WO2015154155A1 - Method and equipment for dyeing cellulose fibres in gaseous medium - Google Patents

Abstract

Invention patent for a method and equipment for dyeing cellulose fibres in gaseous medium, having a basic dye diluted in ethanol, citric acid, tannic acid, a solution of ethanol and water, along with enzyme nanocapsules, having tetrafluoroethane gas as a carrier in the form of a fluid, for the dye, which is applied under pressure, under controlled temperature, wherein the application process comprises a step of inserting the textile article (1) into the tank (2) of the dyeing equipment, which is moved by a roller (3); a vacuum pump (4) removes the air from the tank (2); and the dye (5) is transported to the mixing step (6), along with the auxiliary components (7), ethanol, citric acid, water and alcohol, enzyme nanocapsules and the tetrafluoroethane gas from a storage cylinder (8), forced by the gas pump (9) to the tank (2) which by means of a circulating pump (10) forces the gas to circulate inside the tank (2) and to the return pipe system (11), where the filter pump (12) forces the tetrafluoroethane gas to the filters (13) and to the storage cylinder (8).

Description

 "PROCESS OF DYEING OF CELLULOSIC FIBERS IN THE MEDIUM

 GASOSO AND METHOD OF APPLICATION OF THE PROCESS IN A TEXTILE ARTICLE "

 The present invention comprises a textile dyeing process using suitable gasborne textile dyes by means of dye-screening techniques in order to develop application in the gaseous cellulosic fiber and to develop dyeing process in this process. for the textile and dyeing industry.

 [002] In the textile industry, chemical preparation and dyeing processes are the most resource consuming and wasteful.

 [003] There is an incessant quest to reduce and eliminate the use of these resources, replacing processes and process elements.

According to data from the European Integrated Pollution Prevention and Control (EIPPC), in a dyeing plant that processes cotton fabric, the ratio of the amount of water used in the process to the mass of processed fabric can be as high as 136 L / kg. In addition, in a conventional cotton fabric dyeing process, chemical inputs such as sodium sulfate or sodium chloride, caustic soda, sodium carbonate, acetic acid, surfactant and chelate are used in amounts which may vary From 263 to 680 g of chemical inputs / kg of fabric, based on these data, and in the amount of cotton knit fabric processed in Brazil in 2003, an annual consumption in the order of 25 to 32 million m3 of a dump water and chemicals into bodies ^of water of the order 49-127 thousand tons of solid waste discarded. in this context, the conjugate was developed method enzyme preparation and Cationic Dye (p PETCA process), which optimizes and adapts enzymatic purging and cellulose cationisation technologies, which applied together, increase the degree of reactive dye fixation in cotton fiber, reducing raw materials and ancillary products. From the results presented, it is possible to conclude that the Conjugated Enzymatic Purge and Cationic Dyeing Process (PETCA) presented: 40% reduction in water consumption and wastewater generation; 66% reduction in the consumption of chemical inputs needed for the process; 98% reduction in the level of chlorides in effluents; 63% reduction in effluent conductivity; 15% reduction in the color of effluents and a considerable increase of turbidity around 30 times. (Source: Annals of the 58th Annual Meeting of the SBPC - Florianópolis, SC - July / 2006) "

 [005] Dyeing is known to be a chemical process of color modification of the textile fiber through the application of colored materials through a solution or dispersion, a process which varies from article to article as there are specific dyes for each type of textile fiber. The coloring matters are organic compounds capable of coloring textile or non-textile substrate so that the color is relatively solid to light and wet treatments. Every textile substrate (fabric) undergoes various physical and chemical processes during the bene fi t. The real need of these processes is to improve the appearance, dyeing capacity as well as conditions for a subsequent fabric finishing. Textile articles must be carefully prepared before starting dyeing, undergoing an initial process called preparation or pretreatment, which aims to eliminate all impurities from the substrate (fabric), such impurities are: waxes, natural pectins , lubricating oils, paraffins, gums etc. These impurities can be both natural and artificial. In the latter case, they are added to the yarns, warps or knits when they undergo the process of sizing or lubrication in knitting during weaving in weaving.

 [006] Fabrics arrive in raw dyeing. They are then subjected to both chemical and physical processes depending on the type of fiber and type of final product that one wants to have.

[007] There are three methods for dyeing textile articles: fiber dyeing (used for long fibers (wool) and filaments); yarn dyeing (arranged in reels or during other spinning processes), being most suitable for the production of striped fabrics, chess or jacquard, as well as open or rope dyeing and fabric dyeing, which wastes less dye, the smaller amount of processes involved, producing a fabric with a smooth color, being able to be realized with the fabric in rope (more relaxed) or open (does not form creases) for continuous process. Dyeing of warp with indigo dye (in dyeing machines with indigo dye, is not bleached but rather dyed in raw) can be used the batch process or by batch, where, in the same machine can be made all the processes of preparation, bleaching, dyeing and washing, being able to be with the fabric in rope or open, depending on the machine used, being the most common of type: Barca, Jet, Flow or Jigger; the semi-continuous process uses impregnation of the cloth with a dyeing bath carried out by Foulard, after this process the tissue is allowed to stand for a few hours for the reaction of the dye and subsequent washing. Process known as "pad-batch" and the process Continuous where the reaction of the dye with the fiber is accelerated with the addition of steam or temperature. The most common processes are "pad-steam", with vaporizer, for cotton fabrics, and "pad-dry", with hot-flue circulation, for synthetic fabrics.

 Dyes used in the textile industry are classified for use in cellulose (cotton, viscose, linen, ramie), as reactive dyes, direct dyes, tubs, sulfur, naphthol and indigo; application in polyester, as dispersed dyes; polyamide (nylon) as acid and dispersed dyes and wool in the form of acid and reactive dyes

Colorants are water soluble or water dispersible products having fiber affinity for the purpose of promoting color, classified as reactive and azo dyes, applied to CO (cotton), CL (flax) fibers. Reactive dyes have the advantages of being economically intermediate, high fastness to light and humidity, dispensing fixative and high reproducibility; the disadvantages of reactive dyes are the restriction on chlorine treatment and environmental aggression;

 [010] Azo dyes have the advantage of having the color produced within the fiber, high strength, excellent gloss, full coloring and dispensing fixative; the high cost and the long process, together the aggression to the environment are its disadvantages.

[011] The growing population increase calls for increasing demand for natural resources and for subsistence. Water, fresh air, land for planting and electricity. Water is an increasingly scarce and more expensive resource. The scarcity of rain and the high temperature, makes the search for this resource more intense and worrying, even for Brazil. The consumption of goods is the great villain in the scarcity of these resources, since the industry needs water for human and animal consumption, as well as to generate energy and to serve industry in general.

The textile dyeing industry is targeting environmentalists to reduce water consumption, demanding intensified research and major investments in water-less dyeing technology. A producer of dyes and textile equipment, and clothing, in 2011 developed technology that replaces water with recyclable CO2, thereby reducing energy consumption and eliminating the need for additional chemicals. O process works by placing the carbon dioxide at a pressure of 1,100 Psi (75.8 bar), transforming it into supercritical CO2. This means that it now has the properties of a liquid and a gas. No use of water in the process and there are almost zero waste.

A search in the database of this distinguished institution returns the document PI7705268-4- CLOSED CYCLE APPARATUS FOR QUICK, CONTINUOUS AND WATER-FREE DYEING OF A TEXTILE OR PLASTIC MATERIAL. This document is not available on the website of this institution and, due to the obligation to file this request, this applicant can not request a copy. Further, the Applicant of PI7705268-4, holds several patents in the database of the USPTO, among which, U.S. Patent Nos. 4,407,889-Process for the Rapid, Continuous and Waterless Dyeing of Textile and Plastic Materials, dated 09/01/1976 and US4115054 - Process for the rapid, continuous and waterless dyeing and texturizing and heat-setting of textile and plastic materials, of 12/15/1976, disclose dyeing process of polyester textile materials based on polyethylene terephthalate or the like, but may be applied for the dyeing of nylon, acrylic or other well known commercial textile materials, including materials of natural origin, such as wool or cotton. Said process claims the contacting of the treated textile material with a high boiling organic liquid with respect to high temperature and the cooling of the textured textile material and washing thereof with a low boiling organic liquid which is free or substantially free of water , followed by drying the textured textile material; dependent claims comprise the class for the boiling organic liquid consisting of ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, and the methyl and ethyl mono- and di-ethers of such glycols or lower alkanol or methanol or hydrocarbon chlorinated paraffin; comprises the organic liquid of the class consisting of CH2 Cl2, CCl4 and CHCl3; the high boiling organic liquid contains a suitable dye dissolved, suspended or dispersed therein, through which the textile material is textured, and simultaneously dyeing the heat set; the high boiling organic liquid is a lower alkylene glycol, a lower alkyl ether of a lower alkylene glycol; further claims that the textile material is treated, while in a substantially relaxed or unstressed condition, receiving one or more additives. Having said that, the inventor has researched and developed the process for the dyeing of cellulose-based cellulosic fibers and a method of applying the process to a textile article and which is synthesized by a carrier in the form of a fluid, tetrafluoroethane, to a dye, preferably (cationic), diluted in ethyl alcohol, citric acid and tannic acid, dispensed in dyeing equipment together with nano enzyme capsules. The gas is filtered and, after a certain dyeing time, is released under pressure to cleaning filters, returning to the storage tanks.

 [014] Tetrafluoroethane is commonly used in refrigeration systems, replacing freon, the fluid -Tetrafluoroethane-1,1,1,2, R-134 being an inert, non-toxic, non-flammable gas that does not degrade the layer ozone and liquefies at low pressures.

The dyes that present better dyeing results are the basic dyes (cationic), due to their molecules chromophores that have reactive groups and are substantives for the cellulosic fibers, they present a low washing fastness and in this condition the Tannic Acid is used to increase the substantivity and improve the fixation of the same in the fiber.

 The nano capsules have the function of reducing the surface tensions of the outer layers of the cellulosic fibers, the cuticle and first layer, facilitating the approximation of the dyes to the fiber promoting dyeing.

 Since the Tetrafluoroethane fluid is an inert, non-toxic, non-flammable gas that does not degrade the ozone layer, liquefies at low pressures, it is applied as a vehicle for the dyes inside the dyeing equipment. The gas passes through a set of filters which has several layers of filter elements capable of retaining nano particles.

[018] After the dyeing time the dyeing gas is released under pressure and temperature to the cleaning filters returning to the storage tank. Then the washing step of the dyeing begins with gas that will circulate in the equipment for the programmed time, pass in the filters and return to the storage tanks. If necessary do this procedure more than once.

In the following the object of this patent application will be detailed, also with reference numerals joint the following description, not intending to restrict the configurations of equipment involved in the process, to the one shown here, where: Figure 1 shows an equipment diagram capable of processing the dyeing of cellulosic fibers in gaseous medium, merely illustrative for the understanding of the process and equipment involved.

 According to the above-described figure, the process for the dyeing of gas-filled cellulosic fibers and method of applying the process in a textile article, which object of this patent application comprises a dye, preferably basic (cationic), diluted in a range comprising between 5.0 and 10.0% ethyl alcohol, preferably 7.0%, a range comprising between 0.05 and 0.15% citric acid, preferably 0.1% and a range of from 0 , 5 and 2.00% tannic acid, preferably 1.0%, diluted in 40% water solution and 60% ethyl alcohol, sprayed in the dyeing chamber together with nano capsules, at the rate comprising a range between 1 and 10% SPM (reference unit on the weight of the material), preferably 5.0%.

 The carrier in the form of a fluid for the dye comprises Tetrafluoroethane gas, filtered and injected at a rate comprising a range of from 35.0 to 60.0%, preferably from 50.0%, at a pressure between 12 and 15 bar, at a controlled temperature in the range of 50-65 ° C, preferably 60 ° C.

 A method of applying the present process includes a step of inserting the textile article (1) into the tank (2) of the roller-driven dyeing apparatus (3); a vacuum pump 4 withdraws air from the tank 2 and the dye 5 is charged to the mixing stage 6 together with the auxiliary components 7, ethyl alcohol, citric acid, water and alcohol , nano enzyme capsules and the tetrafluoroethane gas from the storage cylinder 8 forced by the gas pump 9 to the tank 2. A circulation pump (10) forces the gas to circulate inside the tank (2) and to the return pipe (11), where the filter pump (12) forces the tetrafluoroethane gas to the filters (13), and to the storage cylinder (8).

Claims

 1. A process for the dyeing of cellulose fibers and the method of applying the process to a textile article, the textile dye carried by gas, for use in the textile and dyeing industry, characterized in that it comprises dye, preferably basic (cationic) , diluted in ethyl alcohol, citric acid, tannic acid, water solution and ethyl alcohol, together with nano enzyme capsules, Tetrafluoroethane gas as carrier in the form of fluid, for the dye, applied under pressure, at controlled temperature; comprises a method of applying a step of insertion of the textile article (1) into the tank (2) of the roller-borne dyeing apparatus (3); comprises the step of withdrawing the air from the tank (2); comprises loading stage of the dye (5) for mixing (6) together with the auxiliary components (7), ethyl alcohol, citric acid, water and alcohol, nano enzyme capsules and the tetrafluoroethane gas; comprises the step of circulating the gas inside the tank (2) and the return pipe (11), by means of the circulation pump (10), which directs the Tetrafluoretane gas to the filters (13) and the storage cylinder (8). ), by means of the filter pump (12);  2. A process for the dyeing of gas-rich cellulosic fibers and a method of applying the process in a textile article according to claim 1, characterized in that the dye is diluted in a range of from 5.0 to 10 , 0% ethyl alcohol, preferably 7.0%, a range comprising from 0.05 to 0.15% citric acid, preferably from 0.1% and a range of from 0.5 to 2,00 % tannic acid, preferably 1.0%, diluted in 40% water solution and 60% ethyl alcohol, together with the nano enzyme capsules, at a rate of 1 to 10% SPM, preferably from 5.0%; 3. A process according to claim 1, characterized in that the tetrafluoroethane gas is filtered and injected at a rate which comprises a compound of the formula (I) and (III). between 35.0 and 60.0%, preferably 50.0%, at a pressure between 12 and 15 bar, at a controlled temperature in the range of 50 to 65 ° C, preferably 60 ° C;  4. A process according to claim 1, characterized in that the dyeing apparatus comprises a tank (2) with a roller (3), characterized in that it comprises a tank (2) with a roller (3), vacuum pump (4); (5), mixer (6), auxiliary component reservoir (7), storage cylinder (8) for tetrafluorethane gas, return pipe (11), interconnected circulation pump (10), filters ( 13) and storage cylinder (8) and filter pump (12).