纺织涂层工业的环保解决方案（environmental protection solutions for textile coating industry）

纺织涂层工业的环保解决方案（ENVIRONMENTALPROTECTIONSOLUTIONSFORTEXTILECOATINGINDUSTRY）ENVIRONMENTALPROTECTIONSOLUTIONSFORTEXTILECOATINGINDUSTRYXIAYINBINGSHANGHAICO,LTDABSTRACTTHECONTENTOFTEXTILECOATINGINDUSTRYIN“OEKOTEX100STANDARD“WASINTRODUCEDTHEPOLLUTIONSOURCESOFFORMALDEHYDE,TOTALVOC,FLAMERETARDANTSYSTEMANDPVCCOATINGWERESIMPLYANALYZEDANDTHESOLUTIONSWEREPUTFORWARDKEYWORDSENVIRONMENTALPROTECTIONSTANDARDVOCWATEREMULSIONSOLUTIONPVCEMULSIONPREFACEOVERTHEPAST20YEARS,DEVELOPEDCOUNTRIESHAVEBECOMEINCREASINGLYCONCERNEDABOUTTHESAFETYANDENVIRONMENTALAWARENESSOFCONSUMERSCONSUMERSAREALSOINCREASINGLYLOOKINGATTEXTILESFROMANECOLOGICALPOINTOFVIEWANDWILLINGTOPAYTHEPRICECONFORMINGTOTHISTREND,DEVELOPEDCOUNTRIES,ESPECIALLYTHEEUROPEANUNIONCOUNTRIES,HAVEFORMULATEDMOREANDMORESTRINGENTENVIRONMENTALSTANDARDSESPECIALLYAFTERCHINAJOINEDTHEWTO,THESESTANDARDSHAVEBECOMETHESOCALLED“GREENBARRIER“ACCORDINGTOSTATISTICS,THEREAREASMANYAS7BILLION400MILLIONDOLLARSOFEXPORTPRODUCTSBLOCKEDBY“GREENBARRIER“EVERYYEAR“HOWTODEALWITHTHECHALLENGESOFTECHNOLOGICALINNOVATION,FROMTHEEXPENSEOFTHEENVIRONMENT,LOWCOST,LOWVALUEADDEDPRODUCTIONTOENVIRONMENTALPROTECTION,HIGHVALUEADDEDMODETOSUSTAINABLEDEVELOPMENTOFOURTEXTILECOATINGINDUSTRYMUSTSOLVETHEPROBLEMTHISPAPERINTRODUCESTHEOEKOTEX100STANDARDFORTHETEXTILEINDUSTRY,ATTHESAMETIME,LUBRIZOLCOATINGSSHANGHAICOMPANYALSOINTRODUCEDFORTEXTILECOATINGINDUSTRYTOPROVIDESOLUTIONSFORENVIRONMENTALPROTECTIONABRIEFINTRODUCTIONTOOEKOTEX100STANDARDINRECENTYEARS,THEEUHASADOPTEDMORESTRINGENTENVIRONMENTALREGULATIONSANDNORMS,THEIMPACTISVERYLARGEWITHROHSSTANDARDANDOEKOTEX100INTHETEXTILEINDUSTRYCOLLEAGUESOFTENREFERTOTHETWOSTANDARD,BUTWEFOUNDTHATMANYPEOPLEDONOTKNOWTHEDIFFERENCEBETWEENTHETWOTHEFULLNAMEOFROHSISTHERESTRICTIONOFTHEUSEOFCERTAINHAZARDOUSSUBSTANCESINELECTRICALANDELECTRONICEQUIPMENT“INTHEROHSSTANDARD,ATOTALOFSIXHARMFULSUBSTANCESWERELISTED,INCLUDINGLEADPB,CADMIUMCD,MERCURYHG,SIXVALENCECHROMIUMCR6,POLYBROMINATEDDIPHENYLETHERTWOPBDE,POLYBROMINATEDDIPHENYLPBB,ETCTHEEUROPEANUNIONHASIMPLEMENTEDTHEROHSSTANDARDINJULY1,2006ITISWORTHNOTINGTHATROHSISFORELECTRICALANDELECTRONICPRODUCTSMAYCONTAINTHEABOVESIXKINDSOFHARMFULSUBSTANCESINTHEPRODUCTIONPROCESSOFALLRAWMATERIALS,ELECTRICALANDELECTRONICPRODUCTSTHATALLUSEOFORCONTAININGHEAVYMETALSANDTWOPBDEPOLYBROMINATEDDIPHENYLETHERANDPOLYBROMINATEDBIPHENYLSPBBFLAMERETARDANTWILLNOTBEABLETOENTERTHEEUMARKETTHEOEKOTEX100STANDARDISAIMEDATTHETEXTILEINDUSTRYTHESTANDARDISLIMITEDDEMANDVALUEANDECOLOGICALTEXTILETESTRULESONTEXTILETECHNOLOGYOFHARMFULSUBSTANCESRELEASEDBYTHE“INTERNATIONALECOLOGICALTEXTILEASSOCIATIONFORRESEARCHANDTESTING“,FROM1992OFFICIALLYANNOUNCEDITSFIRSTEDITION,WERERELEASEDONTHETWOREVISION,ANDREVISIONFROM1999AFTERALMOSTAYEAR,ITSSCOPEANDREQUIREMENTSINTHECONTINUOUSEXPANSIONANDADJUSTMENTSINCETHEPROMULGATIONOFTHESTANDARD,ITHASGAINEDTHERECOGNITIONOFTHEWORLD,ANDGOVERNMENTSANDTEXTILEENTERPRISESHAVEATTACHEDGREATIMPORTANCETOITATPRESENT,THEOEKOTEX100LABELHASBECOMEASTANDARDFOREUROPEANBUYERSTOBUYTEXTILESALLOVERTHEWORLDTHROUGHTHISSTANDARD,QUALIFIEDTEXTILESWILLBECERTIFIEDBYPRODUCTTESTINGANDAUTHORIZEDTOUSE“OEKOTEXSTANDARD100“LABELTEXTILESTHATGETCERTIFIEDLABELSCANBESOLDINEUCOUNTRIES“OEKOTEXSTANDARD100“LABELTESTITEMSINOEKOTEX100STANDARDWITHPHVALUE,FORMALDEHYDE,HEAVYMETALS,PESTICIDES,PENTACHLOROPHENOL,DECOMPOSABLEAROMATICAMINEDYES,DYESENSITIZATION,ORGANICCHLORIDEHELPAGENT,PLASTICIZERPVCRESIDUESATTHESAMETIMETHESTANDARDSTOBETESTEDANDAWARDEDTHE“CLASSIFICATIONSTANDARDSOFECOLOGICALTEXTILESOEKOTEX100TAGACCORDINGTOTHEFINALUSEOFPRODUCTS,1CLASSIINFANTPRODUCTS,EXCEPTFORCLOTHING,ALLPRODUCTS,BASICMATERIALSANDACCESSORIESUSEDTOMAKEBABIESORCHILDRENUPTOTWOYEARSOLD2CLASSIIDIRECTCONTACTWITHTHESKINPRODUCTS,SUCHASUNIFORMSSHIRT,UNDERWEARANDSOON3CLASSIIIPRODUCTSTHATDONOTTOUCHTHESKINDIRECTLY,SUCHASFILLINGMATERIALS,LININGSANDSOON4CATEGORYIVDECORATIVEPRODUCTS,INCLUDINGRAWMATERIALSANDACCESSORIES,INCLUDINGALLTHEDECORATIVEPRODUCTS,SUCHASWHITECLOTH,WALLDECORATIONCLOTH,FURNITURECLOTH,CURTAINS,CARPETS,MATTRESSESANDSOONBECAUSETHEOEKOTEX100STANDARDSRELATEDTOTEXTILEINDUSTRYINALLASPECTSINCLUDINGFIBERMATERIALS,COTTONPRODUCTION,DYEINGANDFINISHING,TEXTILECOATINGMATERIALANDTECHNOLOGYANDSOONONLYTHETEXTILECOATINGINDUSTRY,ACCORDINGTOTHESTANDARD2006VERSIONOFTHEMAINTESTITEMSOFLIMITEDSOURCESANDHAZARDSOFSUMMARYVALUESANDRELATEDHARMFULSUBSTANCESAREASFOLLOWSTABLE1OEKOTEX100STANDARDSINTRODUCTIONOFTEXTILECOATINGINDUSTRYTESTITEMSLIMITVALUESOURCESOFHARMFULSUBSTANCESHARMIVCLASSIIICLASSIICLASSIFORMALDEHYDEPPMTHREEHUNDREDTHREEHUNDREDSEVENTYFIVEZEROTHEPOLYMERCROSSLINKINGAGENT,FLAMERETARDANTAGENTOFCOTTONDYEING,PRINTINGADHESIVECARCINOGENIC,ALLERGIC,RESPIRATORYTRACTINFLAMMATION,ETCPOLYCHLORINATEDBIPHENYLSZEROZEROZEROZEROFLAMERETARDANTANTISTATICAGENTCARCINOGENICPHVALUE4090409040754075RESIDUALCHEMICALSSENSITIZATIONCONTENTOFHEAVYMETALIONSPPMANTIMONYSBARSENICASLEADPBCADMIUMCDMERCURYHGCOPPERCUCHROMIUMCRCOBALTCONICKELNIONEONEZEROPOINTONEZEROPOINTZEROTWOFIFTYTWOFOURFOURTHIRTYONEONEZEROPOINTONEZEROPOINTZEROTWOFIFTYTWOFOURFOURTHIRTYONEONEZEROPOINTONEZEROPOINTZEROTWOFIFTYTWOFOURFOURTHIRTYZEROPOINTTWOZEROPOINTTWOZEROPOINTONEZEROPOINTZEROTWOTWENTYFIVEONEONEONEGREYFABRICS,FLAMERETARDANTS,DYES,METALCATALYSTS,FINISHINGAGENTSCARCINOGENIC,HARMFULTOHEALTHABNORMALODORVOCNOTHINGNOTHINGNOTHINGNOTHINGRESIDUALCHEMICALSOLVENTS,REAGENTSANDMONOMERSENDANGERONESHEALTHPVCPLASTICIZERTWOPHTHALATEORESTERDINP,DNOP,DIDPDBP,DIDP,ETALZEROPOINTONEPVCCOATINGS,ETCCARCINOGENICOTHERCHEMICALRESIDUESPPMONEHUNDREDONEHUNDREDONEHUNDREDFIFTYDYES,AUXILIARIES,ETCCARCINOGENICITY,SENSITIZATIONTWOLUBRIZOLCOATINGSSHANGHAICOMPANYENVIRONMENTALSOLUTIONSBFGSHANGHAICO,LTD,FORMERLYKNOWNASTHESPECIALCHEMICALSDIVISIONOFTHEUNITEDSTATESOFAMERICAREPUTATIONCOMPANYANDTHEUNITEDSTATESOFAMERICA,HASMORETHAN60YEARSOFEXPERIENCEINTHETEXTILECOATINGINDUSTRYSINCETHE1940INVENTIONOFWATERBORNEPVCEMULSIONTECHNOLOGY,ADHERINGTOTHECONCEPTOFENVIRONMENTALPROTECTION,INTHEPROCESSOFTHEDEVELOPMENTOFENTERPRISESATTACHGREATIMPORTANCETOTHESOCIALRESPONSIBILITYOFTHEENTERPRISE,INORDERTOWATERBORNECOATINGTECHNOLOGYASTHEREPRESENTATIVEOFTHEDEVELOPMENTOFADVANCED,ENVIRONMENTALLYFRIENDLY“GREEN“TECHNOLOGYINTHEFOLLOWING,WEDISCUSSTHEPOLLUTIONSOURCESRELATEDTOTEXTILECOATINGINTHEOEKOTEX100STANDARDANDINTRODUCEOURSOLUTIONS1REDUCEFORMALDEHYDECONTENTTHEMAINSOURCESOFFORMALDEHYDEINTEXTILESARE1MONOMERCROSSLINKINGAGENTNMANMETHYLACRYLAMIDEUSEDINWATEREMULSIONPOLYMERIZATIONINAQUEOUSACRYLATEPOLYMERIZATION,THETECHNOLOGYOFUSINGNMAASONEOFTHEPOLYMERIZATIONMONOMERSWASSUCCESSFULLYDEVELOPEDIN1960THEWATERBORNEACRYLATEEMULSIONPRODUCEDBYNMA/ACRYLICACIDPOLYMERIZATIONSYSTEMHASGOODWATERWASHINGPROPERTY,CHEMICALRESISTANCEANDGOODMECHANICALPROPERTIESATPRESENT,MOSTWATERBORNEACRYLATEEMULSIONSAREPOLYMERIZEDWITHNMAASCROSSLINKINGAGENTHOWEVER,NMAWILLRELEASEALARGEAMOUNTOFFORMALDEHYDEDURINGTHEPOLYMERIZATIONPROCESS,ANDMUSTBEEXTRACTEDAFTERTHEPOLYMERIZATIONPROCESSISCOMPLETEDTOREDUCETHETOTALCONTENTOFFORMALDEHYDEANDUNREACTEDMONOMERINORDERTOSAVECOSTS,MANYMANUFACTURERSDONOTCARRYOUTTHEEXTRACTIONPROCESSBEFORETHEYLEAVETHEFACTORYTHETOTALAMOUNTOFFORMALDEHYDEANDUNREACTEDMONOMERINTHEPRODUCTISABOUT20004000PPMINRESPONSETOTHEMARKETDEMANDFORGREENENVIRONMENTALPROTECTIONTECHNOLOGY,OURCOMPANYHASBEENINCREASINGTHEDEVELOPMENTOFWATERBASEDACRYLATEEMULSIONPOLYMERIZATIONTECHNOLOGYINRECENTYEARSTHEPRODUCTIONTECHNOLOGYWITHOUTUSINGNMAASPOLYMERIZATIONCROSSLINKINGAGENTHASBEENSUCCESSFULLYDEVELOPED,ANDTHEPRODUCTTESTRESULTSHOWSTHATTHEFORMALDEHYDECONTENTISVERYLOWORCLOSETO0THISTECHNOLOGYISALREADYVERYMATUREANDPRODUCESASERIESOFPRODUCTSONTHEMARKET2CROSSLINKINGAGENTADDEDINEMULSIONCOMPOUNDINGPROCESSATPRESENT,INTHETEXTILECOATINGINDUSTRY,WHETHERITISOILYORWATERBASEDCOATING,THEBESTPERFORMANCEANDTHEMOSTWIDELYUSEDCROSSLINKINGSYSTEMISMFSYSTEMMELAMINEFORMALDEHYDERESINSYSTEMCOOKEDATACERTAINTEMPERATUREMUSTBECOATEDFABRICSINTHEPRODUCTIONPROCESS,THESYSTEMOFMFPOLYMERIZATIONTOPAINTFILMCURINGTEMPERATUREATABOUT150DEGC,ACHIEVINGTHEREQUIREDMECHANICALPROPERTIESACCORDINGTOTHEPRODUCTIONPRACTICE,THEMORECOMPLETETHEPOLYMERIZATION,THEMORECOMPLETETHERELEASEOFFORMALDEHYDE,SOTHEAMOUNTOFRESIDUALONTHECOATINGFABRICISLESSFIGURE1FORMALDEHYDEBALANCESHEETINPRODUCTIONPROCESSFROMTHEABOVEANALYSISOFTHESOURCEOFFORMALDEHYDEINTHEPROCESSOFTEXTILECOATINGPRODUCTION,ITCANBECONCLUDEDTHATTHEFOLLOWINGMETHODSCANEFFECTIVELYREDUCETHERESIDUALAMOUNTOFFORMALDEHYDE1ANEWWATERBORNEACRYLICEMULSIONOROTHERFORMALDEHYDEFREEEMULSION,SUCHASPUDWATERBORNEPOLYURETHANEORPVCEMULSION,WASPRODUCEDBYUSINGNEWTECHNOLOGYWITHOUTNMAASPOLYMERIZATIONCROSSLINKINGAGENT2INTHEPROCESSOFCOMPOUNDING,MFCROSSLINKINGSYSTEMISNOTUSEDTHEENDLINKEDDIISOCYANATECROSSLINKINGSYSTEMORSELFCROSSLINKINGSYSTEMWASUSED3ADJUSTMENTPROCESSDURINGTHERIPENINGPROCESS,ASFARASPOSSIBLETHEFORMALDEHYDEEVAPORATEDBUTITSTHESAMETHEENVIRONMENTHASANEGATIVEIMPACTTAKINGINTOACCOUNTTHESPECIFICCIRCUMSTANCESOFTHEACTUALPRODUCTIONANDOTHERPERFORMANCEREQUIREMENTSOFTHEPRODUCT,LUBRIZOLCORPSLISTOFDATAFORVARIOUSENVIRONMENTALSOLUTIONSISASFOLLOWSTABLE2COMPARISONOFFORMALDEHYDERESIDUESCOMPOUNDEMULSIONFORMALDEHYDECONTENTPPMCROSSLINKINGSYSTEMFORMALDEHYDERESIDUEPPMTESTSTANDARDORDINARYEMULSION1000MF20002900AATCC122ORDINARYEMULSION100AATCC122ENVIRONMENTALPROTECTIONEMULSIONZEROCAPPINGNCOOROTHERENVIRONMENTALPROTECTIONSYSTEMSLESSTHAN2OR0AATCC122TWOREDUCETHEOVERALLVOCFROMOILYCOATINGSTOWATERBORNECOATINGSATPRESENT,THEDOMESTICTEXTILECOATINGINDUSTRY,ESPECIALLYFUNCTIONALFABRICS,SUCHASWATERPROOFBREATHABLEFABRICANDSOFTBAGSANDFABRICS,MOSTOFTHEMARESTILLUSINGOILBASEDCOATINGSOILYPOLYURETHANEISTHEMOSTCOMMONLYUSEDOILBASEDCOATINGS,COMMONLYUSEDCHEMICALSOLVENTSAREDMFTWOMETHYLFORMAMIDE,TOLUENEANDMEKBUTANONEINTHENORMALCOATINGFABRICPRODUCTIONPROCESS,THECHEMICALSOLVENTISEVAPORATEDATACERTAINTEMPERATURE,MOSTOFWHICHISDIRECTLYDISCHARGEDINTOTHEAIRASFARASWEKNOW,THEGOVERNMENTHASFORMULATEDENVIRONMENTALREGULATIONSTOLIMITTHEEMISSIONOFDMF,BUTTHEEMISSIONLIMITSFORTOLUENEANDMEKBUTANONEARENOTSTRICTTHECURRENTANNUALPRODUCTIONOFABOUT1MILLIONTONSOFOILYPOLYURETHANE,ASSUMINGTHATTHESOLIDCONTENTIS30DMFANDMEKTOLUENEANDBUTANONETHEDOSAGERATIOOF6040,THEANNUALUSTEXTILECOATINGINDUSTRYEMISSIONSOFABOUT120THOUSANDTONSOFCHEMICALSOLVENTSINTOTHEAIRITHINKEVERYCOMRADEWHOHASBEENTOJIANGSU,W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