Yang
At the ShanghaiTex 2006 exhibition held in Shanghai from July 5 to 8, high efficiency, energy saving, low consumption and less pollution became the focus of dyeing and finishing industry. Based on the key processes of dyeing and finishing, this paper discusses the latest technical progress displayed at the 2006 Shanghai International Textile Exhibition under this hot trend.
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According to the needs of scientific development, China's textile industry is expected to have the following main binding indicators during the Eleventh Five-Year Plan period: fiber consumption per unit of industrial added value decreased by 20% year-on-year; Water consumption per unit of GDP decreased by 36%; Water consumption per ton of fiber decreased by 20% compared with 2005; Energy consumption per unit of GDP decreased by 28%; The power consumption per ton of fiber decreased by 65438 00% compared with 2005; Sewage discharge per unit added value decreased by 22% compared with 2005.
These indicators are closely related to the printing and dyeing industry, because the printing and dyeing sewage emissions account for as much as 80% of the total emissions of the textile industry. During the Eleventh Five-Year Plan period, the task of printing and dyeing industry is extremely arduous, which requires the progress of printing and dyeing materials, machinery and new technology. At the ShanghaiTex 2006 exhibition held in Shanghai from July 5 to 8, high efficiency, energy saving, low consumption and less pollution became the focus of dyeing and finishing industry.
Rinsing machine
In the process of dyeing and finishing, hot water washing is an indispensable process, and it also consumes the most steam energy and water resources.
Countercurrent treatment technology of washing machine rinsing wastewater is one of the hot spots in current research. Its rinsing temperature is above 85℃, which contains considerable heat energy value. Recovering 1 ton of the water per treatment can save the cost and realize the benefit exceeding 10 yuan. According to the calculation, the reuse value of 1 flat washing machine 1 day is more than 2000 yuan.
At present, China discharges a large amount of high-temperature printing and dyeing wastewater every year, which not only pollutes the environment, but also loses huge heat energy. If the wastewater discharged from 654.38 million flat washing machines and overflow dyeing machines in China is treated by this technology, the annual water fee and energy consumption can reach several billion yuan.
Reuse of flat washing machine wastewater after treatment can save energy and reduce consumption and pollution. It adopts four methods to achieve this goal: the "electrodeless ultraviolet catalytic oxidation" technology developed by Wuhan Institute of Science and Technology, which is the highest research achievement of the national 863 major project, a new and efficient physical and chemical combination; Adding additives to improve the efficiency in the flat washing process; Develop and apply efficient washing technology when manufacturing flat washing machines; Development and application of heat energy recovery technology. Among them, the latter two technologies were exhibited at the 2006 Shanghai International Textile Exhibition.
Tube-Tex of the United States introduced a heat recovery device for washing machines at the exhibition. The water consumption of the washing machine is 400 liters per minute, and the temperature is above 85℃. The cost of steam is very important at this time. The company's passive heat recovery device can recover a large amount of heat energy lost in wastewater without additional operating costs, and can provide six different types of devices to meet various practical needs.
Zhejiang Printing and Dyeing Co., Ltd. has successfully developed two high-efficiency washing machines with technical patents, which shows that domestic printing and dyeing machinery manufacturing enterprises attach importance to cleaner production. On the basis of the swing washing machine successfully developed in the past, the company also developed the washing machine with toothed guide roller and circular threading route and the washing machine with toothed guide roller and light roller in the lower row, which strengthened the washing effect and further improved the level of energy saving and consumption reduction. At the same time, the new washing machine adds a waste water heat recovery device, which further reduces the steam energy consumption.
Low liquid feeder
Weko's low liquid supply system has been widely recognized by domestic dyeing and finishing enterprises, and has been widely used for its characteristics of energy saving, low consumption and environmental protection, and will continue to expand its application fields. The system has two modes of water supply and liquid supply (water-soluble chemical solution), and can be installed before (or after) various dyeing and finishing machines that need low liquid supply.
Vico spray tray liquid supply system.
If a low liquid feeder is installed in front of the tenter setting machine, it can replace the pad dyeing machine and dryer in most cases. Generally, fabrics need to be soaked in water or chemical solution before entering the tenter setting machine, and the residual volume rate is about 75%. Then, a certain amount of water is dried, and tentering and setting are carried out at a water content of about 20%. The low liquid supplier can set the liquid supply rate of the fabric within the water content range of 1~40% as required, and it has good repeatability, even left and right, and even front and back.
Because the atomized water or solution particles of 30~70 microns are sprayed on the fabric at the speed of 1500 meters per minute when the liquid supply is low, the air permeability is excellent. The water or solution sprayed on the fabric is absorbed by the fabric, and the water or solution not sprayed on the fabric can be recycled because it is not in contact with the fabric, reducing material consumption and environmental pollution.
Vacuum water absorber
Shanghai Kuanda introduced EVAC vacuum water absorber. In dyeing and finishing, the moisture contained in soaked fabrics can be divided into two types: bound water and free water. EVAC vacuum water absorber can completely absorb the free water on the fabric passing through the water inlet, which is especially effective for wet finishing of hydrophobic fibers and their blended fabrics. Hydrophobic fibers can reduce the water content on the soaked fabric to 65,438 08%.
Structure diagram of EVAC vacuum water absorber.
The system adopts the suction port of UHMW polymer material, which has the characteristics of low friction, corrosion resistance and anti-clogging. The cyclone separator is used to separate the sucked water and sundries from the airflow, which is convenient for cleaning and avoids the blockage of the vacuum pump. Vacuum degree can be set according to different fabrics, with good repeatability.
When used in water washing machine, the water on the fabric can be fully exchanged with the water in the sink, which greatly improves the washing effect. When used in dryer or tenter setting machine, it can partially replace the traditional rolling mill. Because of the low water content after vacuum water absorption, the drying and stentering efficiency can be greatly improved and energy can be saved. When functional finishing is carried out, the finishing agent can penetrate into the fiber, and the finishing effect is particularly excellent for fabrics that are not expected to be squeezed by gravity.
Pile setting machine
When polyester and its blended fabrics are treated by tentering setting machine, the temperature in the box can be as high as 180~220℃, which is the key link of energy saving in dyeing and finishing. At this exhibition, a variety of new achievements were displayed around energy saving.
Temperature and humidity measurement and control
Accurate temperature and humidity measurement is the basis of energy saving. Kuanda demonstrated the advanced EMC system, which is a combined work platform consisting of three modules.
RMS module, namely humidity measurement and control system, is mainly used for cotton, linen, silk, rayon and their blended fabrics. In the process of tentering, drying and preshrinking, the speed of the machine can be controlled by detecting the moisture content of the fabric, thus improving the production efficiency and saving energy. The system can automatically control the production speed of sizing machine and sizing machine.
AML module, that is, exhaust gas humidity control system. The system is mainly used in dyeing and finishing industry to measure the moisture content in the high-temperature waste gas of tentering setting machine and curing machine and control the discharge of high-temperature waste gas. If the moisture content of the discharged high-temperature waste gas is too low, it means wasting energy. Through measurement and control, tentering setting and curing process are in the most economical operation state, and generally using this system can save 20% heat energy.
OMT module, that is, fabric temperature measurement and control system. The system is mainly used to directly measure the actual temperature of the fabric in the box when the chemical fiber and its blended fabric are set and dried at high temperature, so as to automatically control the processing speed and make the processing process in the state of optimal quality, maximum output and minimum energy consumption.
The EMC system consists of a 6.5-inch touch screen, a computer mainframe work box, three module interfaces and a set of tachogenerator, which can be equipped with one module alone or three modules at the same time.
Other energy-saving measures
The most representative is a series of energy-saving measures taken by Montfort Fong's tentering setting machine, such as all fabric conveying is driven by a fully sealed three-phase AC motor controlled by frequency conversion; The oven is made of high-density thermal insulation material with the thickness of 150 mm, which makes the thermal radiation of the oven at a low level; Seals are arranged at the joint and the opening of the oven; An airflow shielding device is arranged at the fabric inlet and outlet; The cloth outlet is equipped with a residual humidity measurement and control device, which digitally displays the drying effect.
Zhejiang Printing and Dyeing Co., Ltd. demonstrated the waste gas heat recovery technology of tenter setting machine, and it has been used in production practice.
Organic solvent recovery machine
When finishing textiles, artificial leather and other products at high temperature, various organic solvents are added according to different needs to improve the functional characteristics of textiles and artificial leather. These organic solvents will disperse into or out of the machine with hot air at high temperature, which will seriously pollute the machine and the environment.
Ecology 6- 12T.
Taiwan Province Ding Qi Industrial Company provided an organic solvent recovery machine at the exhibition. It is said that the recovery rate of organic solvent is 97%, the purity of recovered organic solvent is 99%, and the waste gas elimination rate is 98%.
dyeing machine
More than 65,438+000 dyeing machines were exhibited in this exhibition, including high-temperature dyeing machines, atmospheric dyeing machines, jet dyeing machines and pad dyeing machines. Its technical representative products include Lixin's ECO series dyeing machine, Allwin cheese dyeing machine and German Then air dyeing machine.
Olving cheese dyeing machine
ECO series high-temperature dyeing machines combine necessary automatic control devices, precision instruments and advanced control software, adopt mature liquid separation and rapid circulation technology, shorten the whole process time consumption, and adopt low bath ratio technology, so that the total water consumption per kilogram of fabric (light color) is as low as 38kg.
Allwin cheese dyeing machine adopts a new type of double-cycle heat exchanger, which can reach the target temperature 30% faster than traditional cheese dyeing machine under similar operating environment. With the new patented REV water pump, the flow rate is higher than that of the traditional water pump, and the power of the motor-driven water pump is also relatively reduced; A new water flow reversing device and intelligent leveling control are adopted to avoid uneven dyeing caused by only one-way running of dyeing liquid from inside to outside; In the dyeing process, fast logic temperature control technology is adopted. The progress of these technologies ensures the dyeing quality and reduces energy consumption, water consumption and wastewater discharge.