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J.

of Supercritical Fluids 66 (2012) 291–296

Contents lists available at SciVerse ScienceDirect

The Journal of Supercritical Fluids


journal homepage: www.elsevier.com/locate/supflu

Free of water tanning using CO2 as process additive—An overview on the process
development
Renner Manfred ∗ , Weidner Eckhard, Jochems Björn, Geihsler Helmut
Fraunhofer Institute UMSICHT, Osterfelder Str. 3, 46047 Oberhausen, Germany

a r t i c l e i n f o a b s t r a c t

Article history: Leather is a product traded worldwide. The majority of leathers are cattle skins tanned by using
Received 2 November 2011 chromium-III salt, which are in the focus of this work. The article describes the shortening of tanning
Received in revised form 16 January 2012 time by using compressed carbon dioxide as process additive from 30 to 5 h in lab-scale (63 mL auto-
Accepted 16 January 2012
clave). In pilot-scale (20 L autoclave) a tanning process practically free of wastewater is demonstrated.
Compared to conventional processes less chromium-III salt is used and the process time can be reduced to
Keywords:
2.5 h. Some underlying principles for the process intensification caused by carbon dioxide are described.
Free of water
The article concludes with first results from a demonstration plant of technical size with a volume of
Tanning
Animal skin
1700 L, which is able to tan a mass of up to 700 kg (>100 m2 ) per batch in a rotating drum.
Carbon dioxide © 2012 Elsevier B.V. All rights reserved.
Process intensification

1. Introduction energy for 3%. An overall amount of about 14 million m3 of wastew-


ater is generated worldwide. According to estimations the costs of
Tanning of leather is one of the oldest human technologies. In environmental protection measures in European tanneries account
100,000 B.C. the utilization of leather and fur allowed the Nean- for approx. 5% of their turnover [10].
derthals to survive in climatically not acceptable regions [1,2]. At The high amount of consumables and chemicals used illustrates
that time the animal hides were conserved by using smoke. Later, the enormous demand for an intensified and environmentally
humans chewed fats into the skin. In 2010 a 5500-year-old lace- friendly process. The high consumption of fresh water, mostly
up shoe tanned by vegetable tanning agents was found [3]. In 3000 drinking water, and the strong contamination of water strongly
B.C. the Egyptians imported aluminum salts over thousands of kilo- influence on the perception of leather as a “natural product”. The
meters for tanning for example loincloths of priests [4]. In 1858 new process principle described in the following combines advan-
tanning with chromium salts was developed by Knapp [5]. This tages of the conventional method, mainly high quality, with the
method revolutionized the tanning industry due to the high quality possibility of considerable savings in process time, chemicals and
of chromium tanned leather [6]. water.
Nowadays over 2000 km2 of leather are produced every year. To The following section provides a brief overview on the most rel-
produce this amount, about 7 million tons of skin, 500,000 tons of evant process steps of the conventional tanning process. Tanning
salt, 500,000 tons of chromium-III salt are needed. The turnover methods can be categorized into three groups regarding the tan-
of leather as an intermediate product is approx. US $45 billion. ning agents. It is possible to tan with metal salts like chromium
Approximately 90% of all leather is tanned by using chromium- and aluminum, vegetable tanning agents like quebracho and tara
III salt. After China the EU is the second largest producer in the and synthetic tanning agents like syntane. During the process the
world. Chinas production capacity has doubled since 1998 and was skin has to be prepared for an optimal absorption of the tanning
613 million m2 in 2006. In 2007 the European tanneries produced agent into the skin prior to cross-bonding between skin collagen
approx. 325 million m2 in 1650 tanneries with 26,000 employees and tanning agent [11–14].
[7–9].
Leather manufacturing is extremely intensive with respect to 1.1. Conventional tanning process
raw materials and work. The raw materials account for 50–70%
of the production costs, wages for 7–15%, chemicals for 10% and For conservation purposes, skins are usually salted and dried
for the transport to tanneries or they are transported in chilled
or frozen form. In a tannery, the skins are washed and softened
∗ Corresponding author. Tel.: +49 208 8598 1411; fax: +49 208 8598 1424. at the beginning of the production cycle by washing out salt
E-mail address: manfred.renner@umsicht.fraunhofer.de (R. Manfred). and adjusting moisture. This so-called softening is carried out at

0896-8446/$ – see front matter © 2012 Elsevier B.V. All rights reserved.
doi:10.1016/j.supflu.2012.01.007
292 R. Manfred et al. / J. of Supercritical Fluids 66 (2012) 291–296

equipment described in Section 2.4. In initial experiments, a surplus


of tanning solution was applied, similar to conventional tanning.
The dependency of chromium content and shrinkage temperature
from the time of tanning and pressure was investigated.
In the course of the development an optimized method was
found, where the amount of water was minimized, resulting in a
process practically free of wastewater. For that purpose a part of
the water present in the skin after the pickling step was removed.
This water was replaced by tanning solution 2. The skin thus pre-
treated was introduced into high pressure equipment and treated
under different pressures at varying contact times. The quality was
assessed either by measuring the chromium content and/or shrink-
age temperature.
For both procedures it was found that leather of very high quality
can be obtained at a drastically reduced time of contact by carrying
out the tanning step above a certain pressure of CO2 . Additionally,
wastewater, containing chromium can be reduced to almost zero.

2. Materials and methods

2.1. Tanning solution

Similar to conventional tanning, chromium-III salt was used as


Fig. 1. Chromium complex bound to skin collagen [25].
tanning agent for all experiments. The tanning solution consisted
of water, chromium-III salt, salt, formic and sulfuric acid. In the
pH-values of 7–9. In the next step, the liming – i.e. the fatty top tanning industry all weights are related to the weight of the wet
skin – is destroyed and the hair is removed from the skin by adding skin before the tanning step (example: 150 g water on 100 g wet
lime and sulfur compounds. Proteins are washed out and breaking skin means 1:1.5).
of polypeptide groups leads to higher fibre mobility. During lim-
ing collagen is “exposed” and the penetration of tanning agents 2.1.1. Tanning solution 1
into the skin is facilitated. The high alkalinity of the lime (pH > 10) Tanning solution 1 consisted of 1:10 water, 1:0.09 chromium-
is strongly reduced for the next working step, the pickling pro- III salt (Baychrom F), 1:0.005 formic acid, 1:0.008 sulfuric acid and
cess. This is essential because the skin swells at high pH values and 1:0.12 sodium chloride. That means that a mass of wet skin of 1 kg
swelling can lead to the destruction of collagen chains. During the is contacted with 10 kg of water, 0.09 kg of Baychrom F, 0.005 kg of
pickle, the skin is prepared for the tanning process at a pH value formic acid, 0.008 kg of sulfuric acid and 0.12 kg of salt.
of 2.5 (8–20 h). Lime residues are thus neutralized and removed
and the diffusion capability for the tanning agents is increased fur- 2.1.2. Tanning solution 2
ther [15]. The next step is tanning, taking place in rotating tanning Tanning solution 2 consisted of 1:0.3 water (previously removed
drums over a period of 12–20 h. The skins are brought into intensive from the wet skin), 1:0.05 chromium-III salt (Baychrom F), 1:0.0003
contact with liquid containing a tanning agent, usually a solution formic acid and 1:0.0003 sulfuric acid. That means that from 1 kg
of water and chromium-III salts. During this stage, the pH value is mass of wet skin a mass of 0.3 kg of water is removed and replaced
adjusted from 2.5 at the beginning of the process to 3.8 at the end of by 0.3 kg of water, 0.09 kg of Baychrom F, 0.0003 kg of formic acid
the process [16–18]. This permits optimum penetration of the tan- and 0.0003 kg of sulfuric acid.
ning agent at a low pH value and by steadily raising the pH value the
tanning agent bonds with the reactive groups of the skin collagen, 2.2. Skin
the carboxyl groups [19,20]. This complexation is shown in Fig. 1.
If chromium interlinks collagen molecules via chemical bonds this An average cattle skin has a surface area of 7–9 m2 . It is divided
results in a high mechanical strength and cooking stability of the into several parts. The part with the highest quality and the most
leather [23]. The tanning can be called successful if 3.8 to 5% of regular structure is the so-called “croupon”. The neck (described
Cr2 O3 by weight are absorbed in the leather [21]. This concentra- in Sections 3.1 and 3.2) and the croupon (described in Section 3.3)
tion is used as a first criterion, comparatively easy to monitor, to were taken for this work. The neck had a thickness of 2–2.4 mm and
define high leather quality for trials on laboratory scale [22]. Due to the croupon one of 2.6–3 mm. Both were obtained by splitting the
its color, the intermediate product generated in this step is called whole skin with a band knife. The neck was taken as one part per
“wet-blue”. Subsequently finishing wet blue with colors, oils and trial (area of about 0.25 m2 ). The croupon was divided into 5 parts
specific chemicals brings about different forms of appearance like (with an area of about 0.2 m2 per part). For the experiments shown
smooth leather for clothes, stiff leather for shoes or soft leathers for in Section 3.3 the parts 1–5 (see Fig. 2) were divided further into 4
furniture [17,24]. equally sized parts.

1.2. CO2 -intensified tanning process 2.3. Quality assessment

The basic idea of the new process is to carry out the tanning step Chromium tanned leather has to be resistant against boil-
under the pressure of CO2 . Limed and pickled skins were provided ing water without degeneration of the collagenous structure. As
by a tannery as a whole or in parts as described in Section 2.2. The cooking stability is most commonly used in industry, the quality
skins were put into contact with either of two tanning solutions assessment of wet-blue in this work was carried out by measuring
(Section 2.1). For comparison the tanning was performed at ambi- the shrinkage temperature. This criterion was assessed by using the
ent pressure and at elevated pressures in a CO2 -atmosphere in the equipment shown in Fig. 3. After the tanning process a defined part
R. Manfred et al. / J. of Supercritical Fluids 66 (2012) 291–296 293

Fig. 5. Reduction of process time using CO2 as process intensifier in lab-scale [26].

horizontal autoclave was used for stirring the tanning solution at a


speed of 40 rpm.
Fig. 2. Parts of cattle skin.
2.4.2. 20 L high pressure tanning bin
The PLC-controlled “pilot-scale plant” was especially build for
high pressure tanning. Inside the horizontal autoclave a rotatable
cage can be used for tanning comparable to industrial procedures.
In order to ensure that the skin moves around continuously inside
the cage some metal pins were screwed in vertically. The motion is
relevant for mass transport and regularity of the chromium distri-
bution. The maximum working parameters were 32 MPa, 80 ◦ C and
20 rpm.

2.4.3. 1700 L high pressure tanning bin


To carry out test series in preindustrial scale a “demonstration
Fig. 3. Measurement of shrinkage temperature. plant” with a volume of 1700 L was build. The autoclave is also
positioned horizontally. A mass of up to 700 kg (>100 m2 leather)
of the leather was punched out. This sample was placed firmly with can be tanned per batch in a rotating drum. The design of the drum
an interlock on one side of the apparatus. The other side was con- is comparable to conventional pressure-less tanning bins. The use
nected by a yarn using a hook. A weight tightened the system. The of pins, mounted to the inner side of the rotating drum, intensifies
sample was subsequently submerged into water. The water was the motion of the skins and thus a good contact of gas and tanning
heated up until it boiled. When the leather sample shrinked at a agent. The equipment allows the feeding of tanning liquids against
temperature below 100 ◦ C the quality was not sufficient. pressures of up to 26 MPa.

2.4. High pressure equipment 3. Results

2.4.1. 63 mL high pressure view cell 3.1. Chromium tanning under CO2 -pressure as function of
A conventional high pressure cell was used for carrying out the pressure and contact time
experiments presented in Fig. 4. The autoclave has a volume of
63 mL and a maximum of 250 ◦ C and 35 MPa could be reached. A The results demonstrated in Fig. 5 (63 mL autoclave) and Fig. 6
height adjustable magnetic stirrer mounted in the middle of the (pilot-scale plant) were carried out comparable to conventional

Fig. 4. Left: lab-scale equipment; middle: 20 L pilot-scale plant; right: 1700 L demonstration plant.
294 R. Manfred et al. / J. of Supercritical Fluids 66 (2012) 291–296

Fig. 6. Process time using CO2 as process intensifier in pilot-scale. Fig. 7. Process time using CO2 at different pressures in pilot-scale.

Tanning those skins in our equipment without applying gas


processing using an aqueous phase as reservoir for the mass trans-
pressure, results in bad quality (not shown in Fig. 7).
port of chromium ions (tanning solution 1).
For carrying out experiments under pressure, the soaked skin
A detailed description of the processing is given by Renner et al.
was introduced into the pressure vessel and CO2 -pressure was
[26]. Fig. 5 shows the comparison of conventional processing and
built up in some minutes. During the high-pressure process the
processing under the influence of compressed carbon dioxide at
chromium ions diffuse to the reactive sites (carboxyl groups) of
10 MPa. The skin samples had a diameter of 2 cm. Mass ratios
the skin collagen. Fig. 7 shows the influence of pressure and time.
between skin and solution 1 were identical in all experiments. Dur-
The values for 10 MPa were taken from Fig. 6 and are used to com-
ing tanning each skin sample was tanned individually. The samples
pare the results obtained with solution 1 and solution 2. It can be
were wetted by the tanning solution, not submerged.
seen that the tanning time can be further reduced, even at lower
The quality of the leathers produced was assessed using emis-
pressures.
sion spectrometry, by measuring the reduction of the chromium
The trials carried out at 2 MPa of carbon dioxide pressure failed
content of the tanning solution during tanning. With 3 wt% of
to produce high leather quality. A threshold pressure could be iden-
chromium in skin (equal to 4 wt% of Cr2 O3 ) a high quality is reached.
tified at 3 MPa. At a time of 2 h at 3 MPa and at 5 MPa positive and
A shortening of process time from 30 to 5 h using carbon diox-
negative results were achieved, indicated by overlapping of plus
ide at 10 MPa could be proved. Chromium content and maximum
and minus in Fig. 7. As mentioned in Section 2.2 different parts of
uptake of 3.6 wt% chromium are comparable to industrial values
the skin have been tanned. Some parts were of high quality even
[27,28]. Similar observations in lab-scale have been published by
after 2 h, while others did not reach sufficient cooking stability.
other workgroups [29–31].
At such low times, variations in skin properties (pore distribution,
The results were transferred into pilot-scale. The skin samples
fiber compactness) are of relevance for the tanning results. At con-
weighted about 700–900 g. The tanning sessions were carried out
tact times of 2.5 h and beyond, all parts (either from croupon or
at the same tanning solution to hide mass ratios as in laboratory
neck) were of high quality.
scale. The basket rotation was set to 10 rpm and the hide was pulled
A wastewater reduction of more than 90% was achieved with
continuously through the tanning solution as is done in the conven-
this approach. With a conventional tanning process, approx.
tional process.
1–2 tons of chromium loaded water is generated during the pro-
Tanning sessions that produced high leather quality are shown
duction of one ton of leather. The new method produces less than
in the form of plus signs, and those that produced lower quality
10 kg of wastewater per ton of leather. The amount of chromium-III
in the form of minus signs. Fig. 6 shows that tanning time can be
salt used can be reduced by about 45%, the amount of sulfuric and
shortened to 2.5 h using 20 and 30 MPa and to 3 h using 10 MPa.
formic acid by about 95%.
The main focus of the investigation was on whether the shrinkage
The further reduced process time can be attributed to the greater
criterion of cooking stability was reached or not. It became apparent
surface area available for the diffusion of carbon dioxide. In the
that at 30 MPa, no significant reduction of the tanning time versus
approach applied in lab-scale experiments, lower parts of the hide
10 MPa can be achieved.
were immersed in the tanning solution, while the upper side was in
direct contact with CO2 . The gas could predominantly diffuse into
3.2. Tanning free of chromium contaminated wastewater the skin via the upper side. In pilot-scale, experiments (Fig. 6) with
“free-flowing tanning” solution 1 were performed. In difference to
One of the most important problems of the tanning industry is lab-scale, the skins were moved by means of the rotating drum, thus
the wastewater after the tanning step, which is highly charged with repeatedly exposing both upper and lower side of the skin surface
chromium and salt. The objective of the investigation presented in to CO2 . By this effect, the required contact time for a good quality
this section was the reduction of chemicals and chromium contam- was reduced from 5 h in lab-scale to 3 h in pilot scale. In a second
inated wastewater. The results shown in Fig. 7 were obtained in a approach, no free flowing liquid (tanning solution 2) was present in
modified process. the autoclave. The samples were moved mechanically. Due to the
The skins were partly dewetted mechanically before tanning. lack of free liquid, they have been in continuous contact with the
This removed mass was substituted by tanning solution 2, which gas phase. This method resulted in a further (slight) reduction of
was soaked up into the skin in 30 min. tanning time (3 h to 2.5 h). Even more important than time saving
R. Manfred et al. / J. of Supercritical Fluids 66 (2012) 291–296 295

polynucleate complexes diffusing into the skin, even a slight widen-


ing has a great influence on penetration. According to Nishad [39],
Covington [40] and Braeumer [41], penetration is not the time lim-
iting step, but most of the process time is taken by the diffusion
inside the collagen microfibrils [41]. The chromium complexes have
a size of about 0.75 nm and 1.29 nm [38]. The polynucleate com-
plexes have to diffuse between the fibrils for reaching reactive
binding sites [42]. The gap between the microfibrils is estimated
to be 1.4 nm [43]. The “diffusion tunnels” in the fibrils can take up a
length of several centimeters [44–47]. Having no (free) liquid phase
outside the leather CO2 can penetrate directly over the surface into
the skin. This way the mass transport is influenced positively.
First trials carried out at Fraunhofer UMSICHT using a demon-
stration plant (1700 L autoclave volume) with a rotating drum
showed very promising results. An area of over 100 m2 per batch
can be treated now. It was found that lower pressure than in pilot
scale resulted in very high leather quality, probably because of an
intensified flexing of the material. Flexing is improved from smaller
Fig. 8. Leather shrinkage by variation of pressure and time. to bigger skins which, due to their size and shape, are able to twist.
Torsion seems to improve the mass transport of tanning agents
is the avoidance of waste water and the reduction of the required and CO2 . This assumption is confirmed by know-how from con-
amount of chromium and salt by applying this modified tanning ventional tanning [48].
process. To sum up it can be noted that the newly introduced tanning
process bears a great potential for environmental protection. The
process time for tanning can be considerably reduced. Chromium
3.3. Influence of pressure using a minimum of chemicals for contaminated wastewater can be reduced by over 95%. Theoret-
different parts of skin ically, this could result in savings of 14 billion liters per year.
160,000 tons of chromium can be saved per year because now it
The aim of this investigation was to identify conditions for the is only necessary to use just as much chromium as is needed for
tanning of all parts of skin with varying cross sections and fiber producing high leather quality. Overdosing can be reduced con-
compactness. The ratio of masses was calculated as shown in Sec- siderably. This reduction of the tanning agent may lead to saving
tion 2.1.2. For each point in Fig. 8 four samples were produced and another 6 billion liters of water which would be necessary for the
assessed. The average weight of the samples was around 600 g. production of the chromium.
A process time of 2 h results in leathers with a shrinkage tem-
perature (TS ) between 86 and 92 ◦ C. For 30 and 4 MPa TS does not
increase above 93 ◦ C at a tanning of 4 h. Using 5 MPa TS can be Acknowledgments
increased from 95 to 97 ◦ C at a tanning time between 3 and 6 h.
A shrinkage temperature of 100 ◦ C can be obtained after 2.5 h and The authors would like to thank the German Ministry of Edu-
6 MPa for all investigated parts of the skin. All 20 samples showed cation and Research for the financial support. Furthermore, the
cooking stability. authors would like to thank Helmut Geihsler and the students Jan
Rech, Björn Jochems and Anna Oelbermann for their assistance with
4. Discussion and conclusions the investigations.

The results demonstrate the effectiveness of tanning, which is


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