Pad Batch Dyeing

8/3/2019 Pad Batch Dyeing

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SUMMARY OF Smith 1986 Pad Batch Dyeing2.b.ii Electro1ytes:Smith 1986 Pad Batch Dyeing:HE STATES THATSame as section.2 from Identification and Reduction. . Smith 1986on pad/batch fiber reactive dyeing of fiber reactives on cotton.It covers the same technical area (pad-batch) as Stone979, butthis review focuses mainly on P2 aspects. The pad batch systemaddresses several of the major problems for cotton dyers in thefuture. They are covered in other parts of the outline, ie.Dyeing, 2.a.v Water Conservation, and 2.b.i Color Residues inTextile Dyeing/Printing Wastewater. This information is also verappropriate for 3.j Process alternatives. This section should besubstantially included in the document. Same information under headings noted above.2.a.v Water Conservation:Smith 1986 Pad Batch Dyeing:HE STATESTHAT Same s section 3.2 from Identification and Reduction. . Smith1986 on pad/batch fiber reactive dyeing of fiber reactives oncotton. It covers the same technical area (pad-batch) as Stone1939, but this review focuses mainly on P2 aspects. The pad batcsystem addresses several of the major problems for cotton dyerthe future. They are covered in other parts of the outline, ie2.b.ii Electrolytes, 4.j Dyeing, and 2.b.i Color Residues inTextile Dyeing/Printing Wastewater. This information is also verappropriate for 3.j Process alternatives. This section should besubstantially included in the document. Same information under headings noted above.2.b.i Color Residues in Textile Dyeing/Printing Wastewater:Smith1986 Pad Batch Dyeing:HE STATES THAT Same as section 3.2 fromIdentification and Reduction . . . Smith 1986 on pad/batch fiberreactive dyeingof fiber reactives on cotton. t covers the sametechnical area (pad-batch) as Stone979, but this review focusesmainly on P2 aspects. The pad batch system addresses several ofthe major problems for cotton dyers in the future. They arein other parts of the outline, ie 2 .b. i Electrolytes, 2. a.vWater Conservation, and.j Dyeing. This information is also veryappropriate for 3.j Process alternatives. This section should besubstantially included in the document. Same information under headings noted above.4.j Dyeing:Smith 1986 Pad Batch Dyeing:HE STATES THAT Same assection 3.2 from Identification and Reduction . . Smith 1986 onpad/batch fiber reactive dyeing of fiber reactives on cotton. Itcovers the same technical area (pad-batch) as Stone979, but thisreview ocuses ainly n 2 spects. he ad atch ystemaddresses several of the major problems for cotton dyers in thefuture. They are covered in other parts of the outline, ie 2.Electrolytes, 2.a.v Water Conservation, and 2.b.i Color Residuesin Textile Dyeing/Printing Wastewater. This information is alsovery ppropriate or 3.j Process lternatives. his ectionshould be substantially included in the document. Same informatunder all headings noted above.


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3.j Process a1ternatives:Smith 1986 Pad Batch Dyeing:HE STATESTHAT Same as section 3.2 from Identification and Reduction... 1986 on pad/batch fiber reactive dyeing of fiber reactives oncotton. It covers the same technical area (pad-batch) as Stone1979, but this review focuses mainlyn P2 aspects. The pad batchsystem addresses several of the major problems for cotton dyernthe future. They are covered in other parts of the outline, ie2.b.ii Electrolytes, 2.a.v Water Conservation, and 2.b.i ColorResidues in Textile Dyeing/Printing Wastewater. This informationis also very appropriate for . j Dyeing. This section should besubstantially included in the document. Same information under headings noted above.


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SMITH/B-TC.0 5-33586.0 CHAP-3.0 18/08/868.23.56 PAGE 63.2 Pad Ba tc hD y e in gofCe l lu lo s i cF ib e r s

The pad batch (c o l d) methodo f d y e in gc e l l u l o s i c s i s h a r d l y a newconcept [26-301. I t h a sb e e nu s e dq u i t e u cc es s f u l l y n a wide va r i e t y ofa p p l i c a t i o n s . I n many ways, it i s oneofhe most r e l i a b l e and e a s i e s t - t o -c o n t r o l m ethods a v a i l a b l e o d a y o rc e r t a i na p p l i c a t i o n s .S t r a n g e l ye n o u g h ,however, it has n o tcau g h t on i n h i sc o u n t r y o h ee x t e n t h a t it i s u sed i nCon t in en t a l Europe o r n England , where it was f i r s t d ev el op ed by I m p e r i a lC h e m i c a l n d u s t r i e s.

To qu ic kl y summarize th e pad ba tchmeth o d ,p r ep a r ed ab r i c i s impregnatedw i t h l i q u o rc o n t a i n i n gp r e m i x e d i b e r e a c t i v ed y e s t u f f and a l k a l i ;e x c e s sl i q u i d i s squeezedout on th eman g le ; h e ab r i c is b a t c h e do n t o o l l so r nboxes,andcovered w i t h p l a s t i c i l m op r e v e n ta b s o r p t i o no f C02 from a i r o revapora t ion o f water, t h e ns to red o r two to welv eh o u r s ( see Figure 3.2-1 1.

The goodscan be washed o f f nan y o f severa lconven t ionalways ,depending one q u i p m e n ta v a i l a b l e n h e mill.

Themethod i s i n t e r e s t i n gb e c a u s e it o f f e r s s e v e r a l s i g n i f i c a n ta d v a n t a g e s ,p r i m a r i l y n its s imp l i c i t y n d p eed .Prod uct i on of etween 75an d 150 y ar d s a minute,depending on th ec o n s t r u c t i o n a n dweigh t of thegoodsinvo lved , i s commonly re po r te d. n a ct , h i ski nd of peed an make t h el i m i t i n gf a c t o r the wash-off f a c i l i t i e s , which may no t be able t okeep up .O t h e rb e n e f i t s n c l u d ee s s e n t i a l l ye l i m i n a t i n g h e nee d f o r s a l t o rch emica ls p e c i a l t i e s f r o m the dyebath, w i t h a s s o c i a t e d e d u c t i o n nc o s t and p o l l u t i o ns o u r c e e d u c t i o n .

A n o th e r ac to r h a th a sg e n e r a t e den th u s i a s m o r pad batch i s i t sf l e x i b i l i t y , com pared t o a co n t in u o u s an g e .Eit he r wovens ork n i t sc a n b edone, nd i n many con str uc tio ns.F r eq u en tch an g esof hade a re no problem,


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,- PAD/ BATCH - BEAM STORAGE AND WASH-OFF UNIT

Figure 3.2-1 . Pad/batch - beam storagea n d wash o ff u n i t


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SMITH/B-TC.0 5-33586.0 CHAP-3.0 18 /08/868.23.56 PAGE 8because eac t ives emain water soluble , making c leanup easy. Th i s i t s manys i t u a t i o n s wel l , e s p e c i a l l y when v e r s a t i l i t y i s r equ i r ed . The pad ba t c hsys temcan un he same co l ddye i ng i be r e ac t i vecombi na t i ons tha t a reusua l ly un on packagedye, igs, beams, beck s, j e t s andotherequipment .Washing-off an be donewithbecks, beams, cont inuousequ i pmentorotherava i l ablemachines .

S tudies [301have shown t h a t padba tchdye i ng o rcot ton , ayonandblendsconservesenergy, water, dyesandchemica l s , aborand loor pace.Water consumpt ion orpadbatchdyeingwith beam wash-off i s t yp i ca l l yu n d e rt w o . ga l l onsper pound of dyed fabric, compared t o t y p ic a l ly 20 or more o na tmospher icbecks o r he same f i b e r e a c t i v e d ye d h ad es .Energy onsumptioni s s imi la r l y educe d from about 9000 BTU's per poundofdyed fab r i c orb e c k st ounder 2000 BTU's per pound f o r padba tchwith beam washing. Chemical us e,and a s soc i a t ed BOD and COD l oad i ngs o r waste streams, can be reduc ed up to80%ompared to tmo sph eric becks. Labor os t s a re a l so educed . Forexample, t w o workers per s h i f tc a ndye 200,000poundsof fabr i cp e r i v e - d a yweek.

I ng e n e r a l , h eq u a l i t y o fpadbatchdyeings is much be t t e r t hano t he rdye i ngsys t ems .Spec i f i c so fcos tsav i ngs a re shown inT a b l e s 3.'?.-I, 3. I.--I1,and3.%III. Pad ba tchdye i ngs equ i r eh i gh l y eac t i ve co l ddye i ng" i be rr e a c t i v eco lo rs . Examples f rand names of uch olor s are :

A t l a f i x CX ( A t l a n t i c )Cibacron F ( C i b a Geigy ). n t r a c r o n C ( C & K ). evafix E ( A ) (Mobay1


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fComparison of Annual Operation Cost

Production( 120 h r . wk/ 50 wks ./annum

Labor Cos t sFuel Costs

(Ex t ra Drying)i a er COS ts

Cold Dyeing Reactiveson CottonPad/Batch/2Bern.Wash-of Stands

Dye Costs(Va ries, ee Table 111)

193,050 lbs ./weekor9, 52,500 lbs ./annum

Chemical C o s t s ,S a l tAlkali

$79,560

$ 8,700

0$19,112

ConventionalExhaust Dyeing100% Cotton( 1 9 becks)

193,050 lbs /weekor9,652,500 lbs./annum

$256,360$ 2 7 2 , 0 0 0-$ 98,500

$337,840$ 82,820

$207,672 $1,047 ,520


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Table 3 .I -IrCapi t a l I nves t men t [ 30 1

CostComparisonofPad-BatchwithBecks

Cap i t a l I nves t men t [ 30 1

co s t Conmar isonofPad-BatchwithBecksPad BatchDyeingSystem:Dye Pad fo rK n i t s2 Beam Wash-off StandsI n s t a l l a t i o n est imated t o be 30%( i nc l ude s pad en t ry ,padde r , 2 beam wash-off stands,dye/alkal i pump, 10 beams, r o t a t i o n t a n d ,c r a d l e e t - o f fs c r a y

ExliaustDyeing100%CottonOnly:19 AtmosphericBecks1000 pounds cap aci ty eac hCos t - $30,000 eachI n s t a l l a t i o n e s t i m a t e d o be 30%

$ 160,000

$ 48,000$ 208,000

$570, 00$171 ,000$741,000


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Table 3 .l-IIITy pic al Dye Co st orPad-Batchvs he Same Dyeson Becks [+/pound1

ColorPowder BlueDark RedBright Yel lowBright RedBr ightBlueLight BlueDarkGreenNavy

Pad-Batch Beck-Dyed3 05 035485537463 0

406 35 07 57 0587 05 3

All theabovecost s a re f o rd y e i n go n l y f o r 100% c o t t o n ) ,n o t n c l u d i n gp r e p a r a t i o n . All of th e .beck-dyed c o st s a rec o l d e a c t i v e . n cases where hebeckdyewould be d i r e c t ,pad-batch would pr ob ab lycost more.Beck dyeing w i l l probablyc o s t less .


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SMITH/B-TC.0 5-33586.0 CHAP-3.0 18/ 08 /8 68.23.56 PAGE 9Drimarine K (Sandoz1. Procion M ( I C 1 1

. Remazol ( HoechstOne key t os u c c e s s f u lu s e .of the ys tem by thed y e r i s pH c o n t ro l . Whilea l l r e s p ec t i v ed y e s are n o t a l l e q u a l l y s e n s i t i v e , a pH of10.5 t o 11.5 w i l lbe i d e a l n most cases f o r 1 2 hourbatchi ng. An i n c re a s e n pHmay ben e c e s s a r y o n c r e a s e e a c t i o n r a t e f o rs h o r tb a t c h times ( 2 t o 4 h o u r s ) .

Extensive work ind ev e lo p in g h e pad b a t chsys tem ofd y e in gce l l u lo s ehasbeen one by Cot ton nco rpor ate d [27-301. Some of the ol l owi ng nfo rma tio nwas 'developedb y them i n a c t u a l p l a n t e x p e r i e n c e .

Equipment fo r he padb a t chd y e in gco n s i s t so f :1 . Padding unit

The p ad d in gu n i ts h o u ldh av e h en eces s a r ycon t ro ls o rh an d l in g h e y p eo f a b r i c h a t i s t o be dyed on th eu n i t . n case of k n i t a b r i c s , h ep a d d e rmu s th av ead q u a t egu id ing ,d ecu r l i n gands p r ead in geq u ip men t oh an d le h ek n i t n ope nwidth orm.This i s e s p e c i a l l y m p o r t a n t on s i n g l e k n i t a n dwarpk n i t a b r i c s w h ic h e n d ocur l when leng thwi se ens i on i s applied. Thep a d d e rs h o u lda l s oh a v es u i t ab l ep r es s u r eco n t r o l s oa l l o w h en ip o bec o n t r o l l e dc o n s i s t e n t l y . A d e f l e c t i o n o l lpa d de r may be advant ageou s.A n o t h e rd es i r ab l e ea tu r e i s a small dye rough .This i s imp o r t an t oa c h i e v egood dye l iq uor urn ove r , omi nim ize he amountof " t a i l i n g " , and a l s o t oav o id eac t i v ed yehydro lys i sw h ichmig h tp r o d u ceshad ing f rom beginnin g t o


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SMITH/B-TC.0 5-33586.0 CHAP-3.0 18/08/86 08.23.56 PAGE 10 end f t he ab r i c un . A dye rough of te ng a l l o nc a p a c i t yo r less i s u s u a l l yrecommended. Ad eq uat e pee d ont rol swhi ch on t ro l hepadde r nd ynchron i ze

t h eb a t c h e ru n i t a re abso l u t e l ynecessa ry ., I no r d e r oo b t a i n a q u a l i t yd y e i n g ,u n i f o r m r o ms i d e os i d eand end t o

end , he ab r i c mus t be uni formlyprepa red . The f ab r i c hou l d be scouredand/orbleachedwith a re si d ua l pH of 7 o rs l i g h t l y less . I t shou l dcon t a i nn o r e s i d u a la l k a l i , s t a r c h ,k n i t t i n g o i l s o ra nyo t he r o r e i gnsubs t ance whichw i l l i n t e r f e r e w i t h the evennesso fabsorbencyor hesubsequen tcolor fas tnesso f he ab r i c . The f a b r i c s must w e t o u t a p i d l y a nduniformly ndmust beuni formlypreparedanddr ied . I t is ad van tag eou s o make updye lots off ab r i c s whi ch were p r e p a r e d o g e t h e r oa v o i dp o s s i b l es h a d ev a r i a t i o nw i t h i nt h edye o t .

Pad batchdye inggiv es much lo we rde fec t eve l s han oped y ei n g on manys t y l e s .For xamp l e , ab r i c s of va ry i ng h i ckness uch as 100% rayon acquardt a b l e c l o t h s a re d i f f i c u l t o p r o c e s s n r o p e f o r mwi t hou ts t reaking fdyed byexhaustmethods on be ck su s i n gd i r ec td y e s .

The beautyof hepadba tchsys temus i ng hehigh eac t iv i tydyes i s t h a ta g r e a td e a lo f h ed y e i x e s n 30 mi nu t e s ,a n d h ed i f f e r ence ndep t hbetweenonehour nd ighthours i s ne gl ig ib le n many shades .Thi s i s oner e a s o n o r h eu n u s u a ld e g r e eo fs h a d e e l i a b i l i tya n d i s impor tantbecauset h e a b r i cn e a r h ecor e of t he ake -up o l l i s o b v i o u s l y i r s t on and l a s to f f ,a n dh a sa c t u a l l yb a t c h e d o n g e r h a n h eo u t e r layers .

Becauseof he low p h y s i c a la f f i n i t yo f h e s ec o l dd y e i n g e a c t i v e s , h e ywork extremely well f o r a l l c o n t i n u o u so p e r a t i o n s h a t n c l u d e a paddings e q u e n c e .Co l o ryie ld exh aus t io n nd ixa t io n) end o be lower when dyeingi n a lon g iqu or , compared wi thh i g ha f f i n i t yd y e s t u f f s u c h as vatdyes . A


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SMITH/B-TC.0 5-33586.0HAP-3.0 18/08/86 08.23.56 PAGE 11 wor t hwhi l e nc r ea se n i xa t i oncan be accompl i shed n a s h o r t e r i q u o r , ast he t a b l e be l ow i l l u s t r a t e su s i n g a t yp i ca ldye of th e low s u b s t a n t i v i t ygroup- - in th i s case, CI ReactiveYellow 22.

Liquor- to-goods rat io 30:l

"%8%2%70%nc rea sedo l o r 265% 75%3%8%3%0%7%Dye fullyi x e d 20%0.6: 1:1:l:lO:l0:l

"va l ueus i ng 1 : r a t i o

The advantageso f h i s a p i d i x a t i o na n ds t a b i l i t yo fs h a d e are obviouswhen compared t oo t he r met hods . n j i g andbeckdyeing, or xample, henormal out ine i s t ocon t i nuedye i ng , h ad i ng fnece ssa ry , until the c o r r e c tc o l o r i s obta ined. Dyehouse op er ato rsa r e e e nc o n s t a n t l yc u t t i n g w a t c h e so f f the goods for nspe c t ion .Ev en when th ed y e r i s s a t i s f i e dw i t h h ec o l o r ,i t may be t h a t a l l f i x a b l ec o l o rh a sn o t e a c t e dw i t h h ec l o t h , so t h a te a c hbatchmust be t r e a t e d n d i v i d u a l l y , a n d h a devar i a t ions are i n e v i t a b l e . Withpad batch,however ,exper i encehas shown th at fpadd i ngan dba t ch i ngtemperatures are prope r l ycon t ro l l ed , ep roduc i b i l i t yo fs h a d e i sou t s t and i ng .

There i s s t i l l a n o t h e rb e n e f i to f h i s a p i d i x a t i o n . I t i s a minorpo i n tpe rhaps ,andeas i lyove r l ooked ,but here is a lmost 100% r e p r o d u c i b i l i t yfrom la b op r o d u c t i o ns h a d e s . The pad ba tc h ys te m may be home d es ig n ,b u tit must featureaccura t e nmi x i ngan dme t e r i ng . Two tanks holddyes t u f fanda l k a l i s o l u t i o n s w h i c h are f e d o a mix and d is pe ns in g mechanismwith apropor t i on i ngdevice. Themix is t hen edv ia a pump t o h e pad u n i t. Byemploying a hol lowdi spense r , i t i s poss i b l e okeep hepassage h roughwhi chth e f a b r i cp a s s e s less thanone nchwide.Thiskeeps he volume f l i q u o r


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SMITH/B-TC.0 5-33586. o CHAP-3.0 18/08/868.23.56 PAGE 1 2very low, a bo ute i g h tg a l l o n so r less a n d n s u r e s h e a p i d u r n o v e r of l i q u o rso t h a t dyedecomposi t ion i s k e p t o a minimum. This i s , of cour se , mpor t an tb e c a u s ea d d i n g h ea l k a l i o n c r e a s e e a c t i v i t ya l s oa f f e c t s the s t a b i l i t y oft h ei q u o r . (See Figure 3.1-2.)

Inwork i ngwi thp l an tproduc t ion pad ba tch u n i t s , h e o l l o w i n g o u rp o i n tcheck l i s th a sbeenhe l p fu l navo i d i ngprob l ems :

1 .

2 .

3 .

4.

Keep good a l k a l i co n t r o l by insur ingadequa temixingand / o rmeter ing echniques .Adj us texhaus tdye ec i pe s o rpadbatch by kee pin gaccura t eda t a on l i q uo r a t i o s . Keep t hemmersion long, t h e i q u o rr a t i os h o r t ,an d he volume low i n the pad.Have good preparation.A c t u a l l y , p a db a t c h e l i a b i l i t yh a sreached hepointwhere it can be used as a check on theprepara t ion . f omethingdoesn ' t ook i gh t ,mos tof t en it canbe t r a ced om i s t a k e s np r e p a r a t i o n .Keep good t empera turec o n t r o l ,e s p r c i a l l ya v o i dd y e i n gh o tf a b r i c r e s h from p r e p a r a t i o n . Feed c o l d a b r i c o h ep a do re l s e t he empera ture w i l l r ise . Duringveryhotweather , keept h e mix coolwi th a c o o l i n g water j a c k e to r use i c e i n he mix.

Since many mills t ha thaveagreementswi thmun icipa l sewage ystemspayon some formulabased on th econ t en t o f BOD, COD o ro t h e ru n d e s i r a b l ec o n t e n t sof thee f f l u e n t , h e p adbatchmethodemployingcold eact ives i s a l s oa t t r a c t i v e from t h epo l l u t i on ourceaba t emen t t andpo i n t .Reac t ives do notr equ i r e educ i ngorox i d i z i ngagen t s , as do vatso r u l f u r s .R e a c t i v ed y e sr equ i r eus e of massiveamountsof s a l t when employed in b e c k s ,b u t n h e padba tch method, co l d eac t i ve s equ i r e no s a l t a t a l l ."


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SMITH/B-TC.0 5-33586.0 CHAP-3.0 18/08/868.23.56 PAGE 13The useof chemical s p e c i a l t i e ss u c ha s u b r i c a n t s , e v e l i n ga g e n t s ,

a n t i m i g r a n t s , i x a t i v e s ,d e f o a m e r sa n do t he r pec i a l t i e s by the pad ba,tchdye ing i s u s u a l l yn o t e q u i r e d . S m a l l amountsofde te rgent a r e u s e d nwashing-off .

In summary, ex cel len t es ul tsh a v eb e e no b t a i n e d w i t h thepadbatch( c o l d ) y s t e mu t i l i z i n gh i g h e a c t i v i t ydyes . Dye r shave xperien ced manyb e n e f i t s :

1.

2.3.4.

5.

6.7 .

8.

9.10.

Low ca pi t a l ou t l ayLow energy equi rement sHigh productionspeedReduced labor equirem entHigh colory i e l dO u t s t a n d i n g e p r o d u c i b i l i t yE x c e l l e n tp e n e t r a t i o n ,a n d e v e l i n gc h a r a c t e r i s t i c sR a p i d i x a t i o n

S u b s t a n t i a lo v e r a l lc o s t a v i n g s d y e s ,c h e m i c a l s , a b o r ,water, e tc . 1Reduc t i on n BOD, COD and pH pr o bl em s ne f f l u e n t .

A t t h e i r n c e p t i o n n1 9 5 6 , i b e r e a c t i v e s were n o t e d o r h e i re x c e p t i o n a l l ybr ig ht ha de s. However, the angehas nc r ea seddramat ica l ly .The sh ad e an ge now in cl u de s new dyesof muted to ne s aimed a t s h a d e s h a tp r e v i o u s l y were con sid ere d he domainof d i r e c t , s u l f u r and v atdyes .React iveshavegiven a good account of hem selve s n ermsof a s t ne ssandeconomy a ga i n s t r a d i t i o na l c la s ses of dyes,and utureprospec t sappea rverybr i gh t ndeed .

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