Effects of dye particle size and dissolution rate on the overall dye uptake in supercritical dyeing process

Supercritical fluid technology as a sustainable alternative method for textile dyeing: An approach on waste, energy, and CO2 emission reduction

The clothing industry is considered one of the most polluting industries on the planet due to the high consumption of water, energy, chemicals/dyes, and high generation of solid waste and effluents. Faced with environmental concerns, the textile ennoblement sector is the most critical of the textile production chain, especially the traditional dyeing processes. As an alternative to current problems, dyeing with supercritical CO2 (scCO2) has been presented as a clean and efficient process for a sustainable textile future. Supercritical fluid dyeing (SFD) has shown a growing interest due to its significant impact on environmental preservation and social, economic, and financial gains. The main SFD benefits include economy and reuse of non-adsorbed dyes; reduction of process time and energy expenditure; capture of atmospheric CO2 (greenhouse gas); use and recycling of CO2 in SFD; generation of carbon credits; water-free process; effluent-free process; reduction of CO2 emission and auxiliary chemicals. Despite being still a non-scalable and evolving technology, SFD is the future of dyeing. This review presented a comprehensive overview of the environmental impacts caused by traditional processes and confronted the advantages of SFD. The SFD technique was introduced, along with its latest advances and future perspectives. Financial and environmental gains were also discussed.

UV-visible absorption spectroscopy for in-line API concentration measurement in nanoparticle production process using controlled expansion of supercritical solutions (CESS®)

Most new small drug molecules in pharmaceutical development require improvement of solubility. The controlled expansion of supercritical solutions (CESS®) process is a nanoparticle production technology, dedicated to enhancing the dissolution rate of active pharmaceutical ingredients (APIs) suffering from poor solubility and enabling novel drug delivery opportunities. In this process, the API is dissolved in supercritical carbon dioxide (scCO₂) and nanoparticles are formed through controlled pressure reduction. To improve process visibility and control, ultraviolet-visible (UV-Vis) spectroscopy was incorporated into CESS® process as a process analytical technology (PAT) tool. The tool quantifies the amount of API dissolved in scCO₂ during the solubilization phase of the process. Sample interfacing of the UV-Vis spectrometer was done with a custom-made pressure and temperature rated transmission flow-through cell. In-process calibration was developed to correlate the UV-Vis absorption spectra to the API concentration. Due to the density-dependent molar absorption coefficient of API in scCO₂, the calibration was done for each combination of temperature and pressure. The developed PAT tool provides insight into the process enabling real-time API quantity estimation. It also facilitates process development through Quality by Design (QbD) and offers a system for enhanced process control and troubleshooting. For instance, the in-line API concentration data allows one to study the solubilization behavior of the API in the process and to optimize the process parameters in order to maximize throughput.

Preparation of Ultrafine Disperse Dyes Based on the Efficiency Balance of Grinding and Dyeing

As dispersive dyes are nonionic dyes, the particle size and particle-size distribution will significantly affect the dyeing performance. In this study, the grinding conditions, the granularity of disperse dye, and the dyeing performance were combined to study their connection further and to get better grinding process parameters for monoazo-structure disperse dyes. Through experimental research on three factors, namely, grinding time, size of grinding media, and mass ratio of grinding media to dyes, the preferred results are as follows, which could be selected based on different grinding purposes in detail. The grinding media group is Φ1 mm/Φ0.1 mm (1 : 1 mass ratio) or Φ3 mm/Φ1 mm (1 : 1 mass ratio), the mass ratio of grinding media to dyes is 5 : 1 or 10 : 1, and the grinding time range is 2–5 h. These parameters can make the overall work of coarse dyes’ grinding and dyeing more efficient, avoiding the waste of cost and the increase in workload.

A numerical approach to determine the optimal condition of the gas anti-solvent supercritical process for nanoparticles production

Supercritical gas antisolvent (GAS) process is an efficient method for nanoparticles production, in which accurate selection of operational condition is essential. Thermodynamic models can be applied for evaluation the phase equilibrium behavior and determination the required precipitation pressure of GAS process. In this research, thermodynamic behavior of (CO₂—dimethyl sulfoxide (DMSO)) binary system and both of (CO₂–DMSO-anthraquinone Violet 3RN (AV3RN)) and (CO₂–DMSO-solvent Yellow 33 (SY33)) ternary systems in the GAS process were studied at different temperatures (308, 318, 328 and 338) K and pressures (1.0–14.0) MPa, using Peng–Robinson equation of state (PR-EoS). The minimum precipitation pressure of AV3RN and SY33 at 308, 318, 328 and 338 K were 7.80, 8.57, 9.78 and 11 MPa and 8, 8.63, 9.5 and 10.77 MPa, respectively. Also, the mole fraction of substances in liquid phase of ternary systems were determined by PR-EoS, at 328 K versus pressure. The accuracy of the obtained results were investigated using the experimental data reported in the literatures.

A Dissolution Kinetic Study of Disperse Dye in Supercritical Carbon Dioxide to Design an Efficient Supercritical Dyeing Process

The dissolution behavior of dye in supercritical carbon dioxide influences the overall mass transfer that controls a supercritical dyeing process. Increasing the dissolution rate of the dye leads to shortening of the dyeing process time and can improve the efficiency of the process. Controlling the properties of the carbon dioxide flow is a good method to improve the dissolution rate of dyes. In this study, a dissolution kinetic model was designed by quantitatively analyzing and formulating the dissolution phenomenon of dyes using an in situ UV/Vis spectrometer. Through this model, the dissolution rate was compared by varying the geometric shape of the column containing the dye and the flow rate of carbon dioxide. Moreover, the correlation equation between the Reynolds number and Sherwood number was obtained through mass transfer coefficients derived under various conditions. In order to verify the utility of this equation, it was applied to a scaled-up device and the precise result could be predicted. This study can be useful in the design of dyeing processes and make-up equipment.

Establishment of the Predicting Models of the Dyeing Effect in Supercritical Carbon Dioxide Based on the Generalized Regression Neural Network and Back Propagation Neural Network

With the growing demand of supercritical carbon dioxide (SC-CO2) dyeing, it is important to precisely predict the dyeing effect of supercritical carbon dioxide. In this work, Generalized Regression Neural Network (GRNN) and Back Propagation Neural Network (BPNN) models have been employed to predict the dyeing effect of SC-CO2. These two models have been constructed based on published experimental data and calculated values. A total of 386 experimental data sets were used in the present work. In GRNN and BPNN models, two input parameters, such as temperature, pressure, dye stuff types, carrier types and dyeing time, were selected for the input layer and one variable, K/S value or dye-uptake, was used in the output layer. It was found that the values of mean-relative-error (MRE) for BPNN model and for GRNN model are 3.27–6.54% and 1.68–3.32%, respectively. The results demonstrate that both BPNN and GPNN models can accurately predict the effect of supercritical dyeing but the former is better than the latter.