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Exhaust Dyeing With Reactive Dyes
Exhaust Dyeing With Reactive Dyes
Exhaust Dyeing With Reactive Dyes
Dr. Tanveer Hussain Dean Faculty of Engineering & Technology National Textile University Faisalabad.
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Determines
Sat requirement Alkali requirement Temperature requirement
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The turquoise reactive dye shows an optimum dyeing temperature that is generally about 20 C higher than that of other dyes with the same reactive group
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Dye Substantivity
Substantivity is more dependent on the chromophore as compared to the reactive system. A higher dye substantivity may result in:
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a lower dye solubility a higher primary exhaustion a higher reaction rate for a given reactivity less diffusion, migration and levelness a higher risk of unlevel dyeing, more difficult removal of unfixed dye
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Dye Substantivity
An increase in the dye substantivity may be affected by:
higher concentration of electrolyte, lower temperature, higher pH (up to 11) lower liquor to goods ratio
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Dye Reactivity
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Dye Reactivity
A high dye reactivity entails a lower dyeing time and a lower efficiency of fixation. Reactivity of a dye can be modified by altering the pH or temperature, or both.
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Diffusion Coefficient
Dyes with higher diffusion-coefficients usually result in better levelling and more rapid dyeing. Diffusion is hindered by the dye that has reacted with the fibre and the absorption of active dye is restrained by the presence of hydrolysed dye. Different types of dyes have different diffusion characteristics. For example, the order of decreasing diffusion is: unmetallised dyes, 1:1 metal-complex dyes, 1:2 metal complex dyes; phthalocyanine dyes. An increase in the diffusion is affected by:
increasing temperature, decreasing electrolyte concentration, adding urea in the bath using dyes of low substantivity.
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Dye Solubility
Dyes of better solubility can diffuse easily and rapidly into the fibres, resulting in better migration and levelling. An increase in dye solubility may be affected by:
increasing the temperature, adding urea decreasing the use of electrolytes.
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Effect of Temperature
A higher temperature in dyeing with reactive dyes results in:
a higher rate of dyeing lower colour yield better dye penetration rapid diffusion better leveling a higher risk of dye hydrolysis lower substantivity
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Effect of pH
pH influences primarily the concentration of the cellusate sites on the fibre. Raising the pH value by 1 unit corresponds to a temperature rise of 20 C. The dyeing rate is best improved by raising the dyeing temperature once a pH of 1112 is reached. Further increase in pH will reduce the reaction rate as well as the efficiency of fixation
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Type of Alkali
Different types of alkalis, such as caustic soda, soda ash, sodium silicate or a combination of these alkalis, are used in order to attain the required dyeing pH. The choice of alkali usually depends upon the dye used, the dyeing method as well as other economic and technical factors
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Effect of Electrolyte
The addition of electrolyte results in:
increase in the rate and extent of exhaustion, increase in dye aggregation decrease in diffusion.
The electrolyte efficiency increases in the order: KCl < Na2SO4 < NaCl There may be impurities present in the salt to be used, such as calcium sulphate, magnesium sulphate, iron, copper and alkalinity, that can be a source of many dyeing problems
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Secondary exhaustion
Occurs after addition of alkali
Rate of exhaustion can be increased by selecting dyes of high substantivity, increasing the temperature and increasing the electrolyte concentration. Degree of exhaustion can be increased by selecting dyes of high substantivity, lowering a bit the equilibrium temperature and increasing the electrolyte concentration and dyeing time.
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The higher the dye substantivity, the lower is the migration. The external factors that affect migration are:
concentration of the dye, temperature, time, liquor ratio, liquor circulation the form of the textile material
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high substantivity, lower dye migration too much salt in the dyebath too high rate of exhaustion too high concentration of alkali a rapid shift of dyebath pH, too high rate of fixation too high rate of rise of temperature poor liquor agitation.
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Controlled absorption can be obtained by salt dosing, alkali dosing, and/or controlling the rate of heating.
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For medium shades, both primary and secondary exhaustion steps are important for obtaining level dyeing. Both controlled salt and alkali addition are important in this case. In the case of deep shades, the all-in salt addition may be possible, but during the secondary exhaustion, alkali dosing is important
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Washing-off Factors
Dye substantivity Diffusion behaviour Liquor ratio Washing temperature Electrolyte concentration pH Presence of calcium and magnesium ions in the boiling soap/hardness of water Amount of unfixed dye Washing time Number of washing cycles/washing baths/Filling and draining Washing auxiliary employed Mechanical action
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To maximise wet fastness, particularly in deep shades, it is advisable to apply cationic aftertreatments.
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BASF has developed a new polymer which combines with a reactive dye hydrolysate to eliminate its substantivity for the substrate in the presence of salt.
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