Discuss the optimization direction of polypropylene yarn production process!

polypropylene yarn is a synthetic fiber yarn made of polypropylene as raw material by melt spinning. At present, in order to improve product quality, reduce costs and expand the application range, its production process has a number of optimized directions:

Raw material handling process

Precise polymerization control: In the polypropylene polymerization stage, through more accurate catalyst system and polymerization conditions control, it is possible to obtain a narrower molecular weight distribution and more regular molecular chain structure of polypropylene resin. Precise regulation can reduce yarn strength fluctuations and defects caused by uneven raw materials. For example, the use of metallocene catalysts is expected to synthesize polypropylene with highly consistent performance and build a solid foundation for spinning high-quality polypropylene yarn.

Impurity removal enhancement: Use more efficient filtration and purification equipment to deeply remove very fine impurity particles and unreacted monomers before the raw material enters the spinning process. Even if the content of these impurities is very low, it may cause breakage and filaments in the subsequent high temperature spinning, and upgrading the filtration system can significantly improve the production stability.

Spinning process

Optimized temperature field distribution: Precise design of temperature gradients in melt spinning screw extruders and spinning tubes. The suitable temperature field can not only ensure the uniform and stable extrusion of polypropylene melt, but also accelerate the cooling and solidification of melt flow, and reduce the diameter deviation caused by the uneven temperature. The intelligent temperature control system is used to monitor and adjust in real time to maintain the spinning environment in the best state and improve the uniformity of yarn density.

Improved spinneret design: the hole shape, aperture and arrangement of spinneret are directly related to yarn forming quality. The development of special-shaped spinnerets, such as three-leaf spinnerets and dumbbell spinnerets, can give polypropylene yarn special luster, feel and physical properties; Narrow the diameter deviation of the spinneret hole, optimize the layout spacing, and reduce the yarn dry irregularity to produce a finer and more uniform yarn.

High-speed spinning technology upgrade: To improve the spinning speed is the key to improve production efficiency, the introduction of new high-speed spinning equipment, supporting more robust and stable winding system. At the same time, optimizing the cooling and blowing conditions, adjusting the formula of spinning oil, overcoming the problems such as insufficient cooling and large friction and static electricity during high-speed spinning, and realizing the efficient and stable production of polypropylene yarn.

Post-treatment process

Precise heat setting: Depending on the end use of polypropylene yarn, precise setting temperature, time and tension parameters are set. Proper heat setting can eliminate the internal stress of the yarn, stabilize the size, and adjust the shrinkage rate of the yarn to improve the dimensional stability of the fabric. On-line monitoring equipment is used to feedback yarn tension, temperature and other data in real time to realize intelligent heat setting control.

Multifunctional finishing: The development of antistatic, antibacterial, flame retardant and other multifunctional finishing process in one. For example, the antistatic agent, antibacterial agent and flame retardant are attached to the surface of the yarn according to a reasonable formula by the dipping method, which expands the application scenarios of polypropylene yarn in special fields such as electronics, medical treatment and home textile, and is no longer limited to the conventional packaging and rope use.

Intelligent and environmental protection direction

Intelligent production system integration: Build an intelligent production control platform for the whole process, integrate data sensors for raw material transportation, spinning and post-processing, and realize real-time monitoring and remote control of production parameters and equipment status. In the event of an anomaly, the system quickly warns and provides solutions to improve the reliability and flexibility of the production process.

Green process exploration: Research and development of environmentally friendly spinning auxiliaries to replace traditional auxiliaries, reduce the volatilization and residue of auxiliaries in production; Explore the recycling process of polypropylene yarn waste, and reprocess production waste into low-grade yarn or other plastic products, which conforms to the concept of circular economy and reduces the pressure of environmental protection.