Lyocell, The New Generation of Regenerated Cellulose

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Acta Polytechnica Hungarica
Vol. 5, No. 3, 2008
Lyocell, The New Generation of Regenerated
Cellulose
Éva Borbély
Professor of Dept. of Packaging and Paper Technology, Budapest Tech
Doberdó út 6, H-1034 Budapest, Hungary
E-mail: [email protected]
Abstract: For the majority of the last century, commercial routes to regenerated cellulose
fibres have coped with the difficulties of making a good cellulose solution by using an easy
to dissolve derivative (e.g. xanthane in the case of viscose rayon) or complex (e.g.
cuprammonium rayon). For the purposes of this paper, advanced cellulosic fibres are
defined as those made from a process involving direct dissolution of cellulose. The first
examples of such fibres have now been generically designaed as lyocell fibres to
distinguish them from rayons, and the first commercial lyocell fibre is Courtaulds’ Tencel.
Keywords: cellulose, fibre, lyocell
1
Introduction
The cellulose fibers produced by direct dissolution have the generic name of
lyocell.
Cellulose is one of the most abundant natural resources on earth, and there has
been extensive research on the films, plastics, and fibers from this material.
The history of cellulose fibers dates back to the 1860s, when the first rayon fibers
were commercialized by Courtaulds. But the so-called rayon process includes
toxic chemical treatments to block hydroxyl groups of cellulose to prepare a
spinnable solution, sometimes causing ecological problems.
Many attempts have been made to invent new solvents to directly dissolve
cellulose, and some successful results have been reported [1]. Among these, Nmethylmorpholine-N-oxide (NMMO) hydrate turned out to be the best solvent,
leading to the commercial success of cellulose fibers under the trade name of
Tencel by Courtaulds in 1994 (Figures 1 and 2).
Other lyocell processes include Lenzing Lyocell and TITK Alceru [2]. These
processes are advantageous because they are environmentally benign, using
– 11 –
É. Borbély
Lyocell, The New Generation of Regenerated Cellulose
nontoxic NMMO hydrates instead of toxic carbon disulfide, which can be almost
totally recycled.
The lyocell fiber has a highly crystalline structure in which crystalline domains are
continuously dispersed along the fiber axis. This offers good wet strength as well
as excellent dry strength, which makes lyocell water-washable. Further, it shrinks
less when wetted by water and dried than other cellulose fibers such as cotton and
viscose rayon [3, 4, 5, 6].
Recently, a new lyocell process, the Cocel process [7], was devised, which has
some characteristic features similar to the Tencel process. The new process
dissolves finely powdered cellulose in molten NMMO hydrate within 5 minutes
by means of a pasting stage, which causes much less decomposition of cellulose.
Further, this process can use NMMO hydrates with a hydration number (n) greater
than 1 because it adopts a plasticating extruder. The value of n plays a significant
role in the phase behavior of cellulose solutions [8, 9]. It also affects the physical
properties of the fibers spun from the solution [5, 6, 10].
Figure 1
Structure of N-methylmorpholine-N-oxide
Figure 2
3 Possible Formulas of N-methylmorpholine-N-oxide
– 12 –
Acta Polytechnica Hungarica
2
Vol. 5, No. 3, 2008
Direct Dissolution in Amine-Oxide
Cellulose (%)
NMMO emerged as the best of amine-oxides and Neil Franks and Julianna Varga
[11] developed a way of making a more concentrated and hence economical
solution of cellulose, by carefully controlling the water content of the system.
Figure 3. shows that the concentration of water and cellulose where complete
dissolution of the cellulose occurs (at 95%), lie between lines B and C. Between
lines A and B there can be 95% confidence that the solution would be free from
undissolved cellulose fibres are bound to be present. Similarly, between lines C
and D there is a 95% chance that crystals will always be present to the left on line
D. Figure 4 shows the same information in he more familiar ternary diagram form.
Water (%)
Figure 3
Dissolving Cellulose in NMMO and water mixtures
Figure 4
Ternary diagram showing the effect of temperature on the dissolution cellulose in NMMO
– 13 –
É. Borbély
3
Lyocell, The New Generation of Regenerated Cellulose
The Properties of Lyocell
Comparisons of lyocell with viscose in both laboratory and test markets proved
that the fibres were sufficiently different to deserve separate marketing strategies.
Lyocell is:
• stronger than any other cellulosic fibres, especially when wet
• easy to process into yarns and fabrics alone or in blends
• easy to blend (unique fibre presentation)
• easy to spin to fine count yarns
• very stable in washing and drying
• thermally stable
• easy to dye to deep vibrant colours
• capable of taking the latest finishing techniques to give unique drape
• comfortable to wear
4
The Courtaulds’ Lyocell Process
The Courtaulds’ semi-commercial production system is illustrated in Figure 5.
Dissolving grade woodpulp is mixed into a paste with NMMO and passes through
a high-temperature dissolving unit to yield a clear viscous solution. This is filtered
and spun into dilute NMMO, whereupon the cellulose fibres precipiate. These are
washed and dried, and finally baled as staple or tow products as required by the
market. The spin-bath and wash liquors are passed to solvent recovery systems
which concentrate the NMMO to the level required for re-use in dissolution.
PULP
↓
NMMO → MIXING
↓
DISSOLUTION (HOT)
↓
FILTRATION
↓
SPIN / STRECH
↓
WATER → WASHING
↓
DRYING
↓
STABLE FIBRE OR TOW
Figure 5
Direct Dissolution: Courtaulds’ Lyocell
– 14 –
Acta Polytechnica Hungarica
5
Vol. 5, No. 3, 2008
Lyocell Conversion
Lyocell is similar in strength to polyester and stronger than cotton and all other
man-made staple fibre cellulosics. It also has very high dry and wet modul for
cellulosic fibre in both the dry and wet states. Thes properties allow customers
great scope for making strong yarns in blend with virtually all the other
commercially avaiable staple fibres. They also lead to excellent efficiencies in
converting these yarns to woven add knitted fabrics.
All man-made cellulosics lose strength and modulus when wetted, but lyocell
reduces by much less than others. This is important in determining how properties
of the fabric are developed during dyeing and fnishing. However the fibres do
fibrillate during the abrasion and thus specific techniques are required to achieve
the best results, these are discussed later.
Once lyocell fibre has been producted, either as cut staple fibre or continous tow it
will be converted to yarns and fabrics by a range of conventional textile processes.
The most common way of using lyocell fibre is as cut stable, with 1,4 and 1,7 dtex
fibres being cut to 38 mm and converted into a spun yarn using machinery
developed over many years for handling coton fibres which are similar in linear
density and length to lyocell.
The following comments apply to the processing of Tencel fibres. The Lenzing
Lyocell is made by a wet cut route and has very different processing
characteristics //12, 13, 14/.
5.1
Yarn Manufacture
Tencel can be produced via established yarn manufacturing routes, uses
conventional machinery with few major changes to settings or procedures.
Its processing performance is influenced by the following properties:
•
it possesses a non-durable crimp
•
it has a high modulus
•
there is a little fibre entanglement
Thus lyocell will open easily with little nep. In sliver and roving the fibres packs
together, give high cohesion and require high draft forces. In yields yarns with
high tensile strength and few imperfections. In blends well with other fibres,
especally other cellulosics. In adds strength to the final yarns and enhances the
perfomance and aesthetic values of final fabrics.
– 15 –
É. Borbély
5.2
Lyocell, The New Generation of Regenerated Cellulose
Lyocell in Nonwovens
A nonwoven is broadly defined as a textile structure made directly from fibre
rather than yarn. The fabric is usually made by pruducing a web of fibres which is
then strengthened by bonding using various techniques, for example:
•
Thermal bonding
•
Hydroentaglements
•
Needle bonding
The key properties of lyocell which make is suitable for nonwovens are:
•
high strength
•
biodegrability
•
easy processing
•
absorbency
•
potential to fibrillate
Preparation of fibre web can be done in many different ways, however two main
methods are carding and wet-laying.
Not all webs are sutable for bonding by all methods, however, both wet-laid and
carded webs are suitable for hydroentanglement. This is area in which work has
concentrared on lyocell, owing to the fibres’ability to fibrillate in wet processes.
Hydroentanglement produces bonding entangling the fibres together. This is done
by passing the web under rows of high pressure water jets. As this is a wet
abrasive process lyocell can be made to fibrillate at high water pressures,
producing submicron fibrils, which enhance filtration properties.
Hydroentanglement gives strong lyocell fabrics, which compare well to polyester
and stronger than viscose. Lyocell can be bonded using a wide range of other
techniques, which will not be discussed in detail here. It is being trialled and
developed in nonwovens for a wide range of fend-uses including:
•
surgical swabs, drapes and gowns
•
floppy disc liners
•
filtration applications
•
semi-disposable workwear
•
lining materials
– 16 –
Acta Polytechnica Hungarica
5.3
Vol. 5, No. 3, 2008
Lyocell Papers /15/
The ability of lyocell in fibrillate means that is can be processed and made into a
paper, like wood pulp. The main steps in paper making are:
•
Beating and/or refining – these two processes take a dilute suspension of
short fibre – and mechanically treat the fibre in order to fibrillate it.The
forces exerted on he fibres cause the fibre to fibrillate and can also cut the
fibre.
•
Sheet formation, the refined stock is diluted further and then pumped to
the paper machine where is diposited onto a porous metal belt or wire.
The water is sucked through the belt, leaving the fibre on top as paper
sheet. The paper is then passed through a series of drying cylinders and
presses before being wound on a roll.
Lyocell can be processed into a strong paper. The properties depend upon the
amount of fibrillation generated, increased fibrillation gives more paper strength,
and also affects of properties. In general lyocell papers are strong, with good
opacity and low air resistance owing to the circular nature of the fibres and fibrils.
The end-uses being explored are therefore mainly filtration applications, and also
as an additive to improve the properties of a standard paper made from wood pulp.
References
[1]
C. C. McCorsley, Process for Shaped Cellulose Article Prepared from a
Solution Containing Cellulose Dissolved in a Tertiary Amine N-oxide
Solvent, U.S. patent no. 4,246,221, January 20, 1981
[2]
Berger, W., Possibilities and Limitations of Alternative Processes for the
Dissolution and Forming of Cellulose, Lenzinger Berichte, Rudolstat,
Germany, 1994, pp. 11-18, FW16-FW19 (1992)
[3]
Bullio, P. G., Fibre Tomorrow, Am. Textiles Int. 21(9)
[4]
Anon., Tencel-High Performance Cellulose Fibre, High Perform. Textiles
9(7), 1 (1989)
[5]
Davies, S., Courtaulds Tencel-A New Fibre for the Mass Market, Textile
Outlook Int. 44, 8-18 (1993)
[6]
Hall, M. E., Horrocks, A. R., Seddon, H., The Flammability of Lyocell,
Polym. Degrad. Stab. 64, 505-510 (1999)
[7]
Lee, W. S., Jo, S. M., Kang, H. J., Kim, D. B., Park, C. S.:Pelletized Predope Granules of Cellulose and a Tertiary Amine Oxide Spinning Solution
of Cellulose and the Process for Making Them, U.S. patent no. 5584919
[8]
D. B., Lee, W. S., Jo, S. M., Lee, Y. M., Kim, B. C., Rheological Properties
of Spinning Solution of Lyocell Fiber-Effect of Hydrated Level of NMMO,
J. Kor. Fiber Soc. 37, 681-688 (2000)
– 17 –
É. Borbély
Lyocell, The New Generation of Regenerated Cellulose
[9]
Kim, D. B., Lee, W. S., Kim, B. C., Jo, S. M., Park, J. S., Lee, Y. M.,
Effects of the Water Level Hydrated in NMMO on the Physical Properties
of Cellulose Fiber in Dry Jet-wet Spinning, Polymer (Kor.) 22(2), 231-239
(1998)
[10]
Cuculo, J. A.- Hudson, S. M.: US Patent 4 367 191, Research Corporation
(1983)
[11]
Franks, N. E., Varga, J. K.: US patent 4 145 532, April 1980, to Akz
[12]
C. C. McCorsley, Process for Shaped Cellulose Article Prepared from a
Solution Containing Cellulose Dissolved in a Tertiary Amine N-oxide
Solvent, U.S. patent no. 4,246,221, January 20, 1981
[13]
Chun, S. K., Jo, S. M., Lee, W. S., Kim, J. D., The Effect of Water
Contents on the Properties of Cellulose Fiber from the Solutions of
Cellulose/4-methylmorpholine N-oxide/Water, J. Kor. Fiber Soc. 29(6), 4452 (1992)
[14]
Ingersoll, H. G., Fine Structure of Viscose Rayon, J. Appl. Phys. 17, 924939 (1946)
[15]
P. A. Johnson: Courtaulds Lyocell for Papermaking Applications, TAPPI
Nonwovens Conference, Memphis, March 1997
– 18 –

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