Transcript LTB Process - Bangladesh Textile Today

LTB PROCESS
ASUTEX, COMMITED TO THE FUTURE
In an each time more stringent environment-conscious
future, textile processes must be adapted to fulfill the new
challenges, so that means
- LESS WATER CONSUMPTION
- LESS ENERGY EXPENSES
- LESS PROCESSING TIME
- GREEN CHEMICALS
BGD NOV 2012
LTB PROCESS
ANOTHER LINK IN THE CHAIN:
It is just another step for word with ecofriendly
textile industry. Bangladesh is already a green
country, all of us must contribute to keep this
heritage for the future generations.
We take the legacy of previous jobs and we just
want to be another step in this way.
Picture of Bangladesh
LTB PROCESS
Our commitment with constant INNOVATION in the
TEXTILE FIELD, developing new procedures and
modifying our offers to the newest market
requirements, allows us to introduce the new
LTB PROCESS
LOW TEMPERATURE BLEACHING
SYSTEM
LTB PROCESS
There are three products involved in the LTB PROCESS. All of them
developed in our R&D department.
THE SYNERGETIC COMBINATION OF THREE PRODUCTS ENSURES
THE MAXIMUM EFFICIENCY IN GETTINGS THE SAME WHITENESS
DEGREE AS IF IT IS PRODUCED ACCORDING TO A CONVENTIONAL
TECHNIQUE AND ALSO THE IDEAL HYDROFILITY NECESSARY TO
CARRY OUT ANY OTHER TEXTILE PROCESS WITHOUT AN SPECIAL
CARE.
PRODER LTB
ASUTOL LTB
NaOH 50%
H2O2 50%
ACTIVATOR LTB
0,5-1
0,5
3
2-3
0,5-1
30’ AT 75ºC
GR/L
GR/L
CC/L
CC/L
GR/L
LTB PROCESS
There are three products involved in the LTB PROCESS. All of them
developed in our R&D department.
1.-LTB PRODER :
DETERGENT-WETTING – DISPERSING AGENT
IT HAS BEEN SPECIALLY DEVELOPED TO GET THE MAXIMUM
REMOVAL OF NATURAL OCCURING WAXES CONTAINED IN
COTTON SO AS TO IMPAIR THE MAXIMUM HYDROPHILITY TO
THE SUBSTRATE DURING THE LOW TEMPERATURE NOVEL
PROCEDURE.
IT OVERCOMES THE DRAWBACKS RESULTING FROM THE FACT
OF WORKING AT LOW TEMPERATURES OFFERING VERY
EFFICIENT OUTCOME.
LTB PROCESS
There are three products involved in the LTB PROCESS. All of them
developed in our R&D department.
2.-ASUTOL LTB :
SEQUESTERING – DISPERSING – STABILIZING AGENT
SPECIALLY DESIGNED TO ENSURE THE BEST PERFORMANCE
DURING BLEACHING STAGE, AVORDING THE CATALYTIC
INTERFERENCES CAUSED BY THE PRESENCE OF HEAVY METALS
AND ALKALINE EARTH ELEMENTS.
ALLOWS TO GET OUTSTANDING WHITENESS LEVELS.
IRON SEQUESTERING CAPACITY – QUALITATIVE ANALISE
-20 ppm de Fe+++
-2,5 cc/L NaOH 50%
60 min in reflux at 100 ºC , cool down to 80ºC and filter
2 gr/L ASUTOL LTB
WITHOUT AUXILIAR
LTB PROCESS
There are three products involved in the LTB PROCESS. All of them
developed in our R&D department.
3.-ACTIVATOR LTB :
SPECIFICALLY DESIGNED COMPLEX PRODUCT THAT ENHANCES
HYDROGEN PEROXYDE ACTIVITY PERMITTING TO BLEACH
CELLULOSIC FIBRES INTO MILDER AND SMOOTHER WORKING
CONDITIONS.
CONTROLS PEROXYDE DESCOMPOSITION AND SPEEDS UP THE
DESIRED WHITENESS DEGREE.
Alkaline hydrogen peroxide solutions can be discomposed as
ion (heterolytic decomposition) or as a radical (homolytic
decomposition). Radical decomposition is responsible to
reduce de cellulose DP.
LTB PROCESS
COMPARISON BETWEEN THE NEW/CLASSICAL BLEACHING PROCEDURES
120
TEMPERATURE (ºC)
100
80
3ºC/min
3ºC/min
60
40
20
0
0
10
20
30
40
50
60
TIME (min.)
LTB Process
Traditional process
70
80
90
LTB PROCESS
ECONOMICAL AND ENVIRONMEN ADVANTATGES
OF LTB PROCESS IN FRONT OF TRADITIONAL ONE
 PROCESSING TIME DECREASING UP TO
COMPARED TO CONVENTIONAL BLEACHING.
30’
ENERGY SAVING (30 KCAL/KG ) COMPARED WHEN
RAISING UP BATH TEMPERATURE TO BOIL IS NOT
NECESSARY.
ENERGY SAVING AND TIME & WATER SAVINGS WHEN
COOLING DOWN BATH TEMPERATURE FROM 98ºC TO
75ºC IS NOT NECESSARY.
DECREASING BLEACHING TEMPERATURE INVOLVES
LESS FUEL CONSUMPTION, THIS FACT SUPPOSES LESS
CO2 RATES RELEASED TO THE ATMOSPHERE.
LTB PROCESS
TECHNICAL ADVANTAGES WHEN COMPARING LTB PROCESS
AGAINTS CONVENTIONAL PROCESS
WHEN USING LESSER PROCESSING TIMES,
FORMATION IS ALSO OF LESS IMPORTANCE.
THE
PILLING
 RESULTING HANDLE IS BETTEER, THIS IS MORE RELEVANT
WHEN BLEACHING FINER NUMBERS OR OPEN-END YARNS.
CELLULOSIC YARNS BLEACHED AT LOWER TEMPERATURES
UNDERGO
LESS
DAMAGE,
SO
THAT
RESULTING
POLYMERIZATION DEGREE ARE HIGHER.
WHEN BLEACHING YARN PACKAGES DUE TO THE LESS
SHRINKAGE AT LOWER TEMPERATURES, WIND AND REWIND
OPERATIONS ARE EASIER AND YARN BREAKINGS ARE LESS.
WHEN USING LOWER BLEACHING TEMPERATURES, THE TREND
TO CREASING FORMATION IS LESS, THIS FACT IS OF MAIN
IMPORTANCE WHEN HANDLING CELLULOSIC ELASTANE
MIXTURES.
LTB PROCESS
LTB PROCESS, BENEFITS IN FRONT OF TRADICIONAL BLEACHING PROCESSES
Lower modification of Cellulose Polymerization Degree (DP)
Results for polymerization degree test:
Polymerization degree from raw cotton:
3327
LTB Process at 75 ºC using 2cc/L NaOH 50% & 2cc/L H2O2 50% :
3253
LTB Process at 75 ºC using 3cc/L NaOH 50% & 3cc/L H2O2 50%:
3170
Traditional Bleaching at 100 ºC using 3cc/L NaOH 50% & 3cc/L H2O2 50% : 2515
LTB PROCESS
POLYMERIZATION DEGREE DECREASE
3327
Raw Cotton
3253
3170
2515
LTB PROCESS
LTB PROCESS
Traditional Process
75 ºC
75 ºC
100 ºC
2 NaOH / 2 H2O2
3 NaOH / 3 H2O2
LTB PROCESS
SPECIAL APPLICATION:
CONE YARN BLEACHING
•CORN YARN DYERS ARE SPECIALLY PLEASED WITH THE
BENEFITS BROUGHT BY THE NEW LTB BLEACHING PROCESS.
WHEN BLEACHING AT 75 ºC AND DYEING AT 60ºC THE
SHRINKAGE LEVEL BECOMES MINIMUM WHAT IS TRANSLATED
DIRECTLY TO A MORE STABLE BOBBINE AND MORE
HOMOGENEOUS YARN PACKAGE.
•YARN’S STRENGH IS INCREASED STRIKINGLY, SPECIALLY IN
SHIRT-YARNS (40-50/1H NE OR SUPERIORS) WHERE NUMBERS OF
BREAKINGS DECREASES AROUND 80%.
•THE HIGHEST YARN RESISTANCE ALLOWDS INCREASING
SIGNIFICANTLY THE REWINDING SPEED WHAT BECOMES AT THE
END AND SHORTAGE OF TIME.
•THIS ALSO HELPS REDUCING LIQUID PARAFINE’S PERCENTAGE
OR REPLACE IT BY USING MORE ECONOMIC CHEMICALS AS
POLIETHILENES.
LTB PROCESS
SPECIAL APPLICATION:
CELLULOSIC ELASTANE MIXTURES.
•ONE OF THE MOST CRITICAL POINTS WHEN WORKING WITH THE
COTTON-LYCRA IS HOW TO AVOID THE CREASE MARKS. THIS
PROBLEM IS SPECIALLY WEIGHTLY ONCE WE REACH 80ºC.
• EVEN AFTER PRE-SETTING, IT IS ADVISABLE TO WORK WITH
SPECIFIC ANTICREASE AGENTS AND TAKE AN EXTRA CONTROL
REGARDING PROCESS TEMPERATURE. CONCRETLY, ONCE WE
OVERPASS 80ºC IT IS IMPORTANT TO INCREASE OR REDUCE THE
TEMPERATURE VERY SLOWLY, FOR EXAMPLE AT 1 ºC/min.
•WORKING WITH LTB, WE WILL NEVER CROSS THE CRITICAL
TEMPERATURE WORKING FULL TIME BELOW 80 ºC, IT MEANS IN
THE SAFE CONDITIONS.
•REDUCING THE TEMPERATURE WILL ALSO PROTECT THE LYCRA
ELASTICITY.
LTB PROCESS
COMPARISON LTB vs CLASSICAL BLEACHING PROCEDURES
120
TEMPERATURE (ºC)
100
1 ºC/min
1 ºC/min
80
3ºC/min
60
40
20
0
0
10
20
30
40
50
60
TIME (min.)
LTB Process
Traditional process
70
80
90
LTB PROCESS
BLEACHING OF COTTON KNITTING AT DIFFERENT TEMPERATURES USING LTB PROCESS
80
78,3
78
CHEMICALS DOSES
76,8
75,5
WHITENESS DEGREE
76
73,3
74
72
1 gr/L Proder LTB
0,5 gr/L Asutol LTB
1 gr/L Activator LTB
71,1
30' at 70ºC
70,1
70
30' at 75ºC
68
66
2 cc/L NaOH 50%
2 cc/L H2O2 50%
3 cc/L NaOH 50%
3 cc/L H2O2 50%
4 cc/L NaOH 50%
4 cc/L H2O2 50%
LTB PROCESS
INDUSTRIAL TRIALS ACCORDING TO LTB PROCESS
PRODER LTB
0.5
1
0.5
1
0.5
1
ASUTOL LTB
0.5
0.5
0.5
0.5
0.5
0.5
NaOH 50%
2
2
3
3
4
4
H2O2 50%
2
2
3
3
4
4
ACTIVATOR LTB
1
1
1
1
1
1
74.9
75.83
76.37
76.53
77.3
30’ at 75ºC and LR 1:10
CIE DEGREE
73.9
WICKING TEST FOR HYDROPHILITY
After 5 min of fabric
contact with the
coloured solution
DROP TEST TIME IN SECONDS
FOR COMPLETE WETTING
3”
Instantaneous
2”
Instantaneous
Instantaeous Instantaneous
BGD DEC 2012
LTB PROCESS
AS FINAL SUMMARY FOR LTB PROCESS, WE HAVE:
1.- WHITENESS DEGREE – THE MOST IMPORTANT POINTS ARE:
NAOH / H2O2 CONCENTRATION
TEMPERATURE: THE HIGHER (75 ºC) THE BETTER WITHENESS DEGREE
THE ACTIVATOR: THE HIGHER DOSAGE (1 GR/L) THE BETTER WHITENESS DEGREE.
2-. HYDROPHILITY – THE MUST IMPORTANT POINTS ARE:
NAOH / H2O2 CONCENTRATION
TEMPERATURE: THE HIGHER (75 ºC) THE BETTER HYDROPHILITY
THE DETERGENT DOSAGE: THE HIGHER (1 GR/L) THE BETTER HYDROPHILITY.
3-. OTHER FACTORS SUCH AS COTTON ORIGIN, SUBSTRATE FORM (PACKAGE, HANK,
WOVEN, KNITTED FABRIC, …), TYPE OF MACHINERY (JIG, OVERFLOW, DYE BECK,…) AND
LIQUOR RATIO ARE ALSO OF MAIN IMPORTANCE IN THE FINAL RESULTS.
4-. ADVISABLE RECIPE FOR BLEACHING ACCORDING TO LTB PROCESS IS:
PRODER LTB
ASUTOL LTB
NaOH 50%
H2O2 50%
ACTIVATOR LTB
30’ AT 75ºC
0,5-1
0,5
3
2-3
0,5-1
GR/L
GR/L
CC/L
CC/L
GR/L
LTB PROCESS
STANDARD PROCESS ON CONE YARN BLEACHING – INDUSTRIAL TRIAL
•Yarn : 80/2 Ne CO 100%
30 min
75 ºC
4 º/min
75 ºC
10 min
3 min
Overflow rinse
3 min
Overflow rinse
40 ºC
30-50 ºC
2 min
A
15 min
2 min
B
C
E
A.- PRODER LTB
1 gr/L
ASUTOL LTB
0,5 gr/L
Caustic Soda 50% 3 cc/L
B.- Peroxide 50%
3 cc/L
C.- ACTIVADOR LTB
1 gr/L
D.- Acetic Acid
In case de-mineralization
process is need, then add
ASUTOL A-P in acid
conditions
E.- PEROXFIN MI
RKM(CN/TEX)
Elong.(%)
0,5 %
RAW YARN
LTB
SCOURED
20,25
20,93
19,74
3,95
5,65
4,39
ºCIE WHITE
68
mgCaCO3/gr
0,62
JUNE 2011
LTB PROCESS
STANDARD OPTICAL BLEACHING ON CORN YARN – INDUSTRIAL TRIAL
•Yarn : 70/1 Ne CO 100%
30 min
75 ºC
75 ºC
20 min
3 min
Overflow rinse
4 º/min
3 min
Overflow rinse
2 º/min
50 ºC
30-50 ºC
2 min
A
15 min
2 min
B
D
C
A.- PRODER LTB
1 gr/L
ASUTOL LTB
0,5 gr/L
Caustic Soda 50% 4 cc/L
B.- Peroxide 50%
5 cc/L
C.- ACTIVADOR LTB
1 gr/L
D.- ASUBLANC PIB
In case de-mineralization
process is need, ASUTOL A-P
can be added in the last
rinsing/neutralizing bath
E
E.- Water
Acetic Acid pH 5
RAW YARN
LTB
RKM(CN/TEX)
26,86
26,80
Elong.(%)
5,87
6,76
ºCIE WHITE
127,8
JUNE 2011
LTB PROCESS
STANDARD PROCESS ON KNITTED FABRIC BLEACHING – INDUSTRIAL TRIAL
•Fabric: Jersey 50/1
Liquor Ratio : 1:11
30 min
75 ºC
75 ºC
4 º/min
3 min
Overflow rinse
E
10 min
3 min
Overflow rinse
40 ºC
30-50 ºC
5 min
2 min
10 min
2 min
2 min 2 min
F
A load B
C
G
H
I
D
A.- PRODER LTB
ASUTOL LTB
1 gr/L
0,5 gr/L
B.- Caustic Soda 50%
3 cc/L
C.- Peroxide 50%
3 cc/L
D.- ACTIVADOR LTB
1 gr/L
E.- Water at 75ºC
F.- Acetic Acid pH 6-7
In case de-mineralization
process is need, proceed as
in corn yarn process
G.- PEROXFIN MI
0,5 %
H.- Acetic Acid pH 5
I.- Biopolish or Dye
JUNE 2011
LTB PROCESS
JUNE 2011