Waste Water Instead Of Tap Water, Wan Feng Sheng Creates Dyeing "Legend".

Dyeing process is an important process in printing and dyeing production. Because the pH value, hardness and heavy metal ions of the water affect dyeing, the dyeing process requires higher water quality. According to the traditional practice, most of the dyeing water uses tap water, qualified reclaimed water or treated purified water. However, in the workshop of Shishi Wan Feng Sheng bleaching and dyeing weaving Co., Ltd., the reporter saw that the dye into the VAT was thick black printing and dyeing wastewater. It was unbelievable that the white grey cloth was dyed red in the dye vat, and the dyed waste water could not be discharged.

According to Li, deputy general manager and technical director of the company, this process can not only reduce dyeing water and waste water emissions by more than 90%, but also produce fabric quality indicators that are up to or better than traditional dyeing processes. This innovative dyeing process is a breakthrough in the recycling dyeing of synthetic fiber fabrics in one bath printing and dyeing wastewater. This achievement has completely overturned traditional technology, and experts believe that the technology has reached the international advanced level.

Shishi Wan Feng Sheng bleaching and dyeing weaving Co., Ltd. relies entirely on independent innovation. Its "synthetic fiber fabric one bath printing and dyeing wastewater recycling dyeing technology and application" has won the "textile light" 2018 China Textile Industry Federation first prize in science and technology.

Project Name: synthetic dyeing technology and application of one bath printing and dyeing wastewater

Shishi Wan Feng Sheng bleaching and dyeing weaving Co., Ltd.

Completion personnel: Li Dai, Zheng pin bank, Zheng Biaoyou, Li Zhongzhi, Li Yuanzhi, Cai Feiting, Xie Yunming, Tu tie Jun, Yu Fenglin, Wang Jinliang

Award: "textile light" 2018 China Textile Industry Federation first prize in science and technology

Mysterious mystery: "silt" is not stained.

Printing and dyeing wastewater is not treated directly, and the quality of the dyed fabric is better. If it is not seen with one's own eyes, it is hard to believe that this is true. How did such a "legend" come into being? Lee came up with the secret of "legend" behind the image of "silting without staining": through self developed dyes and auxiliaries, cloth can not absorb dirty things in the waste water, but precisely adsorb dyes. Since 2016, the R & D has been put into operation in 2017, and Li led the team through a sleepless night. After countless trials, the legend finally came true.

It is understood that there are three innovations in the technology. One is the study of the different requirements for the working fluid in the process of dyeing, dyeing and washing in traditional dyeing process. A one-bath dyeing process is developed, which breaks through the traditional dyeing multi bath multi step process and realizes one bath one step dyeing. The dyeing parameters of polyester and nylon fabrics in one bath process were studied, and the whole coloring dyeing formula was formed. A complete process parameter database was established. Two, it is necessary to use fresh water to remove, dye and wash the traditional dyeing process. This project has developed the dyeing process of waste water. For the first time, the printing and dyeing wastewater can be directly recycled for many times without any biochemical treatment. The three is to establish the production process water balance system through the transformation of the existing production process and equipment pipeline, and realize the recycling of printing and dyeing wastewater and its heat in the production process.

According to Li Jiedai, at present, the circular dyeing of synthetic fiber fabric in one bath dyeing and printing wastewater has achieved large-scale production, and waste water is used in pretreatment, dyeing, reduction and washing and multi-channel washing process. This technology has overturned the traditional printing and dyeing water standard requirements, greatly shortened the technological process, saved energy and water resources, reduced the discharge of waste water and the cost of wastewater treatment, and greatly increased the efficiency and efficiency of production.

In addition, compared with the traditional process, the technology saves water and reduces waste water emissions by more than 90%, and energy consumption drops by 40% to 60%. The CODCr output of the unit product is reduced by about 25%, the waste heat energy recovery rate is over 90%, and the auxiliary agent 30% is saved. Compared with traditional dyeing technology, the one bath wastewater dyeing process has shorter delivery time and better product quality. Over the past three years, the company has achieved direct economic benefits of 393 million yuan, profits and taxes of 42 million 400 thousand yuan, and indirect economic benefits of 2 billion 560 million yuan, with remarkable economic benefits.

Behind the Innovation: forcing enterprises to reduce emissions

The reporter noted that the scientific and technological achievements were exclusively completed by Wan Feng Sheng bleaching and dyeing weaving Co., Ltd., according to the general manager of the company, Zheng pin Bank: "this technological innovation is very different. It comes from the production workshop, tackling key problems in the production line, and applying it to the production practice." What is the power to create a revolutionary technology in a private enterprise?

"It's all forced out." Zheng said that the emission index of former enterprises was 10 thousand tons / day. With the increasingly stringent environmental protection policy, the current index is only 1 kiloton / day. In the face of such a rigid index, "either stop production or close down, or create a new road." Obviously, in the printing and dyeing industry for more than 10 years, Wan Feng Sheng chose the latter.

In fact, for many years, Wan Feng Sheng has always attached importance to technological innovation, established standardized environmental protection plant and production line, introduced advanced equipment at home and abroad, and built modern computerized color matching laboratory and quality inspection center. At the same time, the company's R & D team continues to research and develop new technologies and technologies. As early as 2009, the company launched the "new technology of dyeing and finishing with one bath for woven fabrics" in the industry. With the technological innovation, the company won the "textile light" China Textile Industry Federation two prize. The Chinese printing and dyeing industry association also awarded Wan Feng Sheng the honorary title of "China dyeing and finishing R & D production base", which is also the first "innovation and R & D production base for dyeing and finishing" in the national printing and dyeing industry.

In recent years, influenced by factors such as the rising cost of dyestuff materials, the high cost of workers and the escalating environmental protection requirements, many printing and dyeing enterprises in Shishi's Jin Shang Town are facing the test of survival and death, and Wan Feng Sheng is constantly upgrading and upgrading through years of technology accumulation. At the critical moment of life and death, Wan Feng Sheng chose to have sufficient foundation for independent innovation. They independently formed a technological R & D team, and broke through from the aspects of equipment improvement, management upgrading, technological innovation, etc., to improve the traditional technology, find a breakthrough from technological upgrading and technological reform, from small test to big test, from lab sample, sample to workshop cylinder test, and finally. The success achieved a disruptive breakthrough in recycling dyeing wastewater and was successfully applied to the production line.

Zheng Biaochao said that in the past, the daily discharge volume was about 10 thousand tons. Now, through this technology, only 1 thousand tons of water are discharged every day. After the drainage has declined, the output has not been reduced at all.

The innovation of Wan Feng Sheng is visible and tangible. For the first time, they realized the one bath dyeing and printing wastewater recycling dyeing, breaking through the traditional intermittent dyeing technical limitations, breaking through the textile dyeing and finishing industry's water quality standards for reusing water, greatly improving the production efficiency, saving energy and reducing emissions effect is extremely remarkable, and provide important technical support for promoting the transformation and upgrading of the industry.

Facing the future, Wan Feng Sheng plans to further upgrade existing equipment and further reduce water consumption and drainage data. Zheng said that "the environmental protection policy in the future will only become more and more stringent. The company should make technical planning and reserves ahead of schedule, and innovation will always be on the road."