Challenges and Innovations in Technical Textiles

Professor A Mukhopadhyay
Department of Textile Technology,
National Institute of Technology, Jalandhar - 144011, India 1
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 Backstrap-weaving
Cotton hand-picking

Hand spinning

They have come a long way!

Where would you like to go today?

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Artificial Intelligence

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Life Science and Medicine

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Tension fabric structure made out of woven fibre glass fabric at Denever International
Airport
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Use of fibre reinforced composite in rocket motor and satellite antenna
 Through incidental
phenomena
(Newton’s Law)
Through
Invention through mimicking nature
experiment (aeroplane
mimicking bird)

Innovation/
Fundamental Invention
Invention through
through outcome
imagination
apparently failed
experiment

Through serendipity
(invention of bulb by
Through dream Thomas Edison,
(Structure of invention of steam
Benzene) engine)

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Invention through incidental
phenomena

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Archimedes’ principle, physical law of buoyancy
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Invention through mimicking nature

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Inventions Inspired by Nature
Velcro

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 Bio-mimics
Shark Skin Fabric

Fastskin LZR Racer® speed suit developed with the help of

NASA. The suite is constructed from Speedo’s unique LZR pulse
fabric, which is ultra lightweight, strong, water repellent, and fast
drying and woven from chlorine resistant elastane and ultra fine 25
Invention through imagination

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Invention through serendipity

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Invention through dream

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Invention through experiment

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Invention through apparently failed experiment
Quinine

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The chimpanzee genome has revealed a 95-99%
genetic similarity between human and chimpanzee
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DNA
 Cognitive domain
The cognitive domain involves the development of
our mental skills and the acquisition of knowledge.
The six categories under this domain are:

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 New names

• Some people have Knowledge- Remembering

renamed these levels to

make them easier to Comprehension-
Understanding
remember
Application- Applying

• Some people even

Analysis- Analyzing
switch the last two
levels around
Synthesis- Creating

Evaluation- Evaluation

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The test of our progress is not whether we
add more to the abundance of those who
have much; it is whether we provide enough
for those who have too little.
Franklin D. Roosevelt
Second Inaugural Address,
1937

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 Energy

Basic
Requirement

Food & Environment

Water

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Coronavirus Aerosol - Quick spread of pandemics is one of the
greatest risks of globalization
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Each SARS-CoV-2 virion is approximately 50–200 nm in
diameter

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 The most important application areas for technical textiles

1. Agrotech (Agriculture, horticulture and forestry)

2. Buildtech (building and construction)
3. Clothtech (technical components of shoes and clothing)
4. Geotech (geotextiles, civil engineering)
5. Hometech (components of furniture, household textiles and floor
coverings)
6. Indutech (filtration, cleaning and other industrial)
7. Medtech (hygiene and medical)
8. Mobiltech (automobiles, shipping, railways and aerospace)
9. Oekotech (environmental protection)
10. Packtech (packaging)
11. Protech (personal and property protection)
12. Sporttech (sport and leisure)
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Main applications of
Tech-Textiles

Agrotech
Sportech Buildtech

Protech Clothtech

Packtech
Technical Geotech
textiles
Oekotech Hometech

Mobiltech Indutech
Medtech

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Difference between technical and traditional textiles

• Application is quite different

• Performance requirement (e.g., failure of astronaut’s suit
during space walk could be fatal)
• Constituent materials (i.e., high performance material is
used in many cases)
• Manufacturing methods and equipment
• Testing (e.g., testing of geotextiles/filter fabric)
• Life expectancy (In some cases, it could be very high)
• Price
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Why use Technical Textiles?

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1. Material can offer several advantages simultaneously in the
same product that no other industrial product can provide

a. Porous yet strong

b. High flexibility, elongation and recovery

c. 2-D and 3-D structure with adjustable macro-structure

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Example- Material can offer several advantages simultaneously in the
same product that no other industrial product can provide

• Porous yet strong. Porosity

improved tissue infiltration and
growth.

• 3-D structure with adjustable

macro-structure.

• High flexibility, elongation and

recovery

• Biocompatibility (not carcinogenic)

• Bio-stability

• Muscle structure is similar to

braided textile structure

• High fatigue resistance 49

2. Ease of combining with other materials/products for
enhanced performance. For example; smart textiles,
geotextiles.

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Material Physical Characteristics

Metal Inherently Isotropic Non- Behaviour Limitation in

Nonporous Streachable not time structural
dependant maneuverability

Soil Inherently Isotropic Non- Behaviour Limitation in

Porous Streachable time structural
dependant maneuverability

Textile Inherently Anisotropic Streachability Creep and Wide scope in

Porous and recovery stress structural
relaxation maneuverability

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 Soil
Metal

Textile
Material

Low Low High Tensile

Low High High Compression

Low - High Bending

Modulus

Low - High Torsional

Low Low-Medium High Shear

High Low High Tensile

High High High Compression

High Low High Bending

Strength

High Low High Torsional

High Low High Shear

ainly Tensile Shear Many

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of
Mode

failure
Reinforced soil wall formed from sheet geotextiles
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3. There are numerous variables at the disposal of designer
which theoretically offer an infinite number of design
possibility

Filter for air conditioner Industrial fabric filter

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A. Variable fibre resistance against temperature, physical and chemical agents for filtration
Fibre material Maximum temperature Physical resistance Chemical resistance
(0C)

Oxidizing agent

Organic solvent

Relative price
Mineral acids

Organic acids
Under moist
Intermittent
Continuous

Moist heat

Hydrolysis
condition

Abrasion
Dry heat

Shaking

Flexing

Alkalis
Cotton 80 ― 80 G G F G G ― P G F F E ―
Wool 90 120 105 F F G F G ― F F P P F ―
Polyester 135 ― 100 G F G E E P G G F/G G E 1.0
Nylon 110 ― 100 G G E E E ― P F G F E ―
(polyamide)
Polyacrylic 125 ― 120 F F F P/F G G G G G G G 1.6
Polypropylene 90 120 90 G F E E G E E E E G G 1.0
Nomex 190 230 170 E E E E E F P/F E G G E 5.0
Teflon (PTFE) 260 290 260 E E P/F G G E E E E E E 15.0
Glass 260 315 260 E E P/F P/F F G E E G E E 2.5

Ryton 190 ― 150 E E G G G E G G G P E 5.0

(polyphenylen
e sulphide)
Polyimide P84 260 ― ― E ― G G G F G G F ― ― 6.0
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Ceramic 1150
E = Excellent, ― F = Fair,
G = Good, 1150P = Poor
E E ― ― ― E E E G E E ―
B. Variable fibre physical parameters such as fineness, and cross
sectional shape.

Fibre cross section

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C. 2-D and 3-D structure with adjustable macro-structure

Weaving 3D Technology 58
D. Biodegradability/non-biodegradability of fibre material

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Sutures

Both bio-degradable and non-biodgradable sutures are available. Life

time of suture can be varied based on application.

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E. Variable fibre mechanical properties such as tensile
strength, bending and flexural rigidity etc.

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F. Variable mode of assembling either in thread making or
fabric manufacturing

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4. High level of performance

Conversion to fabric filter from ESP 63

Uses of Technical Textiles

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 Agrotech

The textiles are used for various

agricultural applications.

 Ground cover
 Windbreak fences/shading
 Frost protection shades
 Bird nets
 Insect meshes
 Shade nets

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Sunscreen Net

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 Bird Protection Nets

Knitted monofilament net offer

effective protection of seeds,
crops and fruit against damage
caused by birds and a variety
of.

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 Wind Shields

Wind shields are used in

farming to reduce the velocity
of the wind and protect fruit
plantations from wind to avoid
damage to plants.

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 Plant Nets

These are the made from polyolefin

type of fibre. They are mainly used
for the tomato type of plant.
Fruits, which grow close to the
ground, can be kept away from the
damp soil by allowing them to
grow through vertical or row nets
in order to keep the amount of
decayed fruit to minimum

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Root Ball Nets

It is extremely important for

safe and speedy growing of
young plants that root system is
not damaged when they are
dug up, transported or
replanted. Normally the root
balls are wrapped in cloth.
Elastic net tubes are alternative
to this.

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 Insect Net

Clear, woven, and knitted, polyethylene

monofilament meshes to exclude
harmful insects from greenhouses and
tunnels, or to keep pollinating insects
inside. The fine woven screens protect
plants from insect attack (without the
use of insecticides).

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Mulch functioning

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AGRO MULCHES

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Packaging Material for Agro-products

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Hometech

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Clothtech

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 Buildtech

 Lightweight and massive construction

 Industrial building
 Temporary constructions
 Interior fittings etc.

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 Autotech

Air bags, seat cover, seat belts, CFRP

(Carbon Fibre Reinforced Plastics)
as essential part of the main
body structure

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Air Bags
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 Medtech

• Implantable textiles
• Non-implantable Textiles
• Extracorporeal Devices
• Health care and Hygiene textiles

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Implantable medical textiles
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Vascular graft
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 Tissue Engineering

Tissue engineering uses living cells and their extracellular

components with textile-based biomaterial scaffolds to develop
biological tissues for human body repair. The scaffolds provide
support for cellular attachment and subsequent controlled
proliferation into predefined tissue shapes.
Such an engineering approach would solve the severe shortage
problem associated with organ transplants. Textile-based scaffolds
have been used for such tissue engineering purposes. 84
The most frequently used textile-based scaffolds are non-woven structures,
preferably of biodegradable materials, because then there is no permanent foreign-
body tissue reaction toward the scaffolds and, over time, there is more volume space
into which the engineered tissue can grow. 85
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Artificial Heart Valve (Includes knitted fabric)

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Medical Textiles
Non-implantable Textiles

Wound dressing materials

Structure of various types of Bandages 90

Specialty wound care products

Tubular Finger Bandages

Elasticated Flat Bandage

Pressure Gloves Pressure Garments 91

Specialty wound care products

Foam Padded Arm Sling Elasticated Net Garment

Orthopaedic Casting Bandage 92

Extracorporeal Devices

Hemodialysis machine

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Health care and Hygiene textiles

Mask and Cap

Nonwoven disposables

Mask , Caps, Gowns and Drapes 94

 Mobiltech

Cars, ships, aircraft, trains, space travel etc.

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Structure of Tire Cord

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 0ekotech

Environmental protection, recycling,

waste disposal

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 Packtech
Packaging, protective cover systems, sacks, big bags, container
systems

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 Protech
Person and property protection, bulletproof jackets

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Classification of Protective Textiles

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Garment at high altitude 104
Body Armours
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Parachutes

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Components of Space Suit
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 Sporttech
Sports and leisure, active wear, outdoor, sport articles+ equipment,
sports shoes etc.

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 TEXTILES IN SPORTS
Sports foot Sports
Sports wear
wear Sports turf equipment

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Synthetic leather in sport shoes

Segment-Pie: Splitting by Carding

Card-splittable fiber before splitting Card-splittable fiber after carding

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Evolon… The Next Generation

Increased Surface Area

Evolon is a
newly patented,
award winning method for
manufacturing

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300 Islands-in-the-sea As-spun Fiber
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Synthetic leather composed of spunlaced splittable fibers

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Skis and Snowboards

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 Geotech
Road, waste dump construction and erosion control

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Common problems without the use of geotextiles

Crack

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Rutting

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Post-Construction

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Geotextile under railway track
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Construction of railway track
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Geotextile for Drainage

Use of geotextile for in-plane drainage

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Liner for pond
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Lining of Dry Gypsum Pond, Coromandal Fertilizers Ltd., Vishakapatnam
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Landfill site
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Reinforcement, Vishakapatnam Airport, Andhra Pradesh 131
Erosion control

Before After
Erosion Control Mat (Mahanadi Coal Fields, Talcher, Orissa)
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Control of soil erosion 133
 Polymer Rope Gabions

Revetment - Anti Erosion Sea Bund Morbhagwa, Gujarat, India

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Shore Erosion - Swaminarayan Temple, Gujarat, India

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Geotextile Material for Coastal Protection
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Geotextile Bags for Coastal Protection 137
Geotextile for embankment control
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Erection of mud wall reinforced with thickly woven coir geotextiles

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Retaining structure: Geotextiles offer relevant advantages compared to
traditional methods, for example:
- An easy and speedy construction process
- Ability to use on-site backfill material
- The development of flexible and large load-carrying capacity structures

- A substantial reduction in costs if compared to traditional walls and to

the use of Geo-grids.
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Geotubes as Geocomposite

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Large Geotube® containers can be used to reduce the volume of disposed,
dredged materials and to contain the contaminants. Geotube® engineered
textiles allow for the dewatering of dredged spoils on-site, while allowing at least
a 50% volume reduction.
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Geotubes used in artificial Island projects
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Geo-tube for embankment control 144
After installation - During High Tide

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Geotextile tubes were placed on the seafloor, creating a “surf reef” off
the south coast of England. This artificial reef had two objectives:
stabilizing beach nourishment and improving surfing conditions. 146
Indutech

Conveyor belt

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Cross section of conveyor belt
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Power transmission belt Filter fabric

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Background

Haze in the Environment

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The concentration of fine particles in Finland is less
6 μg/m3, which is less than the lowest level on the
globe.

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 Deaths due to Pollution

According to WHO’s latest report

In the world around,
• 4.2 million deaths every year as a result of exposure to ambient (outdoor)
air pollution
• 3.8 million deaths every year as a result of household exposure to smoke
from dirty cookstoves and fuels.
• 91%of the world’s population lives in places where air quality exceeds
WHO guideline limits.
15 of the world’s 20 most-polluted cities are in India

In India
• Around 12.4 lakh deaths were recorded in 2017, said a report
published by Indian Council of Medical Research (ICMR), Public
Health Foundation of India (PHFI), Ministry of Health and Family
Welfare and The Lancet. 152
 Impact on Health

Lungs are anatomically structured to bring large quantities of air

(on average, 400 million litres in a lifetime) into intimate contact
with the blood system, to facilitate the delivery of oxygen.

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Occupational Hazards / diseases due to expose industry and
polluted air

Silicosis (Silico-tuberculosis) Asbestosis

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Health Effect

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Application of Ventilation and other Atmospheric Air filters
[In many cases High Efficiency Particulate Air (HEPA) filter are used.]

• Pharmaceutical
• Bio technology
• Chemical industry
• Nuclear air ventilation
• Medical industry
• Food industry
• Automotive industry
• Nanomaterials
• Space industry
• Military equipment
• Power and energy plants
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 Air Contaminants

Pesticides Diesel Soot Virus Tobacco smoke Radioactive Bacteria Atmospheric Coal dust Pollen Carbon black Beach sand
(0.001 m) (0.01-0.1 (0.005-0.3 (0.01-4 µm) fallout (0.5-10 Dust (1-100 (10-1000 (20-10000 (100-10000 µm)
m) µm) (0.1-10 µm) µm) (0.001-30 µm) µm) m)
m)

Filtration Strategies
REVERSE
OSMOSIS ULTRA FILTRATION PARTICLE FILTRATION

NANO FILTRATION MICRO FILTRATION

Ionic Molecular Macromolecular Micro-particle Macro-particle
0.001 0.01 0.1 1 10 100 1000 10000

Chemical Capture Mechanical Capture and Electrostatic

Capture

Applications

Facemask Respirator Vacuum cleaner filter AC filter 157

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Cleanroom 158
Semiconductor Cleanroom
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Cleanroom for Tissue Culture
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Cleanroom for operation Theater
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In Aerospace

Dispersion of Microbial Aerosols in Passenger Cabins - Effect of

Different Filter Efficiencies 162
Cleanroom Classification

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Classification of depth-loading filters according to EN 779 and EN 1822 164
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Electric Car

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 Gas-borne dust particles, typically in the range of 0.1 – 25
μm may be collected by out of the several techniques, viz.,
• Settling chambers
• Cyclones
• Industrial separators (other than cyclones)
• Electrostatic precipitator
• Fabric filters
• Scrubbers or wet collectors
Arguably the most efficient and versatile is the fabric
collector, especially when processing very fine particles,
which are slow to settle and by virtue of their greater light
scatter, more visible to the naked eye.

The world market for fabric filters and bags to remove pollutants
from stack gases will grow modestly to reach $10 billion by 2015,
up from $8.3 billion in 2010.
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A typical set-up for industrial bag filter unit (developed by Hamon
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Research-Cottrell, USA).
Industrial bag filter unit
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ePTFE Membrane Filters
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Modern manufacturing facilities contain equipment, such as machines for welding, grinding and
cutting, along with CNC machine tools for turning, grinding and milling for example, that give off
oil mist in the production environment when operating.

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Performance numbers were:
• Average inlet: 28.3 mg/m³
• Average outlet: 0.001 mg/m³
• Efficiency: 99.999%
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 Control Vs Prevention

Alternative Fuels and Raw Materials

Reduces or eliminates the hazardous materials that enter the
production process. It reduces waste treatment costs.
The use of low volatile coals in place of high volatile
coals has proved most effective in eliminating smoke and
the substitution of low sulfur fuels for high sulfur fuels has
reduced the SO2 discharges quite appreciably.

Use of gaseous fuel (LNG) which are low-ash fossil fuels

contain less noncombustible, ash-forming mineral matter
and thus generate lower levels of particulate emissions.
Use of biomass as fuel
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Waste segregation and disposal

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Use as a source of energy/raw material

Waste heat boiler from municipal and medical waste incinerator

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Why Garbage Incinerators Are A Bad Deal
For Communities?
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Geosynthetics Clay Liner

GCLs can withstand shear stresses on steep slopes. GCLs contain sodium
bentonite, which is a naturally occurring clay with a high affinity for water.
When hydrated, sodium bentonite swells up to 15 times its original volume.
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 Fabric Filters in Liquid Filtration

Filtration of aqueous fluids

1. Water treatment plants

2. Water desalinization
3. Water discharge treatment plants
4. Industrial process streams
5. Industrial chemicals
6. Drinking water filtration
7. Beverage filtration
8. Filtration of aqueous foods (Sugars, Food processing plants)
9. Medical filtration applications (Blood filters, Vent filters,
Contamination barriers)
10. Pharmaceutical applications
11. Swimming pool filters 181
Filtration of hydrocarbon fluids

1. Industrial hydrocarbon processing (Petrochemicals, Resins

(solvent base), Lacquers)
2. Aviation and diesel fuel filtration
3. Hydraulic fluids
4. Machine tool coolant and cutting oil filtration
5. Edible oil filtration
6. Engine filtration

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Filtration for Purity of product in Pharmaceutical Industry
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Vacuum Filtration

Rotary Drum Filters Horizontal Belt Filters Vertical Disc Filters

Horizontal Pan Filters 184

Pressure Filtration

Filter Presses Pressure Leaf Filters Candle Filters

Vertical Belt Presses Dual Belt Presses

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Emergence of New Materials

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Development stage for functional fibers for next generation
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Application of Spacer fabric

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Fibers from Bovine skin (Collagen fibre)

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Source of Chitin fibre
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Fibres can be extracted from seaweeds (Alginate fibre)

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 COMPOSITE NONWOVENS

Why Composites ?
 Economical solution:

Eliminate steps

One product replaces two or more

 Best technical solution –Engineered

solution

 Profit improvement

Specialized solution
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.
For textiles, the definitive definition of composites given by
Textile Terms and Definitions is as follows: A product formed by
intimately combining two or more discrete physical phases,
usually a solid matrix and a fibrous material.

Types of Nonwoven Composite

• Multi fiber composite nonwoven
• Multi filament composite nonwoven
• Combined fiber and filament composite nonwoven
• Particulate composite nonwoven
• Hybrid composite nonwoven
• Multi formed composite nonwoven
• Multi bonded composite nonwoven
• Laminated composite nonwoven 194
 Multi fiber composite Multi filament composite
nonwoven nonwoven

Combined fiber and filament Particulate composite

composite nonwoven nonwoven

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Hybrid composite nonwoven Multi formed composite
nonwoven

Multi bonded composite Laminated composite

nonwoven nonwoven
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 HydrotubeTM Technology

HydroTube™ fabrics are lightweight hydroentangled (spunlaced) fabrics which

are produced as continuous seamless tubes. The tube diameter can be varied
and the interior can be either left hollow or filled with gels, waxes, cosmetics,
detergents and solid particles to functionalise the fabric as the tube is formed.
Potential applications include reinforced hoses and pipes, electronics,
telecommunications, protective seals and medical dressings.

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Nonwoven Innovation & Research Institute
 Flushable Wipes – How They Works ?
HYDRASPUN®
Suominen’s Hydraspun is composed of about
78% wood pulp, 20% Tencel and 2% bicomponent
fiber, formed as a wetlaid web and then
hydroentangled. The Tencel fiber is cut to a shorter
length than is usual for spunlace fibers; this allows
some entangling to boost wet strength enough for
use, but since so few of these fibers are used, they
form very small, and relatively loosely bonded
agglomerates of fibers. This combination of
relatively short fiber hydroentangling, coupled with
very low-level thermal bonding, provides enough in
use strength for current flushable wipes with
enough dispersibility for most waste treatment
systems. 198
 Nonwoven Abrasives

Advantages -
Nonwoven abrasives are highly conformable.
The abrasive grains are distributed evenly through the product, ensuring a
consistent cut and finish throughout its life.
Open structure reduces clogging significantly.
Nonwoven abrasives can be used wet, dry, with solvents or with cutting fluids

199
 Responsive Filtration Systems

microns
chemical forces mechanical and electro-static
Fiber size in filter

Example materials
of interest

Impaction
. Brownian
Interception
Impaction
diffusion Brownian diffusion
Prion
SARS Herpesvirus Corynebacterium
H2O
10nm
80 nm 150 nm Diphtheria 400nm
Interception
Rhino-
0.26 nm Diesel Soot Poxvirus-Variola Streptococcus Impaction
virus 25 nm
100-150 nm (small pox) 200nm pneumonia 800nm 200
SENSING RESPIRATOR

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Bio-mimics

Bio-mimics: lotus leaf and textile fabric (Lotus leaf consists of waxy surface with many tiny
micron (10-6) size papillae, which in turn covered with hair like tubes made of wax crystals
around 1 nm in diameter.
Biomimetics is the mimicking of biological mechanisms, with modification, to produce202
useful artificial items.
 Bio-mimics
Dirt Repellant Fabric

Dirt repellency also found naturally in the wings of butterflies and dragonflies.
The surface is hydrophobic in nature and has a rough surface under
microscopic observation. This nanoscpoic rough surface repels water and
effectively cleans dirt during the rainfall compare to the smooth hydrophobic
surface

203
Optical Colouring Fiber fabric Bio-mimics

It is interesting to know that the coloration of butterfly wings doesn’t only come
from pigmentation, but also from the structure of the wing scales, which is called
as structural color. This nanolayer is in a pattern of mosaic tiles, where each tile of
pattern has different structural features as well as tiny gap among them for light
refraction. Teijin Fibers Limited of Japan produces a new monofilament named
Morphotex®, a first optical coloring fiber, that mimics morpho butterfly wings, by
using interference to produce color without pigments or dyes. Teijin claimed that
Morphotex has wide applications, e. g. filament, short-cut fiber and powdery
204
materials and could be a renewable source for solar textile.
Wearable Electronics

206
207
• Soft, flexible and portable keyboard comprising entirely fabric components orientated at
90° to each other which become conductive under pressure. Switches and buttons can
therefore be incorporated into clothing as the technology is claimed to be washable.
208
 Wheelchair blanket - a surface comprising thousands of small
switches which are pressure sensitive, enabling a range of potential
medical applications such as pressure sore
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 Biosensor for wound healing

Bandage Tell If Wound is Healing: The bandage covering that cut on your foot could soon tell
you if the wound is healing or becoming infected. Materials scientists in Australia have created
a "smart bandage" from a fiber made of liquid crystals. The fiber changes from red to blue
depending upon the temperature of the wound. Developed mainly to help people with
diabetes who suffer from chronic wounds, bandages and dressings made from the new fiber
could dramatically improve wound care by early detection of recurring infections and 213
inflammation.
214
A new in-shoe device is designed to harvest the energy that is created by walking,
215
and store it for use in mobile electronic devices.
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Challenges and Innovations

219
Body armour

Dragon skin body armour 220

Ballistic Requirements

Physical requirements for military textiles

221
 Sportswear

Functional requirement: Sweat absorption, fast drying,

high tenacity 222
Functional requirement: Low fluid resistance, stretch-abality

223
 Bio-mimics
Shark Skin Fabric

Fastskin LZR Racer® speed suit developed with the help of NASA. The
suite is constructed from Speedo’s unique LZR pulse fabric, which is ultra
lightweight, strong, water repellent, and fast drying and woven from
chlorine resistant elastane and ultra fine nylon yarn. 224
Intelligent compression sportswear
The development of their woven “intelligent compression” fabrics for
swimwear like POWERSKIN Carbon Pro, the first racing suit integrating a
carbon cage to deliver intelligent muscle compression, combined with
unprecedented fit.

225
Functional requirement: Vapour permeability, water proofing, low air resistance, sunlight absorbing and thermal retention

226
 PTFE microporous film Surface of a typical porometric film
(Magnification 500 times) or coating showing the micropores

227
Types of laminates: (a) outer fabric laminate, (b) insert laminate (c) lining laminate, (d) three layer laminate,
(1) outer fabric, (2) breathable film, (3) insert fabric, and (4) lining material.
228
Hot melt coating with engraved roller 229
 COMPOSITE NONWOVENS
3 Layer Composite Fiber –Pulp - Fiber

a. Highly absorbent b. Lower cost

c. Improved appearance d. Softness improved 230
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Super absorbent textiles for Filtration – water extraction

Key application areas:

Aviation – water and particulate removal from aviation fuel
Automotive – water and particulate removal from diesel
Oil – water and particulate removal from wide range of oils and waste oils.

232
 Super absorbent textiles for managing fire (Temperature 500 OF)

The SAF technology simulates the dissipation of heat and moisture through the
absorption and containment of body sweat and affords the wearer a cooling effect –
directly reducing the risk of heat-stress. The fabric is designed for rapid uptakes of
sweat absorption and wick-ability. 233
Application of Geotextiles

Geosythetics clay liners (GCL): These are products manufactured

with bentonite clay placed between two geotextiles. Bonding
method: Needle-punched polymers coated/adhesive bonding.
GCLs can withstand shear stresses on steep slopes. GCLs
contain sodium bentonite, which is a naturally occurring clay
with a high affinity for water. When hydrated, sodium bentonite
swells up to 15 times its original volume.

234
Major steps of the manufacturing process for needle-punched and stitch –bonded
geosysnthetics clay liner

235
HVAC Application

Composition of the composite media HVAC 236

237
Nonwoven filter medium with activated carbon for gas adsorption (REM)238
PLEKX® adsorption medium wherein an activated carbon layer sandwiched between two
nonwoven layers 239
Purafil Triple-Blend Media removes the widest variety of odors and gases from applications where jet fuel fumes, diesel exhaust and automobile emissions are present. The Purafil
chemisorptive process remove contaminant gases by means of adsorption, absorption, and chemical reaction. Gases shall be trapped within the pellet where oxidation changes the 240gases
into harmless solids, eliminating the possibility of desorption. Purafil Triple-Blend Makeup Air Media shall be designed for 95% min. removal efficiency in Purafil systems.
A filter with higher airflow resistance requires more energy
consumption to push air through the filter. 241
242
Hydroentangled composite HYCOSPUN® - spunbond nonwoven with a meltblown fine fibre inside
243
layer
Filter with activated carbon for HVAC application
244
PLEKX® adsorption medium wherein an activated carbon layer sandwiched between
two nonwoven layers
245
246
247
248
249
Challenges to Industrial Gas Filter

Maximum
Minimum Power Particulate
Consumption Capture Efficiency

Challenges for
Pulse Jet
Filtration System

High Filter Media

Life
250
1. Efficient filtration of fine particles
Requirement for lower PM2.5 emission which necessitate compact fabric, whereas it will also lead
to higher differential pressure.

Low air
More compact High
fabric, use of filtration permeability,
fine fibres efficiency More energy

251
Industrial Filter Media

Use of membrane or coating at the upstream side of fabric. Due to the

extreme thickness (12–75 μm) of the membrane, it is essential to
combine it with a suitable substrate either by special adhesives or,
where appropriate, by flame bonding.

One most popular micoporous PTFE membrane is chemically inert and

can withstand high temperature (2600C).

PTFE microporous film (Magnification 500 times) 252

Industrial Filter: Woven glass fiber with PTFE Membrane

• Slightly higher fabric resistance during

first few month
• Negligible dust penetration and
negligible dust peaks from cleaning
pulses
• Average: < 10 mg/Nm3
• Careful installation required
• High gas velocities can cause bag
damage more easily
• Shaking of filter bag is to be
controlled
• Membrane filter leads to high
operating cost
• Life guarantee from 4 y to 6 y
• Largely used in USA but not used in
Australia

253
2. Longer filter life (Most often life is decided by
extent of filter clogging/ depth filtration)

254
3. Size of filter unit

255
4. Control of Temperature and Moisture

Burn of bag by spark or high-temperature particles

Two methods that may minimize corrosion are: (1) reheating
the gases to above their dew point, or (2) using materials of
construction and designs that allow equipment to withstand the
corrosive conditions.
256
5. Challenges in separation of difficult particles

Fabric filtration system is quite versatile as it can handle

large varieties of dust differing in physical and chemical
properties.

Separate/ handle difficult particles like particles with

strong adhesion forces - Paint particles
Abrasive particles – SiC, Alumina
Particles with high reactivity - Dye particles
Nanoparticle with adverse gas properties - Flame
synthesis of TiO2 or SiO2
257
 Light and fluffy particles – Asbestos fibre

Multimedia Drum Filter with Moving Suck-off Nozzle

258
Contd…

Mixtures of solid and liquid particles in the aerosol – Tar

collection
Particles with low sticking efficiency - Sugar
Particles causing fire hazards/explosion - Coal, rubber

Particles causing blinding of pores – Milk powder

Filtration at high temperature is also possible with
appropriate textile material – Fly ash

Particles with one or more of these properties occur in a wide

variety of applications

259
6. Hot gas filtration

260
7. Control of particulate and gases simultaneously

Simultaneous
control of gases
and particles

Through Using non-thermal

Catalytic filter
sorbent injection plasma

261
8. Fibre offering more chemically and hydrolytic resistance
with/without temperature.

9. Material to have more abrasive resistance [e.g., use of

Aramid/P-84 but it is costly; Alternative Strategy: Lower
the velocities (ACR, Inlet Velocity, Can Velocity)]

10. Challenges to disposal of filter bags or re-use after its

lifetime.

262
The new capability of tera scale takes us three orders of magnitude
beyond the present general-purpose and generally accessible
computing capabilities. It lets make supercomputers that fit on the
head of a fiber, and fleets of medical nano-robots smaller than a
human cell to eliminate cancers, infections, clogged arteries.

263
Thank you

264