纺织学报 ›› 2022, Vol. 43 ›› Issue (01): 58-66.doi: 10.13475/j.fzxb.20210909310

• 纺织工程 • 上一篇    下一篇

基于碳中和的人-机-料-法-环五位一体纺纱新技术解析

夏治刚1,2,3, 徐傲1,2, 万由顺4, 卫江4, 张慧霞5, 唐建东5, 郑敏博5, 郭沁生6, 丁彩玲7, 杨圣明8, 徐卫林1,2()   

  1. 1.武汉纺织大学 省部共建纺织新材料与先进加工技术国家重点实验室, 湖北 武汉 430200
    2.武汉纺织大学 纺织科学与工程学院, 湖北 武汉 430200
    3.青岛大学 省部共建生物多糖纤维成形与生态纺织国家重点实验室, 山东 青岛 266071
    4.武汉裕大华纺织服装集团有限公司, 湖北 武汉 430080
    5.际华三五四二纺织有限公司, 湖北 襄阳 441002
    6.经纬智能纺织机械有限公司, 山西 晋中 030601
    7.山东如意科技集团有限公司, 山东 济宁 272073
    8.安徽华茂纺织集团有限公司, 安徽 安庆 272073
  • 收稿日期:2021-09-26 修回日期:2021-11-04 出版日期:2022-01-15 发布日期:2022-01-28
  • 通讯作者: 徐卫林
  • 作者简介:夏治刚 (1983—),男,教授,博士。主要研究方向为纺纱新技术与装备。
  • 基金资助:
    国家工信部智能制造新模式运用项目(2017168);省部共建生物多糖纤维成形与生态纺织国家重点实验室开放课题项目(KF2020215);际华三五四二纺织有限公司委托开发项目(JH3542-KJFB-20191001);湖北省重点研发计划项目(2020BAB082)

Analysis of new five-element-integration spinning technology based on human-machine-material-method-environment for carbon neutralization

XIA Zhigang1,2,3, XU Ao1,2, WAN Youshun4, WEI Jiang4, ZHANG Huixia5, TANG Jiandong5, ZHENG Minbo5, GUO Qinsheng6, DING Cailing7, YANG Shengming8, XU Weilin1,2()   

  1. 1. Key Laboratory Base of New Materials and Advanced Processing Technology, Wuhan Textile University, Wuhan, Hubei 430200, China
    2. College of Textile Science and Engineering, Wuhan Textile University, Wuhan, Hubei 430200, China
    3. State Key Laboratory of Bio-Fibers and Eco-Textiles, Qingdao University, Qingdao, Shandong 266071, China
    4. Wuhan Yudahua Textile and Garment Group Co., Ltd., Wuhan, Hubei 430080, China
    5. Jihua 3542 Textile Co., Ltd., Xiangyang, Hubei 441002, China
    6. Jingwei Intelligent Textile Machinery Co., Ltd., Jinzhong, Shanxi 030601, China
    7. Shandong Ruyi Science & Technology Group Co., Ltd., Jining, Shandong 272073, China
    8. Anhui Huamao Group Co., Ltd., Anqing, Anhui 272073, China
  • Received:2021-09-26 Revised:2021-11-04 Published:2022-01-15 Online:2022-01-28
  • Contact: XU Weilin

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摘要：

传统纺纱工序长而散、用工多,造成单产能耗高、产品一致性差、运营成本高等行业痛点问题;纱线原料的多元化使原料及成品回收难度大。为实现2030年碳达峰、2060年碳中和目标,提出了人-机-料-法-环的五位一体化碳中和纺纱的低碳生产策略,凝练并分析了集约型、简约型和延伸型低碳纺纱技术。分析结果表明:与传统纺纱相比,集约型智能纺技术运行成本降低32.67%,单位产品能耗降低17.5%、产品不良率降低61.54%,有效解决了纺纱行业的痛点问题,实现低碳高质纺纱;简约型高速纺纱技术能缩短或消除纺纱流程,纺纱速度高达550 m/min,实现了降低碳排放、提高效率的目标;低碳纺纱发展方向要向前后端延伸,对前端原料要多应用功能化循环利用技术、变废为宝技术、节能减排技术,在中端要发展固碳纺纱技术和循环利用技术,在终端研发绿色环保纺织品的制冷、隔热等功能纱制备技术。

关键词: 碳中和, 碳达峰, 低碳纺纱, 节能减排, 纺纱新技术

Abstract:

Conventional spinning process is characterized by its long scattered processes and labor intensiveness, causing problems such as high energy consumption per unit production, poor product consistency, and high operating cost. In addition, multiple-type-fiber spinning leads to difficulty in fiber recycling from raw materials and resultant products. As an effort to achieve the goal of carbon peaking in 2030 and carbon neutrality in 2060, this paper establishes a low-carbon spinning strategy as carbon neutralization spinning by integrating human-machine-material-method-environment. In specific, the intensive, simple and the extensive types of low-carbon spinning technologies were analyzed. The analysis results show that after comparison with conventional ring spinning, the intensive intelligent technology achieves low-carbon and high-quality spinning by reducing operation costs by 32.67%, production energy consumption per unit by 17.5%, and product defect rate by 61.54%, effectively addressing the problems in the spinning sector. The simple type can shorten or eliminate steps in the spinning process, achieves spinning speed as high as 550 m/min, realizing the goal of efficiency-improvement and emission-reduction. The extensive type spinning develops a front-end raw material functional recycling to change waste into treasure, reducing energy and emission. The extensive type also develops medium-end carbon-nesting spinning to produce green functional yarns, and resultant manufacturing technology can be used for producing cooling, heat-insulting functional yarns for green terminal textiles.

Key words: carbon neutralization, carbon peaking, low-carbon spinning, energy-saving and emission-reduction, novel spinning technology

中图分类号: 

  • TS104.7

图1

低碳纺纱方案策略框架"

图2

国产化纺纱新方法"

表1

国产智能化纺纱关键装备与国外类比"

智能纺装备名称 100%国产智能纺纱 国外智能高端纺纱 对比结果
纺纱技术关键装备 经纬智能精梳机;万宝脉聚纺 立达全自动精梳机;负压紧密纺 国际先进水平;节能1/3
头并-粗纱物流系统 轨道式物流输送系统 自动导引运输车物流输送 国产效率更高
回花收付系统 全程无死角收付系统 部分收付、忽略全程 国产达到国际先进水平
智能管控系统 100%国产无死角和孤岛 与国内设备兼容差 国产兼容性优越

表2

全国产智能纺纱效果与国内外普通纺、智能纺效果的比较"

对比指标 100%国产智能纺纱技术与国内外技术的比较 国际高端
智能纺纱
测算方法 改造前的现代普通纺 改造后的智能纺 定量指标升降
生产效率 一线员工每小时万元产值提升幅度 锭速15 500 r/min,单产13.07 kg/(千锭·h) 锭速18 500 r/min,单产16.26 kg/(千锭·h) 提升24.40% 同等水平
运营成本 [(建设前运营成本-建成后运营成本)/建设前运营成本]×100% 万元产值运行成本3 931.16元 万元产值运行成本2 647.04元 降低32.67% 同等水平
产品升级周期 [(建设前研制周期-建成后研制周期)/建设前研制周期]×100% 10 d 6 d 缩短40% 同等水平
产品不良率 (建设前不良产品数/总数)×100%-(建设后不良产品数/总数)×100% 0.26% 0.1% 降低61.54% 同等水平
单位产值能耗 [(建设前单位产品实耗能源-建成后单位产品实耗能源)/建设前单位产品实耗能源]×100% 万元工业增加值综合能耗0.80 t标准煤 万元工业增加值综合能耗 0.66 t标准煤 降低17.50% 同等水平
产品质量工艺可追溯率 — 60% 100% 100.00% 同等水平
万锭用工 [(建设前万锭用工-建成后万锭用工)/ 建设前万锭用工]×100% 万锭用工53人 万锭用工14.8人 降低72.08% 同等水平

图3

简约型短流程高速的开放端纺纱技术特征及代表"

图4

简约型短流程中速握持端倍捻直络纺纱技术"

图5

长丝直接纺成大卷装纱线的超短流程纺纱技术"

图6

型膜丝化直接纺成大卷装纱线的超短流程纺纱技术"

图7

无纺-编织的超纺技术"

图8

循环回用纤维的高质化功能纺纱技术"

图9

短流程优质固碳纺纱技术"

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