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A salt-free, near zero-discharge, and dyebath-recyclable cold pad dyeing technology of cotton fabric with less water and energy consumption based on cationic pigment hybrid latexes

Yu Shao,Jiawei Li,Dongming Qi

The conventional reactive dyeing of cotton fabrics creates a large amount of difficult-to-treat wastewater because of a low dye uptake and fixation and uses a large amount of dye-promoting electrolytes. In this research, cationic polyacrylate-encapsulated pigment-colored hybrid latex nanoparticles (PPNs) with three primary colors were synthesized by surfactant-free reversible addition–fragmentation chain transfer (RAFT) emulsion polymerization and then applied for the salt-free, near zero-discharge, and dyebath-recyclable cold pad dyeing of cotton fabrics with less water and energy consumption. The effect of the composition structure of PPNs on their color properties was systemically investigated, and the pad-dyed fabrics were compared with conventional salt-free dyeing samples. The results demonstrated that the PNNs pad-dyed cotton fabrics achieved satisfactory wet rubbing fastness (level 4), color strength , leveling property, hand feel, and air breathability. The color regulation and matching of the pad-dyed fabrics could be designed by adjusting the contents of three primary color PPNs due to their nanosize and intercompatibility, thus making it possible to rapidly manufacture colors. Furthermore, the PPNs dyebath proved to be recyclable for circular pad dyeing of cotton fabrics, remarkably reducing the wastewater discharge. Calculations showed that the comprehensive water, energy, and cost of 1 kg cotton fabrics could be reduced by about 88.9%, 58.5%, and 51.7%, respectively, compared with conventional pad dyeing with reactive dyes. This innovative salt-free and dyebath-recyclable circular cold pad dyeing technology not only significantly reduces pollution generated and wastewater discharged, but also uses less water and energy, providing a valuable reference for environment-friendly near zero-discharge and sustainable pad dyeing methods for textiles.