wp4 textile pre treatment - unisi.it › wp-content › uploads › 2010 › 08 › wp4_ntt2.pdf ·...
Post on 24-Jun-2020
1 Views
Preview:
TRANSCRIPT
Bioprocessing for Sustainable production of COLoured textiles
Çerkezköy July 11th, 2013
WP4 WP4 Textile preTextile pre‐‐treatmenttreatment
BISCOLBISCOLECO/09/256112ECO/09/256112
Characterisation of the plasma treated fabrics
Optimal process parameters for the treatment of woollen fabric are listed in the table below, implemented in the machinery.
Carrier Gas Helium 25 NL/min
Process Gas Nitrogen 2 NL/min
Treatment speed 8 m/min
Electrode number 8
Fabric width 600 mm
Fabric Thickness < 2 mm
Relative Power 12.5%
Nominal Power 565 W
Specific Power 1800 W min/m2 (904 W min/m2 per side)
Passes 2 (1 for each side)
Characterisation of the plasma treated fabrics
By applying those conditions the following benefits can be achieved:
Complete removal of the epicuticle layer without affecting bulk properties of the fibres
Increase in the wettability of the woollen fibres over 72 mN/m
Increase in the absorption rate constant for small molecules including Acid dyestuffs (up to 20‐25%)
Good Dimensional Stability Properties as per WIRA steam relaxation test
Improved mechanical properties
Protocol of dyeing
Dyeing protocol applied for woollen fabrics dyed with a commercial acid dyestuffscommercial acid dyestuffs by using the two auxiliaries set‐up by ACHIMO
Protocol of dyeingDyeing protocol applied for woollen fabrics dyed with byodye SIALB 1byodye SIALB 1 by using the two auxiliaries set‐up by ACHIMO
In order to identify the most proper temperature enabling to dyeing the selected substrates, exhausted baths have been sampled at different temperature in the range 40 – 98 °C for Auxiliary 1 and 40 – 80 °C for the Auxiliary 2.
Conventional dyestuff + BISCOL Auxiliaries
The study carried out with the conventional dyestuff is showing that a significant reduction in the energy required for the fibres dyeing has been achieved.
Dyestuff absorption trend for the untreated samples and plasma treated samples in function of the temperature for Auxiliary 1 and 2.
Auxiliary 1 Auxiliary 2
Conventional dyestuff + BISCOL Auxiliaries
Auxiliary 1
• The removal of the fatty layer and the ablation of the fibres surface is promoting dyestuff uptake enabling to reach the same colour tone and shade by reducing the temperature up to 86 °C. • This induces a reduction of the energy consumed to heat the dyeing bath of 2.7 MJ/Kg (‐19.6%) in comparison with conventional conditions currently applied in dyehouses.
Auxiliary 2
• A lower improvement in the dyeing temperature reduction has been achieved since the levelling agent is representing a limitation to achieve additional benefit since it is specifically designed to delay dyestuff adsorption.
• In any case, this additional reduction that it’s allowing to achieve same colour tone and shade that conventional process and products by reducing energy consumption up to 4.8 MJ, meaning that up to 35% of the total energy can be saved.
Bio‐dyestuff + BISCOL Auxiliaries
The same results observed for the conventional dyestuff has been recorded also for theBiodyes. In the picture, the behaviour for SIALB is reported even if all tested biodyes are showing the same trend.
Dyestuff absorption trend for the untreated samples and plasma treated samples in function of the temperature for Auxiliary 1 (a) and Auxiliary 2 (b).
(a)
Bio‐dyestuff + BISCOL Auxiliaries
• For both the untreated and plasma treated samples a lower optimal temperature is recorded because of the smaller MW of the bio‐synthesised dyestuffs.
• Energy saving for both auxiliaries plasma treatment is promoting energy saving up to 2.5 MJ/kg for the auxiliary 1 and 1.4 MJ/kg for auxiliary 2 respectively. In the overall, in comparison with optimal dyeing process with biodyes without plasma pre‐treatment an overall reduction of the energy is estimated up to 3.9 MJ/Kg.
• If the BISCOL dyeing process is compared with Conventional dyeing process an overall reduction up to 5.7 MJ/kg can be achieved (42% reduction).
(b)
Economical evaluation of plasma pre‐treatment
Additional costs induced by the implementation of the machinery per ton of fabric.
Cost Category Product Unit cost Cost per kg1.
Investment costs Plasma Machinery 150,000 – 180,000 0.0180
Machinery Electrode replacement 450 0.0004
Consumables Helium [m3] 6.88 0.0215
Nitrogen [m3] 5.16 0.0171
Energy Electricity 0.12 kWh 0.0115
TOTAL 0.0686
1 According to dyehouse production capability of 1,000 ton
Economical evaluation of plasma pre‐treatment
Breakdown of the costs for woollen fabric dyeing with and without the plasma pre‐treatment – Conventional dyestuffs
Cost per production chain Conventional
Cost per Kg
Cost per production chain Conventional
Cost per Kg
Cost per production chain BISCOL
Cost per kg1.
NO Pre-treatment - BASOLAN 0.27 PLASMA 0.069
Dyeing Dyeing Dyeing
Consumables 0.108 Consumable 0.108 Consumable 0.108
Energy Aux 2Energy Aux 1
0.3810.458
Energy Aux 2Energy Aux 1
0.3810.458
Energy Aux2Energy Aux 1
0.2980.366
TOTAL Aux 2TOTAL Aux 1
0.4890.566
TOTAL Aux 2TOTAL Aux 1
0.7590.836
TOTAL Aux 2TOTAL Aux 1
0.474 0.543
Economical evaluation of plasma pre‐treatment
• Energy saving is induced a reduction in the process costs for the dyeing process that it is in the range 0.025 – 0.03 €/kg of fabrics. Considering the application of conventional process without the implementation of the Auxiliaries it reach up to 0.09 €/Kg of fabrics.
• Considering that the overall capability of a small to mediumdyehouse is around 1,000 tonns per year, the implementation of the combined process (Plasma pre‐treatment + New auxiliaries) can induce a total cost saving up to 92,000 €/year. The benefit induced by plasma treatment is around 23,000 €/year (meaning at least 4% of the total economical benefits)
• If the replacement of the chemical anti‐felting finishing is considered up to 58% of the costs can be saved with an overall benefit up to 362,000 euro can be achieved.
Economical evaluation of plasma pre‐treatment
Breakdown of the costs for woollen fabric dyeing with and without the plasma pre‐treatment – Biodyes dyestuffs
Cost per production chain Conventional
Cost per Kg
Cost per production chain Conventional
Cost per Kg
Cost per production chain BISCOL
Cost per kg1.
NO Pre-treatment - BASOLAN 0.27 PLASMA 0.069
Dyeing Dyeing Dyeing
Consumables 0.108 Consumable 0.108 Consumable 0.138
Energy Aux 2Energy Aux 1
0.3810.458
Energy Aux 2Energy Aux 1
0.3810.458
Energy Aux2Energy Aux 1
0.2860.267
TOTAL Aux 2TOTAL Aux 1
0.4890.566
TOTAL Aux 2TOTAL Aux 1
0.7590.836
TOTAL Aux 2TOTAL Aux 1
0.474 –0.492
Economical evaluation of plasma pre‐treatment
The benefit induced by the combination of the plasma pre‐treatment and biodyes is not inducing a significant reduction of the costs for Aux 2 since the energy benefits have been balancedby the increase of the dyestuff costs (figure provided by WETLANDS).
In any case, cost range have been reduced in comparison to conventional dyestuff up to a value of 0.492 €/kg, with a reduction from the maximum value of 0.05 €/kg. According to that minimum costs saving is around 74,000 €/year (maximum value is still 92,000 €/year).
top related