ASSIGNMENT

ON

POLYESTER
(CHEMICAL PROCESS
INDUSTRIES-II)

Submitted to:
Dr. Abdullah Khan Durrani
Submitted by:
Aamir Abbas
(M08-PG15)

Polyester:Polyester is a category of polymers which contain

the ester functional group in their main chain. Although
there are many types of polyester, the term "polyester" as
a specific material most commonly refers to polyethylene
terephthalate (PET). Polyesters include naturally-occurring
chemicals, such as in the cutin of plant cuticles, as well as
synthetics such as polycarbonate and polybutyrate.
Polyester fiber is known in England as Terylene. Polyester is
a smooth fiber with an even diameter. The fiber diameter
usually ranges from 12-25 micrometers (10-15 deniers).
The undyed fiber is slightly off-white and partially
transparent. The fibers are approximately 35% crystalline
and 65% amorphous.

History:
In 1926, United States-based E.I. du Pont de Nemours and Co.
began research into very large molecules and synthetic fibers. This early
research, headed by W.H. Carothers, centered on what became nylon, the
first synthetic fiber. Soon after, in the years 1939-41, British research
chemists took interest in the du Pont studies and conducted their own
research in the laboratories of Calico Printers Association, Ltd. This work
resulted in the creation of the polyester fiber known in England as
Terylene.
British chemists, John Rex Whinfield and James Tennant Dickson,
employees of the Calico Printer's Association of Manchester, patented
"polyethylene terephthalate" (also called PET or PETE) in 1941, after
advancing the early research of Wallace Carothers. The saw that
Carothers's research had not investigated the polyester formed from
ethylene glycol and terephthalic acid.

Whinfield and Dickson along with inventors W.K. Birtwhistle and C.G.
Ritchiethey also created the first polyester fiber called Terylene in 1941
(first manufactured by Imperial Chemical Industries or ICI). The second
polyester fiber was Dupont's Dacron.
.In 1946, du Pont purchased the right to produce this polyester fiber in the
United States. The company conducted some further developmental work,
and in 1951, began to market the fiber under the name Dacron. During the
ensuing years, several companies became interested in polyester fibers and
produced their own versions of the product for different uses. Today, there
are two primary types of polyester, PET (polyethylene terephthalate) and
PCDT (poly-1, 4-cyclohexylene-dimethylene terephthalate). PET, the more
popular type, is applicable to a wider variety of uses. It is stronger than
PCDT, though PCDT is more elastic and resilient. PCDT is suited to the
heavier consumer uses, such as draperies and furniture coverings. PET can
be used alone or blended with other fabrics to make clothing that is wrinkle
and stain resistant and retains its shape.

MANUFACTURING PROCESSES
Basic Principles of Polyester Fiber Production:
The most common polyester for fiber purposes is poly
(ethylene terephthalate), or simply PET. This is also the polymer used for
many soft drink bottles and it is becoming increasingly common to recycle
them after use by remelting the PET and extruding it as fiber. This saves
valuable petroleum raw materials, reduces energy consumption, and
eliminates solid waste sent to landfills.
Polyester is a chemical term which can be broken into poly, meaning many,
and ester, a basic organic chemical compound. The principle ingredient
used in the manufacture of polyester is ethylene, which is derived from
petroleum. In this process, ethylene is the polymer, the chemical building
block of polyester, and the chemical process that produces the finished
polyester is called polymerization. PET is made by reacting ethylene
glycol with either terephthalic acid or its methyl ester in the presence of an

antimony catalyst. The reaction is carried out at high temperature and

vacuum to achieve the high molecular weights need to form useful fibers.
PET is melt spun.

Raw Materials:
The main raw materials are described as follows:
(a) Terephthalic Acid (PTA), (p-HOOC-C6H4COOH) produced directly
from p-xylene with bromide-controlled oxidation.
(b) Dimethyl Terephthalate (DMT), C6H4 (COOCH3)2 made in the early
stages by esterification of terephthalic acid. However, a different
process involving two oxidation and esterifications stages now
accounts for most DMT.
(c) Ethylene Glycol (EG),(OH-CH2-CH2-OH) initially generated as an
intermediate product by oxidation of ethylene. Further ethylene
glycol is obtained by reaction of ethylene oxide with water.
Polyester is manufactured by reacting ethylene glycol with either
terephtalic acid or its methyl ester in the presence of an antimony catalyst
Sb3O3
(Antimony Trioxide).TiO2 (Titanium di oxide) is added to make the
polyester fibre / filament dull. The reaction is carried out in an autoclave at
high temperature (ca 300C) for five to eight hours. Then, it placed under a
hard vacuum to achieve the high molecular weights required to form useful
fibers. The General equation for the reaction of a diol with a diacid is:
(n+1) R(OH)2 + n R(COOH)2 ---> HO[ROOCRCOO]nROH + 2n H2O.
Following that, polyester is melt-spun, which involves melting
the polymer chips for extrusion through the spinneret and then directly
solidifying them by cooling. The filaments are drawn and stretched by
about 400% in order to achieve the required characteristics.

Production of polyethylene terephthalate

Polymerization:

To form polyester, dimethyl terephthalate is first reacted with

ethylene glycol in the presence of a catalyst at a temperature of 302410F (150-210C).
The resulting chemical, a monomer (single, non-repeating molecule)
alcohol, is combined with terephthalic acid and raised to a
temperature of 472F (280C). Newly-formed polyester, which is
clear and molten, is extruded through a slot to form long ribbons.

POLYESTER FIBER FLOW CHART

Drying:

After the polyester emerges from polymerization, the long molten

ribbons are allowed to cool until they become brittle. The material is
cut into tiny chips and completely dried to prevent irregularities in
consistency.

Melt spinning:

Polymer chips are melted at 500-518F (260-270C) to form a syruplike solution. The solution is put in a metal container called a
spinneret and forced through its tiny holes, which are usually round,
but may be pentagonal or any other shape to produce special fibers.
The number of holes in the spinneret determines the size of the yarn,
as the emerging fibers are brought together to form a single strand.
At the spinning stage, other chemicals may be added to the solution
to make the resulting material flame retardant, antistatic, or easier to
dye.

Drawing the fiber:

When polyester emerges from the spinneret, it is soft and easily

elongated up to five times its original length. The stretching forces
the random polyester molecules to align in a parallel formation. This
increases the strength, tenacity, and resilience of the fiber. This time,
when the filaments dry, the fibers become solid and strong instead of
brittle.
Drawn fibers may vary greatly in diameter and length, depending on
the characteristics desired of the finished material. Also, as the fibers
are drawn, they may be textured or twisted to create softer or duller
fabrics.

Winding:

After the polyester yarn is drawn, it is wound on large bobbins or

flat-wound packages, ready to be woven into material.

Manufacturing Staple Fiber

In making polyester staple fiber, polymerization, drying, and melt
spinning are much the same as in the manufacture of filament yarn.
However, in the melt spinning process, the spinneret has many more holes
when the product is staple fiber. The rope-like bundles of polyester that
emerge are called tow.

Drawing tow:

Newly-formed tow is quickly cooled in cans that gather the thick

fibers. Several lengths of tow are gathered and then drawn on heated
rollers to three or four times their original length.

Crimping:

Drawn tow is then fed into compression boxes, which force the fibers
to fold like an accordion, at a rate of 9-15 crimps per inch (3-6 per

cm). This process helps the fiber hold together during the later
manufacturing stages.

Setting:

After the tow is crimped, it is heated at 212-302F (100-150C) to

completely dry the fibers and set the crimp. Some of the crimp will
unavoidably be pulled out of the fibers during the following
processes.

Cutting:

Following heat setting, tow is cut into shorter lengths. Polyester that
will be blended with cotton is cut in 1.25-1.50 inch (3.2-3.8 cm)
pieces; for rayon blends, 2 inch (5 cm) lengths are cut. For heavier
fabrics, such as carpet, polyester filaments are cut into 6 inch (15 cm)
lengths.

PHYSICAL AND CHEMICAL PROPERTIES OF

POLYESTER FIBRE
DENIER: 0.5 - 15
TENACITY : dry 3.5 - 7.0 : wet 3.5 - 7.0
%ELONGATION at break : dry 15 - 45 : wet 15 45
%MOISTURE REGAIN: 0.4
SHRINKAGE IN BOILING WATER: 0 - 3
CRIMPS PER INCH: 12 -14
%DRY HEAT SHRINKAGE: 5 - 8 (at 180 C for 20 min)
SPECIFI GRAVITY: 1.36 - 1.41
% ELASTIC RECOVERY; @2% =98 : @5% = 65
GLASS TRANSITION TEMP: 80 degree C

 Softening temp : 230 - 240 degree C

Melting point : 260 - 270 degree C
Effect of Sunlight : turns yellow, retains 70 - 80 % tenacity at long
exposure
RESISTANCE TO WEATHERING: good
ROT RESISTENCE: high
ALKALI RESISTENCE: damaged by CON alkali
ACID RESISTENCE: excellent
ORGANIC CHEMICAL RESISTENCE: good

Polyester Fiber Characteristics: Strong

Resistant

to stretching and shrinking

Resistant

to most chemicals

Quick
Crisp

drying

and resilient when wet or dry

Wrinkle

resistant

Mildew

resistant

Abrasion
Retains
Easily

resistant

heat-set pleats and crease

washed

USES OF POLYESTER FIBER: Polyesters may be produced in numerous forms such as sheets and
three-dimensional shapes. Polyesters as thermoplastics may change
shape after the application of heat. While combustible at high

temperatures, polyesters tend to shrink away from flames and selfextinguish upon ignition.
Polyester fibers have high tenacity and E-modulus as well as low
water absorption and minimal shrinkage in comparison with other
industrial fibers.
Woven polyester fabrics are used in consumer apparel and home
furnishings such as bed sheets, bedspreads, curtains and draperies.
Similarly, industrial polyesters are used in tyre reinforcements, ropes,
fabrics for conveyor belts, safety belts, coated fabrics and plastic
reinforcements with high energy absorption.
Polyester fiber fills are also used to stuff pillows, comforters and
cushion padding.

Increasingly over the last ten years PET has gained acceptance as a
material of choice for beverage bottles. ... Polyester film (PETF) is a
semi-crystalline film used in many applications such as videotape,
high quality packaging, professional photographic printing, X-ray
film, floppy disks, and etc.

Polyester fabrics are claimed to have a "less natural" feel when

compared to similarly-woven fabrics made from natural fibers (i.e.
cotton in textile uses). However, polyester fabrics may exhibit other
advantages over natural fabrics, such as improved wrinkle resistance.
Polyester fibers are sometimes spun together with natural fibers to
produce a cloth with blended properties.
Polyesters are also used to make bottles, films, tarpaulin, canoes,
liquid crystal displays, holograms, filters, dielectric film for
capacitors, film insulation for wire and insulating tapes.

Polyethylene terephthalate is the basis of synthetic fibers such as

polyester, Dacron, and Terylene, bed sheets are being made from
Coolmax and Thermolite fabrics.

Apparel: Every form of clothing.

 Home Furnishings: Carpets, curtains, draperies, sheets and pillow

cases, wall coverings, and upholstery.
Other Uses: hoses, power belting, ropes and nets, thread, tire cord,
auto upholstery, sails, floppy disk liners, and fiberfill for various
products including pillows and furniture.

SPECIALITY FIBRES IN POLYESTER:

HIGH/LOW SHRINK FIBRES: The high shrink fibre shrinks upto

50% at 100 degree C while that of low shrinkage is 1%. The high
shrink fibre enables fabrics with high density to be produced and is
particularly used in artificial leather and high density felt. Low
shrinkage fibre is recommended for air filters used in hot air,
furniture, shoes etc.
MICRO DENIER: Available in 0.5/0.7/0.8 deniers in cut lengths
32/38 mm. Ideal for high class shirts, suitings, ladies dress material
because of its exceptional soft feel. It is also available in siliconised
finish for pillows. To get the best results, it is suggested that the
blend be polyester rich and the reed/pick of the fabric be heavy.

FLAME RETARDANT: Has to be used by law in furnishings /

curtains, etc where a large number of people gather - like in cinema
theatres, buses, cars etc in Europe and USA. It is recommended for
curtains, seat covers, car mats, automotive interior, aircraft interiors
etc.

CATIONIC DYEABLE: Gives very brilliant shades with acid colors

in dyeing / printing. Ideal for ladies wear

EASY DYEABLE: Can be dyed with disperse Dyes at 98 degrees C

without the need for HTHP equipment. Ideal for village handicrafts
etc.

LOW PILL: In 2 and 3 deniers, for suiting end use and knitwear fibre
with low tenacity of 3 to 3.5 gm/denier, so that pills which form
during use fall away easily.

ANTIBACTERIAL: It is antibacterial throughout the wear life of the

garment inspite repeated washing. Suggested uses are under wears,
socks, sports, blankets and air conditioning filters

SUPER HIGH TENACITY: It is above 7 g/denier and it is mainly

used for sewing threads. Low dry heat shrinkage is also
recommended for this purpose. Standard denier recommended is 1.2
and today 0.8 is also available.

MODIFIED CROSS SECTION: In this there are TRILOBAL,

TRIANGULAR, FLAT, DOG BONE and HOLLOW FIBRES with
single and multiple hollows. Trilobal fibre gives good feel.
Triangular fibre gives excellent lustre. Flat and dog bone fibers are
recommended for furnishings, while hollow fibers are used as filling
fibers in pillows, quilts, beddings and padding. For pillows silicoised
fibers is required. Some fibre producers offer hollow fibre with built
in perfumes.

CONDUCTING FIBRE: This fibre has fine powder of stainless steel

in it to make fibre conductive. Recommended as carpets for
computer rooms.

LOW MELT FIBRE: It is a bi-component fibre with modified

polyester on the surface which softens at low temperature like 110
degree C while the core is standard polyester polymer. This fibre is
used for binding non woven webs.

Summary
Polyester is a growing fiber for textile applications, particularly
in the fashion industry. The future of polyester appears bright as more and
more consumers are attracted by its easy care properties. While the use of
polyester is still restricted in some applications because of its low moisture
regain, this is being addressed via denier reduction or topicalfinishes.An
ideal hydrophilic polyester solution has not yet been developed. Denier
reduction can generate a substantial amount of waste, perhaps up to 30%
polyester in effluent, and it lowers the mechanical properties of polyester.
Microfibers are attractive as they combine

Properties such as hydrophilicity and a silk-like hand, however their

applications are restricted to lightweight garments such as blouses. Topical
finishes offer instant wetting but generally lack in durability and softness,
and therefore require the use of additional softener. Lastly, solution costs
also need to be considered. Although a cost can be offset by high-tech
applications, traditional segments like fashion are more price-sensitive.

DIFFERENT INDUSTRIES IN PAKISTAN:

Dewan Salman Fiber Ltd.
Ibrahim Fibres Ltd.
ICI Pakistan Ltd.
Rupali Polyester Ltd.
Pakistan Synthetics Ltd.
Polyester staple fiber (PSF) industry.