Calcul. of Cont Applications

Textile Effects2110024E.ppt

LIQUOR APPLICATIONS / CALCULATIONS

for continuous applications

PretreatmentSlide Show


Automation of product dispensing

All impregnation or continuous methods have one critical factor in common:

A constant concentration of chemicals or products must be supplied to the goods from beginning to end of the batch because this is one of the main factors that finally determines the quality of the results.


Fabric loading

Recipe indication Ckg (g/kg or ml/kg)

The recipe components of impregnation liquor are indicated in g/l and the liquor pick-up is indicated separately. For wet-on-dry impregnation (e.g. Pad Batch Cold Peroxide bleach,…) with almost total liquor exchange this procedure produces

accurate results.For wet-on-wet applications where the liquor exchange differs markedly from

100%, e.g. at high running speeds, with small impregnation troughs and tightly woven goods, this method leads to inaccuracies.To avoid such sources of error, the amount of recipe components should be

calculated directly on the weight of the dry goods.


Fabric loading

Feed liquor

rExpression entrance

of the impregnation-unit

fnLiquor pick up, exit

Recipe in ml/kg or g/kg:

14 ml/kg Ciba® TINOCLARITE® CBB20 g/kg NaOH 100%50 ml/kg H2O2 35%4 ml/kg Ciba® ULTRAVON® CN


Liquor exchange

No liquor exchange liquor exchange rate a = 0Partial liquor exchange liquor exchange rate a = 0.1 – 0.9Complete liquor exchange liquor exchange rate a = 1

When a material with a given residual moisture content from previous treatments (often a wash process) runs through an impregnation unit, a certain amount of this moisture will be replaced, i.e. „exchanged“ by the impregnation liquor,

depending on the process parameters (dip time, machinery, temperature, fabric structure, surface tension). This process is called liquor exchange. The liquor

exchange rate is used for measurement.


Liquor exchangeExample

Fiber cross section

Liquor pick up in l/kg 0.9 0.9 0.9Liquor exchange rate (a) 0 0.5 1.0

Feed liquor



fnLiquor pick up; exit

e.g. 60%0.6 l/kg

e.g. 90%0.9 l/kg


Impregnation equipment

Liquor exchange in %

Liquor exchange rate (a)

Large impregnation vats possibly with intermediate squeezing 15 - 30 m material content

85 -100 %

0.85 - 1.0

Smaller impregnation vats 5 - 15 m material content

40 - 85 % 0.4 - 0.85

Impregnation units 2 - 5 m material content

20 - 40 % 0.2 - 0.4

Pad mangles

10 - 20 % 0.1 - 0.2

Dip rollers, Spraying equipment, Pouring equipment, Foam add-on

0 %

0

Estimated liquor exchange


Liquor volume: 500 - 1000 literLiquor exchange rate: 0.8 - 1.0Liquor pick up: 80 - 100 %


15-20 Metermaterial content

Liquor application unitConventional impregnation vat (Saturator)




Liquor application unit BENNINGER IMPACTA


Liquor application unit BABCOCK SUPER-SAT / ECON-SAT

Liquor volume: 200 - 400 literLiquor exchange rate: 0.7 - 0.9Liquor pick up: > 100 %


Super SatSuper Sat 2

Econ SatLiquor volume: 100 - 200 literLiquor exchange rate: 0.4 - 0.6Liquor pick up: > 100 %





Liquor application unit BRUGMAN BRUBO SAT


Liquor volume: 20 - 30 literLiquor exchange rate: 0 - 0.2Liquor pick up: > 100 %


Liquor application unit GOLLER DIP-SAT (Vario)


Liquor application unit KÜSTERS FLEXNIP






Liquor application unit MENZEL OPTIMAX


Liquor volume: 0 (5 - 10 liter in the pipelines)Liquor exchange rate: 0Liquor pick up: > 100 %

Liquor volume: 0 (5 - 10 liter in the pipelines)Liquor exchange rate: 0Liquor pick up: > 100 %

Liquor application unit KLEINEWEFERS RACO YET


Impregnation bath concentration

Ckg

CL = ----------------------------(fn – r) + (r x a)

Effective pick up = (fn – r) + (r x a) = EP

Under given conditions (depending on dosing system) we need the value of the impregnation bath concentration (CL ). CL is also the standard value for on-line monitoring of impregnation baths.

The impregnation bath concentration depends directly on:• liquor exchange rate (a)

• expression entrance of the impregnation-unit (r)• liquor pick up, exit (fn )


Impregnation bath concentrationExample

Ckg 14---------------------- = -------------------------------- = 15.6 ml/l(fn – r) + (r x a) (0.9 – 0.6) + (0.6 x 1.0)

Ckg 14---------------------- = -------------------------------- = 23.3 ml/l(fn – r) + (r x a) (0.9 – 0.6) + (0.6 x 0.5)

Liquorexchange rate

1.0

Liquorexchange rate

0.5



e.g. 60%0.6 l/kg

fnLiquor pick up

e.g. 90%0.9 l/kg


14 ml/kg Ciba® TINOCLARITE® CBB20 g/kg NaOH 100%50 ml/kg H2O2 35%

4 ml/kg Ciba® ULTRAVON® CN


Impregnation bath concentration Example



e.g. 60%0.6 l/kg

fnLiquor pick up

e.g. 90%0.9 l/kg

Ckg 14---------------------- = -------------------------------- = 15.6 ml/l(fn – r) + (r x a) (0.9 – 0.6) + (0.6 x 1.0)

Ckg 14---------------------- = -------------------------------- = 46.7 ml/l(fn – r) + (r x a) (0.9 – 0.6) + (0.6 x 0.0)

Liquorexchange rate

1.0

Liquorexchange rate

0.0





With some dispensing systems, e.g. those featuring automatic level control by running in water, the user can also add any feed liquor concentration (CN) he chooses. The calculations always refer to the running goods and depend on:

- running speed- weight of goods

- and to some extent the difference between expression at entry and exit

but not on the exchange factor in the impregnation unit.

(without consideration of residual chemicals content)

Feed liquor concentration

Ckg

CN = ----------fn – r


Feed liquor concentrationExample

Ckg 14

Feed liquor concentration = ---------- = ------------- = 46.7 ml/lfn – r 0.9 – 0.6

Ckg 14

Feed liquor concentration = ---------- = ------------- = 46.7 ml/lfn – r 0.9 – 0.6



fnLiquor pick up, exit

e.g. 60%0.6 l/kg

e.g. 90%0.9 l/kg





BABCOCK;POLYKOMATdosing system

BENNINGER;Chemical calculation-/dosing system

KÜSTERS; CONTIDOS dosing system

BRUGMAN;BRUBO-SAT

dosing system

Dosing - systemsExamples


Calculation of feed liquor amountSingle component via level control, without automatic level adjustment by separate water flow

Recipe:

14 ml/kg Ciba® TINOCLARITE® CBB50 ml/kg NaOH 36°Bé50 ml/kg H2O2 35%


Recipe:



Feed liquor

60% 90%

80 m/min

250 g/rm

Liquor exchange rate

= 0.5

Impregnation bath concentration CL

Ciba® TINOCLARITE® CBB 23.3 ml/lNaOH 36°Bé 83.3 ml/lH2O2 35% 83.3 ml/lCiba® ULTRAVON® CN 6.7 ml/l

Feed liquor concentration CN


Feed liquor amount VCNVCN = (g/rm : 1000) x (fn – r) x m/min x 60 min

360 liter/h or 7.5 liter/100m fabric run


Calculation of feed liquor amount Single component via metering equipment, with automatic level adjustment by separate water flow

Feed liquor

60% 90%

80 m/min

250 g/rm


= 0.5

water



Feed liquor concentration (factor 1.5*) CX


Feed liquor amount VCNVCN = (g/rm : 1000) x (fn – r) x m/min x 60 min : factor

240 liter/h or 5.0 liter/100m fabric run

* Depending on pump capacity and product stability

Recipe:



Recipe:




Calculation of feed liquor amount Two components via level control, without automatic level adjustment by separate water flow

60% 90%

80 m/min

250 g/rm


= 0.5

Component 2 (= 2/3)

Component 1 (= 1/3)



Feed liquor conc./-amount by „single component feed“ CN/VCN

Ciba® TINOCLARITE® CBB 46.7 ml/l feed liquor amount 360 liter/hNaOH 36°Bé 166.7 ml/lH2O2 35% 166.7 ml/lCiba® ULTRAVON® CN 13.3 ml/l

Allocation, Dosing ratio + Feed liquor amountCN Component = CN x total parts : dosing ratioVCN Component = VCN x dosing ratio : total partsComponent 1 (dosing ratio = 1)H2O2 35% 500 ml/l feed liquor amount 120 liter/hCiba® TINOCLARITE® CBB 140 ml/l or 2.5 liter/100m fabricComponent 2 (dosing ratio = 2)NaOH 36°Bé 250 ml/l feed liquor amount 240 liter/hCiba® ULTRAVON® CN 20 ml/l or 5.0 liter/100m fabric

The dosing ratio of the two components should be 1:2 (= 3 parts).

Recipe:



Recipe:




Calculation of feed liquor amount Two components via metering equipment, with automatic level adjustment separate water flow

60% 90%

80 m/min

250 g/rm


= 0.5

water

Component 2

Component 1



Allocation + calculation of the concentrations CNCN = single product Ckg x 1000 : Ckg total componentComponent 1H2O2 35% 1000.0 ml/l undilutedComponent 2 (1:2 diluted*)Ciba® TINOCLARITE® CBB 205.8 ml/l; 1:2 diluted = 68.6 ml/lNaOH 36°Bé 735.3 ml/l; 1:2 diluted = 245.1 ml/lCiba® ULTRAVON® CN 58.8 ml/l; 1:2 diluted = 19.6 ml/lwater 666.7 ml/l

Feed liquor amount VCXVCX = (g/rm : 1000) x m/min x 60 min x Ckg total component x dilution factorComponent 1 60.0 liter/h or 1.3 liter/100m fabric runComponent 2 244.8 liter/h or 5.1 liter/100m fabric run

* Depending on pump capacity and product stability

Recipe:



Recipe:




Calculation of feed liquor amount Single liquid products via metering equipment, throughput-related control, with automatic level adjustment by separate water flow



Feed liquor amount(g/rm : 1000) x m/min x 60 min x Ckg

Ciba® TINOCLARITE® CBB 16.8 liter/h or350 ml/100m fabric run

NaOH 36°Bé 60.0 liter/h or1250 ml/100m fabric run

H2O2 35% 60.0 liter/h or1250 ml/100m fabric run

Ciba® ULTRAVON® CN 4.8 liter/h or100 ml/100m fabric run

Recipe:



Recipe:



60% 90%

80 m/min

250 g/rm

Liquorexchange rate

= 0.5


Calculation of feed liquor amount Special programs for recipe calculations

PREMATIC (Version 1990)The special Ciba PREMATIC-system covers the most important continuous impregnation chemicals dosing systems. Menu controlled programs simplify the input of the relevant dates (e.g. recipe amounts, machinery dates etc.).

EXCEL SheetUsing an excel sheet simple calculation programs can be made.


Material guidance in the steamerDifferent systems

For high liquor exchangerates

For low liquor exchange rates

Horizontal inlet

Vertical inlet

Impregnationunit

Cloth transport onroller section“tight strand”

Cloth transport onroller bed“conveyor-belt”


Titration regulationDetermination of the peroxide content in bleach liquors

PROCEDUREA titration flask or glass beaker is charged with 20 – 30 ml sulphuric acid 20%, 10 ml bleach liquor is added with a pipette and titrated with n/10 KMnO4-solution until a faint pink color is obtained (the pink color should persist for about 1 minute).

EXAMPLE8,5 ml n/10 KMnO4 – solution is used for titrating 10 ml bleach liquor. 1 liter bleach liquor thus contains:

CALCULATION

ml/l H2O2 100% w/w: consumption of ml 0,1 N KMnO4-solution x 0,17(8,5 x 0,17 = 1,445 ml/l H2O2 100% w/w)

ml/l H2O2 50% w/w: consumption of ml 0,1 N KMnO4-solution x 0,283(8,5 x 0,283 = 2,41 ml/l H2O2 50Gew.%)

ml/l H2O2 35% w/w: consumption of ml 0,1 N KMnO4-solution x 0,429(8,5 x 0,429 = 3,66 ml/l H2O2 35Gew.%)


Conversion tableConversion factors for commercial hydrogen peroxide

e.g. in place of 15 liter H2O2 35% w/w what would be the equivalentamount of H2O2 50% w/w15 x 0,66 = 9,9 ~ 10 liter H2O2 50% w/w

H2O2 30% w/w 35% w/w 50% w/w

30% w/w 1.00 0.84 0.56

35% w/w 1.19 1.00 0.66

50% w/w 1.79 1.51 1.00

On volume basis (in liter)


Titration regulation Alkali content in bleach liquors

PROCEDURESeveral drops of indicator solution, e.g. bromocresol purple *, are added to 10 ml bleach solution and the whole is titrated with n/10 HCl or n/10 H2SO4 until the color changes from purple to yellow.To determine the alkali content in hypochlorite bleach liquors, a few drops of hydrogen peroxide are first added to the titration sample (=10 ml), to destroy the available chlorine. Titration is then performed as described.

CALCULATIONIn view of equivalence ratios, the following applies to a sample of 10 ml bleach liquor:

for caustic soda (NaOH): consumed ml n/10 acid x 0,4 = g NaOH per liter

for soda (Na2CO3): consumed ml n/10 acid x 0,53 = g Na2CO3 per liter

for ammonia (NH3): consumed ml n/10 acid x 0,17 = g NH3 per liter

for aqueous ammonia (NH4OH 25%): consumed ml n/10 acid x 0,747 = g NH4OH 25% per liter

* or phenolphthalein (change from red violet to colorless)


Conversion tableSpecific gravity and concentration of NaOH at 20°C

772.450.5501535169.814.6201160

710.047.3481500117.710.6151115

649.244.246147090.38.3121090

590.841.044144074.56.9101075

535.637.942141058.95.681060

491.635.540138543.94.261045

386.229.335132029.22.841030

306.024.230126515.11.521015

231.819.22512101.60.1601000

g/lNaOH

% NaOH°BéWeight of 1 liter

g/lNaOH

% NaOH°BéWeight of 1 liter


Edition 2003

Copyright © 2003 Ciba Specialty Chemicals Inc. All rights reserved.All trademarks mentioned are either property of or licensed to Ciba Specialty Chemicals and registered in relevant countries.IMPORTANT: The following supersedes Buyer’s documents. SELLER MAKES NO REPRESENTATION OR WARRANTY, EXPRESS OR IMPLIED, INCLUDING OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No statements herein are to be construed as inducements to infringe any relevant patent. Under no circumstances shall Seller be liable for incidental, consequential or indirect damages for alleged negligence, breach of warranty, strict liability, tort or contract arising in connection with the product(s). Buyer’s sole remedy and Seller’s sole liability for any claims shall be Buyer’s purchase price. Data and results are based on controlled or lab work and must be confirmed by Buyer by testing for its intended conditions of use. The product(s) has not been tested for, and is therefore not recommended for, uses for which prolonged contact with mucous membranes, abraded skin, or blood is intended; or for uses for which implantation within the human body is intended.Please note that products may differ from country to country. If you have any queries, kindly contact your local Ciba Specialty Chemicals representative. Further information at web site: http://www.cibasc.com.

2110024E.ppt - Mar-03, Printed in Switzerland.

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