloride or sodium sulphate, combined with alkali agents I and II, to achieve efficient dye exhaustion, migration, and adsorption on cellulose materials, reducing the amount of water, energy, and manpower required while minimizing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large quantities of electrolyte (salts) are added to provide affinity and acceleration of dyestuff, then dye exhaustion and fixation are improved, but environmental pollution and TDS levels increase
Solution Approach 1:
The invention changes the concentration parameter of electrolyte from conventional high levels (30-100 g/l) to optimized low levels (0.5-5 g/l) while maintaining effective dye exhaustion and fixation through improved process control and the synergistic effect of alkali agents
Solution Approach 2:
The invention introduces alkali agents (sodium carbonate, potassium carbonate, or their mixtures) as intermediary substances that work synergistically with minimal electrolyte to achieve both dye fixation and environmental sustainability, replacing the need for high salt concentrations
2Reliability
If high concentrations of salts and alkalis are used in dyeing, then dye fixation potency is improved, but water consumption and effluent volume increase
Solution Approach 1:
The invention optimizes the concentration parameters of both salts and alkalis, reducing salt to 0.5-5 g/l and alkali to 5-20 g/l ranges, achieving effective dye fixation with reduced water consumption and minimized effluent volume
Solution Approach 2:
The invention uses partial action by applying minimal necessary electrolyte (0.5-5 g/l) combined with optimized alkali treatment to achieve sufficient dye fixation without excessive water usage, balancing effectiveness with resource conservation
3Reliability
If conventional amounts of salts (30-100 g/l) and alkali (5-20 g/l) are used, then dyeing process effectiveness is maintained, but energy consumption and processing time increase
Solution Approach 1:
The invention reduces salt concentration parameter to 0.5-5 g/l and optimizes alkali concentration to 5-20 g/l, achieving effective dyeing with reduced energy consumption and shorter processing time through improved chemical efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in excellent dyeing with perfect levelling properties, lower COD, BOD, and TDS, and a safer environment by reducing the consumption of water, energy, and manpower, while ensuring effective dye fixation and reduced pollution.
Implementation Method 1
using the salt mixture as an electrolyte to provide affinity of the dyestuff, acceleration of the dyestuff association and exhaustion of dyestuff
Implementation Method 2
exhaustion of dyestuff for migration and adsorption with alkali agents I and II to provide fixation of the dyestuff
Data Source
AI summary
The present invention relates to a method of dyeing using a salt mixture as an electrolyte with 0.5 to 5.00 GPL of sodium chloride or sodium sulphate and alkali agents I and II to exhaust and fix a dyestuff to a cellulose material in a reactive dyeing. In the method the cellulose fiber is treated with (i) the salt mixture with sodium chloride or sodium sulphate specifically, putting the pre-treated fiber maintained at a pH between 3 and above and an (MLR) maintained between 1:20 and 1:3 at a temperature between 20° C. and above and exhausted for between 15 minutes and above, (ii) the alkali agent I with a pH between 9.5 and above at a temperature between 30° C. and above and stained for between 20 minutes and above (iii) the alkali agent II with a pH between 10.5 and above at a temperature between 30° C. and above and stained for 40 minutes and above.