摘要
针对棉散纤维活性染料间歇式染缸染色存在效率低、水耗能耗大、用盐量大、废水排放量多的问题,使用研发的散纤维连续染色成套设备提升染色效果。以染色牢度、染色均匀度、固色率和染色深度为评判依据,采用实验室轧车模拟该设备的连续化染色工艺进行单因素探讨,得到较佳的染色工艺参数:活性黑5质量浓度为50 g/L,混合碱(NaOH与Na_(2)CO_(3)质量比为1∶4)质量浓度为20 g/L,室温堆置16 h。采用该工艺在生产型设备上进行产业化验证,结果表明:该工艺染色棉纤维的K/S值为39.86,棉纤维层左、中色差为0.49,右、中色差为0.36,内、外色差为0.27,前、后色差为0.62,各项色牢度与染缸工艺相当;与染缸工艺相比,该技术实现节约用水72%、节约染料31.25%、节约电量48%,节约蒸汽量38%,减少盐用量100%。经计算,散纤维连续染色工艺工作液的染料质量浓度比染缸工艺高3.75倍,纤维表面的染料浓度梯度较高,因此在无需额外加盐的状态下即可完成染料对纤维的上染。
Objective To address the issues of low production efficiency,high water and energy consumption,excessive salt usage,and significant wastewater discharge associated with the traditional exhausting dyeing method for loose cotton fibers with reactive dyes,the development of a complete set of continuous dyeing equipment for loose fibers could effectively solve this problem.In order to enhance the dyeing performance of this equipment,this study investigates the continuous dyeing technology for loose fibers under laboratory conditions,aiming to explore the optimal process parameters.Method A laboratory padder dyeing process were employed to simulate the continuous dyeing technology.Taking the color fastness,evenness,fixation rate and color depth as the evaluation indexes,experiments were carried out,and the optimized process were obtained.The experiment on the equipment of XCYL-15 was conducted in a factory.The color parameters and color fastnesses of fibers dyed with the continuous method were compared with those of fibers dyed with the conventional exhausting method.In addition,the economic and environmental benefits were analyzed.Results The optimized process parameters were identified through laboratory experiments,which are 50 g/L for the concentration of Reactive Black 5,20 g/L for the concentration of mixed alkali(1∶4 of the mass ratio for NaOH against Na_(2)CO_(3)),0 sodium sulfate addition,and 16 h stacking time at room temperature.With this optimal condition,the factory experiment was carried out with the XCYL-15 equipment.For the cotton fibers dyed with the continuous dyeing method,the K/S value was 39.86,the color difference ΔE_(1) between the left and the middle of the cotton fiber layer was 0.49,and the color difference ΔE_(2) between the right and the middle was 0.36,and the color difference ΔE_(3) between the inner and outer was 0.27,and the color difference ΔE_(4) between the front and rear was 0.62,indicating even dyeing of the cotton fiber layer and satisfaction of requirements.The color fastness of cotton fibers dyed via the continuous method was comparable to that of cotton fibers dyed using the traditional exhaust dyeing method.Specifically,the dry rubbing fastness and wet rubbing fastness of cotton fibers dyed by the continuous method were 4-5 and 3-4,respectively.Additionally,the K/S values of cotton fibers dyed by the continuous method and the traditional exhaust dyeing method were 39.86 and 36.57,respectively.However,the dye fixation of the continuous dyeing method reaches 86.5%,much higher than that of the traditional exhausting dyeing method,which is only 70.5%,resulting in high discharge of dyes into the dyeing wastewater.Compared with the traditional exhausting dyeing method,the continuous dyeing method would save 72%of water,31.25%of dyes,48%of electricity,38%of steam,and reduce the salt usage by 100%.Conclusion By adopting the continuous dyeing method for loose cotton fibers,the dye concentration on the fiber surface is 3.75 times that of traditional salt-containing exhausting dyeing method.According to the Fick′s second law,when the dye diffuses into the fiber,the higher the concentration,the greater the concentration gradient along the fiber radial direction.Consequently,the diffusion rate of the dye into the fiber interior is also higher,which is beneficial to the level dyeing.Therefore,the dyeing and fixation of the cotton fibers by the high concentration dye can be completed without the necessity of adding additional salt.This technology will revolutionize the exhausting dyeing process in the cotton color-spinning industry and is of great social,economic,and environmental significance.
作者
金少特
阎克路
黄金杰
陈德芳
史向阳
JIN Shaote;YAN Kelu;HUANG Jinjie;CHEN Defang;SHI Xiangyang(College of Biological Science and Medical Engineering,Donghua University,Shanghai 201620,China;National Engineering Research Center for Dyeing and Finishing of Textiles,Donghua University,Shanghai 201620,China;Xinchang County Yili Machinery Co.,Ltd.,Shaoxing,Zhejiang 312500,China)
出处
《纺织学报》
北大核心
2025年第10期129-134,共6页
Journal of Textile Research
关键词
棉散纤维
连续染色
活性染料
冷堆
节水
节能减排
loose cotton fiber
continuous dyeing
reactive dye
cold pad-batch
water saving
energy conservation and emission reduction
