AMMONIA MERCERIZATION

Submitted To:
Dr. Ummul Khair Fatema
Presented By :
ID Name
2011-1-017 Shahanaz Parvin
2011-1-018 Rifat Jahan
2011-1-098 Nazmun Nahar
2011-1-128 Humayra Akhter Himu
2011-1-208 Nigar Rashida
 WHAT IS MERCERIZATION?
Mercerization is a pre-treatment or finishing treatment of cellulosic materials
with higher concentrated Alkali (NaOH) for short period at lower temperature.
Mercerization gives cotton woven cloth a silky luster, and is the foundation of
many improved and beautiful finishes.

Mercerization was discovered by John Mercer and the process is named

after him : Mercerizing. Later Horace Lowe found that the glazing effect
became even more pronounced when cold caustic soda acted on cotton under
tension. He discovered the actual mercerizing process.
 OBJECTIVES OF MERCERIZATION
To improve luster of cotton materials
To increase ability to absorb dye and moisture
To improve reactions with a variety of chemicals
To improve dimensional stability of materials
To improve strength/elongation and mechanical properties
To improve smoothness
To improve hand
EFFECT OF MERCERIZATION ON COTTON FIBER
 WHAT IS AMMONIA MERCRIZATION?

Ammonia Mercerization is a treatment of cotton fibre with Ammonia

(NH3) produces effect similar to that obtained with caustic soda.

Among various amines, the Liquid Ammonia appears to be unique in

its swelling action on cellulose and its effect on crystal structure.

Liquid ammonia treatment was first developed by Coats in 1960.

 WHY AMMONIA MERCERIZATION?
Liquid Ammonia treatment is a highly effective and well controlled
alternative to caustic soda mercerization.

Anhydrous liquid ammonia, being smaller molecule, penetrates cellulose very

rapidly and complexes with hydroxyl groups of cellulose after breaking
hydrogen bonds in crystalline regions and increases distance between cellulose
chain in crystallites.

Ammonia treatment results in a more rounded cotton fiber, which scatters light
more, in turn resulting in a luster that is less bright.
 WHY AMMONIA MERCERIZATION? ( CONTD.)
This processing makes the inside of the fiber swell equally. There is less fiber-
swelling, therefore the fibers are more pliable, which allows them to bend and
recover more easily when tension or stress is applied.

The permanent-press effects are achieved without the use of cross-linking resins.

The ammonia process was intended as a replacement for conventional

mercerizing for both fabrics and in mercerizing sewing threads (Prograde
process).

The lower pH of ammonia allows safe treatment of more sensitive fibers like
linen (flax) or silk.
APPLICATION ON TYPES YARNS & FABRICS
 Sewing Thread

Denim Corduroy Chambray

 Pillow Material Jute

Linen Cotton PET Blend Cotton Nylon Blend

 PHYSICAL CHANGES
Improvement in strength.
Change in cross section from bean shape to almost circular.
Change in longitudinal view convoluted to cylindrical.
 CROSS SECTION OF COTTON FIBER

After Mercerization After Ammonia

Mercerization
 CHEMICAL CHANGES

Formation of cellulose-III
Improvement in moisture regain properties (more hydroxyl groups)
Improvement in dye uptake
 ABSORPTION OF AMMONIA IN COTTON FABRIC
1 Cross section before mercerization
2-5 Swelling process in ammonia
6 Rinsing process after swelling
7 After state
 PROCESS PARAMETER
Concentration of Ammonia

Time of treatment

Tension applied

Temperature

Surface tension of Ammonia

Impurities of Ammonia
 CHEMICALS
Ammonia

Wetting agent

Temperature : -33c

Absorption period : 0.6 sec

Two processes known as PROGRADE for yarn mercerizing and SANFORSET for
woven and knitted fabrics are widely used.

Schematic Diagram of Ammonia Mercerizing Machine

 Main Parts Of Ammonia Mercerization Machine
Ammonia Impregnation zone
Ammonia Evaporation Zone
Washing Zone
 Principle Of Ammonia Mercerization Machine

Process consist of passing the fabric though a bath of liquid ammonia

with 100% pickup for approximately 10 seconds.
Ammonia is removed with dry heat applied by passing over
blanketed, steam heated dry cans which removes about 90% of the
ammonia which is recovered by a recovery plant and made available
for recycling.
The rest of the ammonia, which chemically bonded to the cellulose, was
removed by light steaming.
Diagram of the Sanfor-set" process
 Ammonia Impregnation zone
The untreated fabric in dry condition, is passed over smoothing rolls and then around
some heated dry cans. The dry cans assure an adequate level of dryness(water
content less than 10%) in the fabric.

Then the fabric is cooled by a fan before entering through a gas lock to the
processing chamber .

In the treatment chamber, the fabric passes over a guide roller and is directed
downward and around an immersion roll disposed in the lower portion of a liquid pan,
which retains liquid ammonia . The liquid ammonia bath is at a temperature of - 33
C.

After passing the liquid ammonia bath, fabric is directed upward to a guide roller.
The fabric web advances at a rate such that its immersion in the liquid ammonia bath
 Ammonia Impregnation zone (Contd.)
The atmosphere within the chamber is saturated with ammonia vapor, such
that the liquid ammonia does not evaporate from the impregnated fabric
emerging from the bath.
The guide roll serves to smooth and apply a slight widthwise tension to the
fabric before it enters the pad rollers.
After having passed through the pad rollers , the fabric passes over a
tension control roller ,to impart a desired amount of warpwise tension.
 Ammonia Evaporation Zone
The fabric passes around some guide rollers and is brought into a pressure contact with
the surface of a heated dryer drum.
The dryer includes a blanket which serves to both press the fabric tightly against the
surface of the heated drum and to geometrically confine the fabric by frictional forces.
The dryer drum typically may be heated by high temperature steam.
Thus, when the fabric, saturated with liquid ammonia at -33 C, comes into contact with
the heated drum surface, the ammonia is almost instantly washed off, to a level at which
no further substantial reaction occurs.
Thus, the reaction period is effectively terminated almost instantly upon contact of the
fabric with the heated drum.
In this heat treatment some 90-95% of the ammonia is removed.
 Recovery of ammonia

Recovery of ammonia occurs by the reaction between ammonia water and

gas that is discharged. Ammonia water is to mix with air, it goes outside and
is then separated through the distillation column. Ammonia is distilled then send
to the storage unit finally.

In the recovery device of ammonia, there are gas vents to wash the top of the
tower, to control the ammonia content, and to lower than the amount for
environment protection.
 Comparison among different mercerization process

Property Conventional Hot Ammonia

Mercerization Mercerization mercerization
Swelling speed Low Fast Very fast

Evenness Uneven Good Good

Luster Good Good Very good
Dye up take Good Not quite good Good
Dimensional Good Good Good
stability
Alkaline chemical Sodium hydroxide Sodium hydroxide Ammonia
 EFFECT OF AMMONIA MERCERIZATION
1. More rounded yarn structure and orientation.
2. Excellent form stability ( having good Wash & Wear properties)
3. Low shrinkage in post washing.
4. Increase in wrinkle resistance.
5. Increase in fiber elasticity.
6. Enhanced tear resistance as well as tensile strength.
7. This process add gentle, elegant luster to the fiber.
8. Fibers keep their soft feel as no damage is done by this processing.
9. Highly uniform dyeing properties.
10. Dye uptake % increased.
 ADVANTAGES OF AMMONIA MERCERISATION
1. Evenness and uniformity of swelling comparatively better.
2. Less pollution.
3. Jute and linen can be mercerized.
4. Safe treatment of more sensitive fibers like flax or silk.
5. Higher productivity.
6. Higher quality fabric.
7. Longer life after long periods of wear and repeated washing.
 DISADVANTAGES OF AMMONIA MERCERIZATION
1. Very costly equipments.
2. Non-availability of machine.
3. Lower color yield.
4. Large capital investment for NH3 recovery.
5. NH3 recovery problem.
6. Leakages cause great harm to personnel working.
Thank You