How does Overflow Dyeing Machine reduce energy consumption?

1. Equipment optimization
Low bath ratio design: The low bath ratio design can significantly reduce water consumption and energy consumption. For example, the bath ratio of the ladder series/high-temperature and high-speed Overflow Dyeing Machine is 1:4.5-1:6, which greatly reduces water consumption compared to the 1:6-1:10 of the traditional dyeing machine.
Optimize nozzle structure: By improving the structure and angle of the nozzle, the circulation efficiency of the dyeing liquid can be improved and energy consumption can be reduced. For example, the SK down-flow overflow jet dyeing machine adopts an adjustable impact stacking structure, which adjusts the height and angle of the baffle according to the properties of different fabrics to optimize the dyeing effect of the fabric.
Variable flow adjustable nozzle: Develop a variable flow adjustable nozzle to automatically adjust the flow and pressure of the nozzle according to the running state of the fabric to reduce unnecessary energy consumption.
2. Process improvement
Two-stage heating energy-saving transformation: The heating section of the process water is divided into two stages. The front stage uses the waste heat resources of the dyeing machine (high-temperature circulating cooling water) for heating, and the rear stage uses steam for heating. This method can improve the utilization rate of waste heat resources and reduce steam consumption.
Optimize the heating rate: Reasonably control the heating rate to avoid energy waste caused by too fast heating. For example, a faster heating rate can be used below 90°C, while the heating rate should be controlled when it is close to 130°C.
Shorten the dyeing cycle: By optimizing process parameters, such as increasing the cloth speed and shortening the insulation time, the dyeing cycle can be reduced, thereby reducing energy consumption. For example, the dyeing process time of the step series/high-temperature and high-speed Overflow Dyeing Machine is reduced from 12 hours to 10.5 hours.
3. Intelligent control
Intelligent temperature control system: Adopt an intelligent temperature control system to accurately control the temperature of the dye solution and avoid energy waste caused by temperature fluctuations.
Automatic operation and control: Realize the automated operation of the dyeing machine, automatically adjust the temperature, pressure and flow through sensors and control systems, and improve production efficiency and energy saving effects.
Process parameter cloud sharing: By sharing process parameters in the cloud, dynamic adjustment of energy consumption of multiple dyeing machines can be achieved, further reducing energy consumption.
4. Waste heat recovery
Waste heat utilization: Utilize the waste heat resources of the dyeing machine, such as high-temperature circulating cooling water, to preheat the process water and reduce the use of steam.
Zoning transformation of circulating cooling water pool: The circulating cooling water pool is divided into high-temperature pool and low-temperature pool, and the use of circulating cooling water of different temperatures is realized through switching of multi-directional control valves.