The Fourth Batch Of Advanced Technologies For Energy Saving And Emission Reduction: 2010-G-4-01: Cotton Fabric Continuous Biochemical Pretreatment Technology

First,

The development of the weak alkali desizing, boiling, bleaching and one bath pretreatment process has realized the pretreatment of cotton fabric without sodium hydroxide short flow. In order to improve the fabric's impurity removal rate, continuous biochemical pretreatment has been developed.

The technology has been widely applied in enterprises, and the sales volume of related auxiliaries is nearly 2000 tons, processing fabrics nearly 300 million meters, saving 130 thousand tons of steam and 700 thousand tons of water, resulting in a total economic benefit of 35 million yuan, which has achieved comprehensive effects of saving energy and reducing consumption, reducing environmental pollution and improving the quality of semi-finished products.

Two, basic principles

The project uses the weak alkali pretreatment process and the compound short flow pre-treatment agent developed by the project. It includes multiple functions such as scouring, infiltration, chelating and dispersing, hydrogen peroxide stabilization, silicon scale inhibition, defoaming, wax removal and desizing. It does not contain strong alkali and APEO. It has excellent stability and refining effect. It solves the problem of excessive decomposition of hydrogen peroxide and poor impurity removal effect in the conventional desizing, boiling and bleaching one bath process.

In order to improve the ability of removing impurities, a self-made compound enzyme was used to pretreat the fabric, partially removing the pulp, pectin and other impurities on the fabric, so as to improve the wettability of the fabric. After washing, the fabric was treated with special oxygen bleaching. The whiteness, wool efficiency, desizing rate and strength of the treated fabric were better than those of the conventional process and the desizing and scouring and bleaching one bath process.

In addition, the process and products do not contain strong alkali components, which solves the problems of high basicity, high energy consumption and poor product quality in the conventional pretreatment process mainly based on sodium hydroxide.

Three, technological innovation

1. A series of environment-friendly cotton fabric pretreatment agents developed by the project include multiple functions such as scouring, infiltration, hydrogen peroxide stabilization, alkali treatment, chelating dispersion and silicon scale inhibition. They have excellent hydrogen peroxide stability and good emulsification and dispersion.

2. The continuous biochemical pretreatment process of cotton fabric developed by the project is made by self-made compound enzyme pretreatment, followed by special oxygen bleaching. No sodium hydroxide is needed in the product and process. The indexes of the treated fabrics are better than those of the conventional process and the one bath pretreatment process.

Four. Scope of application

It can be applied to the pretreatment of all cotton fabrics.

Five, energy saving and emission reduction effect

Compared with the conventional process (the two step process of desizing and bleaching), the new process developed by the project saves water by 40%-25%, saves 35%-30% by steam, saves 100% of sodium hydroxide, and significantly reduces the pH value of wastewater.

Six. Feasibility analysis of input and output (input cost and operation cost: subdivided into water consumption, electricity consumption and others).

No cost is required to add any equipment, but the cost of steam, water and auxiliaries saved by the new technology is 860 yuan, 69 yuan and 180 yuan respectively.

In addition, electricity consumption, labor costs and other savings are also more obvious.

In the comprehensive calculation, the new short flow pre-processing technology can save 1000 yuan / 10000 meters. Taking the medium-sized printing and dyeing factory with an annual processing volume of 60 million meters as an example, the annual processing cost of the enterprise is about 5 million yuan.

Seven. Intellectual property and Awards

Patent application number 200910156664.6, Title: a continuous biochemical pretreatment process for cotton woven fabrics.

Eight, promotion and application (list of 3-5 application units: contacts and contact ways, project name, location, scale, operation time, input and output economic benefits)

So far, more than 60 enterprises have been popularized and applied, more than 20 manufacturers have been used in scale, and the sales volume of related auxiliaries is nearly 2000 tons, and nearly 300 million meters of cotton fabrics have been processed.

Among them, Zhejiang Fu run, Jinhua Honghua, Hangzhou Jia Hao, Zhejiang five oceans and other printing and dyeing enterprises, the total number of auxiliaries used more than 1000 tons, the use time is 1~2 years.