Modscour bl

MCPL

ECONOMICALLY & ECOLOGICALLY IMPROVED PEROXIDE BLEACH

MODHERA CHEMICALS PVT. LTD., offers “MODSCOUR-BL” as a product which is well tried and tested in hydrogen peroxide bleaching. The most distinguished properties of this product lie in that it enables various functions to be performed in one bath and also allow the fundamental needs of the consumers for more environmental compatibility. It is bio-degradable to high degree. Besides preventing redeposition of impurities the product offers good stability against acids (important for acid extraction) and alkalies, excellent wetting and re-wetting properties, inhibition of iron and stabilising action for peroxide. MODSCOUR-BL is suited for all types of machinery (continues and discontinuous) and guarantees minimal fibre damage, while achieving a high degree of whiteness at the same time. The user will benefit in quality from the universal means of applying this hitech MCPL product, and will also have savings in time, water and energy. Advantages:

* Only one product now needed for peroxide bleaching * Optimum degree of whiteness * Reduced use of chemicals possible * Excellent d.p. values * Very good re-wetability * Suitable for all types of machines and processes * Stable to acids, alkali, electrolytes and temperatures upto 135ºC * Energy saving due to shortened processes * Complete dispensation of silicate * Biodegradable Scope of Applications:

� Bleach bath stabilisation � Demineralisation bleaching by one bath / two step process � “Three in one” product

- Wetting / scouring - Dispersing - Stabilisation

Technical Presentation 15/11/98

Good Biodegradibility

Sequestration of Ca, Mg at

the presence of high amount

of alkali

Profile of MODSCOUR-BL

MODSCOUR-BL

Stable to alkali, acids,

electrolytes.

Sequestration of iron &

other heavy metal ions in

hot strongly alkaline liquors

Dispersing power of Ca,

Mg & heavy metal

hydroxides

Support of surface active

componet during extraction

processes.

Stable to temperatures upto

135ºC

Stabilisation by complete

dispensation of silicate

Acid extraction & peroxide

bleaching in one bath

Easily dosable

MODSCOUR-BL : Manganese, Iron, Copper binding capacity at 98ºC.

0

100

200

300

400

manganese iron copper

Metal Ions

mg

meta

l io

ns / g

pro

du

ct pH 7

pH 9

pH 11

Stabilisation with MODSCOUR-BL in relation to magnesium content

0

10

20

30

40

50

60

70

80

90

100

Addition of M agnesium Chloride [ºdH]

Re

sid

ua

l H

2O

2, (%

)

Modscour- BL

Perostab-BLN

Silicate

Dependance of Stabilisation on the Magnesium content of the Bath

2ºd

H

4ºd

H

8ºd

H

12ºd

H

16ºd

H

20ºd

H

32ºd

H

48ºd

H

64ºd

H

80ºd

H

0

10

20

30

40

50

60

70

80

90

Fin

al S

tab

ilisation

Resid

ua

l P

ero

xid

e

in %

Addition of Magnesium Chloride

[ºdH]

Modscour- BL

Waterglass

Machine : Thies Roto Stream Material : 100% cotton Liquor ratio : 1 : 10

BLEACHING OF TOWELLING

Bleaching recipe:

1~1.5 g/l : MODSCOUR-BL 2 g/l : NaOH Flakes 5~5.5 m/l : H2O2 50% Water hardness : 8º Gh = 10ºEh (If only deionized water is available add 0.3 g/l MgCl2 . 6H2O) 95°C 60 min. 95°C 2.5°C/min. 80°C 25°C Drain Production Steps 1. Demineralization / Bleaching (Semi White) 2. Vat Dyeing 3. Reactive dyeing Problematic

Repeatly unlevelness on light Vat and Reactive shades occurred in the past in so far as the package inside was lighter than outside. Analyses of the yarn led to the result that deposits of mineral hydroxides caused a blockage of the liquor flow. The followimg Pre-treatment process solved the problem.

Pretreatment of Dyeing - Cheese

1. Pre-Bleach Process

Machine : Open Thied package bleaching unit, circulation in one Direction, Inside Outside Material : 300 kgs. cotton cheese, Nm 19/1. Liquor ratio : 1 : 10

1.1 First Step Deminerlization 2 g/l : MODSCOUR-BL 5 g/l : ALTRANOL-OL / MODFOR-R-610 1 ml/l acetic acid 60% : pH 4~6 20 min, at 40°C

1.2 Second Step (same bath)

Bleaching 1.2 ml.l NaOH 50% 2 ml/l H2O2 35% 40 min. 95°C 95°C

40°C Drain

- Overflow Rise at 70°C, 15 min. - Rise at 70°C, 8 min.

Addition of 1 g/l MODSCOUR-BL pH after Rinsing 7

2. Vat Dyeing

(on different machine, closed apparatus with alternating circulation)

2.1 Pigmentation

1 g/l MODQUEST-FSN 1 g/l MODLEVELLER-VL 0.25% Pigment (Fine dispersion) 0.061% Pigment (Colloidal) 5 m/l NaOH -10 min. at 80°C

2.2 Vatting

3~3.5 g/l Sodium hydrosulphite - 20 min. at 80°C - 30 min. at 60°C

2.3 Rinsing and Oxidation 2.4 Soaping 1~1.5 g/l MODLEVELLER-VL 1~1.5 g/l MODQUEST-WS

- 15 min. at 96°C 2.5 Acidification

0.5 ml/l Acetic acid 60% - 10 min. at 40°C

2.6 Rinsing at 40°C, and cold

2.7 Softening 2.8 Pressure drying

3. Reactive Dyeing

3.1 Pre-Bleach, same as for Vats 3.2 Dye Process

% shade required Reactive dye 1~1.5 g/l MODQUEST-FSN 50 g/l Glauber’s salt 20 g/l Soda ash

50°C 30 min. 50°C 60 min. 50°C 25°C 25°C Soda ash Drain MODQUEST-FSN Dyestuff Salt 3.2 Rinsing

- 5 min. at 25°C - 5 min. at 25°C - 5 min. at 25°C, addition of 0.4 ml/l Acetic acid 60%

3.4 Washing-off - 10 min. at 98°C

addition of 1~2 g/l MODQUEST-FSN 3.5 Rinsing

- 5 min. at 40°C 3.6 After treatment

0.5 ml/l Acetic acid 60% 2% ECOFIX-2F

- 10 min. at 40°C 3.7 Pressure drying

Bleaching of viscose with MODSCOUR-BL on MCS continuous machine

Method : � Desizing (Enzymatic) � Hydrozen Peroxide treatment Machine : MCS continuous machine

- About 1000 running meters in the machine - Speed : 35 m/min. - Liquor ratio : 1:4 - Fabric: Viscose/Cosa about 10.000 running meters

Recipe :

� Desizing : - MODSCOUR-BL : 0.2~0.5 g/l - Enzyme : As per recommendation

- pH : As per recommendation - Retention time : 12 h

BLEACHING: � Starting recipe - MODSCOUR-BL 1 g/l - NaOH 50% 1 g/l - H2O2 50% 4 g/l If only soft water is available add 0.6 g/l MgCl2, otherwise add only 0.2 g/l MgCl2. � Feed liquor conc. - Machinery : see sketch next page A) 12 g/l Enzymes }

4 g/l MODSCOUR-BL } pH=6 } 500 ltr.

B) 20 g/l NaOH 50% } Stock solutions 3 g/l MODSCOUR-BL } ⇓ Dosage: 80 ltr./hr. C) 40 g/l H2O2 50% }

4 g/l MODSCOUR-BL } 3 g/l MgCl2 }

Classical Procedure Indicative formulation with MODSCOUR-BL 4 g/l Washing agent 10 – 12 g/l MODSCOUR-BL 1 g/l Phosphonate 0.2 g/l Magnesium Chloride 6 g/l Wetting agent 15 g/l NaOH 100% 6 g/l Stabiliser 50 g/l H2O2 35% 25 g/l NaOH 50% 40 g/l H2O2 50% ---------------------------------------------- Retention 18 – 24 h ------------------------------------------- Squeezing effect 75% Squeezing effect 75%

Impregnation Retention Washing

COLD PAD-BATCH

LABORATORY TESTS

Degree of whiteness

Whiteness (Berger)

Degree of polymeri-

zation (repeated

determinations)

Rewettability

Grey fabric 63.9 329 20 sec. MCPL Bleaching 70.8 227 Spontaneous

PRE-TREATMENT COMBINED ALKALI TREATMENT +

OXIDATIVE DESIZING AND BLEACHING

Machinery (see sketch next page) 1. Grey fabric (A-frame) 2. Singeing 3. Alkali treatment + oxidative deszing Padding liquor: Caustic soda 35 g/l Na-persulphate 5 g/l Altranol-CD/Modscour-LF 2 g/l Temperature 90-95°C Pick-up 80% 4. Dwelling

4 hours 5. Washing-off, 4 comparments at90°C – counter current, 1 compartment cold rinse 6. Impregnation compartment

Starting concentration: Hydrogenperoxide 50% 40 ml/l Caustic soda flakes 28 g/l MODSCOUR-BL 10 g/l Magnesium chloride.6H2O 0.2 g/l

7. U-Box Reaction Unit Temp. of steam 101°C

Steaming time 20 min 8. Washing-off compartments, Temp. 80-90°C 9. Drying cylinders

CONTINUOUS PRE-TREATMENT, 2 STEP PROCESS

a) Alkali treatment + Oxidative desizing b) Bleaching

------> 1 2 3 4 5 6

7 8 9

Information about the process run

1. Material Cotton weave, 440 g per running meter Warp, sized with a blend of Corn starch Polyvinyl alcohol Polyacrylate Wax 2. Previous process 1st Step: Enzymatic desizing, dwelling process 2nd Step: a) Washing-off decomposed starch b) Alkali-Pad Steam 3rd Step: Peroxide-Pad steam 3. Process 1st Step: Combined alkali + oxidative treatment, dwelling process 2nd Step: a) Washing-off solubilized impurities and decomposed starch b) Peroxide-Pad steam 3.1 Advantages of the oxidative desizing in the alkali step

- Maximum swelling of cellulose, breaking up of husks, saponification of waxes and grease. - Persulphate decomposes starch as well as polyvinyl alcohol - Alkali solubilizes polyacrylate - Shorter dwell time (4 hours) as compared to enzymatic desizing Remarks : Padding at 90ºC, covering of batching roller with foil Temperature is kept due to exothermic reactions: Starch + Persulphate exothermic > Polyvinylalcohol + Persulphate exothermic >

3.2 Calculation of feed liquor concentration F1 = 60% (Entry mangle) F2 = 90% (Exit mangle) d2 = 30%

90 = 90 = factor 3 F2 – F1 90-60

4. Results

Degree of Damage factor Degree of Whiteness Polymerization by Eisenhut Elrepho Filter

Grey fabric 1820 48.9% Treated fabric (without Mercerization) 1550 0.29 70% No optical brightening 5. Evaluation and actions

The reduction of polymerization degree of 15% and a damage factor of 0.29 are satisfactory results. Bearing in mind that the former practised enzymatic desizing resulted in an incomplete removal of the size the oxidative method is a good alternative.

Pad-steam (U-box) continuous oxidative desizing and bleaching

Process-steps

A: 3 Compartments prescouring 90-95ºC

Recipe 1

Addition into compartment No. 3, with overflow in compartment No. 2 and No.1 0.5 ~ 1g/l ALTRANOL-CD/MODSCOUR-LF 1 g/l MODQUEST-FSN Wash-off, overflow compartment No. 4 B: Combined akali treatment and oxidative desizing

Recipe 2

Starting concentration: 4 g/l Na-persulfate 0.5~1 g/l ALTRANOL-CD / MODSCOUR-LF 25 g/l NaOH flakes Concentration of feed liquor: 4 times

C: Steaming

2 times 15 min/102ºC U-Box-Steamer

D: Recipe 3

3 Compartments at 80-95ºC overflow rinse 1 Compartment cold overflow rinse

E: Peroxide bleaching

Recipe 4

Starting concentration 8 g/l MODSCOUR-BL 20 g/l NaOH flakes 40 g/l H2O2 50% 0.3 g/l MgCl2.6H2O (necessary if water hardness is below 8ºGh or 10ºEh) Concentration of feed liquor : 4 times F: Steaming 15 min/102ºC U-Box-steamer G: Recipe 5

4 Compartments hot rinse overflow (counter current if possible) H: Cylinder-dryer

Fabric

¬ ­ Na2S2O8

NaOH Singeing extinguish 4 x wash-off impregnation bath U-Box-Steamer 50-60 sec. total 4 times conc. of 2 times 15 min/102ºC feed liquor Modscour-BL fabric ® ¯ H2O2 fabric NaOH Impregnation bath, 4 x wash-off 4 times conc. of U-Box-Steamer

50-60 sec. total feed liquor 15 min/102ºC fabric °

4 x wash-off 50-60 sec. total cylinder dryer

Continuous-pretreatment- plant

See recipe 1-5

BLEACHING BY PAD-STEAM METHOD

METHOD : m Singeing m Desizing (Enzymatic) m Hydrogen Peroxide treatment(Pad steam) MACHINE : KÜSTERS Combi-Steamer (with Flexnip “System) STEAM TEMPERATURE : 102ºC STEAMING TIME : 25 min. SPEED : 100 m/min. MATERIAL : 100% Cotton (household linen 120 g/m2) RECIPE : m DESIZING : Enzyme As per recommendation Allendet-NI/Altranol-OL 2 g/l pH As per recommendation Retention time As per recommendation m WASHING : 90ºC, 95ºC, 95 (3 Compartments) m BLEACHING : - Pick-up 100% - Water hardness 15º (french hardness) (=8º German hardness) That means magnesium chloride is not necessary. - Steaming time 25 min. at 102ºC Recipes

COMPETITORS m 30 ml/l NaOH 36 Bè m 70 ml/l H2O2 35% (= 46 ml/l H2O2 50%) m 8 g/l Stabilizer m 6 g/l Wetting agent m 4 g/l Sequestering agent m 1 g/l Defoamer

MODHERA CHEMICALS PVT. LTD.

m 50 m//l NaOH 36Bè m 50 ml/l H2O2 35% m 10 g/l MODSCOUR-BL m WASHING 95ºC, 90ºC, 60ºC, 50ºC (4 Compartments)

RESULTS

DP (STN

2.075/84)

S Degree of whiteness

Water absorbency

Grey Fabric 1883 35 /

Competitor 1879 0 71.1 Spontaneous

MCPL recipe 1917 0 71.2 Spontaneous

S= Damage factor

Bleaching by pad steam method Method : Desizing (enzymatic) – Pad roll, combined alkali / Hydrogen peroxide treatment – Pad steam Machine : Babcock combi steamer Steam temp. : 100ºC Steaming time : 15 minutes Speed : 50 m/min. Material : 100% cotton, plain weave, 216 g/m Recipe (starting concentration)

H2O2 50% 40.0 ml/l NaOH 50% 16.0 ml/l (24.5 g/l) MODSCOUR-BL 10.0 g/l

Water : 8º German hardness=10º English hardness. If only deionized water is available add 0.3 g/l MgCl2.6H2O. Calculation of feed liquor concentration

F1 = 65% (Entry machine) F2 = 95% (Exit mangle) d2 = 30% 95 95

95-65 = 95-65 = 3.2 factor Result

- Desizing = very good (assessment by TEGEWA Violet = standard: note 9) - Water absorbency = Penetration 3 sec. Spreading: Warp 35 mm Weft 31 mm - Whiteness = good - Seed removal = complete - DP decrease = 6% - Damage factor = very good, undamaged (Damage factor Eisenhut: 0.04)

Degree of polymerisation:

In continental Europe fluidity is not normally used as an expression of chemical damage but a measure of the degree of polymerization (DP). It is obtained from the viscosity using a modified Staudinger equation. The development of these equations and their use is given by O. Deschler (textile-Praxis 1958, 13, p 927) Typical values for DP are: ----------------------------------------------------------------------------------------------------------

Fibre DP ----------------------------------------------------------------------------------------------------------

Natural fibres; cotton, flax, ramine 2300-3000 Acceptably bleached cotton 1800-2000 Regenerated cellulose polynosic 1000-1200 Viscose 250- 400 The relationship between DP and fluidity (F) for cotton is given by the equation: DP = 2032 [log10 74.35 + F ] - 573

F And this is shown graphically on page Damage factor:

The damage factor (S), suggested by O. Eisenhut (Melliand Textilber. 1941,22, p 424) relates damage to the change in DP and so takes into account high initial DPs. S=log10 (2000 _ 2000 + 1) log10

2 Ptx Ptx Pt = DP before chemical treatment Ptx = DP after chemical treatment 2000 = reference value The damage factor has been categorized to indicate the degree of damage. ----------------------------------------------------------------------------------------------------------

8 factor comment ----------------------------------------------------------------------------------------------------------

0.01 – 0.2 very good – undamaged 0.21 – 0.3 good – very carefully bleached 0.31 – 0.5 satisfactory 0.5 – 0.75 slightly damaged 0.75 badly damaged ----------------------------------------------------------------------------------------------------------

PEROXIDE BLEACHING - DISCONTINUOUS

Package Yarn (Hanks) Jigger Jet Winch Liquor ratio 1:8 - 1:10 1:15 1:3 – 1:6 1:8 - 1:10 1:20 Temperature 98 98 98 98 Duration (min) 30-45 60 60 30-45 30-45 Magnesium chloride (g/l) ⇒ water hardness 8-12° dH

0.2-0.3 0.2-0.3 0.2-0.3 0.2-0.3 0.2-0.3

MODSCOUR-BL (g/l) 0.8-1.5 0.8-1.2 3-5 1.2-1.5 0.4-0.8 ALTRANOL-CD 0.5 ---- ---- ---- ---- Caustic soda flakes (g/l) 1.5-3 1.5-2 4-5 1.5-3 1-1.5 Hydrogen peroxide 35 weight-% (ml/l) 4-8 4-6 10-15 6-8 2-4

PEROXIDE BLEACHING : COLD PAD-BATCH

Pick-up 100% Dwell time (h) 16-24 Magnesium chloride (g/l)⇒ water hardness 8-12° dh 0.2-0.3 MODSCOUR-BL (g/l) 4-6 Caustic soda flakes (g/l) 15-20 Hydrogen peroxide 35 weight-% (ml/l) 40-60

PEROXIDE BLEACHING : PAD STEAM

Combination U-Box Pad-Roll Steam temperature (°C) 100 97-99 85-90 Dwell time (min.) 7-20 20-50 60-120 Magnesium chloride (g/l)⇒ water hardness 8-12° dH

0.2-0.3 0.2-0.3 0.2-0.3

MODSCOUR-BL (g/l) 4-8 8-10 8-10 Caustic soda flakes (g/l) 20 20 20 Hydrogen peroxide 35 weight-% (ml/l) 60-40 40 40

Pick-up : 100%

The above technical presentation proves MODSCOUR-BL as ECONOMICALLY & ECOLOGICALLY improved

peroxide bleach