Synthetic process optimisation for production of switchable hydrophilicity disperse dyes

聚酯是世界上使用最多的纺织品，每年生产约6100万吨（i），然而，聚酯染色工艺产生大量化学污染，并且每生产1公斤纤维用水量超过110升（ii）。这意味着人们对一种新的染色工艺非常感兴趣，这种工艺消除了污染性的辅助化学品，用水量低。正在开发一种新的聚酯染料，它不需要污染性分散剂，减少水和能源的使用，同时提供与商业上使用的聚酯染色机械相同的性能。这项技术将是一项革命性的技术，可以显著提高纺织印染行业的可持续性，并为循环经济的发展做出贡献。由于这些可能性，快速扩大新型染料的合成规模至关重要，有助于满足项目交付目标并提高产品的商业可行性。使用连续流系统是为了实现这一目标，然而，目前的合成工艺需要在反应速率方面进行优化。为了评估工艺变化的有效性，包括使用碱性催化剂和提高反应温度，通过在线和离线分析技术监测反应速率。一旦优化，反应将被转移到一个连续的过程，以允许大规模的染料生产所需的中试规模的研究。

Polyester is the world's most used textile, with approximately 61 million tonnes produced annually (i), however the dyeing polyester process produces large volumes of chemical pollution, and high water usage with over 110 L per kg of fibre produced (ii). This means there is significant interest for a new dyeing process that eliminates polluting auxiliary chemicals and has low water usage. A new class of dyes for polyester is being developed which removes the need for polluting dispersants, reduces water and energy use, whilst providing equivalent performance within commercially used polyester dyeing machinery. This technology could be revolutionary in significantly improving the sustainability of the textile dyeing industry and contributing to the development of a circular economy.Due to these possibilities, it is critical that there is rapid scaling-up of the synthesis of the novel dyes, assisting in meeting project delivery targets and raising the commercial viability of the product. The use of a continuous flow system is being targeted to achieve this, however the current synthetic processes required optimisation with respect to the rate of reaction. In order to assess the efficacy of process changes, including use of basic catalyst and increase in reaction temperature, the reaction rate is monitored by both online and offline analytical techniques. Once optimised, the reaction will be transferred to a continuous process, to allow large scale dye production required for pilot scale studies.