Conventional batch process for viscose rayon manufacture

Cross-section of rayon fiber

Properties of High Tenacity Rayon

Denier (De)

Strength (dry, g/d)

Strength (wet, g/d)

Elongation (dry, %)

Elongation (wet, %)

Youngs Modulus (kg/mm2)

Crystallinity (%)

High Tenacity Rayon

1.5 1.5 1.5

4.0 2.9 4.6

2.9 1.7 4.5

22 16 5

28 19 7

800 800 850

29 33 61

Regular Rayon
Cotton

Properties of Modal
Produced from beech wood (Lenzing, Austria) Higher tenacity, stronger and more stable than rayon and cotton Kind of HWM(High Wet Modulus), and different from general polynosic in terms of degree of polymerization and crystallinity Overall physical properties

- wet modulus > 0.5, higher whiteness than cotton, gravity ~ 1.5, degree of polymerization ~ 400, high
wet modulus with small elongation rate (%)

Modal vs. Polynosics

Degree of polymerization - Modal ~ 400, Polynosic > 500 Production - Modal: Viscose solution containing amine-based additives is extruded through zinc-concentrated coagulation bath, typicall 40~50 m/min, using typical spinning machine for rayon fiber

- Polynosic: Viscose solution of high DP is spun into coagulation bath of low acidity at low temperature,
and then went to drawing process with higher draw ratio

Spinning of Polynosics

A: viscose solution B: spinneret C: coagulation bath (1% H2SO4) D: guiding roller E: godet roller F: guiding roller G: take-up bobbin H: side-view of E
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Spinning of Cuprammonium Rayon

A: spinning unit B: guiding funnel C: water inlet D: steel rod E: guiding roller F: take-up bobbin
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Comparison: Viscose vs. Lyocell

Viscose

Lyocell

Comparison: Viscose vs. Lyocell

Problems in viscose process - Environmentally unfriendly by-products (Sulfur Compounds, ammonia, Cu salts, Zn Salts), which must be completely removed or chemically disposed of before discharged into the environment. - Viscose not entirely satisfactory for making cotton like fabrics poor mechanical properties, high swelling and increase in wet elongation under low stress

Advantages of NMMO Process - Process utilizes materials that are environmentally clean and recycling of the solvent is an internal part of the process.

- Apart from environmentally friendly the NMMO process for the production of cellulosic fibers is
potentially more cost effective and faster than the viscose process. - Lyocell process take up to three hours to produce fibers compare to 40 hours in the case of viscose process

Overall Properties

Structure and properties of Lyocell - since Lyocell is just dissolved cellulose in NMMO and not making any cellulose derivatives, it has a

different molecular structure than other regenerated cellulosic fibres.

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Diagram of Lyocell process

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Cellulose acetate process

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Position of OHs during 1,4-addition of glucose

Cellulose from b-glucose

Starch from a-glucose : amylose, amylopectin

Amylose : linear polymer of glucose linked mainly by (14) bonds Amylopectin : highly branched polymer of glucose having (16) bonds

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