Journal of Textile Research ›› 2025, Vol. 46 ›› Issue (03): 131-140.doi: 10.13475/j.fzxb.20240106201

• Dyeing and Finishing Engineering • Previous Articles     Next Articles

Cyclic dyeing with wastewater from liquid dispersed dyeing process

YIN Lianbo1,2, LI Jiawei1,2(), DUAN Huimin1,2, SONG Lixiang2, CHEN Yushuang3, LI Xunxun3, QI Dongming1,2   

  1. 1. Zhejiang Provincial Engineering Research Center for Green and Low-Carbon Dyeing & Finishing, Zhejiang Sci-Tech University, Hangzhou, Zhejiang 310018, China
    2. Zhejiang Provincial Innovation Center of Advanced Textile Technology, Shaoxing, Zhejiang 312000, China
    3. Zhejiang Truelove Blanket Technology Co., Ltd., Yiwu, Zhejiang 322000, China
  • Received:2024-01-31 Revised:2024-11-25 Online:2025-03-15 Published:2025-04-16
  • Contact: LI Jiawei E-mail:jiaweili@zstu.edu.cn

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Abstract:

Objective In the field of textile printing and dyeing, the huge water consumption and pollution emission have become a problem restricting the sustainable development. Currently, polyester is the largest variety of chemical fiber, and it is reported that each ton of polyester fabric dyeing consumes about 60-80 tons of water and emits a large amount of wastewater. In response to the above issues, cyclic dyeing was implemented to reduce water consumption and wastewater emission so as to achieve low-carbon and environmental protection requirements.

Method The dyeing properties, dyeing kinetics, half dyeing time and diffusion coefficient of liquid C.I. Disperse Red 60 and powder C.I. Disperse Red 60 were studied. The cyclic dyeing of liquid dispersed dye dyeing wastewater was explored, and the economic analysis was also conducted.

Results The results shows that the uptake rate of C.I. Disperse Red 60 on polyester fibers is relatively fast in the initial stage. With the prolongation of dyeing time, the adsorption of the dye on the fibers gradually slows down until about 60 min later when the dyeing reaches equilibrium. Liquid C.I. Dispersed Red 60 has higher dyeing rate constants, greater diffusion coefficients and shorter half-dyeing times on polyester fabrics compared to powder C.I. Disperse Red 60 at a dyeing temperature of 130 ℃. In addition, as cyclic dyeing progresses, the color of the dyeing residue solution gradually deepens, and the chemical oxygen demand (COD) value of the dyeing solution also progressively increases. Compared with powder dispersed dyes, liquid dispersed dyes are more suitable for dyeing wastewater recycling dyeing by means of their dyeing residue showing lighter color and lower COD. Subsequently, the organic matter in the dyeing residue is decomposed using COD degrading agent to achieve rapid degradation of COD. When the amount of COD degrading agent is added up to 6.0 g/L, the COD value of dyeing residue decreases from 2 628 mg/L to 45 mg/L, and the COD removal rate in dyeing residue is above 98%. Afterwards, the dyeing residue treated with COD degrading agent is subjected to cyclic dyeing, and it is found that the liquid dispersed dyes still show good dyeing effect on polyester fabrics, as result that the cyclic dyeing of polyester fabrics using the treated wastewater is achievable. Liquid C.I. Disperse Red 60 dyeing wastewater was utilized to dye the polyester fabric using liquid C.I. Disperse Blue 291. The result indicated that the color light fastness of the dyed fabric is consistent with the dyed fabric using the fresh water as dyeing medium. However, when 10 cycles of dyed wastewater were used as dyeing medium, the color of dyed fabric became lighter, the green and blue light were weakened in comparation with the color parameter of the fabric dyed by fresh water.

Conclusion An effective method was developed for cyclic dyeing of polyester fabrics using liquid dispersed dye dyeing wastewater to reduce water consumption and wastewater emission. The results showed that the dyeing residue after 10 dyeing cycles could still be reused for dyeing after treatment with commercial COD degrading agent, and the water saving rate of 10 dyeing cycles reached 73% compared with the normal polyester dyeing process, which is in line with the requirement of low carbon and environmental protection.

Key words: liquid dispersed dye, cyclic dyeing, chemical oxygen demand, emission reduction, polyester fabric, dyeing kinetics, residual liquid

CLC Number: 

  • TS193.5

Fig.1

Dyeing process curve"

Fig.2

Schematic diagram of circulating dyeing"

Fig.3

Standard working curve of C.I. disperse red 60 in water/acetone mixed solvent"

Tab.1

Influence of dye dosage on K/S value, dry/wet rubbing fastness, and soap washing fastness of dyed polyester fabrics"

染料用量/
%(o.w.f)		 粉体分散染料 液体分散染料
K/S值 耐干摩擦色
牢度/级		 耐湿摩擦色
牢度/级		 耐皂洗色
牢度/级		 K/S值 耐干摩擦色
牢度/级		 耐湿摩擦色
牢度/级		 耐皂洗色
牢度/级
1 13.27 4 3~4 3~4 15.78 4 4 4
2 21.34 3~4 3~4 3~4 22.81 4 3~4 4
3 25.34 3~4 3~4 3~4 26.77 3~4 3~4 4
5 26.13 3~4 3~4 3~4 27.28 3~4 3~4 4

Fig.4

Dyeing effect and dyeing wastewater photos on polyester fabric under different dye dosage. (a) Dyeing effect of powder dispersed dye; (b)Dyeing effect of liquid dispersed dye; (c) Dyeing wastewater photo of powder dispersed dye; (d) Dyeing wastewater photo of liquid dispersed dye"

Fig.5

Dyeing rate curves of powder dispersed dye and liquid dispersed dye on polyester fibers at dyeing temperature of 130 ℃. (a) Uptake rate; (b) Fitting curves of quasi-second order kinetic equations;(c) Relationship between uptake amount and t1/2"

Tab.2

Quasi-second order kinetic parameters, diffusion coefficient, and half dyeing time of C.I. disperse red 60 adsorbed on polyester fibers"

染料形态 拟合公式 拟合系数
R2		 染色速率常数
k/min-1		 扩散系数/
(10-15 m2·min-1)		 半染时间/
min
粉体 y=0.006 55x+0.230 41 0.991 06 4.52×10-4 15.987 17.56
液体 y=0.007 09x+0.187 43 0.992 12 5.56×10-4 16.235 15.05

Fig.6

Circulating dyeing effect and dyeing wastewater photos of polyester fabic. (a) Circulating dyeing effect of powder C.I. disperse red 60; (b)Circulating dyeing effect of liquid C.I. disperse red 60;(c) Circulating dyeing wastewater photos of powder C.I. disperse red 60;(d)Circulating dyeing wastewater photos of liquid C.I. disperse red 60"

Tab.3

Uptake rate of circulating dyeing, K/S value, unevenness, dry/wet rubbing fastness and soap washing fastness of circulating dyed polyester fabrics"

循环
次数		 130 ℃(粉体) 130 ℃(液体)
上染
率/%		 K/S
值		 ΔE值 耐干摩擦色
牢度/级		 耐湿摩擦色
牢度/级		 耐皂洗
色牢度/级		 上染
率/%		 K/S值 ΔE值 耐干摩擦色
牢度/级		 耐湿摩擦色
牢度/级		 耐皂洗色
牢度/级
1 98.6 25.34 0.032 3~4 3~4 3~4 99.1 25.93 0.026 3~4 3~4 4
3 98.5 24.98 0.031 3 3 3 98.9 26.02 0.027 3~4 3~4 4
5 97.9 25.16 0.034 3 3 3 98.8 26.11 0.027 3 3 3~4
10 91.5 22.85 0.036 2~3 2~3 3 98.2 25.73 0.029 3 3 3~4

Tab.4

L*,a*,b*,C*,and h* values of cyclic dyed polyester fabrics"

染料种类 循环次数 L*值 a*值 b*值 C*值 h*值
粉体 1 34.72 53.35 9.36 54.17 9.95
3 34.97 53.83 10.44 54.84 10.93
5 35.97 54.98 10.62 56.00 10.90
10 38.37 60.92 10.33 61.79 9.62
液体 1 34.52 53.82 7.56 53.18 8.27
3 34.96 54.34 8.34 54.99 8.78
5 34.70 54.50 11.28 55.66 11.62
10 35.88 56.28 7.95 56.84 8.04

Tab.5

Comparison of COD values of powder and liquid C.I. disperse red 60 dyeing residue at 130 ℃"

循环染色
次数		 染料残液的COD值/(mg·L-1) 液体较粉体残液的
降低率/%
粉体 液体
1 1 597 1 027 35.7
3 3 208 2 024 36.9
5 4 415 2 628 40.5
10 7 050 3 945 44.0

Tab.6

Influence of amount of COD degrading agent added on COD value"

COD降解剂质量浓度/(g·L-1) COD值/(mg·L-1)
0 2 628
1.0 1 296
2.0 483
4.0 124
6.0 45

Tab.7

Uptake rate, K/S value, unevenness, dry/wet rubbing fastness, and soap washing fastness of polyester fabrics of dispersed dyes after repeated dyeing cycles"

循环次数 上染率/% K/S值 ΔE值 耐干摩擦色
牢度/级		 耐湿摩擦色
牢度/级		 耐皂洗色
牢度/级
1 97.5 23.89 0.030 3~4 3~4 4
3 98.1 24.01 0.032 3 3 4
5 98.2 23.57 0.031 3~4 3 3~4
7 97.9 24.11 0.034 3 3 3~4
10 97.5 23.92 0.035 3 3 3~4

Tab.8

L*, a*, b*, C*, and h* values of polyester fabric after repeated dyeing cycles"

循环次数 L*值 a*值 b*值 C*值 h*值
1 32.50 54.99 17.94 57.85 18.07
3 33.17 55.70 17.73 58.45 17.66
5 37.05 61.05 15.88 56.08 14.58
7 36.66 55.80 11.03 56.88 11.18
10 35.33 53.90 7.25 54.38 7.67

Tab.9

Dyeing data of C.I. disperse blue 291 using deionized water and C.I. disperse red 60 dyeing residues"

染色用水 K/S值 L*值 a*值 b*值 C*值 h*值 耐干摩擦色
牢度/级		 耐湿摩擦色
牢度/级		 耐皂洗色
牢度/级
鲜水 2.48 64.83 -18.12 -31.83 36.63 240.36 4 3~4 4
循环1次的染色残液 2.47 63.18 -18.26 -32.56 37.33 240.72 4 3~4 4
循环5次的染色残液 2.35 65.21 -16.23 -29.21 38.21 241.89 4 3~4 4
循环10次的染色残液 2.16 66.58 -12.36 -26.37 37.56 242.05 3~4 3 3~4

Tab.10

Main cost estimates for ordinary dyeing process and cyclic dyeing process"

染色工艺 耗水量/t 水处理
成本/元④		 COD降解剂
质量/kg
普通染色工艺[3] ① 30② 141 0
循环染色工艺 8③ 28.2 0.48
成本变化情况 节省73% 降低80% 新增COD降解剂
0.48 kg
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