Journal of Textile Research ›› 2022, Vol. 43 ›› Issue (01): 58-66.doi: 10.13475/j.fzxb.20210909310

• Textile Engineering • Previous Articles     Next Articles

Analysis of new five-element-integration spinning technology based on human-machine-material-method-environment for carbon neutralization

XIA Zhigang1,2,3, XU Ao1,2, WAN Youshun4, WEI Jiang4, ZHANG Huixia5, TANG Jiandong5, ZHENG Minbo5, GUO Qinsheng6, DING Cailing7, YANG Shengming8, XU Weilin1,2()   

  1. 1. Key Laboratory Base of New Materials and Advanced Processing Technology, Wuhan Textile University, Wuhan, Hubei 430200, China
    2. College of Textile Science and Engineering, Wuhan Textile University, Wuhan, Hubei 430200, China
    3. State Key Laboratory of Bio-Fibers and Eco-Textiles, Qingdao University, Qingdao, Shandong 266071, China
    4. Wuhan Yudahua Textile and Garment Group Co., Ltd., Wuhan, Hubei 430080, China
    5. Jihua 3542 Textile Co., Ltd., Xiangyang, Hubei 441002, China
    6. Jingwei Intelligent Textile Machinery Co., Ltd., Jinzhong, Shanxi 030601, China
    7. Shandong Ruyi Science & Technology Group Co., Ltd., Jining, Shandong 272073, China
    8. Anhui Huamao Group Co., Ltd., Anqing, Anhui 272073, China
  • Received:2021-09-26 Revised:2021-11-04 Online:2022-01-15 Published:2022-01-28
  • Contact: XU Weilin E-mail:weilin_xu@wtu.edu.cn

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Abstract:

Conventional spinning process is characterized by its long scattered processes and labor intensiveness, causing problems such as high energy consumption per unit production, poor product consistency, and high operating cost. In addition, multiple-type-fiber spinning leads to difficulty in fiber recycling from raw materials and resultant products. As an effort to achieve the goal of carbon peaking in 2030 and carbon neutrality in 2060, this paper establishes a low-carbon spinning strategy as carbon neutralization spinning by integrating human-machine-material-method-environment. In specific, the intensive, simple and the extensive types of low-carbon spinning technologies were analyzed. The analysis results show that after comparison with conventional ring spinning, the intensive intelligent technology achieves low-carbon and high-quality spinning by reducing operation costs by 32.67%, production energy consumption per unit by 17.5%, and product defect rate by 61.54%, effectively addressing the problems in the spinning sector. The simple type can shorten or eliminate steps in the spinning process, achieves spinning speed as high as 550 m/min, realizing the goal of efficiency-improvement and emission-reduction. The extensive type spinning develops a front-end raw material functional recycling to change waste into treasure, reducing energy and emission. The extensive type also develops medium-end carbon-nesting spinning to produce green functional yarns, and resultant manufacturing technology can be used for producing cooling, heat-insulting functional yarns for green terminal textiles.

Key words: carbon neutralization, carbon peaking, low-carbon spinning, energy-saving and emission-reduction, novel spinning technology

CLC Number: 

  • TS104.7

Fig.1

Scheme strategy framework of low-carbon spinning"

Fig.2

New method of domestic spinning"

Tab.1

Comparison of domestic intelligent spinning key equipment with foreign"

智能纺装备名称 100%国产智能纺纱 国外智能高端纺纱 对比结果
纺纱技术关键装备 经纬智能精梳机;万宝脉聚纺 立达全自动精梳机;负压紧密纺 国际先进水平;节能1/3
头并-粗纱物流系统 轨道式物流输送系统 自动导引运输车物流输送 国产效率更高
回花收付系统 全程无死角收付系统 部分收付、忽略全程 国产达到国际先进水平
智能管控系统 100%国产无死角和孤岛 与国内设备兼容差 国产兼容性优越

Tab.2

Comparison of fully domestic intelligent spinning with ordinary and foreign intelligent spinnings"

对比指标 100%国产智能纺纱技术与国内外技术的比较 国际高端
智能纺纱
测算方法 改造前的现代普通纺 改造后的智能纺 定量指标升降
生产效率 一线员工每小时万元产值提升幅度 锭速15 500 r/min,单产13.07 kg/(千锭·h) 锭速18 500 r/min,单产16.26 kg/(千锭·h) 提升24.40% 同等水平
运营成本 [(建设前运营成本-建成后运营成本)/建设前运营成本]×100% 万元产值运行成本3 931.16元 万元产值运行成本2 647.04元 降低32.67% 同等水平
产品升级周期 [(建设前研制周期-建成后研制周期)/建设前研制周期]×100% 10 d 6 d 缩短40% 同等水平
产品不良率 (建设前不良产品数/总数)×100%-(建设后不良产品数/总数)×100% 0.26% 0.1% 降低61.54% 同等水平
单位产值能耗 [(建设前单位产品实耗能源-建成后单位产品实耗能源)/建设前单位产品实耗能源]×100% 万元工业增加值综合能耗0.80 t标准煤 万元工业增加值综合能耗 0.66 t标准煤 降低17.50% 同等水平
产品质量工艺可追溯率 — 60% 100% 100.00% 同等水平
万锭用工 [(建设前万锭用工-建成后万锭用工)/ 建设前万锭用工]×100% 万锭用工53人 万锭用工14.8人 降低72.08% 同等水平

Fig.3

Technical characteristics and representatives of simple-type short-process high-speed open-end spinning"

Fig.4

Simple-type short-process medium-speed double-twisted and direct-cone-winded nip-end spinning"

Fig.5

Ultra-short process spinning technology of filament direct spun into large cone yarn package"

Fig.6

Ultra-short process spinning technology of film-filamentation spun into large cone yarn package"

Fig.7

Superspinning technology by integrating non-weaving and weft-knitting"

Fig.8

High-quality functional spinning technology of circulating reused fibers"

Fig.9

Short-process high-quality carbon-trapping spinning"

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