ALTRANOL-GEO

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Minerals In Textile Processing
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Clay Chemistry

• The textile industry is constantly searching for
  environmentally friendly solutions.
• Over the years a lot of chemical components have
  been replaced (Phosphates, Nonyl phenols etc) in
  the textile industry.
• The demand for low COD and BOD values, reduced
  levels of MBAS and BiAS and easily biodegradable
  products was the reason to search for alternative
  sources.

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Elements of Earth
8.32 kms crust
by weight in crust
O 49.2Si 25.7Al 7.5Fe 4.7Ca
3.4Na 2.6K 2.4Mg 1.9other 2.6
12500 km dia
Geotechnical engineers are interested mainly in
the top 100 metres of the earth crust. As you can
see from the table, 82 of the elements are
oxygen, silicon and aluminium.
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Soil Formation
Residual soil
Transported soil
in situ weathering (by physical chemical
agents) of parent rock
weathered and transported far away
by wind, water and ice.
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Genesis of Clays
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Parent Rock
formed by one of these three different processes
sedimentary
igneous
metamorphic
formed by alteration of igneous sedimentary
rocks by pressure/temperature
formed by gradual deposition, and in layers
formed by cooling of molten magma (lava)
e.g., limestone, shale
e.g., marble
e.g., granite
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Minerals - Introduction

• Mother earth supplies us with a large variety
  of minerals.
• Approx. 4000 different minerals are known
  worldwide, most of them are very nice but not
  all of them can be used for technical purposes.
• Rosa Quartz Roselite
  Biotite Kaolinite Rosasite Topaz
• 99 of the earth is composed out of only 8
  minerals.
• The mineral group of silicates is the most
  important and well known for
• - Clays (Aluminium/Metal oxides Silicium
  dioxide)
• - Zeolites (Aluminium/Metal oxides Silicium
  dioxide)
• - Silicate (Metal oxides Silicium dioxide)

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Basic Structural Units
Clay minerals are made of two distinct structural
units.
0.26 nm
Silicon tetrahedron
Aluminium Octahedron
All clay minerals are made of two distinct
building blocks tetrahedrons and octahedrons.
The tetrahedron on the left has oxygen atoms at
the corners, and there is a silicon in the
centre. Octahedron has six oxygen or hydroxyl
atoms in the corners, and an aluminium or
magnesium ion at the centre.
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Mining of Clay
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Mining process of Clays
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Microscopic Photograph of Clay
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CLAY TYPES

• Depending on the type and quantity of metal
  oxide, the ratio with SiO2 and the specific
  crystalline structure, different types of CLAY
  are known such as
• - Kaolin Aluminium oxide
• - Smectite Aluminium- and Magnesium oxide
• - Vermiculite Aluminium- and Magnesium oxide
• - Illite Aluminium-, Magnesium- and
• Potassium oxide
• - Hectorite Magnesium- and Lithium oxide

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CLAYS

• Clay mainly consists of SiO2 and Al2O3
• Other ions may be present Mg, Ca, Fe, Li, Mn,..
• Some clays can stabilize H2O2 bleaches

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Character of Semectite Clays

• 3-Layer Silicate
• Small particle size
• Sheet Structure
• Delaminating of layers by simple dispersing
• High specific surface area(upto 750m2/g
• after dispersed
• Negative charge on the surface, cationic
• charge at border
• Inner crystalline capability of swelling

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Isomorphous Substitution

• substitution of Si4 and Al3 by other
• lower valence (e.g., Mg2) cations

• results in charge imbalance (net negative)

positively charged edges
negatively charged faces
Clay Particle with Net negative Charge
The clay particle derives its net negative charge
from the isomorphous substitution and broken
bonds at the boundaries.
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A Comparison
Mineral Specific surface(m2/g) C.E.C (meq/100g)
Kaolinite 10-20 3-10
Illite 80-100 20-30
Montmorillonite 800 80-120
Chlorite 80 20-30
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CLAYS

• Amongst the big number of minerals, clays have
  very useful characteristics for textile
  applications
• Some clay-classifications
• Kaolin (Aluminium China clay)
• Semectite (Aluminium Magnesium)
• Hormite (more Iron)
• Some exceptional properties of clay
• Thickening agents in paints
• Oil and dirt absorber
• Absorber of inks in e.g. paper industry
• Stabilizer for hydrogen peroxide bleaches
• Softening agents in household products

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CLAYS

• In water the clay particles are anionic charged
  and show a large adsorption effect for
• Hydrophobic waxes and oils
• Metal ions (cation exchange capacity)
• Hydrophilic materials and polymers

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Application of Clays in Industry

• Nature Bentonite
• Cat litters
• Agro industry
• Civil industry
• Beverage refinery industry

• Acidic activation
• (with HCl / H2SO4)
• Food industry
• Paper industry
• Beverage refinery industry
• Industrial catalyst

• Alkaline activation
• (With soda ash)
• Foundry industry
• Civil drilling industry
• Detergent, paper, textile industry
• Beverage refinery industry
• Rheological additive industry

• Organic activation
• (With organic cation subst)
• Pigment paint industry
• Sealing industry
• Fat lubricant industry
• Cosmetic industry

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CLAYS

• All these classes (and many sub-classes) have
  different characteristics
• Because of this different special industrial
  applications e.g. paper coating
• In the past clays were used by Indian and
  Egyptian women to clean and smoothen their faces
  and to shampoo their hair. Clay masks and still
  popular!
• The clay structure is based on sheets
• By separating these sheets e.g. by stirring, a
  very big surface is created
• This surface (till 800 M2 per gram) makes it
  possible to absorb all kind of components like
  dirt, oil, greases etc.
• This gives an unique detergency effect

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Minerals

• The most widely known mineral in the textile
  industry is sodium silicate as a mineral
  stabilizer for hydrogen peroxide bleaching
• L.N.s challenge look for other minerals with
  the good properties of sodium silicate and with
  success!!
• Clay minerals have been selected on the specific
  characteristics and formulated in new auxiliaries
  for the textile industry

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Problems During Bleaching Process

• NaOH
• Gives irreversible yellowing to cotton due to
  high alkaline
• High COD amount in waste water
• Water glass
• Salt reaction
• Needs to look for effective conventional
  auxiliaries
• Building deposits on the fabric and machineries
• Complex Builder
• Ecological problem
• Effective depend on the degree of water hardness
  and heavy metal contamination on the raw
  materials

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• Adsorption of strong metal contamination
• Organic complex builder fully or partially
• to be substituted
• Water glass fully or partially to be
• substituted

An organic Ions Exchanger with capability of
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A selection of high quality minerals for
excellent results

• In hydrogen peroxide bleaching,
• both continuously and
• discontinuously
• In continuous desizing of
• synthetics
• In post scouring reactive dyed
• and printed cellulosics

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ALTRANOL-GEO/ ALTRANOL-ELB

• One of the new applications for claysis as a
  one-shot product for the discontinuous bleaching
  applications
• It is based on this mineral technology
• A clay based multifunctional auxiliary for the
  discontinuous bleaching of cotton with hydrogen
  peroxide on jets, winches and overflows
• Prescouring of PES/EL and PA/EL
• Alternative for the ecologically unfriendly
  hypochlorite bleach

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Emulsifying capacity for silicone oil
2g/l Altranol-GEO
Clearly to see is that the silicon oil is not
well emulsified.
Altranol- GEO well disperse/emulsifies the
silicon oil.
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ALTRANOL-GEO

• Excellent hydrogen peroxide stabilizer
• Unique wash performance
• Good wetting out of the fabric
• Excellent lubrification properties
• Low foaming no defoamer required
• Ecologically very friendly
• Gives fabric a smooth handle

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Why Should One Use Altranol ELB

• Altranol GEO allows almost 35 reduction in the
  BOD COD levels in the wash effluent
• Altranol GEO further reduces the COD/BOD levels
  by eliminating/reducing the need for additional
  auxiliaries in treatment baths i.e. wetting
  agents, chelating agents, surfactants, lubricants
  defoamers.
• The effluent of treated textiles is easily
  readily treated by flocculating, precipitating or
  filtering the natural clays its adsorbed
  /precipitated contaminants, which are removed by
  any standard separation technique like filtering
  etc.
• The resultant effluent is significantly more
  environmentally acceptable than current effluents
  containing organic components inorganic
  contaminants.

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Why Should One Use Altranol ELB

• Altranol GEO, besides reducing pollution due to
  lower BOD COD levels, also results in lower
  volatile organic chemicals (VOCs)
• Is an outstanding lubricating agent providing a
  softer hand for treated textile goods
• Is non-foaming extremely effective in removing
  processing oils excess auxiliaries other
  impurities from the substrates. Treated
  substrates are cleaner which improves dyeability
  dye penetration resulting in increased colour
  yields of 1030
• Is suitable for processing all textile materials
  i.e. all fibres, filament, yarns, fabric all
  products made from them. They include textured
  non textured filaments yarns, woven, knitted or
  non-woven fabrics.

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Why Should One Use Altranol ELB

• Excellent extracting effect to silicone or
  mineral oils from
• elastane fibers when blended with cotton /
  polyamide /
• polyester
• Stabil whiteness degree with possibility of
  increasing
• whiteness degree after every bleaching
  process
• Reduction of COD value in waste water
• Heavy metals adsorption reduction of potential
  pin holes
• problem
• Softness effect on cotton fiber anti crease
  mark effect

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Altranol- GEO

• Bleach for dyeing indication recipe
• 95-98ºC during 20-30 minutes
• 1-2 ml/l Altranol-GEO
• 2-3 g/l Caustic flakes
• 2-5 ml/l Hydrogen peroxide 35
• Neutralize peroxide with Quench-PN

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Altranol- GEO

• Bleach for whites indication recipe
• 1-3 ml/l Altranol-GEO
• 2-3, 5g/l Caustic flakes
• 6-10 ml/l Hydrogen peroxide 35
• X Optical brightening agent
• 95-110ºC during 90-30 minutes

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Altranol- GEO

• Some practical results
• Cotton on winches 95ºC 60 mins
• Customers standard LNCI
• Basic white 84 85
• Total white 155 158
• S-factor 0.36 0.32

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Altranol- GEO

• Practical results continued
• Knitted Cotton/EL on Thie? jet
• Customers standard LNCI
• Basic white 72 77
• Total white 144 156
• S-factor 0.2 0.1

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Altranol- GEO

• Other experiences
• Jig bleaching applications
• Bleaching of Cotton on X-cones
• Discontinuous bleaching of Linen
• Prescour PA/EL
• Prescour PES/EL
• Etc..

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Altranol- ELB
Clay technology for pretreatment of elastane
fibres
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Altranol- ELB

• elastane fibres (PolyUrethane filament fibres)
  are commonly used nowadays in all kind of knits
  and fabrics.
• elastane fibres provide knits and fabrics stretch
  and retention effects.
• elastane fibres are blended with all kind of
  other fibres like PA, PES, Wo and Co.

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Altranol- ELB

• Articles can contain between 2 20 elastane
  fibres.
• Articles can contain between 2 6 silicone
  oils.
• Depending on the fibre blend this silicone oil,
  in combination with other fibre preparations
  (mineral oils, waxes, lubricants etc) could cause
  problems during further processing.

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Altranol- ELB

• Insufficient elimination of silicon oils will
  cause problems during subsequent processes and/or
  dyeings
• - silicon spots and/or stripes on the material
• - silicon deposits in the machine
• - fumes and yellowing during thermofixation
• Silicone oil on the elastane fibres is absolutely
  necessary to provide sufficient elasticity and
  avoid aging.
• What is a safe way of processing elastane fibres
  ?

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Altranol- ELB

• Altranol-ELB is a specially formulated clay in
  combination with special non ionic surfactants.
• The clay in Altranol-ELB is from the same origin
  as in Altranol-GEO
• Altranol-ELB removes all superficial silicone
  oil, providing level dyeings, without totally
  removing the silicone oil.
• A certain amount of residual silicone oil is
  required to guarantee durable elasticity and to
  avoid ageing of the elastane-fibre.

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Altranol- ELB

• Very good wetting and scouring effect.
• Level dyeings as Altranol-ELB levels out all
  irregular oil contents.
• Residual silicone oil to protect the Elastane
  fibre in order to maintain durable elasticity and
  avoid ageing.
• Simple to dispense and easy to handle.
• Lubrication action due to the presence of clay .
• Applicable on all fibre blends with Elastane
  fibres.
• Non foaming.
• Ecological product (COD 560 mg O/g, BiAS 210
  mg/g)
• APEO free.

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Altranol- ELB Continuous scouring PA/EL fabrics
Soda ash pH 9-10 (1 g/l) Altranol- ELB 2
ml/l 1 ml/l
water 2-3 l/kg overflow 30C
water 6-8 l/kg
Grey
C 30 30 80
80 80 60
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Altranol- ELB Discontinuous prescouring PA/EL
PA/EL KNITS
Ratio 101
Dyeing
15 min _at_ 50C
Refill and add Altranol-ELB 0.5 ml/l other
dyeing auxiliaries dyestuffs
Fill the machine and add Altranol-ELB 12
ml/l Soda ash 0.5 1 g/l
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L.N.Chemical Industries
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400 059 Tel.- 91- 22- 4221 6789 (30 Lines)
91- 22- 6692 4112 Fax -91-22- 2836 6434
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Lines) Fax -91- 22- 4141 9888
Email ID ketan_at_lnchem.in
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