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The effects of package dimensions, structure, and density on the flow of air and
water through yarn packages have been investigated. Packages are considered
as homogeneous porous bodies, and the experimental results are correlated by
theoretical relationships based on Darcy's law and the Kozeny-Carman equation.
The particular importance of variations in density and radius, which, under
some conditions, can cause relatively large variations it) permeability, is pointed
out.
INTRODUCTION
The fundamental problem of package processing, whether scouring,
bleaching, dyeing, or drying, is to ensure that the processing fluid penetrates
to all parts of every package, and is distributed as evenly as possible within
any one package and equally between one package and another. Ideally, a
number of identical packages are subjected to a common pressure head and
each receives the same flow of liquor and undergoes an identical processing.
In practice, however, packages vary to a greater or less extent in hardness and
size because of variations in tension and other factors in winding. These
variations are of major importance, since, in wet processes, hard dense
packages are less easily penetrated by the liquor than soft ones, and
diflFerences in flow rate can lead, for example, to shade differences in dyeing.
Similarly, differences in rates of drying can occur between packages when
hot air is circulated through them.
Several papers have been published in recent years concerning both the
practical and theoretical aspects of package processing. Armfield^ studied
the eflect of the rate of flow of a dye liquor through a package on the levelness,
and showed that the higher flow rates give better levelness. Boulton and
Crank^ have described a theoretical model of a yarn package and discussed
the level absorption of dye in such a package. They showed the importance
of the eflects of flow velocity, and the rate of strike and levelling properties
of the dyestufl". In a second paper^, results from practical experiments were
examined in the light of the theoretical model.
The uniform presentation of dye liquor to the textile material is of
obvious importance, and, in a previous paper, the present author® has
examined the difficulty of removing air trapped inside a package during the
wetting-out process. Hadfield and Lemin^^ have described the efl'ects of air,
present because of foaming, on the permeability of packages.
Very useful general information on the technology of package processing
has been presented by Whittaker^', who also reviewed the types of package
in general use and called attention to the care needed in their preparation.
Fox^° has summarized the major factors contributing to the production of
high-quality dyed yarn, and in particular discussed some of the faults that
can arise from unsatisfactory packages.
All these authors point out the importance of packages being uniformly
constructed and of nearly equal permeability. The purpose of this paper is
to describe the effect of the size, density, and structure of packages on their
permeability to fluids and thus to assess the relative importance of these
quantities in producing packages of equal permeability.
CHARACTER OF THE FLOW THROUGH PACKAGES
Before discussing further the effect of package properties on permeability,
it is necessary to determine whether the liquor-flow is streamline or turbulent.
Cotton Yarn Packages—Denton T229
Since the pressure drop needed to produce a given flow rate is proportional
to the flow rate only when the flow is streamline, the type of flow is easily
found by plotting flow rate against pressure drop. Typical curves for three
packages of different densities are shown in Fig. 1 for air-flow and in Fig. 2
for water-flow. These are substantially linear over the practical range and it
is concluded that the flow is, therefore, streamline.
10
Package Oenstty
8 \
u p= 0-4 5 g/cc
a.
Q
UJ
iX
3
5 10 15
FLOW RATE (iitres/min)
Fig. 1
The relation between air-flow rate and pressure drop (20s American cotton yarn)
THEORY
Darcy® found that the results of his experiments on the streamHne flow
of fluids through sand-filtration beds could be expressed in the form
-=^4. (1)
where R is the flow rate and \i the viscosity of the fluid, and P the pressure
drop across a bed of depth / and area A; R/P, the ratio of flow rate to
pressure drop, is the permeability of the bed; Ks, the constant of the equation,
is called the speciflc permeability and is independent, as far as is possible, of
the size and shape of the porous body and the nature and condition of the
flowing fluid. In more general terms, for bodies of any shape, the specific
permeability K, is related to the permeability K by the following equation:
D C
K = = AT ^'>\
p ^« „ ' v-i;
T230 21—The Permeability of Cross-wound
where 5 is a shape factor depending on the dimensions of the porous body
and the paths followed by the fluid through it. Since the flow with which we
are concerned is also streamline and a direct proportionality exists between
the pressure drop across the package and the flow rate through it, the
permeability can similarly be defined as the ratio offlowrate to pressure drop.
0-8
E 06
\
Package Density
10 15
FLOW RATE
Fig, 2
The relation between water-flow rate and pressure drop {20s American cotton yam)
5 = (3)
log
r,, To, and h being as shown in Fig. 3. Thus, if the permeability of such a cheese
be measured, its specific permeability can be calculated, and the effects of
wind, density, and yarn properties compared.
The above equations express the dependence of the permeability of
porous bodies on their dimensions and shape. The effect of the fine porous
structure of the materials making up the body will now be considered. The
various theories developed to explain the effect of the structure of the material
may be divided into two main groups. In the first, the capillary models
assume the pores of the medium to consist of fine capillary tubes of various
sizes in series and parallel, theflowthrough the medium as a whole depending
on the flow through the individual capillaries, in which the flow is governed
by Poiseuille's law or a similar expression. In the second group of theories,
the resistance to flow is assumed to be due to the drag on theflowingfluidof
the inside surface of the porous medium. Perhaps the best known of the
Cotton Yarn Packages—Denton T231
(1 -
in which e is the porosity of the porous body (the fractional volume available
to flow in unit volume of porous material), S^ the specific surface, or surface
area of the material making up the porous body in unit volume, g the
gravitational acceleration constant, and K^ another constant, usually known
as the Kozeny constant.
Fig. 3
the Rotameter flowmeter. Packages, mounted in the holder, the end faces
being covered to ensure radial flow, could be compressed to any desired
length. The pressure drop across the package was measured by means of a
vertical U-tube water manometer; when this was not sufficiently accurate, it
was replaced by an inclined tube.
Flowmeter — Manometer —
Comprejied
Air
*
u
Rickaqe
in holder
Reservoir
Needle i
valve
Fig. 4
The air-permeability apparatus
RESULTS
Preliminary Experiments
Experiments to determine the nature of the flow have already been
mentioned. Two further experiments were performed to check the application
of Darcy's law to packages: the first to determine the effect of the viscosity
of the flowing fluid and the second to confirm the effect of package radius
(equation (3)).
According to equation (2), the flow rate through a package is inversely
proportional to the fluid viscosity [i. This relationship has been investigated
in the case of a cheese of spun glass yarn, a variation in viscosity being
achieved by varying the temperature of the circulating water. Glass yam
was chosen for this experiment rather than cotton in order to avoid the
complication of having diflerent coeflicients of swelling of the yarn at dififerent
temperatures. The results obtained, shown in Fig. 5, confirm the linear
relationship between the package permeability and If
Cotton Yarn Packages—Denton T233
0
(poise)-1
Fig. 5
The efTect of viscosity on permeability in a package of spun glass yarn
3-0
. 2-0
cr
O
0
2-0 2-5
Fig. 6
The relation between package radius and air-permeability (20s American cotton yarn)
(5)
P 2nh r,
and the package density from the equation
M
(6)
M being the package mass. In Fig. 7, package density is plotted against
specific permeability. As the variation in specific permeability is very great
(roughly 100:1), it is convenient to plot on a logarithmic rather than a linear
scale.
It will be noticed that the specific permeability varied rapidly with
changing density. Varying wind, however, had little effect, points from any
Cotton Yarn Packages—Denton
particular wind being evenly distributed on both sides of the line. The
effect of wind may, however, be masked by the hairiness of cotton yarn, as
three is some evidence to suggest that permeability does vary a little with
wind in packages of continuous-filament yarn. In Fig. 8, the large number of
points of Fig. 7 have been reduced to manageable proportions by calculating
the 'centres of gravity' of groups of points in regions of change of package
density each of 0-02 g/cm^.
0-60
^ 0-50
I—
5 040
Q
UJ
O
030
020 I [ 1 I • I I I I I r 1 i I I I I f I I I I I t
10"'* 10"'
SPECIFIC PERMEABILITY
Fig. 7
The effect of package density on specific permeability (air) (16s American cotton yarn)
s = l - - ^ , (7)
CT being the yarn density or mass per unit length of the yarn divided by the
yarn cross-sectional area. Equation (4) can therefore be written
where q = p/a.
The plot of package density (p) against the logarithm of package permeability
is found to be nearly a straight line over a wide range of values of p. Now,
the function / = loge (1 — qY/q^ (see equation 8) has a similar property,
having a point of inflexion at 9 = 0-45, and being substantially linear for
0-3 < q < 0-6. The gradient of this function varies only between —9-9 and
— 11-0 over this range of q, the average value being —10-15. Hence the
effective yarn density a can be calculated directly from the gradient of the
loge Kg versus p curve, as:
d (logeK,) 1 g+ 2 10-15
dp a q(q ~ I) a ' ^
T236 21—The Permeability of Cross-wound
The effective yarn density a was calculated from the gradient of the
lower, linear, part of Fig. 7 by means of equation (10) and was found to be
0-59 g/cm^
By substituting this value of a in equation (7) and reading values of Kg
and p from the graph, gjK^So^ was calculated to have a value of 1 -42 x 10-^;
and, \^ Ko is assumed to have its usual value of 5, l/5,r is 7-25 x 10"^ cm^.
The effective diameter of the yarn, calculated from the density (a) and
the known mass per unit length (3-43 x 10"^ g/cm), was 2-72 x 10-^ -^ cm.
Direct measurement (projection method) gave the value 2-49 x 10~^ cm.
0-60
Kozeny-Carmon equation
Lord's curve
Electrical analoque
0-30
0-20 J—I t i
,-3
10"** • 10
SPECIFIC PERMEABILITY (K5)
Fig. 8
Relations between package density and air-permeability for flow around yarns (continuous
curve) and flow through yams (dotted curves)
For a perfectly smooth cyhndrical yarn, 1/5,, = djA, d being the yarn
diameter, but for a rough-surfaced yarn this must be written 1/5^ = flf/49,
9 being the roughness factor. From the values of l/S^- and d given above,
9 was calculated to be 2-5. Similar air-permeability measurements with
packages of a Courlene X3 monofilament (diameter 0-025 cm, circular cross-
section) and a continuous-filament Terylene yarn (50 denier (5-6 tex), 24
filaments) yielded values of roughness factor of 1-04 and 1-14, respectively,
in reasonable agreement with values estimated from yarn cross-sections
(1 and 1-2). The high roughness factor observed for the cotton yarn may
therefore be due to the hairy nature of its surface, as projecting fibres may
well change the pattern of flow around the yarns as well as increasing the
drag over the surface.
The curve K, = 1 42 x lO-^ (1-p/O-59)7(9/0-59)2 is shown plotted
in Fig. 8 (continuous line). The fit of the practical points is good over the
lower linear portion (p < 0-35 g/cm^), but, as the density is increased, the
practical observations show a considerably higher permeability than that
predicted by the theory. This theory is, however, concerned only with flow
round the yarns and assumes them to be completely impermeable.
Cotton Yarn Packages—Denton T237
Specific Permeability:-
0-50 Yarn Package Package
Count Density Density
0-25g/cc 0 45g/cc
5 3-1X10'^ 7 9x10*^
9 3-3 . 9-6 .
u 12 2-2 H 7-4
u 16 2-0 .. 8-9
0-40 20 1-4 .. 6-4
24 1-5 „ 7-2
30 1-1 « 6-6
LL)
o
< 0-30
0-20
tO^ 10 lO""
Fig. 9
The dependence of specific permeability (air) on yarn count
Table n
Nominal yam count (cotton
system) 30 24 20 16 12 9 5
Yam diameter (cm x 10~^) 1-97 234 2-50 290 3 26 3 98 5 40
The yarn swellings as deduced by this method were less than 15%, but
the permeability change was much greater than could be expected from this
result, the specific permeability (water) varying from about one-quarter to
one-sixth of the specific permeability (air) as the package density varied from
0-2 to 0-5 g/cm^. A calculation of roughness factor gave an average result of
4-7, but, as this figure is extraordinarily high, it seems probable that the water-
flow may have some influence on the package structure other than causing
Cotton Yarn Packages—Denton T239
yarn swelling. The greater drag forces occurring with water-flow may, for
example, be great enough to distort the yarns (thus increasing the specific
surface and constricting the flow channels) or to cause fibres from the yarn
surface to float into the inter-yarn spaces, thus reducing the efliective pore
sizes and again increasing the resistance to flow. Gassing of the yarn reduces
the hairiness, and is found in practice to increase package permeability.
specific PermeabHity:-
0-50
Yarn Package Package
Count Density Density
025g/cc 0 45 g/cc
5 5'4)(10'^ 1-2x10"^
o 9 6 7 . 1-5 »
12 4-2 1 '3
0-40
>- 16 64 1*6
20 3 3 . M .
Z 2-4 46 13 .
UJ 30 34 1-5 .
Q
0-30
U
0-20
,I . . 11
-5
to
-4
10- 3
SPECIFiC PERMEABILITY (water)
Fig. 10
The dependence of specific permeability (water) on yarn count
/s:
S9
\^ log
but, as a straight-line relation has been found to exist over the practical
range between the logarithm of the package specific permeability and the
package density, the above expression can be written
Inh
a e~Pp , (10)
log
T240 21—The Permeability of Cross-wound
where a and p are constants, p depending on the effective yarn density, and
a on the yarn density, type, and structure, p = 10-15/a (see equations 10
and 11) and, for the cotton yarns tested, varied between 14 and 18 for air,
and between 16 and 19 for water.
Package Density
Itf
0)
o
CO
LU
cC
LU
Q. P - 0-4 g/cc Yarn Count
... 5
• 9
U
UJ 12
a.
CO •16
10 = 0-5 g/cc
+ ••• 20
• - • . 24
0- -30
' I > • I • I
J ' • • •
r5
10
SPECIFIC PERMEABILITY (air)
Fig. II
Comparison of specific permeabilities for air and water
In addition, equation (7) gives the relation between the package mass,
size, and density.
From equations (6) and (10), the effect of any of the variables A, r^,, p, and
M on flow through the package can easily be calculated. The effect of a 1 %
increase in each of these variables is shown in Table III. Values, typical of
industrial packages, have been assumed as follows: r^ = 2 cm, r^ = l cm,
A = 15 cm, p = 17, p = 0-35 g/cm^, M = 740 g.
Table UI
Effect of Package Dimensions on Flow during Processing.
1% a change in
increase produces >- flow velocity
in of
with M and /•„ constant -6%
with /-„ and h constant -6%
with M and h constant
with P and M constant 1 /o
with 9 and h constant -1%
ro with M and h constant +ii°/(
h with P and constant 0%
h with P and M constant
h with M and constant +6%
M with P and constant 0%
M with and h constant
M with and h constant -6%
Catton Yarn Packages—Denton T241
Vijriation of Package Density
I The package density has a greater effect on the package permeability
than any of the other variables, and the control of package density during
\Viinding is of prime importance. This is particularly true of packages wet-
j/^^ocessed on rigid centres. When packages wound on compressible springs
are squeezed together on the dyeing stalk, the softer, less dense, packages are
compressed more than the hard, dense, ones. Though density variations
are thereby compensated for to some extent, they are not altogether
eliminated.
SUMMARY
The necessity for uniform packages of equal permeability at all stages
of package-processing is pointed out. The flow of both air and water through
packages is shown to be streamline at normal industrial flow rates. Darcy's
equation has been applied to a cylindrical package (i.e., a cheese) and the
relation between the pressure drop, the flow rate, and the dimensions of the
cheese has been experimentally verified.
At low package densities, the Kozeny-Carman equation is shown to
correlate the permeability of packages with their density satisfactorily, and
yarn diameters calculated from permeability measurements are shown to be
in reasonable agreement with those measured directly. At high package
densities, an appreciable proportion of the flowing fluid passes through the
yarns, and permeabilities approach those for uniform plugs of fibres.
The effects of variations in package dimensions, mass, and density on
package permeability are discussed, attention being drawn particularly to
the large variations in permeability that can be caused by relatively small
changes in package density.
T242 21—The Permeability of Cross-wound Cotton Yarn Packages—Denton
APPENDIX
Table IV
Effect of Package Radius on Permeability
Units: Package density (p), g/cm^; package permeability {K)., litres/min cm water gauge.
REFERENCES
^ W. Armfield. / . Soc. Dyers Col., 1947, 63, 381,
= W. Armfield, J. Boulton, and J. Crank. J. Soc. Dyers Col., 1956, 72, 278.
' J. Boulton and J. Crank. J. Soc. Dyers CoL, 1952, 68, 109.
* H. C Brinkman. Research, 1949, 2, 190.
* P. C. Carman. Trans. Instn Chem. Engrs, 1937, 15, 150; 1938, 16, 168.
* H. P. G. Darcy. Tes Fontaines Publiques de la Ville de Dijon\ Victor Delmont, Paris.
1856.
' M. J. Denton. Shirley Inst. Mem., 1959, 32, 27; or / . Text. Inst., 1959. 50, T521; and
Shirley Inst. Mem., 1963, 36, 61; or / . Text. Inst., 1963, 54, T406.
8 M. J. Denton. Shirley Inst. Mem., 1962, 35, 41; or 7. Text, Inst., 1962, 53, T477.
« S. L. Fowler and K. L. Hertel. / . Appl. Phys., 1940, 11, 496.
'" M. R. Fox. / . Soc. Dyers Col., 1962, 78, 393.
" H. R. Hadfield and D. R. Lemin. J. Soc. Dyers Col., 1961, 77, 198.
^2 J. Kozeny. Wasserkraft, Munch., 1927, 22, 67, 86.
^^ E. Lord. Shirley Inst. Mem., 1954, 27, 309; ox J. Text. Inst., 1955, 46, T191.
** A. A. Robertson and S. G. Mason. Pulp and Paper Mag. Canada, 1949, 50, 103.
1^ R. R. Sullivan. J. Appl. Phys., 1941, 12, 503.
'« R. R. Sullivan and K. L. Hertel. Text. Res., 1940, 11, 31.
" J. Whittaker. J. Soc. Dyers Col., 1961, 77, 690.
Cotton Silk and Man-Made Fibres Research Association,
Shirley Institute, Received 10.6.1963
Didsbury, Accepted for publication 1.10.1963
Manchester 20. Released for publication 6.12.1963