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    Dyeing of Cotton With Vat Dyes

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    İbrahim Güneş
    This document provides information on the properties and dyeing process of vat dyes. Vat dyes are insoluble in water but can be converted to a water-soluble form through a process called "vatting." This involves reducing the dye using sodium hydrosulphite to form a leuco compound, which is then used to dye cotton fabrics. After dyeing, the fabric is oxidized to convert the dye back to its insoluble form within the fibers. Proper amounts of reducing agent and alkali are needed along with steps like soaping to achieve bright shades and good fastness. Various dyeing methods like exhaust, semi-continuous and continuous are described.

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    Dyeing of Cotton With Vat Dyes

    Uploaded by

    İbrahim Güneş
    1K views37 pages
    This document provides information on the properties and dyeing process of vat dyes. Vat dyes are insoluble in water but can be converted to a water-soluble form through a process called "vatting." This involves reducing the dye using sodium hydrosulphite to form a leuco compound, which is then used to dye cotton fabrics. After dyeing, the fabric is oxidized to convert the dye back to its insoluble form within the fibers. Proper amounts of reducing agent and alkali are needed along with steps like soaping to achieve bright shades and good fastness. Various dyeing methods like exhaust, semi-continuous and continuous are described.

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    textile dyes

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    This document provides information on the properties and dyeing process of vat dyes. Vat dyes are insoluble in water but can be converted to a water-soluble form through a process called "vatting." This involves reducing the dye using sodium hydrosulphite to form a leuco compound, which is then used to dye cotton fabrics. After dyeing, the fabric is oxidized to convert the dye back to its insoluble form within the fibers. Proper amounts of reducing agent and alkali are needed along with steps like soaping to achieve bright shades and good fastness. Various dyeing methods like exhaust, semi-continuous and continuous are described.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    1K views37 pages

    Dyeing of Cotton With Vat Dyes

    Uploaded by

    İbrahim Güneş
    This document provides information on the properties and dyeing process of vat dyes. Vat dyes are insoluble in water but can be converted to a water-soluble form through a process called "vatting." This involves reducing the dye using sodium hydrosulphite to form a leuco compound, which is then used to dye cotton fabrics. After dyeing, the fabric is oxidized to convert the dye back to its insoluble form within the fibers. Proper amounts of reducing agent and alkali are needed along with steps like soaping to achieve bright shades and good fastness. Various dyeing methods like exhaust, semi-continuous and continuous are described.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 37

    GENERAL PROPERTIES OF VAT DYES

    INSOLUBLE IN WATER
    CAN NOT BE USED DIRECTLY FOR DYEING
    CAN BE CONVERTED TO WATER SOLUBLE FORM
    POSSESS AFFINITY TO CELLULOSIC FIBRES
    PROCESS OF CONVERTING WATER INSOLUBLE FORM TO
    WATER SOLUBLE FORM KNOWN AS VATTING

    INVOLVES TWO STEPS


    REDUCTION OF VAT DYE INTO WEAKLY ACIDIC LEUCO FORM
    SALT FORMATION BY NaOH

    REDUCING AGENT USED IS SODIUM HYDROSULPHITE


    Na2S2O4 + 2H2O 2NaHSO3 + 2H
    DYEING OF COTTON WITH VAT DYES
    PRINCIPLE
    CONVERSION OF WATER INSOLUBLE VAT DYE
    INTO ITS SOLUBLE FORM
    DYEING OF COTTON
    RECONVERSION OF SOLUBLE VAT DYE ON FIBRE
    INTO PARENT INSOLUBLE FORM
    INDIGO IS ONE OF THE OLDEST NATURAL VAT DYE
    SYNTHETIC INDIGO AND OTHER VAT DYES ARE
    MANUFACTURED SINCE EALY 1900S
    CHEMICAL CLASSIFICATION OF VAT
    DYES
    TWO MAIN CLASSES
    INDIGOID VAT DYES: DERIVATIVES OF INDIGO OR
    THIO-INDIGO
    ANTHRQUININE VAT DYES
    REDUCTION OF VAT DYE
    REDUCTION OF VAT DYE
    REDUCING PROPERTY OF SODIUM HYDROSULPHITE

    Na2S2O4 + 2H2O 2 NaHSO3 + 2H


    REDUCTION OF INDIGO
    REDUCTION OF VAT DYE
    AMOUNT OF Na2S2O4 AND NaOH
    STOICHIOMETRICALLY 1 MOLE OF Na2S2O4 AND 2 MOLES OF
    NaOH ARE CONSUMED PER ANTHRAQUINONE RING IN DYE
    MOLECULE
    IN PRACTCE GREATER AMOUNT OF Na2S2O4 AND NaOH IS
    USED
    DECOMPOSITION OF Na2S2O4 BY ATMOSPHERIC OXYGEN
    AND DISSOLVED OXYGEN IN WATER AND ENTRAPPED IN
    FIBRE
    NEUTRALIZATION OF NaOH BY ACIDIC DECOMPOSITION
    PRODUCTS OF Na2S2O4
    Na2S2O4 + 2H2O 2NaHSO3 + 2H
    NaHSO3 + NaOH Na2SO3 + 2H2O
    DISSOLVED CO2 IN WATER ALSO CONSUMES SOME ALKALI
    IN PRACTICE AMOUNT OF Na2S2O4 USED IS 2-3 TIMES HIGHER
    AMOUNT OF NaOH USED IS 1.5-2 TIMES HIGHER THAN
    NEEDED STOICHIOMETRICALLY
    STEPS IN VAT DYEING
    FOUR STEPS
    1. REDUCTION: CONVERSION OF INSOLUBLE FORM TO ITS
    SOLUBLE FORM IN PRESENCE OF STRONG REDUCING
    AGENT AND CAUSTIC SODA (LEUCO VAT DYE)

    2. DYEING: DYEING OF COTTON WITH LEUCO VAT DYE

    3. OXIDATION: OXIDATION OF VAT DYE INSIDE THE FIBRE


    INTO WATER INSOLUBLE FORM (OXIDATION)

    4. SOAPING: SUBSEQUENT TREATMENT OF DYED MATERIAL


    WITH HOT WASHING LIQUOR CONTAINING ANIONIC
    DETERGENT TO OBTAIN BRIGHT SHADES, DYE
    AGGREGATION AND EXTREMELY GOOD FASTNESS
    PROPERTIES
    CLASSIFICATION ACCORDING TO
    APPLICATION
    FOUR GROUPS ACCORDING TO VATTING AND
    DYEING CONDITIONS
    1. IK
    2. IW
    3. IN
    4. IN SPECIAL

    DYEING STEPS
    PREPARATION OF STOCK VAT
    DYEING
    THE CONDITIONS OF DYEING DEPENDS ON VAT
    DYE CLASS USED
    RECIPE FOR STOCK VAT

    CLASS DYE QTY CAUSTIC Na2S2O4 water Temp. Time


    kg SODA kg litre 0C min.
    (32.5%) litre
    Iw 1 1.5 0.5 50 50 10

    In 1 3.0 0.75 50 60 10

    In special 1 6.0 1.50 100 60 10


    DYE BATH ADDITIONS
    Process Iw In In special
    Additions 1:20 1:10 1:5 1:20 1:10 1:5 1:20 1:10 1:5

    NaOH ml/l 8-10 12-15 18-23 15-20 22-26 32-40 22-26 32-38 48-58
    32.5%

    Hydro g/l 3-4 5-6.5 8-12 3.5-4.5 5.5-8 9.5-13 3.5-4.5 5.5-8 9.5-13.5

    NaCl g/l 15-25 15-20 15-20 -------------------------------------------------------

    Dyeing
    Temp. 0 c 45-50 50-60 50-60
    DYEING AUXILIARIES
    REDUCING AGENT
    SODIUM HYDROSULPHITE OR SODIUM
    DITHIONATE
    SENSITIVITY
    HYDRO IS SENSITIVE TO ATMOSPHERIC OXYGEN
    DECOPOSES DURING VATTING AND DYEING OF VAT DYE
    EXCESS MUST ALWAYS BE PRESENT
    DECOPOSITION INCREASES WITH
    TEMPERATURE
    AGITATION OF DYE LIQUOR
    EXPOSED SURFACE AREA OF DYE BATH
    HYDROSULPHITE DECOMPOSITION

    NEUTRAL MEDIUM
    2Na2S2O4 + H2O Na2S2O3 + 2NaHSO3

    ALKALINE MEDIUM
    2Na2S2O4 + 2NaOH Na2S2O3 + 2Na2SO3 +H2O

    REACTOION WITH ATMOSPHERIC OXYGEN


    (ALKALINE MEDIUM)
    Na2S2O4 + 2NaOH +O2 Na2SO3 + Na2SO4 +H2O
    DYEING AUXILIARIES
    ALKALI
    MAINTAIN REDUCED DYE IN WATER SOLUBLE FORM
    ALKALI ALSO CONSUMED DURING DYEING BY DYE, REACTION
    WITH HYDROSULPHITE, AND ATMOSPHERIC OXYGEN, EXCESS
    MUST BE PRESENT
    TEST
    HYDRO: VAT PAPER, YELLOW PAPER TURNS BLUE
    ALKALI: PHENOLPHTHALEIN PAPER, WHITE PAPER TURNS PINK
    ELECTROLYTE
    MOST COMMON NaCL OR Na2SO4
    OTHER AUXILIARIES
    WETTING AGENT HELPS IN WETTING OF FABRIC DURING DYEING,
    ASSIST DYE PENETRATION
    ANIONIC DETERGENT USED DURING SOAPING, FACILITATES
    REMOVAL OF SURFACE DYE,
    DYE AGGREGATION INSIDE FIBRE
    DEVELOP TRUE SHADE AND GOOD FASTNESS PROPERTIES
    DYEING OF COTTON FABRIC
    EXHAUST DYEING
    JIGGER IS THE MOST COMMONLY USED MACHINE FOR EXHAUST
    DYEING
    STEP 1
    VATTING: CONVERSION OF INSOLUBLE FORM TO SOLUBLE FORM
    STOCK VAT: REDUCTION IN STRONG CONCENTRATION. CHEMICAL
    REACTION INCREASES WITH CONCENTRATION
    VAT DYE X PARTS
    HYDRO 2 X PARTS
    CAUSTIC SODA 1 X PARTS
    WATER 50 X PARTS
    TEMPERATURE 50-60OC
    TIME 10-15 MIN.
    TEST FOR VATTING:
    SPOT VATTED DYE SOLUTION ON FILTER PAPER. SPREADING OF
    SPOT WITHOUT DEPOSITION OF INSOLUBLE DYE PARTICLES
    EXHAUST DYEING
    BLANK DYE BATH
    CAUSTIC SODA 20 g/l
    HYDRO 15 g/l
    DYEING
    LOAD THE FABRIC UNIFORMLY WITHOUT CREASES ONTO ONE OF
    THE ROLLER OF JIGGER BY PASSAGE THROUGH PLAIN WATER
    RUN THE FABRIC (2 ENDS) THROUGH BLANK BATH AT ROOM TEMP.
    ADD HALF THE QUANTITY OF STOCK VAT
    RUN FOR 2 ENDS
    ADD THE REMAINING STOCK VAT
    RAISE TEMP SLOWLY TO 60OC
    CONTINUE DYEING FOR 45 MIN (8-10 ENDS)
    AFTER EACH END CHECK FOR PRESENCE OF HYDRO WITH VAT
    PAPER (DYED WITH NAVINON YELLOW 5G) COLOUR CHANGE
    YELLOW TO BLUE AND ALKALI WITH PHEOLPHTHALEIN PAPER.
    COLOUR CHANGE COLOURLESS TO PINK.
    IF FOUND INSUFFICIENT PREDISSOLVE AND ADD TO JIGGER
    WHILE STATIONARY.
    OXIDATION
    AFTER DYEING DRAIN THE DYEBATH
    RINSE THE FABRIC THROUGH COLD WATER (2ENDS) TO
    REMOVE LOOSE DYE AND EXCESS HYDRO AND ALKALI
    CONVERT THE LEUCO VAT DYE TO ITS ORIGINAL OXIDIZED
    FORM BY TEATMENT WITH 2 g/l H2O2 AT 40-50OC (4 ENDS)
    RINSE WITH COLD WATER
    SOAPING: ABSOLUTELY ESSENTIAL FOR DEVELOPMENT OF
    TRUE SHADE AND BEST FASTNESS PROPERTIES.
    REMOVAL OF SURFACE DYE AND AGGREGATION OF DYE
    INSIDE THE FIBRE
    SOAP AT BOIL USING 2 g/l LISSAPOL D (ANIONIC
    DETERGENT) AND 2 g/l SODA ASH (4 ENDS)
    RINSE WITH COLD WATER (2 ENDS)
    UNLOAD FROM JIGGER
    DRY
    SEMI-CONTINUOUS DYEING
    MANY VAT DYES HAVE STRONG AFFINITY FOR
    COTTON
    PENETRATION IN CLOSELY WOVEN FABRIC IS
    DIFFICULT
    SEMICONTINUOUS OR CONTINUOUS METHODS
    USED

    PIGMENT PAD-DEVELOPMEMNT ON JIGGER


    PAD WITH VAT DYE DISPERSION
    DRY
    DEVELOP ON JIGGER USING HYDRO AND CAUSTIC SODA
    OXIDIZE AND SOAP IN JIGGER
    THE METHOD IS USED FOR DYEING TIGHTLY WOVEN
    FABRIC LIKE SUITING.
    SEMI-CONTINUOUS METHOD
    PAD-JIG METHOD
    PREPARATION OF DYE DISPERSION:
    USE ONLY ULTRA FINE VAT DYES
    STIR THE VAT DYE POWDER IN 10-20 TIMES ITS
    WEIGHT OF WATER AT 500C WITH HIGH SPEED
    STIRRING
    FILTER THE DISPERSION
    MAKE THE TOTAL VOLUME
    ADD WETTING AGENT OR LEVELLING AGENT.
    READY FOR PADDING.

    PADDING
    PADDING
    USE WELL SCOURED BLEACHED FABRIC IN DRY STATE
    GOOD WETTING OF FABRIC IS ESSENTIAL
    SATURATE THE FABRIC WITH DYE DISPERSION
    SQUEEZE OUT EXCESS LIQUOR (EXPRESSION 70%)
    PADDING MANGLE SPEED 20 M/min.
    IF FABRIC IS TOO TIGHT CONSTRUCTION, PAD AT HIGH TEMP (60-700C)

    DRYING
    DEVELOPMENT MAY BE DONE IN WET STATE OR AFTER DYRYING
    IF WET, DEVELOP WITHOUT DELAY
    UNIORM DRYING OF PADDED FABRIC ALONG THE WIDTH AND BACK
    AND FACE OF FABRIC IS ESSENTIAL
    MACHINE USED EITHER HOT FLUE OR STENTER
    HOT CYLINDER DRYING IS NOT ADVISABLE DUE TO BACK TO FACE
    DYE MIGRATION.
    DEVELOPMENT ON JIGGER
    SET THE JIGGER BATH WITH REQUIRED AMOUNTS OF
    HYDRO AND CAUSTIC SODA.
    ADD SMALL QUANTITY OF PADDING LIQUOR TO THE BLANK
    BATH IN JIGGER TO COMPENSATE FOR THE DYE WHICH
    BLEEDS OUT FROM FABRIC
    THE DEVELOPMENT IS SIMILAR TO JIGGER DYEING
    OPERATION FOLLOWED BY OXIDATION AND SOAPING
    TREATMENT.
    CONTINUOUS METHOD

    PAD-STEAM PROCESS
    PRINCIPLE: INCREASE IN RATE OF DYEING WITH
    INCREASE IN TEPERATURE.
    DYE REDUCTION ON FABRIC SURFACE
    IMMEDIATE DYE ADSORPTION

    PIGMENT PAD DRY CHEMICAL PAD (CAUSTIC


    SODA, HYDRO, COMMON SALT) STEAM (30-60
    SEC.) RINSE OXIDIZE SOAP -> RINSE (8
    COMPRTMENT OPEN SOAPER) DRY
    CHEMICAL PADDING
    AFTER PIGMENT PADDING AND DRYING, COOL THE FABRIC
    TO AVOID DYE REDUCTION IN CHEMICAL PAD TROUGH
    PAD THE FABRIC WITH SOLUTION OF HYDRO AND CAUSTIC
    SODA (CHEMICAL PAD LIQUOR)
    THE CONCENTRATION OF HYDRO AND CAUSTIC SODA
    DEPENDS ON CONCENTRATION OF DYE ON FABRIC.
    DYE CONC. ON FABRIC NaOH/Na2S2O4
    g/kg g/l
    10 25-30
    30 35-50
    50 50-70
    5-10 LITRES OF PIGMENT DISPERSION/100 LITRE OF
    CHEMICAL LIQUOR ARE ADDED TO THE BATH
    STEAMING
    CHEMICAL PADDED FABRIC IN WET CONDITION
    IMMEDIATELY PASSED INTO STEAMER
    STEAM FOR 20-30 SEC. IN SATURATED AIR FREE STEAM

    AFTER TREATMENT
    THE FINAL TREATMENTS INVOLVING OXIDATION AND
    SOAPING ON 8 COMPARTMENT OPEN SOAPER
    METHOD IS SUITABLE ONLY FOR PALE TO MEDIUM DEPTH
    OF SHADES
    THE STEAMER SHOULD BE SITUATED AS CLOSE AS POSSIBLE
    TO CHEMICAL PADDING MANGLE, TO MINIMIZE HYDRO
    DECOPOSITION IN AIR BEFORE STEAMING.
    CONTINUOUS METHOD
    DYEING OF COTTON WITH INDIGO
    INDIGO HAS POOR AFFINITY TOWARDS COTTON
    CONVENTIONAL EXHAUST OR CONTINUOUS
    METHODS ARE NOT SUITABLE
    SPECIAL METHOD OF MULTIPLE DIP AND NIP (5 DIP
    AND 5 NIP) METHOD IS USED IN COMMERCIAL
    PRACTICE
    MAJOR APPLICATION FOR DYEING OF COTTON
    WARP FOR PRODUCTION OF STONE WASH
    DENIM/JEAN FABRIC
    INDIGO DYEING
    STOCK VAT
    INDIGO X g/l
    CAUSTIC SODA X g/l
    HYDRO Xg/l
    TEMP. 60OC
    TIME 15 MIN.

    DYEBATH
    INDIGO 3 g/l
    CAUSTIC SODA 2 g/l
    HYDRO 1.5 g/l
    WETTING AGENT 1 g/l
    DYEING TEMP. ROOM TEMP.
    INDIGO DYEING

    CONTINUOUS DYEING RANGE


    TROTMAN P453
    SOLUBILIZED VAT DYES
    DISULPHURIC ESTERS OF INDIGO OR AQ VAT DYES
    LEUCO VAT DYE OBTAINED BY TREATMENT OF VAT DYE WITH
    HYDRO
    TREAT LEUCO VAT DYE WITH CHLOROSULPHONIC ACID (ClSO3H) IN
    PRESENCE OF PYRIDINE AT 60-700C
    TREAT THE PRODUCT WITH SLIGHT EXCESS OF Na2CO3 OR NaOH
    REMOVE PYRIDINE BY STEAM DISTILLATION
    CONCENTRATE TO CRYSTALLIZE OR
    SALT OUT WITH NaCl
    GENERAL PROPERTIES
    SOLUBILITY
    LOW SOLUBILITY, 50 g/l AT 50-600C
    SOLUBILITY RANGE IS SUFFICIENT
    USED FOR DYEING PALE SHADES
    DO NOT DISSOLVE IN BOILING WATER: PREMATURE DYE
    OXIDATION

    LIGHT SENSITIVITY
    SENSITIVE TO SLIGHT IN POWDER AS WELL IN SOLUTION
    FORM.
    PREMATURE OXIDATION TO INSOLUBLE VAT DYE
    EXPOSURE TO LIGHT SHOULD BE AVOIDED
    ACTION OF LIGHT CAN BE MINIMIZED BY ADDING SMALL
    QUANTITY OF SODA ASH TO DYE SOLUTION
    GENERAL PROPERTIES
    SUBSATNTIVITY
    LOW AFFINITY TO COTTON
    GOOD LEVELLING AND PENETRATION ON TIGHTLY WOVEN
    FABRIC
    STANDING BATH MAY BE USED
    DYEBATH IS REPLENISHED AFTER DYEING ONE LOT BY DYE
    CONCENTRATION EQUIVALENT TO THAT TAKEN BY FABRIC
    EXCELLENT REPRODUCIBILITY OF SHADES
    ADDITION COMMON SALT IMPROVES DYE EXHAUSTION
    DYEING MAY BE CARRIED OUT AT ROOM TEMPERATURE.

    OXIDATION
    CARRIED OUT UNDER ACIDIC CONDITIONS
    H2SO4 + NaNO2, NaNO2 + HCOOH, K2Cr2O7 + H2SO4 ARE
    COMMONLY USED
    APPLICATION
    THREE STEPS
    1. PADDING OR EXHAUSTION OF DYE FROM SLIGHTLY
    ALKALINE OR NEUTRAL SOLUTION
    2. DEVELOPMENT ON FABRIC IN PRESENCE OF OXIDIZING
    AGENT NaNO2 + H2SO4 (MOST COMMON) AT ROOM TEMP
    OR 50-600C OR EVEN HIGHER DEPENDING ON EASE OF DYE
    OXIDATION
    3. AFTER TREATMENT: NEUTRALIZATION, AND SOAPING,
    RINSING
    DYEING METHODS
    EXHAUST METHOD (JIGGER DYEING)
    PAD-DEVELOP METHOD

    JIGGER DYEING
    SET DYE BATH WITH 0.5 g/l SODA ASH AND 5-10 g/l NaNO2
    DYEING TEMP. ROOM TEMP 400C
    ADD HALF THE QUANTITY OF DISSOLVED DYESTUFF, GIVE ONE END
    ADD SECOND REMAINGING DYESTUFF, GIVE ONE END
    ADD 10-40 g/l SALT OVER TWO ENDS
    EXCESS SALT CONC. PRECIPITTES THE DYE
    COMPLETE DYEING IN 4-6 ENDS
    DEVELOP THE BATCH ON TO ANOTHER JIGGER IF STANDING BATH
    IS TO BE USED.
    RUN TWO ENDS THROUGH H2SO4 BATH AT 50-600C
    RINSE, SOAP AT BOIL, RINSE
    CONTINUOUS DYEING
    LOW AFFINITY. MOST SUITED FOR CONTINUOUS DYEING
    TYPICAL PAD LIQUOR COMPOSITION
    DYE X g/l, Na2CO3 1 g/l, NON-IONIC WETTING AGENT 1 g/l,
    NaNO2 10 g/l
    PAD AT ROOM TEMPERATURE
    DEVELOP IN A BATH CONTAINING 10 g/l NaNO2 AND 10 g/l
    H2SO4 AT 600 C IN THE 1st COMPARTMENT OF THE 8
    COMPARTMENT OPEN SOAPER
    SOMETIMES THE PADDED FABRIC IS DRIED BEFORE
    DEVELOPMENT
    INTERMEDIATE DRYING GIVES BETTER COLOUR YIELD
    AFTER ACID DEVELOPMENT GIVE
    COLD RINSE SODA ASH NEUTRALIZATION HOT WATER
    RINSING SOAPING AT BOIL COLD RINSE DRY.
    SEMI-CONTINUOUS DYEING
    PAD THE FABRIC WITH DYE SOLUTION
    DEVELOP ON JIGGER LIKE IN EXHAUST DYEING
    COLD RINSE, SOAP, COLD RINSE

    IMPROVEMENT IN COLOUR YIELD IS OBTAINED BY

    DRYING THE PADDED FABRIC BEFORE DEVELOPMENT

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