Synthetic process optimisation for production of switchable hydrophilicity disperse dyes

涤纶是世界上使用最多的纺织品，年产量约为6,100万吨(一)，然而涤纶染色过程产生大量化学污染和高用水量，每生产一公斤纤维就有110多L(二)。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的辅助化学品，而且用水量很低。一种用于聚酯的新型染料正在开发中，它消除了对污染分散剂的需求，减少了水和能源的消耗，同时提供了与商业使用的聚酯染色设备相同的性能。这项技术在显著提高纺织印染行业的可持续性和促进循环经济发展方面可能是革命性的。由于这些可能性，关键是迅速扩大新型染料的合成，帮助实现项目交付目标，并提高产品的商业可行性。为了实现这一点，目标是使用连续流动系统，但目前的合成工艺需要在反应速度方面进行优化。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度。一旦优化，反应将转移到一个连续的过程，以便进行中试研究所需的大规模染料生产。

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.