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Reaction Mechanism of Reactive Dyes in Bengal Hurricane Group On Cellulose
Reaction Mechanism of Reactive Dyes in Bengal Hurricane Group On Cellulose
Prepared By :
Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh
right
CONTENTS
Introduction
Raw Materials
Importance of The Survey
Reason of using Reactive dyes in major
textile industry in Bangladesh
Methods of Dyeing & Printing Cotton
Goods with Reactive Dyes
Technical Deficiency of Reactive Dyes,
Causes and Remedies of Technical
Deficiency
Conclusion
Chapter 1
Acknowledgement
Project Work is an academic function of the Pabna Textile Engineering College. Our teacher Md. Abdul
Mannan, Principal, Pabna Textile Engineering College, gave us an opportunity to choose preferable
mills for Project Work. I chose Bengal Hurricane Dyeing & printing (pvt.) Ltd. joyfully with the
supervision of Mithun Biswas, Asst. Manager(production).
During the Project with Bengal Hurricane Dyeing & printing (pvt.) Ltd. I worked in all the
departments related with Dyes and Chemicals. Beside these, I learned about Dye Quality Control and
Storage System,printing, Garments, Store & Inventory , finishing & specially dyeing.
Our deepest appreciation goes to Mithun Biswas, Asst. Manager(production)Dyeing, Bengal Hurricane
Dyeing & printing (pvt.) Ltd. to give us the opportunity to have project work at BENGAL
HURRICAN GROUP.
I would like to thank Engr. Md. Iqbal Mahamud (Head of the Factory), GM, Dyeing, Bengal Hurricane
Dyeing & printing (pvt.) Ltd. for helping to know about the all aspects of BENGAL HURRICAN
GROUP.
Our gratitude also goes to all the employees of BENGAL HURRICAN GROUP for their sincere cooperation, support and valuable advice which they have provided us during the two months of
training.
Lastly I express my gratitude to our supervising teacher, the name that should be mentioned first, Shib
Shankar Chakraborty, Head of the Dept. Wet Processing Technology for his valuable direction &
supervision.
However, I have prepared my Industrial Attachment overcoming all the difficulties & also the shortage of
time. Here I would like to present the report.
Chapter:2
Application of reactive dyes in
major textile industries in
Bangladesh
Chapter:3
Project Abstract
The use of reactive for Dyed products has dramatically increased over the last 50
years. Reactive dyes are now used to produce multiple products. Reactive
coloring components are inert into materials which are adhered to the base
substrate by the application of soda ash which act as fixing agent.
The main goal of our project is to provide information about the reason of using
reactive dyestuff in major textile industry in Bangladesh, different methods
using in our industry for cotton dyeing with reactive dyes, technical deficiency
of reactive dyes during dyeing & causes and remedies of deficiency of reactive
dyes.
During reactive dyeing there is a rule of using different amount of soda ash with
fixed amount of salt & auxiliaries. In case of dyeing of cotton with reactive dyes
alkali pH should be correctly maintained as during dyeing more electrolytes
required for exhaustion and alkali for fixation.
However the rubbing fastness and hand feel properties of dyed fabric depends on
the amount of soda ash. When we use fewer amounts of soda ash then hand
feel is good but rubbing fastness is not good. And when we use more amounts
of soda ash then rubbing fastness is good but hand feel is not good.
Chapter 4
INTRODUCTION
With the evaluation of the wet processing industries the use of the reactive dyes
in the most of the industries increases day by day. As a result to complete the
project it is has become a part to discus about the evaluation or growth of the
wet processing industries in Bangladesh. Now the number of the wet processing
industries and finishing industries in Bangladesh is 193 which are totally export
oriented according to the survey of the BTMA which has been provided into
their we address.
But the interesting matter is that with the growth of the textile wet processing
mills the number of the employee is not increasing. This is because of to reduce
the cost and increase the quality the modernization of the machine is also
increasing which reduce the number of worker in wet processing industries. But
what is the actual number of the worker in wet processing industries has not
been found due to the lack of proper survey in this sector.
Our project work was estimated as:
APPLICATION OF REACTIVE DYES IN MAJOR TEXTILE IN BANGLADESH &
DEFICIENCY OF REACTIVE DYE:
The project work is interesting as well as lengthy but we must admit that we had
to really work hard and it helps us a great deal to know about whole procedure
of reactive dyeing on dyed fabric. Though reactive dyeing products exhibit
intrinsic characteristics which make them suitable for multiple products
application but reactive dye has it main problem with hydrolysis while dyeing as
a result wastage of the reactive dye increase and it become difficult to match
the proper
Chapter 5
RAW MATERIALS
Raw material is a
unique substance in
any production oriented
textile industry. It not
only plays a vital role
in case of continuous
production & for high
quality fabric but also it
is related to the profit
of the industry.
Fabric:
Different types of fabric treated in Bengal Hurricane Group pvt
Ltd. dyeing section are namely
dyeing section
dyeing section
Single Jersey
Single jersey with Lycra
attachment
Single Jersey with slub
Double Jersey
Polo pique
Back pique
Rib Fabric
Flat back Rib
Interlock
Fibres dyed:
g.Etc.
Trade names
Some trade names of this dye are mentioned:
Trade name
Manufacturer
Country
Procion
I.C.I
U.K
Ciba cron
Ciba
Switzerland
Remazol
Hoechst
Germany
Levafix
Bayer
Germany
Reactone
Geigy
Switzerland
Primazin
BASF
Germany
Drimarine
Sandoz
Switzerland
Cl
Hetreocyclic ring
C - NH
N
-N
N-
Triazine group
Pyridimine group
Quinoxaline dyes
Example:
Triazine derivatives: procion, cibacron.
Pyridimine derivatives: reactone
Quinoxaline derivatives: levafix.
b)Activated vinyl compound:
Vinyl sulphone
Vinyl acrylamide
Vinyl sulphonamide.
Example:
Vinyl sulphone: remazol
Vinyl acrylamide: primazine
Vinyl sulphonamide: levafix.
STRUCTURE
H-OH
CH3-CHOH-CH3
CH3-CH2-OH
H-CH2-OH
C6H12O6
REACTIVE RATE
1.0
0.7
7.4
12.3
5.5
So from the above table it is obvious that secondary hydroxyl group is the beast reactive while
primary one is the most reactive.
When fibre is immersed in dye liquor, an electrolyte is added to assist the exhaustion
of dye. Here NaCl is used as the electrolyte. This electrolyte neutralize the negative
charge formed in the fibre surface and puts extra energy to increase dye absorption. So
when the textile material is introduces to dye liquor the dye is exhausted on to the
fibre.
3.
Alkali
1. D-SO2-CH2-CH2-OSO3Na + OH-Cell
pH10-12.5
alkali
2. D-SO2-CH2-CH2-OSO3Na + OH-Wool
3.
pH1012.5
3. Wash-off:
As the dyeing is completed, a good wash must be applied to the material to remove extra
and unfixed dyes from material surface. This is necessary for level dyeing and good
Application method of reactive dyes varies significantly with type of dyes, shade
required, and available equipments in the mill. These are 3 application procedures
available:
2. The
Full
stripping:
recipe
is as below: Na-hypochlorite : 1% at room
temperature
For complete stripping the goods are first treated with
Na-hydrosulpite: at boil.
(hydrose) at boil then washed off
Time sodium: hydrosulphite
30 min
D-R-Cl
+
H-OH
D-R-OH
and bleached with 1% sodium hypochlorite (NaOCl) at
+ H-Cl
room temperature. This is carried out for 30 min.
Hydrolysis of activated vinyl compound containing dye,
D-F-CH2-CH2-OSO3H + H-OH
D-F- CH2-CH2-OH + H2SO4
2) Amount of alkali:
The amount of alkali used for fixing depends on the depth of shade dyed and the
liquor ratio employed.Some quantities of alkali required for fixing the reactive dyes
are given table 28.
3) Dyeing temperature:
Since increase in temperature affects the rate of physical and chemical processes
involved in dyeing, it is important in dyeing reactive dyes also. The affinity of the
dye for the fibre decreases with increases in temperature and at the same time the
rate of hydrolysis of the dye increases and adversely affects the fixation of color
yield. However the rate of diffusion of the dye in the fibre increases with increased
temperature. At temperatures lower than 20oc, the rate of fixation is very low.
Hence for most of the dyes a temperature of 20 o to 25oC is the recommended
temperature while for some other dyeing at 50 o to 60oC with sodium bicarbonate as
the alkali gives maximum color value.
5) Time of dyeing:
Generally the dye may be added in two portions. The salt may also be added
in two lots. The exhaustion takes place in 20 to 30 min. There is generally no
advantage in extending the period beyond 30 min. The alkali is then added
and the dyeing continued for 30 to 90 min. The depth of shade and reactivity
of the dye decide the time of dyeing. For deeper shades larger times are
required.
6) Liquor ratio:
With decreased liquor ratio, both exhaustion and fixation take place to
increased exert. However the rate of fixation of most of the dyes is not
significantly affected. As the liquor ratio is decreased, the effectiveness of
increasing salt addition also decreases. Hence lower amount of salt are
sufficient to get optimum exhaustion.
If the reactivity of the dye is increased considerably, the rate of reaction with the fibre
increases. There fore, the dyeing can be carried out in a short time. However in this case the
rate of dye also increases, leading to deactivation of a part of the dye. This results in
wastage of the dye. If on the other hand the reactivity of the dye is decreased, the extent of
hydrolysis can be reduced considerably. However this results in the slower rate of reaction
with the fibre also. The ultimate object of dyeing is to react as much of the dye ass possible
with the fibre and minimize the hydrolysis of the dye. This is achieved in practice in two
stages. The dyeing is first started from the aqueous medium under neutral conditions when
the dye does not react either with the fibre or with water. Then gluber salt or common salt is
added to exhaust the dye onto the fibre as much as possible. In this respect, this stage of
dyeing (exhaustion) resembles the dyeing of direct dyes on cotton. Then the second step (that
of fixation or reaction with the fibre) is carried out by adding the alkali (usually used soda
ash). Since the exhausted dye is already on the fibre, it is more likely that the exhausted dye
reacts with the fibre in preference to water. However the dye present in the dye bath (which
contains a substantial amount of the reactive dye) can now react with water since it is under
alkaline condition. It is already stated that the hydrolyzed dye cannot further react with the
fibre but dye to the affinity forces; it is absorbed by the fibre and is retained in it. During the
subsequent washing or soaping the substantivity held hydrolyzed dye gets stripped into the
treatment of the dyeing with boiling soap or detergent solution removes almost all hydrolyzed
dye. However if the affinity is very low, exhaustion of the dye bath prior to fixation cannot be
achieved substantially. This results in a larger amount of the reactive dye remaining in the
dye bath and getting hydrolyzed when alkali is added subsequently. If the dye has high
affinity for cellulose like a direct dye, it becomes difficult to remove the hydrolyzed dye from
the dyeing since it is also absorbed by and retained in the fibre by fairly strong affinity
forces, through not as strong ass the covalent bond formed between the dye and the fibre.
Hence in actual practice low affinity dyes are selected for converting in to reactive dyes.
Dyestuffs:
Dye
REACTIVE
DYE
Brand name
Bezactive
Origin/source
Bezema , Switzerland
Ciba
Ciba , Switzerland
Dychufix
Kemafix
Jaychem,India
Levafix
Dystar , Germany
Procion
Dystar, Germany
Jackazol
India
Kemazol
Jaychem,India
Remazol
Dyestar , Germany
Solazol
Solarfine , Taiwan
Solacion
Solarfine , Taiwan
Chemicals:
Brand name
Novolube Jet
Bluton BVB1
Cibacel DBC
Cibafix ECO
Cibafluid C
SandocleanPCLF
Permacol FA
Novostone CR
Cotton white T
Cyclanon E
Cyclanon ECO
Jinlev RLF349
Eulysin S
Felosan NOF
Uvitex EBF
Jinlev CL-225
Oxalic caid
Palegal FA-8
Respumit BU
Permacol SQ
Na thiosulphate
Uniperol O
Uvitex EVF
Uvitex 2B
Mollan129
Acetic acid
Reduction HCS
Mollan130
Bluton 2B
Type
Anti creasing agent
Violet tone brightener
Sequestering agent
Fixing agent
Anticreasing agent
Detergent
Stabilizer
Enzyme
Redder tone brightener
Fixing agent
Reduction cleaning agent
Dispersing agent
pH buffer in PET dyeing
Detergent
Whitening agent
Levelling agent for reactive dye
Iron remover
Levelling agent for disperse dye
Antifoaming agent
Sequestering agent
Peroxide killer
Washing agent for PET dyeing
PET brightener
Yellow tone brightener
Soapinging agent
pH controller
Reduction cleaning agent
Sequestering agent
Whitening agent
Source
Techna,Italy
CHT,Germany
Ciba,India.
Ciba ,Switz.
Ciba ,Switz.
Clarient,Germany
Techna,Italy
Techna,Italy
CHT,Germany
BASF,Germany
BASF,Germany
Geigy,Taiwan
BASF,Germany
CHT,Germany
Ciba ,Switz.
Geigy,Taiwan
BASF,Germany
BASF,Germany
Techna,Italy
BASF,Germany
Ciba, Switz.
Ciba ,Switz.
Rota,dystar
Geigy,Taiwan
Rota,dystar
Ciba,India
Remark
The list is for the time of our industrial
attachment. It varies according to the
availability of the material & their price.
The price has not been supplied to us due to
their secrecy act.
The annual requirement was not available &
is a record of the procurement department.
Chapter 6
The main goal of our project is to provide information about the reason
of using reactive dyestuff in major textile industry in Bangladesh,
different methods using in our industry for cotton dyeing with
reactive dyes, technical deficiency of reactive dyes during dyeing &
causes and remedies of deficiency of reactive dyes.
As these topics are very sensitive for dyeing industries, it is very much
important to make a survey. It will be very helpful not only for our
studying period but also for our future career.
Chapter 7
Reason of using Reactive Dyes in Major Textile Industries in Bangladesh
Maximum textile industries in Bangladesh are based on cotton knit fabric and reactive dyes are easily applicable
to cellulose fibres.
3. The dyes have very stable electron arrangement and can protect the degrading effect of ultra-violet ray.
4. Textile materials dyed with reactive dyes have very good wash fastness with rating about 4-5 due to strong
covalent bonds formed between fibre polymer and reactive group of dye.
5. Reactive dyes give brighter shades and have moderate rubbing fastness.
6. Dyeing method of reactive dye is easy. It requires less time and low temperature for dyeing.
Chapter 8
Anionic in nature.
2.
Soluble in water.
3.
4.
5.
6.
3. Conc. of electrolyte.
4. Time.
5. Liquor ratio.
Dyeing:
60 0C
50 0C 10min
50min
Bath drain
35 C
PH +Hardness Check
0
20min 30min
10min
10min
Salt (15min) 1 g/l Soda Rest Soda
(30min)
(60min)
35 0C Cold
wash
Process steps:
Dyeing:
10min at 4050OC,
Soaping:
Soaping Agent (.5 g/l)
20min at 7080OC,
Fixing & Softening:
Fixing Agent (.5 g/l)
15min at
40OC,
20min at
40OC,
Bath
Drain
800C 40min
Sequestering Agent Color Dosing
Leveling Agent
Linear (30min)
60 0C
50 0C 10min
50min
Dyeing curve:
Bath Drain
350C
20min 30min
10min
10min
PH +Hardness Check Salt (15min) 1 g/l Soda Rest Soda
(30min)
(60min)
35 0C Cold wash
Dyeing:
60min at 60OC,
Neutralization (Dyeing):
A. Acid (1 g/l)
10min at 40-50OC,
10min at 40
50OC,
Soaping:
Soaping Agent (.5 g/l)
20min at 70-80OC,
20min at 7080OC,
40 C,
20min at
40OC,
Bath Drain
30'
Acetic acid 1.0 g/l
H2O2 killer 0.5 g/l
60oC x 10'
Acetic acid 0.8 g/l (To control pH = 4.55.5)
Enzyme 1.5 g/l
55oC x 45' - 60'
Kappaquest FE / Sequestering Agent
0.35 g/l
90oC x 5'
Sarabid LDR 0.5 g/l (leveling agent)
60oC x 5'
Gluber Salt (Runtime 10')
60oC x 10'
Dye stuff
60oC x 35' Runtime 20'
Soda ash
60oC x 40' Runtime 60'
Bath drop after shade matching
Hot rinse
60oC x 10'
Soaping
80o - 95oC x 10'
Cold rinse
45oC x 10'
Neutralize (Acetic acid = 0.5 g/l)
45oC x 10'
Fixing
40oC x 15'
Softening
Unload
Caustic 3 g/l
60oC x 15'
Hydrogen peroxide 10.0 g/l
60oC x 10'
Syno white 4BK/Optical brightener
(60o 80oC)
105o x 60'
Acetic acid 1.0 g/l
NT x 10'
Acetic acid 0.8 g/l [To Control PH4.5 - 5.5]
Enzyme 1.5 g/l
55oC x 45' - 60'
Sequestering agent
0.5 g/l
90oC x 5'
N. Hot
Unload
40oC x 10'
60oC x 5'
Caustic 2 g/l
60oC x 15'
Hydrogen peroxide 2.5 g/l
(60o - 80oC)
Temperature rise up to 105oC
30'
Acetic acid 1 g/l
H2O2 Killer 0.5 g/l
60oC x 10'
Acetic acid 0.8 g/l [To Control P H- 4.5 - 5.5]
Enzyme 1.5 g/l
55oC x 45'
Sequestering agent / Kappaquest FE 0.35
g/l
90oC x 5'
Sarabid LDR 0.5 g/l (leveling agent)
60o x 5'
Dye stuff
Hot rinse
60o x 10'
Soaping
45o x 10'
Neutralize
45o x 10'
Softening
Unload
60o x 5'
Caustic = 2 g/l
60oC x 15' [Dossing]
Hydrogen peroxide (H2O2) = 2.5 g/l
(60o - 80oC)
Temp rise up to 105oC & Run - 30'
60o x 5'
Dye stuff
60 x 40'
Bath drop after shade matching
Soaping
45oC x 10
Cold rinse - 45o x 10'
Softening
Unload
60o x10'
Anticreasing 1.0 g/l [Only for S/J]
Temperature rise up to 80oC [ Run time 20']
60oC x 5'
80oC x 20'
Caustic 2 g/l
cooling to 60oC
60oC x 15'
(60oC - 80oC)
soda ash
Temperature rise up to 105oC
40o x 10'
Sequestering agent 0.35
Neutralize
90oC x 5'
45 o x 10'
Sarabid LDR 0.5 g/l
Fixing [ For medium & dark shade]
Anticreasing agent 0.5 g/l [for S/J]
40 o x 10'
Dye stuff
60oC x 35' Run time - 20'
Softening
Unload
COLOR
BLACK
RECIPE
Sample
(Dyeing)
SATAZOL YELLOW 3RS=1.649%
SATAZOL RED 3BS =O.912%
SATAZOL BLACK NNT=8.47%
RED
KIRA.YELLOW HB=1.4%
KIRA. RED HB =2.0%
KIRA. RED SP2B=6.64%
MERUN
KIRA.YELLOW HB=0.47%
KIRA. RED HB =3.8%
KIRA. BLUE HB =0.86%
DK-BLUE
KIRA.YELLOW RR=0.188%
KIRA. RED RR =0.29%
KIRA. BLUE RR =1.26%
PINK
DK- TURGISH
SAMPLE
Sample (Dyeing)
COLOR
RECIPE
CLASSIC BLUE
GOLD RUST
VIO-LET
TURGISH
LIGHT YELLOW
=0.65%
=O.48%
=1.40%
NATURAL
BEZ.YELLOW SLF=0.154%
BEZ.RED SLF
=0.05%
BEZ.BLUE SLF
=0.132%
DEEP LILAC
E/B. YELLOW-4GL=0.008%
RED 3BSN
=1.1%
BE. BLUE VRN =1.14%
SAMPLE
Style of printing:
Direct style.
Method of printing:
Block and screen-printing method.
Sample:
One piece of square size bleached, scoured cotton fabric (small) and One
piece of square size bleached, scoured cotton fabric(bigger)
Combination color:
Total Dyes = 1.8gm
Blue = 0.6gm
Red = 0.6gm
Yellow = 0.6gm
Recipe:
Dye:
Total Dyes = 1.8gm
CIBA CRON RED = 0.6gm
CIBA CRON BLUE = 0.6gm
CIBA CRON YELLOW = 0.6gm
Urea = 8gm
Thickener = 70gm
Alkali = 8gm
Additional water = as required.
Preparation of thickener:
1)16 gm of starch and 200cc water are taken in
bowl.
2)Heat is applied and solution is stirred
continuously until a thick viscose solution is
obtained.
3)By continuous stirring and boiling a specific
viscosity is obtained.
4)The heat application is stopped otherwise
viscosity falls down. So temperature is
maintained strictly.
Printing process:
Screen-printing method:
1) The fabric is placed on the printing table of flat screenprinting machine. The table is made of soft by laying
on it.
2) Then the screen is placed on the sample fabric.
3) The printing paste is taken on the screen perforation.
4) Thus we can find the printed fabric with a smooth
wooden strike the paste is spread over the screen with
slight pressure.
5) So that the dye particles can penetrate through the
screen perforation.
6) Thus we get printed fabric.
After treatment:
The printed fabric is steamed for 5-10 minutes
in a cottages steamer at 1050-1100C and
washed with cold water for removing unfixed
dye and exhausted thickener and then dried.
Conclusion
Chapter 9
Technical Deficiency of Reactive Dyes, CAUSES AND THEIR
REMEDIES
Salt concentration:
When the cellulosic textile material is sink into water it convert into negetive charge or anionic
charge. But the reactive dye is also convert into anionic charge. So the surface of the cellulosic material repel
the dye molecules. To overcome the problem we use electrolite material like salt. It hepls to netralize the
negetive ion over the textile material and helps the reactive dye ion to fix on the surface of the materail. As a
result If we increase the concentration of the salt hydrolysis of the reactive dye will decrease.
2.pH:
if the pH of the medium increase hydrolysis of the reactive dye also increase. This is for, reactive dye
ionised more in alkaline medium and as a result it react with hydroxyl group of the water.
3.Temperature:
With the increase of temperature hydrolysis of the reactive dye increases.
4.Substantivity:
With the increase of the substantivity hydrolysis of the reactive dye increase.
5.Reactive group of the reactive dye:
Hydrolysis of the reactive dye depends on which group does it bears. Vinyl sulphone dye hydrolyize
more than the Triazinyl group.
Hydrolysis of water:
Hydrolysis of the water is also a cause
of the technical deficiency of the reactive dye.
Faults and their remedies for the technical deficiency of reactive dyes:
There creates many problems and defects in dyed fabrics when dyeing with Reactive
dyes due to technical deficiency. Some defects may be remedied by some process.
Those are described below:
Defect: Colors are not fast to washing, Abrasion; Staining in the fabric when
transporting from place to the other, water marks on the fabric
Remedy : Wash the fabric with soap and soda ash at right temperature. Adding
sequestering agent will yield good results. Treating with Ammonia will also give good
results.
Defects in the fabric due to Printing- Need to take out full color
Remedy: Treat the dyed fabric with Sodium Hydrosulphite with 5-10 gm Sodium
Hydrosulphite at 75 deg C for 30-45 minutes. Add 5-7 gms Caustic Soda for even
removal of colors. The color becomes light yellow or brown after removal. Wash it
thoroughly with soap.
The color can also be removed by solution of Sodium Hypochlorite. Treat the fabric
with a sodium hypochlorite solution ( 3-5 gms Chlorine) for 20-30 minutes. Keep the
pH between 9-10. The fabric is treated with Acetic acid after removal of color to
remove chlorine and to neutralize the fabric.
The fabric can be re-dyed after removal of color
Chapter 10
Conclusion
Obviously the project work we have discussed has many other arguments
but as far as we believe the presented view to a large extent is one
that has a predominant role in our textile sector especially in
REACTIVE DYEING & thus has the ability to influence our thoughts.
The project work has given us a special interest & has been arranged as a
presentation of the application reactive dyes in cotton dyeing. I think
anyone can research in future about this topic which will enrich our
textile knowledge.
Any absolute conclusion is impossible but waiting the pros & cons Im
certain that my position is a tenable one.
right