A brief analysis of the four major energy-saving and emission-reduction measures for printing and dyeing enterprises
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1. Strengthen production management and reduce resource waste
By formulating a reward and punishment system for energy conservation and consumption reduction, we have strengthened the cultivation of employees’ awareness of energy conservation and consumption reduction, and involved all employees to do everything possible to reduce gas consumption, electricity consumption, water consumption and dye and chemical material consumption. Many companies have installed electricity meters and water meters in each production workshop, and implemented a daily report system for dye and chemical material consumption. Each department evaluates and rewards unit electricity consumption, unit water consumption, and unit consumption of dye and chemical materials to mobilize the enthusiasm of all employees to save energy and reduce consumption. .
Apply computer management technology to install online automatic measurement and control systems at key process points of the production line; equipped with automatic weighing, chemical and distribution systems for auxiliaries, color pastes, dyes and chemicals; equipped with automatic steam control systems and automatic measurement and control of moisture on the cloth surface Systems, etc., can achieve precise control according to process requirements and reduce dependence on labor, and can play a very good role in saving energy, water, dye additives, etc.
2. Adopt new printing and dyeing technologies and processes to achieve energy conservation and emission reduction
In terms of pre-treatment, new equipment is adopted and efficient additives are used to shorten the process flow, reduce water consumption, save steam and electricity without reducing treatment quality, and achieve the effect of energy saving and emission reduction. Since the mid-1980s, my country’s printing and dyeing industry has conducted research on short-process pre-treatment processes from both process and equipment aspects. Various high-efficiency water washing machines, high-feed impregnation machines, combined steamers and other pre-treatment equipment provide the equipment basis for shortening the process. Various new high-efficiency pre-treatment aids such as: high-efficiency refining agents, non-silicon hydrogen peroxide stabilizers and various Pretreatment enzyme preparations make short-process technology more mature. At present, pretreatment technology has undergone revolutionary changes compared with the original traditional alkali-alkali oxygen process. The one-step pretreatment process of biological enzyme compound plus hydrogen peroxide is being widely used in the pretreatment of cotton and its blended chemical fiber fabrics. In process.
Cold-rolling batch pre-treatment technology and cold-rolling batch coloring technology have made rapid progress in recent years, and cold-rolling batch pre-treatment technology has been widely used in actual production. The fabric is stored for a certain period of time after passing through the padding pre-treatment working fluid, and then undergoes short steaming and high-efficiency water washing to achieve pre-treatment effects such as removing impurities, improving whiteness, and improving the wool effect of the fabric. Compared with the conventional three-step pre-treatment process, steam consumption and water consumption are greatly saved, and the COD of pre-treatment wastewater is also significantly reduced.
The reactive dye cold pad-batch coloring process technology has also made rapid progress due to the improvement of equipment and dye performance in recent years, and has now become the mainstream process for corduroy coloring. Cold pad batch dyeing is used to dye corduroy. It improves production efficiency, makes the cloth full in color, and evenly dyes without “black air”. It is incomparable to the reactive dye pad-baking-pad-steaming method of corduroy dyeing. . Other pure cotton fabrics, such as gauze, silk, etc., have also been successfully colored by cold padding with reactive dyes. This energy-saving and water-saving coloring technology still has a large space for promotion and application in our country.
Other new processes and technologies, such as low-alkali pre-treatment process, low-temperature coloring process of reactive dyes, reactive dye alkali substitute process, one-bath knitted fabric dyeing process, rapid coloring process of disperse dyes, etc., can all achieve great results. Good energy saving and emission reduction effect.
3. Promote the secondary utilization of printing and dyeing wastewater and improve the water reuse rate
Currently, printing and dyeing wastewater treatment technology is progressing rapidly. It is the goal of joint efforts to minimize treatment costs while ensuring water quality. After thorough treatment, the water quality of printing and dyeing wastewater can be comparable to that of tap water. It can be used in every printing and dyeing process, and the reuse ratio reaches 50-60%. This technology has become increasingly mature, and there have been many successful cases in the country.
While paying attention to wastewater treatment, of course, what needs to be paid more attention to is how to improve the reuse rate of water, how to reduce the amount of printing and dyeing wastewater, how to reduce the amount of pollutants in wastewater, and how to improve the reuse rate of water. Many companies have done fruitful work in this area, such as using production water as cooling water for coloring and recycling part of the waste heat; installing heat recovery devices on machines that generate hot waste water , recycle the heat in the wastewater; adopt advanced steam condensate traps and use pump-less back pressure to reuse the hot steam condensate to the boiler room or machines that use hot water; process the printing and dyeing wastewater through biochemical-physical processes After treatment, it should be used for rinsing water, washing water after medium and dark dyeing, etc.
4. Utilization of smoke and dust removal waste heat from heat setting machine waste steam
The direct emission of high-temperature exhaust gas from heat setting machines not only causes air pollution but also takes away a large amount of heat energy. The currently developed printing and dyeing exhaust gas treatment system integrates exhaust gas spraying and extraction, oil and water separation, cleaning water recycling, waste heat utilization, Waste oil collection and utilization and other technologies are another major contribution to energy conservation and emission reduction. The effective use of this device not only achieves the environmental benefits of smoke and dust elimination, but alsoIt also allows the waste heat in the exhaust gas and the grease in the exhaust gas to be recovered, achieving the dual effects of environmental protection and cost reduction and efficiency improvement.
In short, with the advancement of science and technology, the improvement of printing and dyeing processes, the updating of printing and dyeing equipment, and the application of new materials, energy conservation and emission reduction work will gradually deepen and achieve more effective results. At the same time, doing a good job in energy conservation and emission reduction is also an opportunity for enterprises to expand their living space and expand their living space. It is an important measure to reduce costs and increase efficiency. Only by continuing and doing a good job in this work can we promote the healthy and sustainable development of the industry, and can enterprises stand firm in the face of the current severe situation and strive for new progress. .
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