Manufacture of
Polyester fiber
Presented By
Adithia
Praniga
Tarak
Chetan
Raveena
Khanagathara
Chemical Technology
What is
Polyester
• A category of polymers that contain the ester functional
group (RCOOR’) in every repeat unit of their main chain.
• It is a manufactured synthetic fiber & is essentially a kind
of plastic and is usually derived from petroleum.
• Alternatives to oil-derived polyester exist, including those
made from recycled plastic, agricultural crops, or even
waste
What is
Polyester
Polyester filament are chemically formulated of at least
85 % by wt. of an ester of a substituted aromatic carboxylic
acid, including Terephthalate units and Para substituted
hydroxyl benzoate units.
Polyethylene Terephthalate (PET) is the repeating unit of
the polyester polymer with a degree of polymerization of
115-14 0 units (i.e. n= 115-140). It is the most produced
form of polyester polymer.
Polyester is a versatile type of plastic, and it comes in
several different forms, each with unique uses and
properties.
Some Types includes
[Link] (Polyethylene Terephthalate)
2. PBT (Polybutylene Terephthalate)
3. PLA (Polylactic Acid)
4. Alkyd Resin
5. Polycarbonate
1. PET (Polyethylene Terephthalate):
This is the most common polyester, used
in everyday products like clothing fabrics and
plastic bottles. It’s strong, lightweight, and
doesn’t absorb water easily.
2. PBT (Polybutylene Terephthalate):
Known for its toughness and resistance to
chemicals, PBT is often found in car parts,
electrical components, and home
appliances.
3. PLA (Polylactic Acid):
Unlike other types, PLA is biodegradable, made
from renewable resources like corn or sugarcane.
It's often used in eco-friendly packaging and
disposable items that break down naturally over
time.
4. Alkyd Resin:
This type of polyester is mainly used in paints
and coatings. Alkyd resins are known for their
durability, helping to protect surfaces like wood and
metal from wear and tear.
5. Polycarbonate:
While not a typical polyester, polycarbonate
shares some similarities and is often grouped
with them. It’s extremely strong and
transparent, making it useful in things like
eyeglass lenses, CDs, and even bulletproof
windows. These different forms of polyester
show how flexible the material is, making it
valuable across a wide range
History of polyester manufacture:
The history of polyester manufacturing can be traced back to the 1930s and
1940s, when scientists discovered how to create synthetic fibers:
1930:
W.H. Carothers, a DuPont employee, discovered that he could create fibers by
mixing alcohols and carboxyl acids. However, he shelved the project when he
discovered nylon.
1941:
British scientists Whinfield and Dickson patented polyethylene terephthalate
(PET), which forms the basis for polyester. They created the first polyester
fiber, called Terylene. 1946 DuPont bought the legal rights to Terylene from
Imperial Chemical Industries (ICI).
1951:
Polyester was introduced to the American public and marketed as a “magic”
fabric that was wrinkle-resistant and didn’t need ironing
1970:
The popularity of “The Leisure Suit” gave polyester a
bad reputation for a generation.
1990:
Performance polyester was developed with new
cross sections and geometries.
1996:
Dri-fit first appeared in US Olympic Uniforms.
2000:
Polyester yarn production moved to China and East
Asia. Today, China is the world’s largest producer of
polyester, with Japan, India, Indonesia, and the
United States also being large producers.
Polyester application:
Polyester is used in a variety of applications, including:
Clothing
Polyester is a durable and inexpensive option for clothing,
especially outerwear. It’s also a good choice for shirts, pants,
suits, and jackets because it keeps its shape and doesn’t
wrinkle.
Homewares
Polyester is used to make microfiber, which is soft and
absorbent and is used for bath towels, face towels, and kitchen
towels. Polyester is also used for blankets, rugs, upholstery,
and curtains.
Industrial applications
Polyester is used for LCD displays, holographic film, boats,
tarps, and bottles.
Formation of Ester linkage
Fischer Esterification:
(excess)
Catalyst : HCL, p-Toluenesulfonic acid, Conc.H2SO4
Temperature : 60 – 100°C (depends on boiling points of
reactants)
Pressure : atmospheric pressure
Flowsheet
Production Process
Step 1: Create the polymer solution
The PET resin pellets is obtained and stored in a dry
silos under controlled environment, which are melted
for extrusion later.,
Step 2: Spinning
Types of spinning:
i) Melt spinning
ii) solution spinning
a) Gel spinning
b) Emulsion spinning
c) Solvent spinning
Production Process
Step 2: contd.,
Melt spinning is most economical and widely used
in industries
1. Melt the polymer solution at 260 – 270°C
2. Extrude the polymer sol. with spinneret
t to form long filaments
3. Blast with cold air to solidify into fibers
4. Apply finish to reduce friction b/w fibers
a and prevent static buildup
Production Process
Step 3: Drawing / Stretching
The extruded fibers are then stretched, to align the polymer
chains and improve the strength, tenacity, and elasticity of
the fibers.
This stretching orients the polymer molecules in the
direction of the fiber axis, making the fiber stronger and
more flexible.
The fibers are typically drawn to several times their original
length (about 3 to 6 times their initial length).
Production Process
Step 4: Final processing
They are wound onto bobbins or cut into
shorter lengths(1.5’ – 6’) to suit specific
applications
MAJOR ENGINEERING PROBLEMS
AND SOLUTION FOR IT
Raw Material Sourcing and Quality:
In polyester manufacturing, the purity of key raw materials like
ethylene glycol and terephthalic acid (or dimethyl terephthalate)
is crucial. Impurities in these raw materials can cause side
reactions that negatively affect the polymerization process,
leading to lower-quality polyester with reduced strength,
durability, or clarity. Additionally, there is a challenge in
securing cost-effective and sustainable sources for these
materials, as they are often derived from petrochemical
processes. This reliance on fossil fuels also introduces
environmental and supply chain concerns, which manufacturers
must navigate.
Polymerization Process Control:
Polyester production involves a highly controlled
polymerization process where maintaining the right
temperature, pressure, and catalyst concentration is
critical. Even small deviations in these parameters can
lead to incomplete polymerization, resulting in
inconsistent polymer chain lengths and affecting the
material’s final properties like strength and flexibility. By-
products such as water or methanol need to be carefully
removed during the process to prevent reverse reactions
or polymer degradation. Proper control ensures high-
quality polyester with desirable physical characteristics
for applications like fibers, bottles, and films.
Thermal Degradation:
During the high-temperature processing, polyesters
are susceptible to thermal degradation, which affects
molecular weight and reduces polymer quality.
Ensuring a controlled environment to avoid
degradation is critical.
Molecular Weight Distribution:
Achieving the correct molecular weight and narrow
distribution is important for the physical and
mechanical properties of the polyester. Inconsistent
molecular weight leads to poor performance in
applications like fibers or packaging
Recycling and Environmental Impact:
Engineering processes for efficient and high-quality recycling
of polyesters like PET is a growing challenge. Contaminants
and degradation during recycling can reduce the quality of the
recycled material, making it less suitable for high-end
applications.
Reducing the environmental footprint of polyester production,
such as lowering energy consumption and emissions, is an
ongoing challenge, especially with increasing
regulatory pressures.
Processing Challenges:
Crystallization and melt processing require precise temperature
control. If cooling or heating is not managed well, the polymer
may exhibit poor mechanical properties like brittleness or irregular
crystallinity, affecting the final product's quality.
Controlling the viscosity during melt processing is also critical, as
too high or too low viscosity can cause defects in products like
films or fibers.
Catalyst Management:
Catalyst systems used to speed up reactions can be expensive
and difficult to handle. Catalyst residues can also remain in the
polyester, impacting the material’s properties and necessitating
additional purification steps.
Energy Consumption:
The polymerization and crystallization processes are energy-
intensive, making cost-effective energy management an ongoing
issue, especially with global efforts toward sustainability and
carbon footprint reduction.
SOLUTIONS
1. Improve Raw Material Quality: Use bio-based alternatives and
advanced purification for cleaner, sustainable inputs.
2. Advanced Process Control: Implement real-time monitoring,
automation, and optimized catalyst systems for consistent
polymerization.
3. Minimize Thermal Degradation: Use temperature-stable
additives and better heat management.
4. Optimize Molecular Weight: Apply precision controls and
stabilizers for uniform molecular weight.
5. Enhance Recycling: Invest in advanced chemical recycling and
contamination management technologies.
THANK YOU
Chemical Technology
