PROJECT NAME

Study of dye buildup effects on polyester fabric by Disperse Dye with carrier and without carrier

Student Name

ID

ACKNOWLEDGEMENT

We are greatly indebted to Professor M.A Khaleq, Dean, School of Engineering & Head department of Textile Engineering, Primeasia University, for his permission to do this project. We would like to express our deepest sense of gratitude to our supervisor Professor Dr. A.B.M Abdullah, Professor, Department of Textile engineering for his continuous advice, encouragement and guide to make the project possible. We are thankful to Mr. Nayon Chandra Ghosh and Mr. Delowar Hossain Molla Lecturer, Department of Textile engineering for his continuous advice, encouragement and co-operation to make the project possible. We are also specially thankful to our laboratory coordinators Mr. Salauddin, Mr. Hassan in Wet Processing Technology Lab and Mr. Haque and Mr. Baki in Testing and Quality Control Lab for their constant support and technical help during the work. We also thankful to all faculty members of Textile Engineering department for their kind advice during the work. Finally last but not least we are grateful to our parents supporting us to study in this University.

ABSTRACT

Textiles are very important industrial sector as it is second to food only. Presently Bangladesh is to get a position in world textile market. Both natural and synthetics textiles are manufacturing here with modern technologies. Synthetics particularly polyester are very widely use manmade fiber were used in manufacturing wide range of garments both woven and knit where various wet processing technologies are used. Dyeing of polyester with disperses dye with different technologies are very common in present time. Wet processing industries have got various apparatus equipment machineries and facilities for dyeing and finishing of synthetic materials. In this study a simple of observation was made to observe color buildup affect on polyester fabric dyeing with disperse dye with and without carrier. Here after water washing polyester fabric sample were dyed with (0.5-1.45) % shade covers 40 sample with standard recipe from light color to dark color were buildup. This clearly indicates that in all percentage shade color buildup in grater then without carrier.

ABSTRACT
Carrier process are not encourage for commercial use for it some disadvantages such as;  Residual carrier in the dye bath contributes to effluent pollution and may be environmentally harmful


Carrier that is volatilized during dyeing or subsequent heat setting becomes an atmospheric contaminant Residual carrier in the fiber can be a health hazard, as well as causing an unpleasant odour on heating or during storage. Still it is one the important technology used in newly set industries.

INTRODUCTION

With the advancement of civilization, science and technology coloration of textile materials changes with the change of fibers material. Initially natural fibers such as cotton, wool, and silk were dyed by indigenous way and that was location and country oriented. Modern textile are based on scientific and technological information and innovation so with changing time textile technologies particular wet processing technology that is dyeing fishing or coloration changes with the discovery of new fibers, dyes and chemicals. Dyeing of natural fibers such as cotton, wool, silk etc, which are hydrophilic in nature are done by direct, acid, vat, sulphur etc, dyes which are water soluble or made soluble by reduction. On the other hand hydrophobic fibers made their appearance they presented a serious problem in dyeing. When cellulose acetate rayon was introduced soon after First World War, faced a problem in dyeing as the OH group has been blocked by COOCH3 group. Therefore, affinity for dyes has been checked.

INTRODUCTION
Scientists took attempts of creating new dyes and developed acetate dyes or disperse dyes. The term disperse dyes means free from ionizing groups, low water solubilising and are suitable for dyeing hydrophobic fibers from colloidal dispersion by carrier, high temperature and pressure, thermosol techniques. In Bangladesh both natural and synthetic fibers materials are dyed with modern technologies such as jigger dyeing, winch dyeing, high temperature and pressure and carrier dyeing methods in synthetic by Thies, Brazzoli etc are mostly used. In this study effect of carrier on polyester dyeing were observed. A range of colored samples of polyester fabrics were dyed by disperse dye with carrier and without carrier in open bath. In all cases better colored buildup observed with carrier one.

OBJECTIVE OF THE STUDY

To know color build up on polyester fabric using disperse dyeing with carrier and without carrier. To know about the Polyester fiber. To know about the Disperse Dye. To know about the wet processing methods for these fabrics. To observe shade variation in different shade%. To know about carrier and carrier use in polyester dyeing.

POLYESTER

Polyester is a chemical term which can be broken into poly, meaning many, and ester, a basic organic chemical compound. Polyester is a term often defined as long-chain polymers chemically composed of at least 85% by weight of an ester and a dihydric alcohol and a terephthalic acid. Polyester is a synthetic fiber derived from coal, air, water, and petroleum. In 1926, United States-based E.I. du Pont de Nemours and Co. began research into very large molecules and synthetic fibers. 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.

POLYESTER

Polymerization Condensation polymerization occurs when the acid and alcohol are reacted in a vacuum at high temperatures. The polymerized material is extruded in the form of a ribbon onto a casting trough or cooling wheel. After the ribbon hardens, it is cut into chips.

POLYESTER

POLYESTER

Spinning

Polymer chips are melted at 500-518F (260-270C) to form a syrup-like solution. The molten polymer is then extruded through a spinneret and the filaments are subsequently drawn into the desired polyester fiber. Spinnerets having hole of different shapes such as round, trilobal, pentalobal, hexalobal or octalobal can be used for special effects like opacity, luster or its suppression, wicking, comfort or feel. Hollow fibers may be produced to make it lightweight and for providing greater cushioning or insulative properties. Certain additives may also be combined with the spinning solutions for specific properties.

POLYESTER

Drawing After extrusion from the spinneret, the fibers are drawn or elongated, with the help of godet wheels. Depending upon the desired properties, the polyester fibers are usually drawn up to five times its original length. For higher tenacity, the filaments are drawn to a greater extent. After the polyester yarn is drawn, it is wound on large bobbins or flat-wound packages, ready to be woven into material.

POLYESTER

Weaving After the yarns are made, they are shipped out to textile mills to be woven into fabric. Polyester can be made into both woven and knitted fabrics (such as the infamous double-knit!)

POLYESTER
Finishing Processes
Finally, after the fabric is made, one or more of the following finishing processes is often used to improve the quality of the fabric:

Heat setting--creates a permanent shape singing--improves the hand, reduces pilling, and increases smoothness Anti-static finish--reduces static electricity Water and stain repellency--increases comfort and makes it easier to clean; also used for rainwear Resin finishes--increases ease of care Calendaring--increases smoothness and reduces pilling Embossing--creates a design and/or luster

POLYESTER




Blends
At this stage, polyester can also be combined with other fibers to produce a variety of effects. Polyester and cotton is probably the most famous and popular blend. The polyester helps the fabric retain its shape and resist stains and wrinkles. The cotton makes the fabric more absorbent and comfortable. Polyester is combined with wool to give it wrinkle-resistance and shape retention in all kinds of weather. Since polyester is stronger than wool, it increases the durability and life of the fabric. The wool contributes good draping characteristics and elasticity. Polyester and nylon produce a strong fabric because of nylon's strength and abrasion resistance and polyester's wrinkle-free properties. This combination produces a yarn that is strong, durable, stable, easy to launder, and resistant to mildew and insects.

POLYESTER
Types of Polyester Yarns
Filament Yarns PET Polyester is used to make filament yarns either in monofilament or multifilament forms. The direction and amount of twists are decided by the desired end use. The properties are also pre-determined. Textured Yarns These yarns are made of PET multifilaments. Texturizing is either done along with the drawing process or afterwards during throwing or texturizing process. Yarn texturing: Texturing is the physical or chemical modification of flat/round filament yarn for the increase of the total bulk and/or elastic stretch. Spun Yarns They are made of staple or cut PET or PCDT polyester fibers. The staple may be bright, semi dull or dull and tenacity may be regular, mid or high. It may be polished to reduce crimp and increase luster. It may either be spun alone or blended with other staple such as cotton, wool or rayon and then spun into yarn.

PROPERTIES OF POLYESTER
Physical properties: strong resistant to stretching and shrinking resistant to most chemicals quick drying crisp and resilient when wet or dry wrinkle resistant mildew resistant abrasion resistant able to retain heat-set pleats and creases easily washed

PROPERTIES OF POLYESTER
CHEMICAL PROPERTIES:

Polyester fibers have good resistance to weak mineral acids, even at boiling temperature, and to most strong acids at room temperature. Hydrolysis is highly dependent on temperature. Thus conventional PET fibers soaked in water at 70C for several weeks do not show a measurable loss in strength, but after one week at 100C, the strength is reduced by approximately 20%. Polyesters are highly sensitive to bases such as sodium hydroxide and methylamine, which serve as catalysts in the hydrolysis reaction. Alkaline attack is sometimes used to modify the fabric aesthetics during the finishing process. The porous structures produced on the fiber surface by this technique contribute to higher wet ability and better wear properties. Concentrated solutions of benzoic acid and o-phenyl phenol have a swelling effect. Polyester fibers have a low moisture regain of around 0.4%, which contributes to good electrical insulating properties even at high temperatures.

PROPERTIES OF POLYESTER
OPTICAL PROPERTIES: PET has optical characteristics of many thermoplastics, providing bright, shiny effects desirable for some end uses, such as silk-like apparel. Recently developed polyester microfiber with a linear density of less than 1.0 denier per filament (dpf), achieves the feel and luster of natural silk.

PROPERTIES OF POLYESTER
DYEING PROPERTIES:
Because of its rigid structure, well-developed crystalline and lack of reactive dye sites, PET absorbs very little dye in conventional dye systems. Polyester fibers are therefore dyed almost exclusively with disperse dyes. Third monomer--Polymerizing a third monomer, such as dimethyl ester, has successfully produced a cationic dye able polyester fiber into the macro-molecular chain. Low temperature (40C) process--This method employs a disperse dye in a micro emulsion of a small proportion of alkyl halogen and phosphoglyceride. Plasma technique--Spun bond PET nonwoven webs have been treated by (SO2+O2) plasma and (N2+H2+He) plasma. Results show that spun bond PET nonwovens web can be colored by conventional water-soluble acid dyes.

PROPERTIES OF POLYESTER
Polyester fibers display good resistance to sunlight but long-term degradation appears to be initiated by ultraviolet radiation. Although PET is flammable, the fabric usually melts and drops away instead of spreading the flame. Polyester has good oxidative and thermal resistance. The resistance of polyester fibers to mildew, aging and abrasion is excellent. Molds, mildew and fungus may grow on some of the lubricants or finishes, but do not attack the fiber.

DISPERSE DYE:
Disperse dyes include water insoluble dyes which could applied on synthetic fibers. The first disperse dyes were reported for cellulose acetate rayon by British Celanese Corpn. In 1920 none of the other classes of dyes had been good for dyeing cellulose acetate. With the introduction of polyester fibers in 1950 there occurs the rapid development in this field to make dyes suitable for polyester fibers and several modifications have been carried out. The chemical constitution of many of the disperse dyes is unknown . However, most of the disperse dyes belong to azo and anthraquine.

DISPERSE DYE:
General properties of disperse dyes: Solubility Disperse dyes are insoluble in water or slightly soluble in water. It makes fine dispersion with water with dispersing agent. It dissolves in organic solvents like benzene, Toluene etc Fastness to washing The fabric dyed with disperse dyes shows moderate to good washing fastness. Light fastness Most of the disperse are very fast to light. The minimum light fastness rate is 4-5. Sublimability Due to electronic arrangement disperse dyes have good sublime ability.

DISPERSING AGENT:

A dispersing agent, often of a surface active chemical, that promotes formation of a dispersion or maintains a state of dispersion by preventing settling or aggregation. Use in dying called Disperse Dying Should be effective under dying condition Stable to hard water, high temperature and other dying assistance Turkey red oil, soap powder, alkylsulphates, formaldehyde etc. are the recommended dispersing agent

DISPERSING AGENT:
Functions Particle size reduction of the dye Enable the dye in powder form in to dispersion Maintain dispersion in fine form through out dying process Increase solubility of disperse dye

CARRIERS
Carrier is an organic compound It accelerated the adsorption of disperse dye by the fiber Tumescal- A.C.I Matexil- A.C.I Levagol- Bayer Dilatin- Sandoz are commercially used carrier available in the market

CARRIERS

O-Phenyl phenol, tend to lower the light fastness of many dyes if carrier residues remain in the dyed fiber.

Chlorobenzenes have no effect on this property, but strong odour and are both toxic and difficult to biodegrade. Biphenyl is relatively non-toxic to river life but is not readily biodegradable. Methylnaphthalene, also of low toxicity, is moderately biodegradable.

Butyl benzoate is relatively efficient in promoting migration on PES/WO blends N-alkylphthalimide has no odour and good efficiency

ACETIC ACID

Acetic acid, CH3COOH also known as ethanoic acid, is an organic acid that gives vinegar its sour taste and pungent smell. It is a weak acid, in that it is only a partially dissociated acid in an aqueous solution. Pure, water-free acetic acid (glacial acetic acid) is a colorless liquid. Use of acetic acid: Acetic acid is one of the simplest carboxylic acids. It is an important chemical reagent and industrial chemical, used in the production of polyethylene terephthalate mainly used in soft drink bottles; cellulose acetate, mainly for photographic film; and polyvinyl acetate for wood glue, as well as synthetic fibers and fabrics. In households, diluted acetic acid is often used in descaling agents. The global demand of acetic acid is around 6.5 million tones per year

ACETIC ACID

Nomenclature The trivial name acetic acid is the most commonly used and preferred IUPAC name. The name acetic acid derives from acetum, the Latin word for vinegar. Glacial acetic acid is a trivial name for water-free acetic acid. To emphasize the role of the active hydrogen in forming the salt sodium acetate, some people write the molecular formula as HC2H3O2. To better reflect its structure, acetic acid is often written as CH3CO2-H, CH3COOH, or CH3CO2H.

ACETIC ACID

Chemical properties The hydrogen (H) atom in the carboxyl group (COOH) in carboxylic acids such as acetic acid can be given off as an H+ ion (proton), giving them their acidic character. Acetic acid is a weak, effectively monoprotic acid in aqueous solution, with a pKa value of 4.75. Its conjugate base is acetate (CH3COO). A 1.0 M solution (about the concentration of domestic vinegar) has a pH of 2.4, indicating that merely 0.4% of the acetic acid molecules are dissociated.

ACETIC ACID


 

Chemical reactions Acetic turns blue litmus red, neutralizes alkalis to form salt and water. It also decomposes carbonates and bi carbonates to liberate carbon dioxide. CH3COOH + NaOH CH3COONa +H2O NaHCO3(s) + CH3COOH (aq) CH3COONa (aq) + CO2 (g) + H2O (l)

METHODOLOGY:
Dyeing of polyester: Carrier dyeing at near or at boiling temperature

HT dyeing at 120 140oC Pad-Thermosol dyeing

EXPERIMENTAL:
Raw materials are use: Polyester fabric: 5yards purchased from local market. Machine /equipment uses in wet processing in the PAU. Textile Engineering Dyeing Laboratory: Beaker Burner Stirrer Manual balance Dryer Pipette Measuring cylinder Thermometer Etc

EXPERIMENTAL:
Chemical uses: Acetic acid Dispersing agent Carrier Hydrous Pretreatment: Only hand wash are done at room temperature for 5 minutes.

EXPERIMENTAL:
Recipe Without carrier Disperse dye 0.5% OWF Acetic acid 3cc/l Dispersing agent 1.5cc/l PH 4-5 Time 30 min Temperature 80-95c M: L 1:30

With carrier Disperse dye 0.5% OWF Acetic acid 3cc/l Dispersing agent 1.5cc/l Carrier 1.5cc/l PH 4-5 Time 30 min Temperature 80-95c M: L 1:30

EXPERIMENTAL: DYEING CURVE

EXPERIMENTAL:

EXPERIMENTAL:

EXPERIMENTAL:
Reduction clearing: When very heavy shades have been dyed it may be necessary to give a reduction clearing to avoid lack of fastness to rubbing. In this study the goods are treated with 1gm/l hydross for 20 minutes at 45c-50c.

RESULT AND DISCUSSION

Dyeing of polyester with disperses dye with different technologies are very common in present time. Wet processing industries have got various apparatus equipment machineries and facilities for dyeing and finishing of synthetic materials. In this study a simple of observation was made to observe color buildup affect on polyester fiber dyeing with disperse dye with and without carrier.

RESULT AND DISCUSSION

Here in this study a standard recipe as shown below

Disperse dye Acetic acid 1.00% OWF Disperse dye 3cc/l Acetic acid 1.00% OWF 3cc/l

Dispersing agent 3cc/l

Dispersing agent 3cc/l Carrier 2cc/l 4-5 30 min 80-95c 1:30

PH Time Temperature M: L

4-5 30 min 80-95c 1:30

PH Time Temperature M: L

RESULT AND DISCUSSION

Here after water washing polyester fabric sample were dyed with (0.5-1.45)% shade covers 20 sample with above recipe from light color to dark color were buildup which are shown in the sample attachment. It is observed that is all cases better color build up was found with the samples dyed with carrier dyeing process. Here dyeing was performed at 80-95c in open bath. Without the use of carrier proper swelling of polyester fabrics was not possible but with addition of carrier fabric swelling was effected and better color buildup was possible

RESULT AND DISCUSSION

But carrier has some problems, Such as

Residual carrier in the dye bath contributes to effluent pollution and may be environmentally harmful Carrier that is volatilized during dyeing or subsequent heat setting becomes an atmospheric contaminant Residual carrier in the fiber can be a health hazard, as well as causing an unpleasant odour on heating or during storage.

RESULT AND DISCUSSION

Moreover presently dye house effluent control and environment protect are very important to protect ecological degradation. Particularly a populous country of Bangladesh where agriculture, fisheries, forestry and living almost in same ecological area. So environmentally sustainable technologies are always in demand yet this study is useful for preliminary observation to sea effect of carrier on dyeing polyester with disperse dye.

CONCLUSIONS
Bangladesh is a very small and highly populous country. Industrial development is necessary for employment generation and national development. Textile is a basic industries second to only food. Bangladesh has got natural blessing for agriculture due to our soil and climatic condition. As we have huge unskilled labor and facilities for developing qualified Engineer and technologists which are obviously an indicator for choosing textile as our priority sector. Already Bangladesh has achieved its position in world textile field. So there is a potential for further development of this sector. In this study simple observation was made to see effect of carrier in open bath polyester dyeing. Which are widely used in the initial time of industrialization.

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