PRESENTED BY:RAJALAXMI BEHERA ROLL- 709cmp229

INTRODUCTION:Fibres have been in use to clad human beings since the dawn of history. The material to be used as a textile fiber, it is important that the materials possess sufficient length, strength and cohesiveness to permit them to be made in to a continuous length suitable for fabric construction. Together with length and strength, the fibre must be fine enough to allow the construction of a yarn of desirable size and weight. As most household and clothing materials are comparatively fine and light in weight a textile fibre for its better use must be soft and pleasing to the touch. It is also necessary that a fibre possess the ability to absorb liquid readily in order that it may be bleached or dyed. The comfort with which fibers can be worn next to the body depends greatly on their ability to absorb and give off moisture. The readiness with which a lienen fabric takes up and gives off moisture causes it to fell cool. In contrast to this, wool absorbs moisture readily and gives off heat of absorption. Wool gives of moisture slowly, thus preventing cold when it is worn. The extent to which cloth can enmesh air, which is one of the best insulating agencies, determines to a great extent its value as a heat2 retaining material.

 Natural Fibres  Semi Synthetic Fibres  Synthetic Fibres

 Natural Fibres Wool, cotton, mohair, silk, alpaca, vicuna, flax, hem and jute are the natural Fibres.  Semi Synthetic Fibres Viscose acetate fibres are called the semi-synthetic fibers. These are prepared starting with natural fibers to impart special properties.  Synthetic Fibres synthetic or man made fibers constitute one of the largest chemical industries in the world. Nylon, Dacron or ethylene, oblong, saran, carillon, dyne etc. are the synthetic fibers. The advantages of synthetic fibers are unlimited, besides their availability, the synthetic fibers differ from natural fibers in most of their physical properties. There is a great deal of difference between the natural and synthetic 4 fibers.

Polyamides:Polyamides are defines as that group of polymers which contain the amide groups ( - CONH) in the main polymer chain. Polymers of this type are synthetic linear aliphatic polyamides which are capable of fiber formation. These polymers are commonly known as nylons. Polyamide research was initiated by Carothers in 1929 and the first known product was nylon 6,6. This was the first synthetic polyamide developed that richer technical importance as a fiber. Since then, nylon-6 has also become a commercial product and has assumed an important position among man-made textile fibers. There are also other nylons such as nylon 6, 10, nylon 11 and nylon 12 etc.

Nylon 6 or Person L This is a polyamide fiber known as Person L (Germany) or Nylon 6 (U.S.A) Commercially nylon-6 is manufactured from caprolactam. Caprolactam can be prepared from cyclohexanone oxide by treatment with H2SO4. O N-OH CH2-CH2-CO H2N-OH H2SO4 CH2 CH2-CH2-NH Cyclohexanone Cyclohexanone Oxime CO-(CH2)5-NH Caprolactam

The fibre is obtained by prolonged heating of caprolactam at 250-270oC Preparation . In a typical process, a mixture of caprolactam, water (5-10% be weight) and acetic (about 0.1%) is fed into a reactor in presence of nitrogen. The mixture is heated at 250oC for 12 hours and at about 15 atmospheric pressure. The product is extruded as ribbon, quenched in water and chopped into chips. The mixture consists of 90% of the high molecular weight polymer and 10% low molecular weight compounds.
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Nylon 6,6
H term nylon 6,6 is derived from the fact that the polymer is obtained from a six carbon aliphatic diamines , hexamethylene diamine and a six carbon aliphatic dicarboxylic acid, adipic acid. Manufacturing Process . The nylon salt produced by the above method is a polymer of low molecular weight i.e. 2,500-5,000. The nylon salt solution is first of all pumped into evaporators and kept at the room temperature foe evaporation. In order to stabilize the salt solution, some amount of acetic acid is added to the mixture. After evaporation, it is converted to nylon 6, 6 by heating.
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(a) Salt Preparation

HOOC(CH2)4 - COOOH +H2N- (CH2)6 NH2 Adipic acid Hexamethylene diamine O O H3N (CH2)6 NH3 ] 6, 6 Salt [O - C(CH2)4 - C - C ]

(b) Polycondensation
[H3N (CH2)6 NH3 ]

O Vac

[O - C(CH2)4 - C - O ]

O O H2N [ (CH2)6 NH - C(CH2)4 - C - NH ]n (CH2)6 NH2 Nylon 6,6 The reaction proceeds through the intermediate salt formation. The polycondensation reactions continue till a high molecular nylon 6,6 is obtained.

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PROCEDURE In a 50-60% aqueous solution, containing 0.5% acetic acid, and nylon salt is heated in an auto clave. Heating continues until a pressure of 200-230 psi is obtained and then released. The water is distilled off. The clear melt is quickly extruded, quenched and clipped. This polymer is a linear polymer with molecular weight above 10,000. The crystal structures have been observed in two forms, a and b, although there is little information on the b form. The glass transition temperature is reported to be 50oC and its melting point at 250-252oC.

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Nylon 6, 10 Nylon 6, 10 is prepared from the nylon salt, hexamethylene diammonium sebacate by the similar method as described in case of nylon 6, 6. H2N (CH2)6NH2 + HOOC(CH2)8 COOH sebacic acid O + + Heat [H3N (CH2)6NH3 [O - C(-CH2)8 COO] O O H2N[(CH2)6NH- C(CH2)8 C-NH]n (CH2)6NH2 nylon 6, 10
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POLYETHYLENE TEREPHALATE Polyethylene terephthalate (PET) fiber is a polyster fiber. The fibre was first prepared in 1941 by Whinfield and Dickson of the Calico Printers Association Ltd. (U.K). The large scale manufacture of this fiber started in 1953 by E.I. du Pont de Nemours and Co. (U.S.A) and Emperial Chemical Industries Ltd. (U.K). Chemical Structure Now a days dimethyl terephthalate is used instead of terephthalic acid. This is because terephathalic acid is non - violatic and slightly solublc in most of the organic solvents. On the other hand, dimethyl terephthalate (DMT) can be purified by easy distillation. In addition, the lower melting point of the easter (DMT) and its greater solubility in the glycol make the ester more convenient to carry out the reaction at the early stages of polyesterification. Raw Materials for PET The raw materials for the preparation of Terelyne or Dacron are (i) Dimethyl terephthalate and (ii) Ethylene glycol
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Manufacture of Dimethyl Terephthalate (DMT)

Dimethyl terephthalate is generally obtained from p-xylene as shown below CH3 COOH COOHCH3 Oxidation NHO3 on air 150 - 250o C CH3 p-xylene COOH CH3 OH 0.01% H2SO4 at 150o C COOHCH3

Terephthalic Dimethyl acid terephthalate p-xylene used for manufacturing DMT is largely obtained from petroleum sources by fractionating reformed naphtha. There is also a second method for the manufacturer of DMT from p-xylene CH3 CH3. CH3 COOH COOCH3 partial CH3OH AIR CH3OH XX CH3 COOH COOHCH3 COOCH3 COOCH3

Monomethyl terephathalate DMT is a white solid , m.p. 142oC

DMT (Dimethyl Terephthalate) 14

Artificial Silk or Rayon Artificial Silk or Rayon is one of the most important commercially used synthetic fibers of he modern era. Although this fiber was discovered in the seventeenth century, it becomes prominent in the textile world for the first time in France in 1980. Artificial Silk is a man made or artificial fiber whose chemical base is the cellulose , i.e. it can be prepared from cellulose. There are four important types of rayon or artificial silk manufactured from cellulose.  Nitro cellulose Rayon or Chardonent silk or Pyroxylin  Cuprammonium Rayon  Acetate Rayon  Viscose Rayon Nitro cellulose Rayon or Pyroxylin Nitro cellulose rayon is manufactured from colloidion cotton. The colloidion cotton is obtained by the coagulation of cotton in collcidion cotton is dissolved in a mixture of alcohol (1 vol) and other (3 vol) to form a colloidal solution of collusions. The solution is filtered and the forced through a spianarette as shown in fig. The streams of solution are turned into filaments as a result of coagulation in water bath. The solvents are evaporated by using hot air. 15

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When hot air is passed through the chamber, the threads are dried and the solvent vapours are taken by it through an outlet provided at the top of the chamber. The treads often passing round the pully wheel W, converge and get wound on the hobbin B. Nitro cellulose is inflammable as well as explosive and is not a good material to be used as a fiber. It is, therefore essential to denitrate the spun material, because dentitracted yarn is safter to use. The nitrate groups are removed by dipping the spun material either in the bath of sodium hydrogen sulphide or ammonium hydrogen sulphide (NH4HS). The denitrated fiber has the quality of the silk fiber and largely used for the manufacturing cellulose.

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Cuprammonium Rayon
The cuprammonium rayon yarn is manufactured from filaments obtained by the coagulation of a solution of cellulose in an ammoniacal solution of copper hydroxide called Seweitzers reagent. The cupric hydroxide is obtained by treating copper sulphate with sodium hydroxide. CuSO4 +2NaOH Cu (OH)2 + Na2SO4 The cupric hydroxide thus formed is filtered, washed and dissolved in excess of ammonia solution to get the Seweitzers reagent. This is deep blue in colour and is a cuprammonium complex, [Cu(NH3)4 (OH)2 The cellulose used is either wood pulp or cotton pulp.

Manufacture of Wood Pulp

Wood pulp is produced by the sulphite process. Chips of wood are digester in a digester with aqueous solution of calcium bisulphate and with excess of sulphurous acid at a temperature of 130o to 145o C and a pressure of 70 to 100 psi for 7 to 12 hours. After the digestion, the pulp formed is washed with water , bleached and pressed into sheets.

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Manufacture of Cotton Pulp

Cottin linters are attached to the cotton seeds. The linters are digested with 3 percent caustic soda solution at about 60 psi for four hours. After this period, the pulp is washed with water, bleached and formed into sheets. The cotton pulp contains 98% of a - cellulose while the wood pulp containing 88-92% of a - cellulose.

Preparation of Cuprammonium Rayon

The wood pulp or cotton linter pulp is taken in a mixture filled with a stirrer and connected to vaccum. The pulp is dissolved by adding. Seweitzers reagent with constant stirring. The excess of ammonia in the solution is withdrawn from the mixture through the vaccum line. The cellulose is dissolved by stirring and the resultant solution is filtered several times. The filtrate is forced through the orifices of the spinnerette into a stream of water which stretches the filaments and these are then passed through a 1.5 percent solution of sulphuric acid. The latter destroys the cuprammonium complex and precipitate cellulose. The filaments are thoroughly washed to remove all soluble substances, bleached, dried and passed round the puly and finally got round on the bobbin. These filaments are better than silk-fibers.

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Acetate Rayon
The manufacture of acetate rayon involves three steps.

(i) Acetylation of the cellulose formation of cellulose triacetate.

Wood pulp or cotton linters are heated in acetic acid. The pulp is then taken in a mixture fitted with a stirrer. It is charged with a solution containing a mixture of acetic anhydride and glacial acetic acid, together with a small quantity of sulphuric acid which acts as the catalyst. The reaction mixture is cooled to 45o F and stirred continuously for 6-8 hours. Cellulose reacts with acetic acid forming cellulose triacetate . After the acetylation, the solution becomes heavy, viscous, semi transparent acrid-smelling fluid, called the primary acetate.

Formation of triacetate
[C6H7O2(OH)3]n + 3n CH3COOH [C6H7O7(CH)3COO)3]n + 3n H2O Cellulose Triacetate

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(ii) Formation of Cellulose Diacetate Cellulose

triacetate is not suitable for making filaments, because it is only soluble in expensive chlorinated solvents and the threads are brittle. The diacetate formed by partial hydrolysis of triacetate by water gives satisfactory properties. The cellulose triacetate is taken in a container. Strong acetic acid is added to it and the mixture is diluted with water. It is allowed to stand for 15 hrs at 100oF. During this period the triacetate is partially hydrolysed to the diacetate. The diacetate is precipitated in the form of white flakes by pouring the solution into a large tank of cold water. The cellulose acetate flakes are washed in warm water until free from acid and then dried.

Formation of Diacetate
[C6H7O2(CH3COO)3]n + n H2O Cellulose Triacetate [C6H8O2(CH)3COO)2]n + n CH3COOH Cellulose Diacetate

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(iii) Preparation of Spinning Solution- The spinning

solution is prepared by dissolving the diacetate flakes in acetone. The flakes are taken in a cross mixture machine into which acetone is added and left for 12-24 hours for completed soluble of flakes. The cellulose acetate content in the final solution is 15-20 percent. From the mixture, the solute is run into tanks where batches of solution are blended. The contents of these blending tanks are then filtered several times and finally the solution is drawn into storage tanks where all the air bubbles are removed. The solution is now ready for spinning.

(iv) Spinning the Solution Acetate yarn is spun by the dry

spinning process. In this spinning method, the spinning solution is delivered from the storage tanks to the spinneret on the spinning machine and is forced fownward through the solution under controlled pressure into an enclosed spinning chamber. The spinning solution emerging our of the spinneret comes in contact with a warm air which evaporates the acetone. The filaments are dried by extrusion into warm air and twisted into threads.

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VISCOSE RAYON
This is one of the most widely used process for the manufacture of artificial silk. This process consists of three steps. Step . I - Preparation alkali cellulose The wood pulp or cotton linter pulp is first bleached and then dipped in 16% sodium hydroxide solution for about two hours when the cellulose is treated with sodium hydroxide alkali cellulose is formed. (C6H10O5)n + n NaOH [C6H9O4 ONa]n + n H2O Cellulose Alkali Cellulose

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STEP -2

Ripening of xanthate cellulose

The viscose solution is filtered several times through cotton pads to remove dust, dirt and undissolved particles. The xanthate solution so obtained is ripened for sometimes before use. Ripening is necessary to impart proper tensile strength and spinning property to the yarn. Ripening is carried out by passing the filtered viscose through a series of storage tanks is series and it takes 4-5 days.

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The ripening cellulose is mixed the sufficient amount of NaCl solution to initate coagulation of the viscose. The repaired viscose is forced by a pump into a spinnerette, which is placed in a bath of sulphuric acid containing Na2SO4. The threads of sodium cellulose xanthate formed immediately reacts with dil Na2SO4. The acid regenerates the cellulose with precipitation of some fine sulphur which is removed by reacting with sodium sulphide. The silky thread obtained are spun on a bobbin , disulphurised, washed with soap solution, twisted to form the yarn, bleached with NaOCI and dried. This silk is known as Viscose Rayon.

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