Since 2008, the prices of water, electricity, steam, oil and other energy sources have been rising, and the prices of dyeing and chemical additives have been rising with the changes in the international energy situation. The implementation of the new labor law has further increased the labor costs of enterprises. The cost pressure of enterprises is getting bigger and bigger, and the profit margin is getting smaller and smaller. Especially in the textile printing and dyeing industry, it has reached a point where it is difficult to survive. Enterprises can't change the objective environment. To survive, we must focus on the internals of the enterprise, further adjust the process, and save energy and increase efficiency. Around this goal, we have made adjustments and applications in the following aspects, and achieved certain results.
1 Application of high-fixing reactive dyes Generally, the fixing dyes have a fixing rate of 50% to 70%. After dyeing, a large amount of dye remains in the dyebath. Some of them are hydrolyzed dyes. The deeper the color, the more dyes remain. . In response to this situation, some high-lifting reactive dyes have been selected, which have two vinylsulfone groups and one monochlorotriazine, all having excellent high exhaustion rate and high lifting power, and the hydrolysis dye is easy to remove. For example, dyeing black with about 9% of reactive dyes, using high-strength dyes for reactive dyes is only about 5%.
The required dyeing depth can be achieved with a small amount of material, which can reduce water washing by 2 to 3 times and reduce sewage discharge. It can save about 130 yuan per ton of dark cloth.
2 Application of biological enzymes in the pretreatment process The biological enzyme refining technology is a revolutionary breakthrough in the traditional cotton pretreatment process. It features low energy consumption, low wastewater discharge, low COD and BOD.
2.1 Traditional pre-treatment process: blank → refined oxygen bleaching → water washing → peracid → deoxygenation → dyeing.
Process recipe:
30% hydrogen peroxide 5g/L
Sodium hydroxide 1.5g/L
Scouring agent LCF-123 1g/L
Stabilizer ST-201 1g/L
Process conditions: bath ratio 1:10, temperature is 95 ° C, heat preservation for 60 min, then naturally cool to 70 ° C drainage, 80 ° C hot water wash in the pot for 20 min, cool to 60 ° C, drain, acid, deoxygenation.
The cost of the additive is: 370 yuan / t.
The caustic soda remaining on the fabric in the late stage of the bleaching process requires a large amount of hot water to be washed, and a large amount of alkaline waste water is generated. This pollutes the environment and increases the load on the sewage treatment system.
2.2 Biological refining enzyme pretreatment process: blank → bio-scouring enzyme scouring → water washing → dyeing.
Process recipe:
Scouring enzyme 2 g / L
Penetrant 1 g/L
Process conditions: 55 ° C, heat preservation for 50 min.
The cost of the additive is: 365 yuan / t.
Bio-refining enzyme pre-treatment and boil-free one-bath pre-treatment, saving water costs 50 yuan / t, saving electricity costs 40 yuan / t, saving steam costs 200 yuan / t; fabric dyeing rate after pretreatment with biological enzymes It can save 0.5%~0.8% dye, save time about 60min, reduce the amount of some pre-treatment additives, simplify the process and shorten the process flow; bio-enzyme refining does not require high temperature, high pressure, strong alkali and The catalytic action of the strong acid can be carried out: not only the treatment efficiency is high, but also the fabric is not damaged, the weight loss of the fabric is about 3%, the hand feeling is soft, the strong damage is small; the biological enzyme is easy to completely biodegrade, and the bio-scouring enzyme does not cause environmental pollution. .
Pre-treatment of medium and light-colored products, the shade is dark, and the cottonseed husk is not clean.
3 The test and application of dyeing substitute alkali agent is poor in water solubility, easy to block and block the filter screen of the equipment, and the chemical material is not easy to cause color rickets; it is difficult to wash after dyeing, and reacts with calcium and magnesium ions in water with high hardness. White spot. After several years of improvement and improvement of dyeing substitute alkali agents, the products are increasingly able to meet the needs of reactive dyeing. The amount of substitute base is 1/8~1/10 of the amount of soda ash, which can greatly reduce the amount of soda ash; the washing and wet fastness after substituting alkali fixation have different degrees of improvement; using substitute alkali agent 2 times Washing can reach the pH value of soda ash 3 times washing, easy to wash, save water and electricity; compared with soda ash fixing, it can save about 240 yuan per ton of medium and deep grey fabric by substituting alkaline agent, and the COD value of residual liquid after dyeing Reduce it by about 1700. In addition, compared with soda ash, it has a greater influence on the red dyeing rate, and is not suitable for dyeing red as the main color.
4 The adjustment of the cotton dyeing process is based on the dark color. The original process curve is shown in Figure 1. The adjusted process curve is shown in Figure 2.
As shown in Fig. 1 and Fig. 2, from the adjustment of the process curve, the dyeing per cylinder can be saved by 60 minutes, and the electricity cost is 137 yuan/t.
Figure 1 Pure cotton dyed traditional process curve
Figure 2 Pure cotton dyed dark adjustment process curve
5 One-bath dyeing process is applied to the dyeing of multi-component fibers (such as more than three kinds of fibers). The conventional dyeing process requires multi-bath dyeing, which not only consumes time and energy, but also discharges more. Through test analysis, additive selection, process adjustment, try to control one-bath two-step or two-bath dyeing to achieve maximum energy saving, emission reduction and consumption reduction. For example, there are four kinds of fibers in the fabric: polyester, cotton, sticky and nitrile. The acrylic fiber is incubated at 98 °C for 30 minutes, then cooled to 60 °C, and the precipitation inhibitor is added for 15 minutes. Then the disperse dye is added to the temperature to be dyed at l30 °C, and finally cooled. Restore cleaning, draining, washing, dyeing and adhesive.
6 Application of acidic soaping agent The soaping agent commonly used is an alkaline soaping agent. After dyeing, it needs 2 to 3 times of water washing and then acid soaping. The use of acidic soaping agent to reduce the acid acid link, and reduce the water washing, the dyeing cost of the dark product is greatly reduced, about 10 yuan / t.
7 The improvement of dyeing success rate can improve the success rate of dyeing, reduce the repair rate, reduce energy consumption, reduce sewage discharge and improve production efficiency. Generally, the following measures are taken:
a. Strengthen process monitoring, strictly implement processes, and monitor equipment status in a timely manner;
b. Timely test different batches of dyes and auxiliaries, improve the process according to the actual conditions of the test, and make the production and laboratory consistent;
c. The new order improves the dyeing pass rate by proofing, double sample and stakeout. The return order is based on different batches of yarn, and the production process is reviewed separately. The production process is adjusted in time to avoid the problem of color difference and color correction caused by replacing raw materials.
8 Conclusion Through the above process adjustment and application, we have successfully passed the difficult first half of 2008. Although various costs have been rising, under the premise that the prices of dyeing and finishing products have not been adjusted, we have absorbed some of the cost increase factors and achieved good economic benefits.
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