DE2524295A1 - WASTE-WATER-FREE PAINTING PROCESS AND DEVICE FOR ITS IMPLEMENTATION - Google Patents

Description

Patent attorneys
Dipl.-Ing. Roland Mertens
Dipl.-Phys. Dr. Rainer Keil
6 Frankfurt / M.
Ammeiburgstrasse 3 ^

P 82 P 87

Carlos Humbertο da Silva.Cardona
Arrancada do Vouga (Portugal)

Wastewater-free dyeing process and device for its

execution

The invention relates to a wastewater-free dyeing process
and a device for performing this method.

As is well known, the most widely used staining technique consists of dipping fabrics at each stage of the process Fabrication - raw material, thread or fabric or fabric - in watery baths heated to appropriate temperatures, which can be between 4o and 14o C, with a large

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Amount of heavily contaminated wastewater is produced.

A method for dyeing without water has already been proposed To date, various improvements have been introduced to the process to make it more useful and accessible to make, but its effectiveness was never doubted, nor was its usefulness denied. These improvements include the introduction of water as a valuable resource, albeit in a very small one Amounts. Since the name of the process, namely process for dyeing without water, seems nonsensical, the new one became Process called "wastewater-free dyeing process", the following will be explained in more detail.

The new dyeing process differs from all others in that it introduces atomization as the basis for one Dyeing of the highest quality, both on natural and synthetic fibers. It is characterized by the fact that the dyeing takes place at the same time as the preparation or treatment (preparacao) and the spinning, whereby the Friction between the fibers is used to evenly distribute the color. The atomization and consequently the coloring occurs in normal ways of lubricating or oiling the fibers, or using machines that are suitable for the same effect. A dye / lubricant mixture is used for spraying used beforehand according to the material to be colored and the type of coloring agent required has been calculated. What characterizes the process most, in spite of everything, is the fact that there is no waste water because they are all in the dye-lubricant mixture contained products are absorbed by the fibers. In this form the invention is about economics in addition, undoubtedly a valuable contribution to reducing water pollution, especially since it, without that wastewater (efluentes) arise, to a considerable extent

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consumption as well as the treatment of wastewater (Äguas residuais) decreased.

The method according to the invention also offers the following advantages:

It's economical in terms of time, energy, dyeing equipment, products, and water that make a thread of high quality and still with the possibility of special effects. In the case of bulky fibers tHB.) it is possible to use blends and threads (moulinSs), and Making threads that are impossible to make using ordinary methods. It reduces the usual losses between the spinning and the end use. Colors that are exactly identical to a pattern can be colored, and in quantities on the order of thousands of kilograms in a single spinning batch

The run-off or waste water-free dyeing process according to the invention can also be used in spinning worsted yarn as well as in Carded yarn spinning can be applied, only changing the method of initial application of atomization will. While the pulverization of worsted yarn is carried out in ordinary machines with minor changes, at Carded yarn the effort of a machine specially adapted to the effect is unavoidable, and what from the present one Acknowledgment has been made,

For a better understanding of the method according to the invention is The following description is divided into two parts, the first based on combed materials and the second based on carded references.

Worsted yarn (ρenteados)

As is well known, the raw materials for spinning lend themselves to that

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Comb system in the form of strands or flakes (mechas) and with parallel fibers, eliminating the application of atomization in the first mixer by ordinary devices is easy to lubricate the strands. Practical implementation, however, revealed that atomization of certain liquid dyes leads to environmental pollution, be it through unpleasant smell it by possible toxicity of the same. Therefore, it has become necessary to improve these conventional devices by they were isolated to make the procedure work without any fear. These innovations will be when the opportunity arises from the machine builders pre- --- sent.

The dyeing starts at the same time as the spinning, therefore it is necessary to use the appropriate lubricant for the dye to match the same material, so you can be sure that the "a, b, c" of the invention will be:

a) knowledge of the color to be imitated and the quality of the fibers to be dyed;

b) the choice of stains and the determination of the exact percentages in the laboratory for the conventional Procedure;

c) the selection of the appropriate lubricant that could enable good spinning and that also do dyeing would not affect. The ionic behavior is beyond the indispensable properties for the thermal Treatment to fix the colorant is fundamental.

Once you have followed the ABC of the procedure, you are able to carry it out. The wastewater-free dyeing process summarized in the following three phases:

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1) Application of the color-lubricant mixture to the Strand at the beginning of preparation or treatment;

2) impregnating and leveling the mixture into the fibers during preparation or treatment and spinning;

3) Fixing the coloring agent by means of suitable thermal treatments ·

use

In the first phase, atomization takes place by means of adjustable atomizers, which in the first treatment device

are attached so that a uniform distribution of the Dye / lubricant mixture is guaranteed. Because a mixture is of the utmost importance to the quality of the end result the following are the basic rules for obtaining mixtures of good quality, ease of use and better yield.

Choice of colorants

- One should always follow the criterion of choosing those of better reliability, with preference among them that are presented in a liquid and most concentrated form. It is to be taken into account that it the main goal is to always follow a maximum color intensity with a minimum amount of liquid, because the excess Moisture is not good for spinning, much more it can impair it. If it is not possible, on to obtain dyes in liquid form from the market and, if necessary, to use them in this process, a solution of identical colorants in powder form proves to be inevitable. In this case you have to have a good one Solution with a minimum of liquid from the already

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given reasons.

Almost all colorants can be used in the process according to the invention may be used, except for those that require post-development need, which is the case with chromium dyes (cromos) in wool, in indanthrene dyes in cotton, etc. Also excrete all the dyes that need large amounts of acids for their development, because in this case it is necessary to give the machines a great deal of sensitivity. The tests carried out so far show that the The state of preservation of the machines is perfect, with these machines operating in the range of pH 4-8, even during "" " long periods of time. One explanation for this almost utopia lies in the dye-lubricant mixture, because the lubricant In addition to its main function, it also acts in another, no less important direction, namely preservation of the machines

lubricant

This general term was chosen in view of the fact that the main function is to make the fibers lubricious so that they slide one on top of the other, allowing the dye molecules to simultaneously deposit, slowly and uniformly, on the fibers and without them make stretching difficult. In the case of synthetic fibers, an antistatic agent or even an emollient agent can advantageously be used instead of the ordinary lubricant, which combines the basic properties. Given the variety of combinations that allows the procedure and the large number of existing products on the market it is impossible to guess some of it here, because everything is fibers mainly by the F to be dyed _a and of the site-

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depend on the working conditions. As a general rule it can be added that the modern spin finish and spinning products fully adapt to the procedure, provided that the rules of compatibility are always observed.

Composition of the dye-lubricant mixture

As it is a general rule and also impossible, all hypotheses anticipated, the compilation is done in the following way:

a) In the laboratory, a pro "" percentage determined for the colorants to achieve the desired color ';

b) The χμ laboratory recipe obtained is converted to a final formulation, which is always higher Io%, which means that a percentage in the laboratory with a value of 0.6% to a final formulation of 0.66%, respectively. Then the necessary amount of coloring agent is calculated as a function of the kilogram of material to be colored and the necessary lubricant. Depending on the fiber, this is calculated at 0.5 - 2% , depending on whether it is synthetic or natural fibers.

Examples

For 2,000 kg of synthetic fibers?

Percentages and respective amounts

0.5 % - liquid yellow ..... lo, ooo g variable 0.025 % - liquid blue ... 5oo g

0.015 % - liquid red .... 3oo g constant 0.5 % - lubricant lo, ooo g

1.0 ^ 0 % 2o.8oo g

variable 0.96 % water 19,2oo g

2.00 % total lo, ooo g

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According to these percentages for the colorant, care must be taken to regulate the atomizers so that 20,8oo g are distributed over 2,000 kg of material. In practice, however, it turns out that in order to avoid the problem of constantly adjusting the atomizers correctly, it is better to always start from a single application percentage. It is known that for synthetic fibers an application percentage of 2% is ideal, or, what is the same, that every 100 kg of this type of fiber consume 2 kg of mixture. Whenever the total formulation of the dye / lubricant mixture does not reach 2 % , water must be added until this percentage is met. In the above example with 1.04% as the stated percentage, it is necessary to add 0.96% water until an ideal percentage of 2 % is reached Proposal did not emerge as a better means of regulating the percentages and therefore indispensable for the non-draining dyeing process.

In the case of intense colors, in which a calculated percentage exceeds 2% , it is advisable to test small quantities in the case of raw material for carding, while in the case of worsted yarn (penteados) it is essential, namely during spinning Difficulties can arise. While this is the only drawback of the process, since there is so little opportunity to achieve dark colors, various studies have been made to overcome such drawback and its solution will be found in due course by dye and machine manufacturers. In short, in the case of synthetic fibers, it is not appropriate to exceed the 2% use percentage without preliminary testing, wherein

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this disadvantage can be partially overcome by moving to concentrated liquid dyes.

This problem does not arise for natural fibers, since these fibers can withstand those amounts of moisture in the order of 8% without difficulty in spinning, and in the case of carded yarn it can even go up to 10% or 12% application percentage. In this case it should also be noted that it is essential to increase the percentage of lubricant up to 2%. In any case, it is important to keep the two goals in mind - spinning and dyeing - for the later special cases of any company.

Optionally, you can use the dye / lubricant mix Add other products that promote or support the intended goal. These include emollients, the dehumidifying agents, dispersants and others, one of which is called urea to promote development and Fixation of the dyes should highlight.

Impregnation and leveling

After applying the dye / lubricant mixture, the material shows up as irregularly colored and with many white dots. One must wait for the passage through the following machines for the leveling to occur, through the Mixing and stretching, which leads to the fibers rubbing against each other until they are completely equalized.

Also, at the beginning of the application of the mixture, it is advisable to make color tests by taking a small amount of the strands decreases from the output of the machine from the third or fourth bobbin in order to be more sure of the evenness. Thereafter one lets this small amount - loo or 200 g - through several times

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run a gill until you get a uniform color. Then the color is developed and fixed - by placing a sample in an autoclave at a temperature appropriate for the fibers and the dyes, performing the respective treatment. The result obtained is then compared with the type sample. So it is impossible for a color to be badly imitated because it can always correct itself. Assuming that the color is light, it is put together by adding the missing color components to the already prepared mixture so that these are not more than 10% above the total percentage of use. This means that if the application percentage is 2% - ■ - <* - , no more than 0.2 % coloring agent may be added, whereby the rules mentioned further must be observed. In the case of dark color, there are two solutions: the first is to proportionally increase the amount of material to be colored and the amount of water; the second is to reduce the percentage of use and discard the remaining excess of the mixture.

If it turns out that the dye is almost always fixed only at the end of the spinning, it was feared that the preparatory and spinning machines were overly colored at the end of one color. But since practice has shown that the resulting Coloring is only noticeable in the machine with which the dye / lubricant mixture is applied but nevertheless this coloring, since it is an oily mixture, can be easily removed.

The dyes are not yet at this stage of manufacture fixed, so they are not fixed yet. Therefore, it turns out to be extremely important that the handling always done carefully, and in particular it is necessary to avoid touching them with a wet hand. Meanwhile, can

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the thread that has already been produced is stored in dark warehouses or in opaque bags for long periods of time and wait for further manufacturing stages, such as twisting, winding, reeling, etc.

Fixing the dyes

This phase is undoubtedly the most sensitive of the procedure and must always be carried out in automated machines, so that unobjectionable uniformity between the fixations of the same spin batch is achieved. Examples taken from practice show that the safest The method of fixing the dyes is the one that is carried out in automatic autoclaves. Meanwhile, will in future the fixation will be carried out continuously in suitable machines. As can be easily seen, it proves impossible to set rigid norms for fixing dyes when such a large number of them are in the process can be used. Therefore, there is only one general rule for automatic autoclaves:

Pressure and temperature controlled to Io3 C in 15 min.

Vacuum of 3 min;

Pressure un
increase;

Fixation at Io3 ° C for 15 to 45 min, depending on the dye Type;

Cool down and vacuum, 2 min.

This cycle has been used in practice with the best results when it comes to the fixation of dyes acted, the textile material being in the form of threads wound on bobbins or reels. If one intends the fixation can still be carried out in the phase of the strands, or at the beginning or at the end of the preparation The fixation cycle can be shortened more, whereby the vacuums at the beginning and at the end are omitted and, if possible, also the cooling.

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The general rule given has been specially designed for polyacrylonitrile fibers, with and without high bulk (HB), and can also be used, and even with good results, for woolen threads. For polyester, the temperature must be increased to values on the order of 13o C and even above; the particulars of F _a rbstoffhersteller are valuable in this case.

When the dyeing cycle is finished with the fixation of the dyes, the dyeing process without wastewater is completed at the same time, It does not matter in which phase the fixation takes place, because from then on everything is normal and customary. the Accumulated quality samples were found to be identical to those from conventional procedures, with cases being proven were, in which the results were superior to the usual ones, if this procedure eliminates auxiliary products, which can reduce the quality. The most obvious case is that of acrylic resins where the results are generally superior to normal results because the fiber is unsaturated and especially because it is not attacked by baths of hot water, which adds so much to the detrimental aspect of the Contribute pilling. This is how you get high quality threads at the lowest price, because you take advantage of the possibilities of fibers and dyes is perfect. This method avoids the difficulties of reproducibility, the imperfections of the irregularity in the synthetic threads, which are deformed with the dyeing in devices, mainly when the dyed is on reels.

Carded yarn

The raw materials, natural or artificial, which are suitable for spinning carded, have confused and matted F _a on fibers, which impregnation with the dye-ZGleitmit-

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tel mixing difficult. A machine had to be created which, without complicating or complicating the subsequent stages of its own spinning process, works like a mixing plant for the worsted yarn material. The invention thus includes a machine which is essentially characterized by the following features:

1) A raw material feed, consisting of one with drivers equipped conveyor belt that regularly feeds a conveyor belt (2) at a constant speed loaded;

2) Conveyor belt (2), consisting of a roller belt, which also contains the raw material of the atomization by the atomizer (3) suspends and moreover promotes to the impregnation system (4);

3) Atomizers, which are arranged over the »conveyor belt (2) and ensure the even distribution of the dye / Ensure the lubricant mixture. They are equipped with electrical control devices that are included in the Are able to stop the atomization in the event that the loading stops. This avoids agglomeration of dyes. Regulating the percentage of use and the amount of dispersion of the same is done by means of compressed air, with which the container (io) and the associated Atomizer is acted upon. This gives a homogeneous and regular distribution of the mixture;

4) _# Impregnation system, consisting of a group of corrugated rollers, one of which is fixed, the other of which is adjustable to achieve a certain pressure on the raw materials that have already been dusted. The function of this group of rollers once 1st support impregnation with the applied to the raw material mixture, simultaneously preparing for the next phase;

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5) ReiiS mixing system consisting of a group of drums, which are covered with slightly inclined drivers. The diameters of these drums were calculated so that one at the same time tearing apart the raw material and equalizing or homogenizing the through friction Dye achieved. At the exit of the system there is a drum with a medium diameter, which discharges the Ensures raw material by placing it on the removal belt (6);

6} take-off belt, a roller belt that transports the raw material to the press rollers (7);

7) pressure rollers, designed to facilitate the subsequent packing and to assist in leveling the color, once they cause the fibers to come into contact with pressure ;

8) Ram, whose only function is to move the raw material to be pressed, being fed to the packaging;

9) Packing device whose intended purpose is the raw material for easier transport to the subsequent processing stages to concentrate;

10) Storage tank for the mixture, where everyone for the process flow is located necessary products.

In addition to the wastewater-free dyeing process for which it was created, this system can also be used in an advantageous manner Use of "ensimagens" or for the application of products can be used for a wide variety of purposes, provided they are able to et wickein this process.

With the introduction of this system, the difficulties which the carded yarn raw material in relation to the

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exhibited flow-free dyeing processes, and they were equal also offers the options already described in the "Worsted" chapter. This is how it works in the same way in 3 phases:

1) Use of the dye / lubricant ~ Geinisch by atomization;

2) impregnation and leveling;

3) Fixing the dyes.

The first 2 phases are carried out in the system described and as with worsted yarns, it is fixed in an autoclave. . ",",

The same procedure as for worsted yarns is used when selecting the dyes and making the dye / lubricant mixture described before. Once the raw material has been colored, i.e. at the exit of the system, the most recommended way is the immediate loading of an autoclave to carry out the dyeing. This ensures handling and quality, whereby the spinning follows as usual. The result is a loose material that cannot be obtained by other methods without Kinks or bridges or matting (bearing on the skin).

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Claims (10)

PATENT CLAIMS Wastewater-free, both on worsted and carded yarn materials Applicable dyeing process, characterized in that both natural and synthetic fibers at the same time with preliminary treatment and spinning by introducing the atomization of a dye / conductive mixture are dyed using the friction between the fibers to level the colorants. 2) Method according to claim 1, characterized in that the color emitter / lubricant mixture with the lubricant or oiling the fibers is atomized. 3) Method according to claim 1 or 2, characterized in that the dyeing is applied simultaneously with the spinning of the dye / lubricant mixture on the fiber flakes at the beginning of the preparatory treatment, followed by impregnating and leveling the mixture in the fibers and fixing the dyes by means of suitable ones thermal treatment. k) Method according to one of claims 1 to 3, characterized in that mixtures in liquid and in the most concentrated possible form or in the case of the powder form of the dye with a minimum of liquid are used for dyeing. 5) Method according to one of claims 1 to 4, characterized in that that antistatic or emollient agents are used for synthetic fibers in the mixture. 509851/0781 6) Method according to one of claims 1 to 5, characterized in that the percentage of use of the colorants is initially determined in a color sample in the laboratory, and an increased use percentage of the colorant and lubricants between 0.5 and 2 % are used for practical coloring, the application percentage is supplemented to its ideal value of 2% with water and, if necessary, auxiliaries, emollients, dispersants, urea are added. 7) The method according to any one of claims 1 to 6, characterized in that in the case of light color of the mixture already prepared, the respective missing dyes, if they are not more than Io % above the total use percentage, are added, in the case of dark color either the amount of the material to be colored and proportionally the amount of water increased or the application percentage decreased and the excess final mixture discarded. 8) Method according to one of claims 1 to 7 »characterized in that that the fixing of the dyes as the most sensitive process stage in automatic systems, especially continuously in automatic autoclaves according to the following general fixing rules for automatic autoclaves, especially for polyacrylonitrile fibers with or without a large volume, but also for wool fibers, namely at a vacuum of 3 min, a pressure and temperature increase controlled to Io3 C in 15 min, fixation at lo ~ C for 15 to 45 min, depending on Dye type, and cooling and vacuum of 2 min, against it for polyester resin material at temperatures of 13o C and above. 509851/0781 9) Method according to one of claims 1 to 8, characterized in that that in the case of fixing in the flake phase or that of the raw material or at the beginning the preparatory treatment after applying the dye / lubricant mixture, the fixation cycle is shortened is done by the vacuums at the beginning and at the end and if possible also the cooling, possibly also the Control of the increase in pressure and temperature can be omitted. 10) Device for performing the method according to one of claims 1 to 9, characterized essentially through the following features: 1) a raw material feed, consisting of a conveyor belt equipped with drivers, which with a feed conveyor belt (2) is regularly fed at a constant speed; 2) Conveyor belt (2), consisting of a roller belt, which also contains the raw material of the atomization suspends through the atomizer (3) and moreover promotes to the impregnation system (4); 3) Atomizers, which are arranged above the conveyor belt (2) and ensure even distribution ensure the dye / lubricant mixture, equipped with electrical control devices, able to stop the atomization in the event that the feed stops, regulating the percentage of application, as well as the amount of dispersion the same takes place by means of compressed air, with which the container (lo) and the associated atomizer are acted upon; 509851/0781 4) Impregnation system consisting of a group of Corrugated rollers, some of which are fixed, the other are adjustable to a specific one To achieve pressure on the raw materials that have already been pollinated, in support of the impregnation with the mixture applied to the raw material and at the same time preparation for the following Phase; 5) Ripping-mixing system, consisting of a group of drums covered with slightly inclined flights are, the diameter of these drums is calculated so that by friction at the same time to achieve the tearing of the raw material and the leveling or homogenizing of the dye is, at the exit of the system a drum of medium diameter, which discharges the raw material ensures by placing it on the removal belt (6) is arranged; 6) Take-off belt, a roller belt that transports the raw material to the press rollers (7) ^ 7) Pressure rollers to facilitate the subsequent packing and to support the leveling of the Color; 8) ram for pressing the raw material with feeding for packaging; 9) Packing device for easier transportation of the raw material for compacting for easier transportation to the following processing stages and 10) Storage container for the dye-lubricant mixture with all products necessary for the process flow. 509851/0781 Blank