https://doi.org/10.33263/Materials23.373390 ISSN: 2668-5728 https://materials.international Volume 2, Issue 3, Pages 0373-0390 2020 Received: 9.06.2020 Accepted: 2.09.2020 Review Published: 10.09.2020 Development of Textile Dyeing Using the Green Supercritical Fluid Technology: A Review Tarek Abou Elmaaty* 1 , Abdallah Mousa 2 , Hatem Gaafar 2 , Ali Hebeish 2 , Heba Sorour 1 1 Department of Textile Printing, Dyeing & Finishing, Faculty of Applied Arts, Damietta University, Damietta 34512, Damietta, Egypt 2 Department of Textile Printing, Dyeing & auxiliaries, National research center, Cairo, Egypt * Correspondence: [email protected]; Scopus ID: 6603460941 Abstract: Recently, a green supercritical carbon dioxide dyeing process with zero waste-water emission is a hot topic. This review gives light on advances in recent years, including solubilities of different dyes in the supercritical solvent as well as most recent reports about the dyeing of synthetic and natural fibers under supercritical carbon dioxide medium. Keywords: supercritical carbon dioxide; solubility; synthetic fibers; natural fibers; dyes. © 2020 by the authors. This article is an open-access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/). 1. Introduction Supercritical carbon dioxide (scCO2) is an eco- disposal in the water streamlet [6,7]. Textile wet friendly solvent known for its potentiality as a processing can outstandingly get an advantage from replacement for aqueous textile wet processing, the utilization of scCO2 as a dyeing medium. scCO2 mainly dyeing [1-4]. A supercritical fluid is a matter has lower mass transfer resistance and higher in a closed system above its critical temperature and diffusion rates than water. This property makes the pressure. It is difficult to determine the borderline dye penetrates much faster into the fibers, leading between the liquid and gaseous state. This state of to slower reaction times. Besides, water-free dyeing matter is known as a supercritical state. Although does not require drying and consequently saving several substances are useful as supercritical fluids, energy. Moreover, the absence of water prevents carbon dioxide has been the most extensively dye hydrolysis, which is a significant problem in utilized [5]. traditional dyeing. In the textile industry, traditional textile wet In scCO2, the wanted color shade is achieved processing utilizes a vast volume of freshwater. This with a small concentration of the dyestuff. Also, the copious water is given away as effluent unreacted dyestuff, as well as CO2, are recycled, contaminated with unreacted dyes and auxiliary leading to cost-effective and green methodology [8]. chemicals. A remarkable share of the money is spent eliminating this waste-water before the MATERIALS INTERNATIONAL | https://materials.international | 373 Cite This Article: Sorour, H.; Elmaaty, T.A.; Mousa, A.; Gaafar, H.; Hebeish, A. Development of textile dyeing using the green supercritical fluid technology: A Review. Mat Int 2020, 3, 0373-0390. https://doi.org/10.33263/Materials23.373390 Heba Sorour, Tarek Abou Elmaaty, Abdallah Mousa, Hatem Gaafar, Ali Hebeish • • • 2. What is Supercritical Fluid? The supercritical state is known as the fourth happens since an increment in density diminishes state of matter. A supercritical liquid is characterized mean “intermolecular distance,” expanding the as “a substance over its critical temperature and number of interactions between the solvent and pressure”. At these conditions, the liquid has solute [2,9]. interesting properties. It does not condense or evaporate to create a fluid or a gas. Figure 1 revealed that the supercritical state exists at temperature and pressure conditions over the so-called “critical point”. As the “critical point” of a substance is drawn closer, its isothermal compressibility tends to limitlessness. Consequently, the particular volume or thickness of the substance changes drastically. Within the “critical region”, a substance that’s a gas at standard conditions shows liquid-like density and Figure 1. Pressure-temperature diagram. a much-increased “solvent capacity”. This conduct 3. Supercritical carbon dioxide dyeing apparatus A photograph of three types of supercritical carbon dioxide machines is shown in Figure 2. (a) Figure 2a shows the lab-scale dyeing apparatus located in SCF lab in Damietta UNIVERSITY, Egypt, Figure 2 b shows the pilot-scale machine installed in UNIVERSITY OF Fukui, Japan, and Figure 2c shows the industrial-scale machine of Dycoo, Netherland. The dyeing system includes a cylinder for storing carbon dioxide CO2, a cylinder connected to a pump and regulator. The pump and regulator (b) consist of pump CO2 into and out of the temperature/ pressure vessel. A heating apparatus configured to heat the temperature/pressure vessel's contents according to signals received from a temperature controller [10]. (c) Figure 2. Photograph of supercritical carbon dioxide apparatuses. (a) Lab-scale supercritical carbon dioxide dyeing equipment, b) pilot-scale ScCO2 dyeing equipment (SCF lab, University of Fukui, Japan) (c) Industrial ScCO2 dyeing equipment (Dycoo, Netherland). 4. The solubility of dyes in supercritical fluid Supercritical dyeing requires studies of phase up the system temperature and pressure optimally. equilibrium between dyes and the supercritical Since the beginning of the supercritical technology, solvent. Dye solubility data is one of the most the solubility of substances in supercritical fluids crucial factors for selecting the dyestuff and setting MATERIALS INTERNATIONAL | https://materials.international| 374 Development of textile dyeing using the green supercritical fluid technology: A Review • • • (SCF) has been determined in detail, and several dimethyl-9,10-anthraquinone (Q4)”. They articles reported on solubility [11,12]. estimated the solubility of dyes under investigation The correlation results between the calculated in a large scope of temperature and pressure. They and experimental solubility were estimated with reported on the phenomena that, at constant system three density-based models: (a) “Chrastil, Bartle; (b) temperature, the increase of pressure causes a Mendez-Santiago–Teja models” (c) “Ziger–Eckert” significant increase in solubility of dyes “Q1-Q4”. semi-empirical correlation.[13-15]. Also, using two On the other hand, increasing system temperature “cubic equation-of-state (EOS) models, namely the resulted in a decrease in CO2 density. The order of “Peng–Robinson EOS (PR-EOS) and the Soave– solubility of the dyes understudy is “Q3 > Q1 > Q2 Redlich–Kwong EOS (SRK-EOS)”. [16,17]. This >> Q4” respectively [20]. section will cover the most important reports that investigated the solubilities of different dyes in ScCO2. Skerget et al. presented a review article discussing solubility data generated from different substances in sub- and supercritical fluids. They organized their study utilizing tables as a form besides the ranges of temperature and pressure. Figure 4. Structures of aminoanthraquinone They also screened the different correlation derivatives. methods experimented in the reports for data modeling. They arranged the compounds into Bae et al. studied the effect of adding a solvent classes based on their chemical behavior “inorganic, to the dye on the solubility in scCO2. The results organometallic, aromatic, nonaromatic organic, indicated that the solubility of non-volatile solid in polymer”. Most of the applications favored the ternary system, inclusive of co-solvent, is correlated very well with the liquid model. They “ScCO2” as a medium [18]. 4.1. The solubility of disperse dyes. agreed that solubility of non-volatile solutes such as 4.1.1. Solubility of anthraquinone disperse dyes. “CI disperses red 60” (Figure 5), “phenanthrene, Many studies reported on the solubility of fluorene and acridine” in SCF at different pressure, anthraquinone disperse dyes in “scCO_2” and temperature, and co-solvent concentration can be estimated the solubility using dynamic and static determined by the liquid model without critical processes. characteristics and solute vapor pressure [21]. For example, Kautz et al. measured the solubility of “1, 4-bis-(n-alkylamino)-9,10- anthraquinones” (Figure 3) in scCO_2 at different ranges of system pressure and temperature Figure 5. Disperse red 60. employing a “flow method”. They also investigated the effect of many C-atoms in alkyl-chain and Shamsipur et al. estimated the solubility of “ solubility of dyestuff, showing a maximum for 9,10-anthraquinone derivatives “(Figure 6), in phenyl-derivative [19]. ScCO2 at different temperatures and pressures employing an easy static method. They correlated the experimental data with the “Peng–Robinson equation of state (PR-EOS)” [22]. Figure 3. “ 1,4- bis- (n- alkylamino)- 9,10- anthraquinones”. Utilizing an easy static technique, Shamsipur et al. studied the solubility of four “anthraquinone disperse dyes” in ScCO2. Figure 4 shows the structure of those dyes that are mainly “ 1-amino-2- Figure 6. Structures of 9,10-anthraquinone derivative. methyl-9,10-anthraquinone (Q1), 1-amino-2-ethyl- Bao et al. measured the solubility of “C. I. 9,10-anthraquinone (Q2), 1-amino-2,3-dimethyl- disperse red 60” (Figure 5) in scCO_2 at various 9,10-anthraquinone (Q3), and 1-amino-2,4- MATERIALS INTERNATIONAL | https://materials.international | 375 Heba Sorour, Tarek Abou Elmaaty, Abdallah Mousa, Hatem Gaafar, Ali Hebeish