Synthetic process optimisation for production of switchable hydrophilicity disperse dyes

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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.