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Keshav Dhawan
B.Tech(Textile Chemistry)-VII Sem
Introduction
Current SCF Dyeing Technologies
Environmental Aspects
Process Steps
Process Parameters
Economization
Product Quality
Future Trends
Conclusion
Increasing consideration of ecologic consequences of industrial processes as
well as legislation enforcing the avoidance of environmental problems have
caused a reorientation of thinking and promoted projects for replacement of
conventional technologies. Quality standards to be met by industrial
wastewaters will certainly be raised in the future which will in turn cause
unpredictable increases in costs, in particular those incurred by having to
dispose of dye house effluents.
Dyeing process of fibers in supercritical carbon dioxide (scCO 2) is an example
of a ‘clean’ process suitable for fulfilling many of the requirements of
sustainability. In this process, a recyclable process medium(CO2) is used
together with an efficient and minimum input of chemicals(only dyes, no
auxiliaries) and energy (low dyeing times, fusion of processes, no drying) and
with minimal emissions and waste production. The quality of the dyed
materials is also very high.
Any gas above its critical temperature retains the free mobility of the gaseous
state but with increasing pressure its density will increase towards that of a liquid.
Supercritical fluids are such high compressed gases and as such they combine
valuable properties of both liquid and gas.
Conventional Dyes
After treatment in an aqueous dye-bath
and post-dye washing, the fibers show Complete
complete dye penetration. Colorfastness
and adherence is low to moderate when Penetration
exposed to cleaning agents.
.
Time : For a dye uptake of 2% ,a dyeing time of 40 minutes in Technical
plant and 60 minutes in Industrial plant is needed.
Although treatment time in scCO2 is significantly lower compared with the water
dyeing process including drying, the energy consumption of both processes seems to be
similar.
The warm up before dyeing and cooling in extraction step II of the thicker steel
walls of the scCO2 plant, need more energy compared with a water dyeing plant.
Based on the significantly shorter process times, in scCO 2 theoretically up to six process
cycles could be accomplished per day.
All shades as in water dyeing but also high color yields are obtained.
No differences in the reflectance spectra at the inside, middle, and outside of
the fabric pack were found indicating a high levelness of dyeing.
All dyes applied in this technology are approved by the Oecotex Standard 100.
Compared with the water dyeing process on an industrial scale, wash fastness
of PET when dyed in the same shade is sometimes up to one grade higher.
Stress–strain and viscosmetric molecular weight measurements of scCO 2 dyed
PET show that no fiber damage takes place under optimum dyeing conditions
The UV stabilizer or even perfumes may be transferred to fiber.
New classes of polymeric compounds have been developed with good
solubility in liquid CO2. These compounds are applied for non-aqueous
sizing.
Supercritical NH3 can be used for mercerization.
High Investment Cost.
High Pressure required for dye solubility.
Impact of dyeing machine weight is related to circulation.
Difficult to dye Natural Fibers.
Textile dyes classification:
Directs
Reactive NOT DISSOLVED
Acids/Basics
Sulphur IN SC- CO2
Vat
Mordant
Disperse
DISSOLVED IN
Pigments SC-CO2
Dyeing of supercritical fluid was limited to the synthetic fibers but the dyeing of
natural fibers is under progress. Chemical modification of natural fabrics before
dyeing is one of the possible treatments. Reverse micelles provide a stable
aqueous micro environment consisting of a water pool in non-aqueous medium.
The cellulose material by impregnating with hydrogen bond breaking chemicals
and or modification of cotton is done and afterwards pressure and temperature
release the dyestuff will be trapped inside the fiber.
Dyeing in super critical carbon dioxide has been identified as one of the
best alternatives to water-based dyeing. But, this favorable concept is
waiting for its commercial implementation. The Successful
commercialization of the above said concept will definitely improve the
economics of dyeing by the way of elimination of wastewater discharges.
www.appliedseparation.com
Process for dyeing hydrophobic textile material with disperse dyes from super-
critical carbon dioxide, US 5 199 956. 1993-04-06.