intensification of wet textile processing by … · color fastness to domestic washing (uni en iso...
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M. Giansetti, A. Battù, G. Rovero, S. Sicardi Politecnico di Torino, DISMIC, C.so Duca degli Abruzzi 24, Torino, Italy
INTENSIFICATION OF WET TEXTILE PROCESSING
BY ULTRASOUND APPLICATION
22nd INTERNATIONAL IFATCC CONGRESS May 5-7, Stresa 2010 - Italy
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Project and Partners
INTEXUSA (Piemonte Regional Project) INnovation in TEXtile productions by UltraSound Application Dyeing intensification by ultrasonic technologies and its integration with automatic on-line control
Ultrasound application in dyeing
OBEM
CIMI
FLAINOX
ENEA
Politecnico di Torino
Finissaggio di Trivero
Finissaggio e Tintoria Ferraris
ITT – Industria Tessile Tintoria
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Goals and scope of the investigation
Development and optimization of US application to improve wet textile operations, particularly dyeing and washing, which could lead to:
Ultrasound application in dyeing
• Improve the standard of industrial processes and products through the reduction and/or optimization of the amount used of utilities and chemicals.
• Reduce the specific consumption of water and energy per unit product and the related costs.
• Increase the process efficiency, thus reducing the environmental impact due both to the amount of wastewater and gaseous emissions.
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Project development
Ultrasound application in dyeing
Bench scale equipment
Preliminary apparatus
Prototype pilot equipment
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Preliminary apparatus
Ultrasound application in dyeing
1 – DRIVEN CYLINDER
2 – ENLARGING CYLINDER
3 – US TRANSDUCER
Operating characteristics:
• Flat parallelepiped PTZ transducer • Frequency: 40, 80 or 120 kHz • Output power: up to 500 W • Variable fabric velocity • Fabric to transducer distance: 45 or 105 mm (at same dye-bath ratio)
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Prototype plant equipment
Ultrasound application in dyeing
Multi-purpose unit suitable to dye hanks, fabric and garments
Operating characteristics:
• Flat transducer (frequency range: 25-120 kHz, maximum output power: 600 W)
• Cylindrical transducer (frequency: 28 kHz, maximum output power: 1000 W)
• 3 US transducer configurations: flat (bottom), flat (lateral), cylindrical (bottom)
• Minimum dye-bath ratio: about 1:10
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Dyeing parameters
Ultrasound application in dyeing
q Equipment: preliminary apparatus
q Material: pure worsted wool fabric (180 g/m2)
q Fabric velocity: 3 m/min
q Net exposure time to US: 12 min (average)
q Overall dyeing time: 180 min (average)
q Fabric to transducer distance: 45 or 105 mm
q Dye-bath ratio: 1:70 or 1:115
q Dye-bath pH: 5 (acetic acid)
q Operating temperature: 85°C (isothermal)
q Dyestuff class: acid dyes
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Dyeing results – Exhaustion curves and kinetics (1)
Ultrasound application in dyeing
0
20
40
60
80
100
0 50 100 150 200
Exh
aust
ion
[%]
t [min]
NO US US: 40 kHz, 500 W US: 80 kHz, 500 W
Comparison between conventional dyeing and US-enhanced dyeing at 500 W, liquor ratio 1:70, 45 mm distance, effect of frequency.
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Dyeing results – Exhaustion curves and kinetics (2)
Ultrasound application in dyeing
Comparison between conventional dyeing and US-enhanced dyeing, variable power, liquor ratio 1:70, 45 mm distance.
0
20
40
60
80
100
0 50 100 150 200
Exh
aust
ion
[%]
t [min]
US:40kHz,500W US:40kHz,250W US:80kHz,500W US:80kHz,250W
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Dyeing results – Half-dyeing time
Ultrasound application in dyeing
Half-dyeing time (t1/2): time required for the fibre to absorb half of the colorant that could be absorbed at equilibrium.
Half-dyeing time at liquor ratio 1:70, 45 mm distance, variable power.
Ultrasounds Frequency (kHz) Power (W)
Final exhaustion
(%)
Half-dyeing time (min) R0.5
NO - - 76 70 1
YES 40 500 81 35 0.50* YES 80 500 80 40 0.57
YES 40 250 80 40 0.57
YES 80 250 77 50 0.71
R0.5 = t1/2, US / t1/2
* R0,25 = 0.56 , R0,65 = 0.53 , R0,95 = 0.54
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Dyeing results – Overall kinetics constant evaluation
Ultrasound application in dyeing
Valldeperas modification of Cegarra-Puente equation:
-6
-4
-2
0
2
0 2 4 6
ln(-ln(1
-Et2 /E ∞
2 )
ln(t)
NOUS
40kHz,500W
K40kHz = 0.0143 min-1
KNO US = 0.0078 min-1
K40kHz / KNO US ≈ 2
related to R ≈ 0.5
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Dyeing results – Color fastness
Ultrasound application in dyeing
Color fastness to domestic washing (UNI EN ISO 105 C01)
Ultrasounds Frequency (kHz) Power (W) Degradation Staining on
wool Staining on
cotton
NO - - 4 4-5 5
YES 40 500 3-4 4-5 5
YES 80 500 4-5 4-5 5
YES 40 250 4 4-5 5
YES 80 250 4-5 4-5 5
Identical values were obtained for perspiration (UNI EN ISO 105 E04) and rubbing (UNI EN ISO 105 X12) .
Color fastness to artificial light (UNI EN ISO 105 B02) did not show any difference between conventional dyeing and US-enhanced dyeing.
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Dyeing results – Mechanical properties
Ultrasound application in dyeing
Determination of the bursting strength by sphere method (UNI 5421)
Bursting strength and distension for repeated measurements related to: a) Untreated, b) 6 hours treated.
Test Strength (daN)
Distension (mm)
1 39.6 3.779
2 38.9 3.715
3 40.2 3.739
4 40.7 3.755
5 39.6 3.743
Average values demonstrated no mechanical damage occurring in the fabric properties .
Test Strength (daN)
Distension (mm)
1 37.9 3.650
2 38.4 3.726
3 38.9 3.699
4 38.6 3.777
5 39.5 3.816
a) b)
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Dyeing results – SEM analysis
Ultrasound application in dyeing
SEM analyses were carried out on the fabric to detect any fiber structural modification.
Comparison of the wool fibers: a) Untreated, b) 6 hours treated.
a) b)
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Conclusions and comments
Ultrasound application in dyeing
q Application of US increased the dyeing kinetics, especially at low frequencies, helping the overall mass transfer of the dyestuff to the fiber.
q Influence of dye-bath ratio: better performance was obtained at lower dye-bath ratio. In this view the prototype is expected to provide excellent results.
q Influence of US frequency: 40 kHz generated the best results. Even better results are expected by operating at lower frequency.
q Influence of US power: the results demonstrates that only a part of the energy given to the transducer is effective to enhance the kinetics of dyestuff mass transfer.
q Influence of the fabric to transducer distance: increasing the distance causes a reduction of the US effect.
q Color fastness evaluation does not show noticeable differences between US-treated and non-treated samples.
q No mechanical damage of the fabrics was observed during 6 hours of direct treatment by US.
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Acknowledgments
Ultrasound application in dyeing
The Authors of this presentation wish to thank the industrial Partners of the INTEXUSA project for collaboration and useful discussion