Synthetic Fibers

Preface

Contents??????????????????????????????

1 Introduction??????????????????????????????????????????

1.1 General Remarks????????????????????????????????????????????????????

1.2 Conditions for the Production of Textile Fibers????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

1.3 The Most Important Fiber Raw Materials??????????????????????????????????????????????????????????????????????????????????????????????????

1.4 Economic Development??????????????????????????????????????????????????????????????

1.5 Price Developments??????????????????????????????????????????????????????????

1.6 Raw Materials????????????????????????????????????????????????

References??????????????????????????????????

2 Polymer Specific Processes??????????????????????????????????????????????????????????????????????

2.1 Polymerization, Polycondensation, and Polyaddition

2.1.1 Polymerization??????????????????????????????????????????????????????

2.1.2 Polycondensation??????????????????????????????????????????????????????????

2.1.3 Polyaddition??????????????????????????????????????????????????

2.2 Polyamides (PA)????????????????????????????????????????????????????

2.2.1 Introduction??????????????????????????????????????????????????

2.2.2 Polyamide 4 (PA4)????????????????????????????????????????????????????????????

2.2.3 Polyamide 6 (PA6)????????????????????????????????????????????????????????????

2.2.4 Polyamide 66 (PA66)????????????????????????????????????????????????????????????????

2.2.5 Other Polyamides??????????????????????????????????????????????????????????

2.3 Polyester (PES)????????????????????????????????????????????????????

2.3.1 Introduction??????????????????????????????????????????????????

2.3.2 Production of Dimethyl Terephthalate (DMT), Terephthalic Acid (TPA) AND Ethylene Glycol (EG)

2.3.3 Process for the Production of Polyethylene Terephthalate (PET)??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

2.3.4 Autoclave Polycondensation to PET????????????????????????????????????????????????????????????????????????????????????????????

2.3.5 Continuous Polycondensation to PET??????????????????????????????????????????????????????????????????????????????????????????????

2.3.6 Spinning and Drawing of PET????????????????????????????????????????????????????????????????????????????????

2.3.7 Polybutylene Terephthalate (PBT)??????????????????????????????????????????????????????????????????????????????????????????

2.4 Polyolefines??????????????????????????????????????????????

2.4.1 Polypropylene (PP)??????????????????????????????????????????????????????????????

2.4.2 Polyethylene (PE)????????????????????????????????????????????????????????????

2.5 Polyacrylonitrile (PAN)????????????????????????????????????????????????????????????????????

2.5.1 Production of Acrylonitrile ( = Vinylcyanide)????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

2.5.2 Polymerization to Polyacrylonitrile (PAN)????????????????????????????????????????????????????????????????????????????????????????????????????????????

2.5.3 Spinning and Aftertreatment of Polyacrylonitrile??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

2.6 Polyvinyl Chloride (PVC)??????????????????????????????????????????????????????????????????????

2.6.1 Production of PVC????????????????????????????????????????????????????????????

2.6.2 Solving and Spinning of PVC and VC-Copolymers????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

2.6.3 Syndiotactic PVC??????????????????????????????????????????????????????????

2.7 Polyvinyl Alcohol (PVAL)??????????????????????????????????????????????????????????????????????

2.7.1 Production Process up to the Spinnable Solution????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

2.7.2 Solution Wet Spinning????????????????????????????????????????????????????????????????????

2.7.3 Dry Spinning??????????????????????????????????????????????????

2.8 Spandex or Elastane Yarns (EL, also PUR)

2.8.1 Production of the Polyurethanes????????????????????????????????????????????????????????????????????????????????????????

2.8.2 Installations and Apparati??????????????????????????????????????????????????????????????????????????????

2.8.3 Wet Spinning System and Equipment????????????????????????????????????????????????????????????????????????????????????????????

2.8.4 Dry Spinning Processes and Installations??????????????????????????????????????????????????????????????????????????????????????????????????????????

2.8.5 Reaction Spinning Process????????????????????????????????????????????????????????????????????????????

2.8.6 Properties

2.8.7 Polyurethane Hard Fibers

2.9 Polytetrafluorethylene Fibers (PTFE)

2.9.1 Spinning and Drawing of the Filaments

2.9.2 Properties

2.10 High Tenacity–High Modulus Filaments According to the Gel Spinning Process

2.10.1 Principle

2.10.2 Process, Machines, and Plants

2.10.3 Properties of PE Gel Filaments and Their Uses

2.11 High Temperature and High Modulus Fibers

2.11.1 General Remarks

2.11.2 Polyaramides

2.11.3 Polyetherketone (PEK, PEEK, etc.)

2.11.4 Polysulfones and Polyether Sulfones

2.11.5 Liquid Crystals

2.11.6 Polyimides

2.12 Other Polymer Fibers and Further Processes

2.12.1 Silicone Dioxide Fibers

2.12.2 Polycarbosilane and Silicon Carbide Fibers

2.12.3 Yarn Production via Carrier Filament

2.12.4 Phenol Resin Fibers

2.12.5 Super-Absorbing Products (SAP) as Fibers

2.12.6 Thermo Bonders

2.12.7 Organic Optical Fibers (POF)

2.12.8 Electrically Conducting Filaments

2.12.9 Interfacial Polycondensation Spinning

2.12.10 Reaction Spinning

2.12.11 Emulsion and Suspension Spinning

2.12.12 Electrostatic Spinning

2.13 Fibers from Natural Products

2.13.1 Protein Fibers

2.13.2 Alginate Fibers

2.13.3 Filaments on Cellulose Basis

2.13.4 Basalt Fibers

References

3 Theoretical and Experimental Principles

3.1 Reactors for Production and/or Dissolving

3.1.1 Selection Criteria

3.1.2 Preferred Reactor Cascades

3.1.3 Reactor Design

3.2 The Spinning Mechanism

3.2.1 General View over Melt Spinning

3.2.2 Solution Spinning

3.3 Filament Take-Up and Filament Cooling

3.3.1 Filament Cooling

3.3.2 Take-Up Forces

3.3.3 Filament Temperatures

3.4 Drawing Mechanism

3.4.1 Drawing Process

3.4.2 Consequences for Drawing

3.5 Twisting

3.6 False Twist Texturing

3.6.1 Principle

3.6.2 Influence of the Filament Way Profile

3.7 Bobbin Construction

3.8 Cops Built-Up in Draw-Twisting and Cops Take-Off

3.9 Draw and Holding Forces for Filament and Tow

3.10 Contact Heating and Drying of Filaments

3.11 Stuffer Box Crimping

3.12 Heat Setting

3.12.1 Basics

3.12.2 Heat Setting Processes for Synthetic Yarn and Fiber Production

3.13 Crystallinity

References

4 Plants, Equipment, and Machines for the Production of Synthetic Yarns and Fibers

4.1 General

4.2 Chemical Equipment

4.2.1 Autoclaves

4.2.2 Dissolving and Mixing

4.2.3 Pipes and Insulation

4.2.4 Pipe Transport Systems for Granules, Powder, and Fibers

4.3 Strand Casting and Cooling, Granulating

4.3.1 Strand and Ribbon Casting

4.3.2 Ribbon and Strand Cooling

4.3.3 Granulating

4.3.4 Cutting Forces [29], Drive Powers

4.3.5 Mechanical Chip Dehydration

4.3.6 Granulators

4.3.7 Chip Production from Powder

4.4 Initial and Intermediate Products, Final Products: Delivery Conditions and Storage

4.4.1 Shipping Forms, Packaging

4.4.2 Chip Storage and Transport

4.5 Drying, Crystallization, and Solid Phase Polycondensation

4.5.1 Vacuum Drying and Similar Processes

4.5.2 Continuous Chip Drying

4.6 Melt Spinning Plants

4.6.1 Calculation of the Plant and Equipment Sizes

4.6.2 Survey of Melt Spinning Installations for Filaments

4.6.3 Chip Gate Valves

4.6.4 Spin Extruders

4.6.5 Spinning Heads and Spinning Beams

4.6.6 Polymer or Melt Valves

4.6.7 Static Mixers

4.6.8 Spinning Pumps and Other Gear Pumps

4.6.9 Melt and Solution Filters

4.6.10 Spinnerets

4.6.11 Spin Packs (Housings) and Bolting

4.6.12 Spinning Pump Drives

4.7 Quench Cabinets

4.7.1 General

4.7.2 Preferred Quenches

4.7.3 New Quench Chamber Developments for Very High Spinning Speeds

4.7.4 Construction Elements for Quench Chambers

4.7.5 Quench Chamber Accessories

4.8 Spin Finish Application Systems

4.8.1 Roll Application

4.8.2 Rod (Bar) Application

4.8.3 Spray Application

4.8.4 Dipping Bath Application

4.8.5 Pin Application (Metered Spin Finish)

4.9 Spinning Take-Up Machines

4.9.1 The Various Types of Take-Up Machines

4.9.2 Yarn Inlet Zone

4.9.3 Rolls, Godets, Draw Rolls

4.9.4 Separator Rolls

4.9.5 Winders

4.10 Drawtwisting and Draw-Winding Machines

4.10.1 Drawtwisting Machines (Drawtwisters)

4.10.2 Construction Elements for Drawtwisters

4.11 Warp Drawing, Warp Sizing and Slashing

4.12 Texturizing and Drawtexturizing

4.12.1 Comparison of Texturizing Processes

4.12.2 False Twist Texturizing Machines

4.12.3 Stuffer Box Crimping Machines for Filament Yarns

4.12.4 Air Jet Texturizing; for Loop- and Entangled Yarn

4.12.5 Air Consumption and Yarn Tensions of Texturizing and Aspirating Jets

4.12.6 BCF (Bulked Continuous Filament) Texturizing

4.13 Staple Fiber Plants

4.13.1 Overview

4.13.2 Melt Spinning Lines for Staple Fibers

4.13.3 Spinning Take-Up Walls and Can Take-Up

4.13.4 Creels

4.13.5 Tension Compensation and Dipping Bath

4.13.6 Drawing Frames

4.13.7 Hot Drawing Ovens

4.13.8 Tow Spreading and Plying

4.13.9 Stuffer Box Crimpers

4.13.10 Dryers and Heat-Setting Machines

4.13.11 Tow Packaging

4.13.12 Staple Cutters

4.13.13 Staple Fiber Transport

4.13.14 Balers

4.14 Dry-Spinning Plants

4.14.1 Principle of Dry-Spinning

4.14.2 The Dry-Spinning Tube (Shaft, Duct)

4.14.3 Staple Fiber Dry-Spinning Lines

4.15 Solution Wet-Spinning Plants

4.15.1 Wet-Spinning Process

4.15.2 Constructional Details of Wet Spinning Lines

4.15.3 Aftertreatment Lines for Dry-Spun Tow

4.15.4 Solution Wet-Spinning of Multi- and Monofilaments

4.16 Piston (Rod) Spinning Units

4.16.1 Spinning of Very Small Quantities

4.16.2 Ram Extrusion

References

5 Special Processes and Plants

5.1 Short-Spinning Process

5.1.1 "Automatik" Compact Staple Spinning System for PP, PE, PA and PET, Combined with a Fleissner Drawing and Crimping Line

5.1.2 "Barmag" Compact Staple Spinning System for PP,PE and PET [152]

5.1.3 Other Compact Spinning Plants

5.1.4 Compact Staple Spinning Plants for Take-Up Speeds up to 2000 m/min

5.1.5 Compact Spinning Machines for Coarse Filaments and Fibers

5.1.6 Compact Spinning Machines for Filaments

5.1.7 Film Tapes and Monofilaments

5.2 Bi-and Multicomponent Yarns and Fibers

5.2.1 Bicomponent Spinning Processes, -Spinnerets and -Filament Cross-Sections

5.2.2 Melt Manifolds for Bicomponent Yarns, etc.

5.3 Hollow Filaments

5.4 Fine Filament Man-Made Fibers

5.4.1 Microfilaments

5.4.2 Superdrawing

5.4.3 Melt Blowing Process

5.4.4 "Flash" Spinning

5.5 Spunbond

5.5.1 Spinning Equipment

5.5.2 Filament Take-Up Devices

5.5.3 Spunbond Lines

5.5.4 Web Bonding

5.5.5 Properties

5.5.6 "Claw" Mats

5.6 High Temperature Spinning

5.6.1 Melt Spinning at Temperatures up to ca. 550°C

5.6.2 Melt Spinning Plants for Temperatures above 700°C

5.7 Carbon Fibers

5.7.1 Processes

5.7.2 Process Stages for PAN Precursor Fibers

5.7.3 Composites and Prepregs

5.8 Converters (Tow to Top or Tow to Spun Yarn Process)

5.8.1 PET Tow for Stretch-Break Conversion

5.8.2 The Sydel Stretch-Break Converter; The Schlumberger Converter

5.9 Tirecord and Other Technical Yarns

5.9.1 Yarn Production

5.9.2 Cord Construction

5.9.3 Cord Physical Properties

5.10 Fiberfill

5.11 Biodegradable Fibers

References

6 Auxiliary Plants and Equipment

6.1 Package Handling

6.1.1 Simple Yarn Package Transport Equipment

6.1.2 Doffer Systems

6.1.3 Bobbin Transport, Storage, and Packing

6.2 Air Conditioning: Conditions and Plants

6.2.1 Quench Air Conditioning Plants

6.2.2 Air Conditioning of the Winding Room

6.2.3 Air Conditioning of Staple Fiber Plants

6.2.4 Climatization of Other Rooms

6.2.5 Dust Content of Conditioned Air

6.2.6 Air Conditioning State Plotted on ix-Diagram

6.2.7 Air Conditioning Plants

6.3 Heating Systems and Heat Transfer Media

6.3.1 Heating Plants

6.4 Protective Gas

6.5 Compressed Air

6.6 Cleaning of Polymer-Soiled Parts

6.6.1 Burning-Out Ovens

6.6.2 Molten Salt Bath Ovens

6.6.3 Aluminum Oxide Fluidized Bed Process

6.6.4 Hydrolytic (Pre-) Cleaning

6.6.5 Solvent Cleaning

6.6.6 Vacuum Pyrolysis

6.6.7 Final Cleaning and Comments

6.6.8 Cleaning Plants

6.7 Spin Finishes and Spin Finish Systems

6.7.1 Spin Finish

6.7.2 Frictional Behavior

6.7.3 Filament Cohesion

6.7.4 Antistatic

6.7.5 Emulsifiers

6.7.6 Spin Finish Application in Practice

6.7.7 Spin Finish Preparation

6.7.8 Uniformity of Spin Finish Application

6.8 Delustering and Spin Dyeing

6.8.1 Delustering

6.8.2 Dyestuffs for Spin Dyeing

6.8.3 Addition of Pigments/Dyestuffs

6.8.4 Additives

6.9 Testing of Spinning Pumps

6.10 Testing of Spinnerets

6.11 Yarn Containers (Spinning Tubes, etc.)

6.12 Maintenance

References

7 Auxiliary Devices, Calculations, and Construction

7.1 Control Drives

7.1.1 Mechanically Adjustable and Control Drives

7.1.2 Control Motors

7.1.3 Current Converters and Inverters

7.2 Yarn Guides,Spin Finish Applicators, and Yarn Sensors

7.3 Yarn and Tow Cutters

7.4 Air Jets

7.4.1 Yarn Aspirator Jets

7.4.2 Intermingling Jets (Tangling Jets)

7.5 Rotating Cylinders (Godets, Yarn Bobbins, etc.)

7.6 Inclined Rolls

7.7 Melt and Solution Viscosity

7.7.1 Melt Viscosity

7.7.2 Solution Viscosity

7.7.3 Molecular Weight, Polymerization Degree, etc.

7.8 Uster Uniformity Testing

7.9 Temperature Measurements, Melt Pressure Measurements

7.9.1 Temperature Measurement

7.9.2 Melt and Solution Pressure Measurement

7.9.3 Moisture Measurement

7.10 Fluid Mechanics

7.10.1 Air Flows for Re = 0.1...500

7.10.2 Laminar and Turbulent Flow

7.10.3 Heat Transfer from Yarn to Air

7.11 Construction Materials

7.12 High Temperature Threads

References

8 Waste Processing and Recovery (Recycling)

8.1 Overview

8.2 Chemical Processing of PA 6 Waste

8.2.1 Recovery of Caprolactam from PA 6 by Thermal Decomposition

8.2.2 PA 6 Recovery through Depolymerization-Filtration-Re-Polymerization

8.2.3 Recovery through Reprecipitation of PA 6

8.2.4 Lactam Recovery across the Entire Production Process

8.3 Chemical Processing of PA66 Waste

8.4 Depolymerization of Polyester

8.4.1 Conversion of Polyester to TPA or DMT

8.4.2 DMT Recovery via Glycolysis of PET

8.4.3 Recovery of DMT via Polyester Methanolysis

8.4.4 Gaseous Byproducts in PET Production

8.5 Mechanical Waste Processing

8.5.1 Polyester Bottle Granulate

8.5.2 Polymer Blocks (Solid Waste and PET Bottles)

8.5.3 Compaction of Filament Waste

8.5.4 Yarn to Staple Processing

8.6 Direct Extruder Processing of Yarn and Film Waste

8.7 Recovery and Cleaning of Gases and Fluids

References

9 Testing and Influencing the Properties of Man-Made Fibers

9.1 Introduction to Testing

9.1.1 Aims and Tasks

9.1.2 Fundamental Principles of Textile Testing

9.1.3 Quality Systems

9.2 Terminology and Morphology

9.2.1 Man-Made Fiber Terminology

9.2.2 Morphology of Man-Made Fibers

9.2.3 Application and Fiber Properties

9.3 Physical and Textile Properties

9.3.1 Fiber Structure and Fiber Properties

9.3.2 External Form and Constitution of Fibers

9.3.3 Mechanical Properties

9.3.4 Shrinkage and Shrinkage Force

9.3.5 Uniformity of Yarns and Fibers

9.4 Fiber and End-Use Properties

9.4.1 Cause and Effect Chain Between Fiber and Endproduct

9.5 Methods of Fiber Identification

9.5.1 Diagnostic Dyeing Tests

9.5.2 Microphotographs of Fibers

9.5.3 Solubility

9.5.4 Type Reactions

9.5.5 Embedding the Fiber in Specific Reagents

9.5.6 Thermal Tests

9.5.7 Infrared Spectral Analysis

Literature and Further Reading

10 Conversion Factors and Other Tables

10.1 Decimal Definitions and SI Units

10.2 Dimensional Conversion Factors

10.3 Molecular Weights of Raw Materials

10.4 Definition of Yarn Types According to Spinning and Drawing Speed

10.5 Abbreviations for Fibers, Polymers, Pre-and Intermediate Products

10.6 Formulas for Spinning??????????????????????????????????????????????????????????????????

10.7 Statistics

10.8 Pre-Products????????????????????????????????????????????????

References

11 Fiber Tables

Index