Acrylic (Polyacrilonitrile)- Manufacturing Process and Properties

Polyacrilonitrile ( Acrylic)

vinyl Cyanide, more commonly known as acrylonitrile, can under go addition

polymerisation to form polyacrylonitrile.

Raw Material

Acrilonitrile is the main main raw material for the manufacture of acrylic fibres. It is
made by different methods. In one commercial method, hydrogen cyanide is treated
with acetylene:

acetylene + Hydrogen cyanide --> Acrilonitrile

2nd Method

Ethylene--Air Oxidation--> Ethylene oxide + HCN--> Ethylene cyanahydrin--

Dehydration at 300 deg C (catalyst)--> Acrylonitrile

In a continuous polymerisation process, 95% acrylonitrile and 6% methyl acrylate (400

parts) 0.25% aqueous solution of K2S2O8(600 parts), 0.50 % Na2S2O5 solution ( 600
Parts) and 2N sulphuric acid (2.5 Parts) are fed into the reaction vessel at 52 deg C
under nitrogen atmosphere giving a slurry with 67% polymer. The slurry is continuously
withdrawn, filtered and washed till it is free from salts and dried.

Acrilonitrile is dry spun. The material is dissolved in dimethyl formamide, the solution
contains 10-20 polymers. It is heated and extruded into a heated spinning cell. A
heated evaporating medium such as air, nitrogen or steam moves counter current to
the travel of filaments and removes the solvent to take it to a recovery unit. The
filaments are hot stretched at 100 to 250 C depending on the time of contact in the hot
zone, to several times their original length.

Properties of Acrylic Fibres

1. Acrylic has a warm and dry hand like wool. Its density is 1.17 g/cc as compared to
1.32 g/cc of wool. It is about 30% bulkier than wool. It has about 20% greater insulating
power than wool.

2. Acrylic has a moisture regain of 1.5-2% at 65% RH and 70 deg F.

3. It has a tenacity of 5 gpd in dry state and 4-8 gpd in wet state.
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4. Breaking elongation is 15% ( both states)

5. It has a elastic recovery of 85% after 4% extension when the load is released
immediately.

6. It has a good thermal stability. When exposed to temperatures above 175 deg C for
prolonged periods some discolouration takes place.

7. Acrylic shrinks by about 1.5% when treated with boiling water for 30 min.

8. It has a good resistance to mineral acids. The resistance to weak alkalies is fairly
good, while hot strong alkalies rapidly attack acrylic.

9. Moths, Mildew and insects do not attack Acrylic.

10. It has an outstanding stability towards commonly bleaching agents.

Uses

1. Knit Jersey, Sweater, blankets

2. Wrinkle resistant fabrics.
3. Pile and Fleece fabrics
4. Carpets and rugs.

Manufacturing Process and Properties of Nylon 6,6

Properties of Nylon 6,6

Strength

The most outstanding property of nylon is its strength and elasticity. The tenacity varies
from 8.8-4.3 gpd while corresponding elongation at break varies from 18-45%. The wet
strength of nylon is 80-90% of its dry strength and the elongation at break increases by
5-30% on wetting.

Density: 1.14 g/cc

Elastic Recovery

When nylon yarn is stretched 1,2 and 4% with a load of 0.25 gpd for 30 seconds and

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then released the recovery after 60 seconds is 38, 63 and 73% respectively.

Moisture Regain

Nylon has a moisture regain of about 4% at 65% RH and 70 deg F.

Action of Light

Like other fibres, nylon undergoes degradation and weakens when exposed to lights.

Appearance

Nylon is dull and semi opaque before cold drawing, but on orientation its lustre is
greatly incresed. Delustering is done by adding TiO2 in the polymerisation mixture.

Action of Heat

Nylon melts at 262 deg C in an atmosphere of Nitrogen and at 250 deg C in air. When
a very hot iron is used for ironing nylon garments, sticking or even fusion may take
place. Therefore ironing should not be done above 180 deg C. Permanent set may be
applied to Nylon by heat setting with 25 psi pressure with saturated steam. The pleats
thus set remian on wearing and washing even in hot water.

Chemical Properties

Nylon is extremely stable chemically. For example dry cleaning solvents, alcohols,
aldehydes, ketones, ethers, hydrocarbons, chlorinated hydrocarbons, soaps and
synthetic detergents and water including sea water do not affect Nylon.

Also it has got a remarkable stability towards alkali.

Biological Properties

Nylon is not a nutrient for Mildew or bacteria and is not eaten up by moth larvae. But
they bite their way up when imprisoned in nylon cloth. It is harmless to human skin.

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Properties of Nylon 6

Properties of Nylon 6

Nylon 6 has certain advantages over Nylon 6,6,. Firstly the systheisi fo caprolectum is
easier than that of Hexamethylene Diamine and Adipic Acid. Therefore it is cheaper to
make Nylon 6 than Nylon6,6. Secondly Nylon 6 has greater affinity for acid dyes than
Nylon6,6,

Mechanical Properties

Density: 1.14 g/cc

Tenacity: Dry= 4.2-5.8 gpd, Wet=4.0-5.3 gpd
Elongation at Break--> Dry = 24-40, Wet=28-43
Elastic Recovery at 4% extension= 100%
Moisture Regain= 4%
Because of low MR, wet nylon dries quickly.
Melting Point= 215 deg C ( Nylon 66-250 deg C)
It is weakened by prolonged exposure to sunlight.

Chemical Properties

1. It is resistant to most organic acids such as benzene, chloroform, acetone, esters

ethers etc.

2. It dissolves in phenol, cresol and strong mineral acids.

3. good resistant towards alkalies.

4. Resistant to inorganic acids

These fibres are cylinderical in shape, with smooth surfaces and without having any
markings. The fibres are unifrom in diameter and appear round in cross section.

Uses

a. Tyre Cord Manufacturing

b. Fishing Lines
c. Luxury Yachts
d. Stockings with good fit, sheerness, quick washing and drying properties.

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Manufacturing Process and Properties of PVA

Polyvinyl Alcohol Fibres

Polyvinyl alcohol (water soluble compound) can be described as a polyhydric, having

secondary alcoholic groups on alternate carbon atoms of an aliphatic macromolecule.

Because of the presence of a large number of hydroxy groups, in its molecular

structure, it is soluble in water. This is solublised in water by a treatment with
formaldehyde.

Manufacture of Polyvinyl Alcohol

1. Production of acetic acid from acetylene

For this purpose, limestone is calcinated to give quicklime (CaO) which is treated with
coke at elevated temperature to form calciium carbide. Acetylene is generated by
treating calcium carbide with water. A part of acetylene is converted into acetic acidby
combined hydration and oxidation.

Synthesis of Vinyl Acetate

The acetic acid formed in the above step is reacted with acetylene in the presence of
zinc acetate catalyst when vinyl acetate is formed.

Polymerisation of Vinyl Acetate

A solution of vinyl acetate in methanol is used for the polymerisation of vinyl acetate in
the presence of a peroxide or azo compound as a catalyst.

Conversion of PVAcetate into PVA

NaOH is added in PV Acetate solution in methanol, when alcoholysis of the acetate

groups takes place.

Spinning

The precipitated PVA as obtained in the preceding step is pressed and dried. It is then
dissolved in water to give a 15% solution of the polymer. This solution is extruded into a
spinning bath containing sulphuric acid ( 20%), Glauber's Salt ( 25%), formaldehyde
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(5%) and water (50%)

Properties

Shrinkage Properties: 10% at 220-230 deg C.

At 220 deg c, It begins to turn yellow and shrinks.

The fiber is inert to animal, vegetable and mineral oils and to most common organic
solvents.

It has good resistance to acids under normal conditions, Hot or concentrated mineral
acids cause swelling and shrinkage. Its resistance to alkali is generally good. Strong
alkalies cause yellowing without affecting the tenacity.

Fabrics made from this fibre do not get solied easily. They are easy to wash and quick
to dry. They have good crease retention.

Specific Gravity: 1.28

Staple Filament
Tenacity ( GPD)
Dry 3.8-6.2 6.0-8.5
Wet 3.2-5.0 5.0-7.6
Elongation at Break
Dry 13-26% 9-22%
Wet 14-27% 10-26%
Elastic Recovery 65-85% 70-90%
Moisture Regain 4.5-5% 3-5%

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What is the difference of Modal from Viscose
Modal is type of Rayon, however it is different from Viscose in many aspects.

Viscose fiber, is one of the most widely used man-made fiber as it is versatile ,
affordable and its properties resemble to cotton .However, ordinary viscose staple
fibers have low initial modulus i.e. they can be easily stretched under low load specially
in wet condition . It has poor elastic recovery and is very sensitive to the effect of
moisture.

Modal fiber, introduced in the year 1930 seems to be the right answer to these
disadvantages. Modal as defined by the International Bureau for Standardization of
Manmade Fibers (BISFA) is a distinct viscose rayon fibre genre, which has a higher wet
modulus and satisfies a minimum value of tenacity in the wet stage at 5% elongation.

Modal has number of advantages over viscose fiber and mercerised Cotton.

1. Modal posses lower elongation and higher wet modulus as it has higher rate of
polymerization than viscose.

2. Its exceptional similarity to cotton and silk in terms of texture (luster, sheen and
gloss) results in a surface smoother than mercerized cotton .

3. It can be blended with almost all textile fibres, viz. cotton, wool, silk and other
synthetic fibers.

4. Modal displays high dimensional stability, both for low shrinkage and low
unrecoverable extension.

5. It is more hygroscopic in nature than cotton i.e. absorbs 50% more water than cotton,
has more tensile strength with excellent wear resistance and is less likely to form pills
as a result of friction.

6. Modal is also resistant to wear and strong while maintaining a soft, silky feel. Modal
fibres have found a wide variety of uses in clothing, outwear and household furnishings.

7. Textiles made from modal fibres do not fibrillate, or pill, like cotton does and are
resistant to shrinkage and fading.

8. It causes reduced growth of bacteria when compared to cotton, if both stored for the
same period of time and it age like cotton. Today, Modal is widely used in clothing as a
replacement for cotton or mercerized cotton and viscose. (Source)

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