synthetic fibre from corn
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JUNE 2,2001 IIT DELHI
ECO FRIENDLY SYNTHETIC FIBRE FROM
CORN
R.B.CHAVANDEPARTMENT OF TEXTILE
TECHNOLOGY,INDIAN INSTITUTE OF
TECHNOLOGY,HAUZ-KHAS, NEW DELHI
110016
JUNE 2,2001 IIT DELHI
TEXTILE APPLICATIONS
CONVENTIONAL CLOTHING FOR BODY
PROTECTION HOME FURNISHINGS MADE-UPS FOR DOMESTIC
APPLICATIONS
NON CONVENTIONAL TECHNICAL TEXTILES
JUNE 2,2001 IIT DELHI
FUTURE CHALLENGES
DEPLETING FOSSIL FUEL (CRUDE OIL)
ENVIRONMENTAL POLLUTION
JUNE 2,2001 IIT DELHI
DEPLETING FOSSIL FUEL
CURENT PREDICTIONS
POPULATION LEVEL DOUBLE
EVERY 35 YEARS
INCREASED NEEDS FOR TEXTILE GOODS
INCREASED LAND NEED FOR FOODSTUFFS
LESS LAND AVAILABILITY FOR NATURAL FIBRE CULTIVATION
JUNE 2,2001 IIT DELHI
INCREASED REQUIREMENT OF OTHER COMMODITIES SUCH AS SHELTER, TRANSPORT ETC.
INCREASED STRAIN ON MANUFACTURING RESOURCES ESPECIALLY CRUDE OIL
OIL WILL BECOME SCARCE COMMODITY
LOW PRIORITY FOR SYNTHETIC FIBRE MANUFACTURING COMPARED TO TRANSPORTATION, AVIATION, HEAVY CHEMICAL INDUSTRIES ETC.
JUNE 2,2001 IIT DELHI
ENVIRONMENTAL POLLUTION
MOST OF SYNTHETIC FIBRES PRODUCED TODAY ARE NON-BIODEGRADABLE
WAY OUT F IND RENEWABLE SOURCES AS
RAW MATERIAL FOR TEXTILE PRODUCTION TO TAKE CARE OF DEPLETING FOSSIL FUEL RESOURCES
SYNTHESIZE BIO-DEGRADABLE FIBRES FOR ENVIRONMENT PROTECTION
JUNE 2,2001 IIT DELHI
DEVELOPMENT OF NEW SYNTHETIC POLYESTER FIBRE
CORN AS RENEWABLE RAW MATERIA (AGRICULTURE PRODUCE)
TOTALLY BIO-DEGRADABLE
JUNE 2,2001 IIT DELHI
NON FOOD CROP AS RENEWABLE SOURCE
RECENTLY THERE IS A WIDE SPREAD RECOGNITION OF NON FOOD CROPS AS A MAJOR SOURCE OF FEEDSTOCK FOR CHEMICAL INDUSTRY
IN 1995 IT IS REPORTED
BIOTECHNOLOGY HAS THE POTENTIAL TO MAKE AVAILABLE HUGE RANGE OF BASIC RAW MATERIALS INTERMEDIATE FEEDSTOCK AND EVEN FINAL END PRODUCTS FOR CHEMICAL INDUSTRY
IN 1998 IT IS REPORTED
THERE IS GROWING SENSE OF URGENCY TO MOVE AWAY FROM OUR DEPENDENCE ON DEPLETING FOSSIL FUELS AND TO SEEK OUT NEW FEEDSTOCK
JUNE 2,2001 IIT DELHI
ADVANTAGES OF NON FOOD CROPS AS FEED STOCKS
RENEWABLE RESOURCE, SUSTAINABLE IN THE LONG RUN COMPARED TO FOSSIL FUELS WHICH ARE DWINDLING RAPIDLY
AT CURRENT CONSUMPTION LEVELS CRUDE OIL RESERVES ARE PREDICTED TO DEPLETE WITHIN 50 YEARS
GAS RESERVES WITHIN 75 YEARS
COAL RESERVES IN ABOUT 200 YEARS
JUNE 2,2001 IIT DELHI
THE USE OF FOSSIL FUELS CAUSE ALL KINDS OF POLLUTION
CROPS BEING GENERALLY LESS POLLUTING, LOCK UP CARBONDIOXIDE FROM THE ATMOSPHERE IN THE FORM OF CARBOHYDRATES, LIPIDS AND PROTEINS, THEREBY MINIMIZING THE EFFECTS OF GLOBAL WARMING
MAJORITY OF PRODUCTS DERIVED FROM PLANT FEED STOCK WOULD BE COMPLETELY BIO-DEGDABLE
JUNE 2,2001 IIT DELHI
NEED FOR BIO-DEGRADABLE FIBRES AND PLASTICS
SOLID WASTE DISPOSAL,GOBALLY BURNING PROBLEM
DECREASE IN THE AVAILABILITY OF LANDFILL SPACE
OCEAN DUMPING IS ILLEGAL
INCINERATION AS THE WAY TO TREAT THE MAJORITY OF WASTE IS NO LONGER ACCEPTABLE
FOR THESE REASONS
ORGANIC WASTE COMPOSTING AND THE USE OF BIODEGRADABLE FIBRES AND PLASTICS IS THE ONLY WAY FOR ENVIRONMENT PROTECTION
JUNE 2,2001 IIT DELHI
THEORETICAL BASIS FOR BIODEGRADATION OF FIBRES
DEPOLYMERIZATION DUE TO EITHER HYDROLYSIS OR OXIDATION OF FIBRE (POLYMER) DUE TO ENZYME SECRETED FROM CERTAIN MICRO-ORGANISMS
ENZYME MAY ACT AT THE END OF POLYMER CHAIN (END GROUP ATTACK) OR AT ANY POINT ON CHAIN (RANDOM ATTACK)
TO FACILITATE DEPOLYMERIZATION, THE ENZYMES MUST BE ABLE TO TIE THESELVES WITH THE FIBRE AND TO ARRIVE TO THE CENTRE THAT CAN BE HYDROLYSED OR OXIDIZED
JUNE 2,2001 IIT DELHI
MAJORITY OF BIO-DEGRADABLE FIBRES ARE HYDROPHILILC, FORMED FROM FLEXIBLE CHAINS WITH LOW LEVEL OF CRYSTALLIZATION
THEY HAVE THE MAIN CHAIN WITH TIES CONTAINING OXYGEN OR NITROGEN OR BOTH
THIS DESCRIPTION CORRESPONDS TO NATURAL FIBRES
JUNE 2,2001 IIT DELHI
NON BIODEGRADABLE FIBRES
NON-BIODEGRADABLE FIBRES HAVE OPPOSITE CHARACTERISTICS
THE POLYMERS WITHOUT OXYGEN SUCH AS POLYETHYLENE, POLYPROPYLENE RESIST COMPLETELY BIOLOGICAL DEGRADATION
THE AROMATIC POLYESTER (PET) THOUGH CONTAINS OXYGEN, RESIST BIO-DEGRADABILITY DUE TO CHAIN RIGIDITY AND CRYSTALLIZATION
JUNE 2,2001 IIT DELHI
SAME APPLIES TO POLYAMIDES THOUGH THEY CONTAIN NITROGEN
CONTRARY TO AROMATIC POLYESTER, THE ALIPHATIC POLYESTERS ARE SUSCEPTIBLE TO BIODEGRADATION.
THEY ARE ALSO THERMOPLASTIC AND LIKE ANY OTHER POLYESTER CAN BE CONVERTED INTO FIBRES AND FILMS
JUNE 2,2001 IIT DELHI
BIODEGRADABLE ALIPHATIC POLYESTERS
JUNE 2,2001 IIT DELHI
BIODEGRADABLE ALIPHATIC POLYESTERS
BIO-DEGRADABLE ALIPHATIC POLYESTERS CAN BE FORMED ON INDUSTRIAL SCALE BY POLYMERIZATION OF
GLYCOLLIC ACID (PGA)
LACTIC ACID (PLA)
HYDROXY BUTYRIC ACID (PHB)
CAPROLACTONE (PCL)
AMONG THESE, THE POLYMERS BASED ON POLYLACTIC ACID (PLA) ARE MOST PROMISING
JUNE 2,2001 IIT DELHI
POLY LACTIC ACID FIBRES
POLYMERIZATION OF LACTIC ACID WAS CARRIED OUT BY CAROTHERS IN 1932
UNSUITABLE POLYMER DUE TO LOW MELTING POINT
FURTHER INVESTIGATIONS ABONDONNED
LACTRON WAS INTRODUCED BY KANEBO (JAPAN) in 1994
AGRICULTURE MULCH FILM APPLICATION
JUNE 2,2001 IIT DELHI
1998 OTHER APPLICATIONS LIKE PLASTIC CUPS, THERMO FORMING FILMS WERE EXPLORED
TODAY IN JAPAN PLA PRODUCTION IS 500 - 1000 TONS/ANNUM
PLA/RAYON BLENDS DEVELOPED TO REDUCE COST AND IMPROVE BIO-DEGRADABILITY
1997 FIBERWEB (FRANCE) DEVELOPED NONWOVEN, DEPOSA
JUNE 2,2001 IIT DELHI
Production forecast
GALACTIC LABORATORIES(BELGIUM) FORECASTED BY 2008
PLA FIBRE/PLASTIC PRODUCTION 3,90,000 TONS/ANNUM
PRICE AROUND 2 DOLLAR/Kg
JUNE 2,2001 IIT DELHI
CARGILL DOW POLYMERS (USA)
50 : 50 JOINT VENTURE STARTED IN 1997
LEADER IN TECHNOLOGY OF PLA
PLA POLYMER MARKETED UNDER TRADE NAME NATURE WORKS PLA
CURRENT PRODUCTION 4,000 TONS/ANNUM
JUNE 2,2001 IIT DELHI
INSTALLED A NEW PLANT WITH 70,000 TONS/ANNUM CAPACITY
HAVE PLANS TO SCALE PRODUCTION TO 1,40,000 TONS/ANNUM
ANTICIPATION, BY 2002 MANY COMPETITORS WOULD ENTER INTO PRODUCTION OF THIS NEW POLYMER
JUNE 2,2001 IIT DELHI
PRODUCTION ROUTE
TRADE NAMES
LACTRON (KANEBO, JAPAN) , NATURE WORKS PLA (CARGILL DOW POLYMERS, USA)
CORN AS RAW MATERIAL
POSSIBLE TO USE OTHER PLANT MATERIALS
RICE, WHEAT, SUGAR BEETS AND EVEN AGRICULTURE WASTE
JUNE 2,2001 IIT DELHI
PRODUCTION ROUTE
MILLING
MILLING OF CORN TO SEPARATE STARCH FROM RAW MATERIAL
PROCESSING OF STARCH TO GET UNREFINED DEXTROSE/SUGAR
JUNE 2,2001 IIT DELHI
FERMENTATION
FERMENTATION OF DEXTROSE/SUGAR TO LACTIC ACID
PROCESS SIMILAR TO THAT USED BY BEER AND WINE PRODUCERS
IT IS THE SAME LACTIC ACID
USED AS A FOOD ADDITIVE AND
FOUND IN MUSCLE TISSUE IN HUMAN BODY
JUNE 2,2001 IIT DELHI
INTERMEDIATE PRODUCTION
THROUGH A SPECIAL CONDENSATION PROCSS A CYCLIC INTERMEDIATE DIMER “ LACTIDE” IS FORMED
POLYMER PRODUCTION
LACTIDE IS PURIFIED THROUGH VACUUM DISTILLATION
RING OPENING POLYMERIZATION OF LACTIDE THROUGH SOLVENT FREE MELT PROCESS
POLYMERS WITH WIDE RANGE OF APPLICATIONS THROUGH CONTROL OF MOLECULAR WEIGHT AND CRYSTALLINITY
JUNE 2,2001 IIT DELHI
CHEMISTRY
CONVERSION OF LACTIC ACID INTO DIMER LACTIDE BY WATER ELIMINATION
SPECIAL RING OPENING POLYMERIZATION OF LACTIDE TO POLYLACTIDE (PLA)
FAMILY OF POLYMERS DEPENDING ON STEREO CHEMISTRY OF LACTIC ACID AND ITS DIMER
THREE FORMS OF LACTIC ACID : L - ISOMER, D- ISOMER AND MESO - ISOMER
JUNE 2,2001 IIT DELHI
POLYMERIZATION OF L - ISOMER PRODUCE CRYSTALLINE POLYMERS
THAT CONTAIN MORE THAN 15% D - ISOMER PRODUCE AMORPHOUS POLYMERS
BETTER CONTROL OF STEREOCHEMISTRY OF DIMERS EXPLAINS THE SUPERIORITY OF POLYESTERS THAN THOSE OBATAINED BY CAROTHERS IN 1932
JUNE 2,2001 IIT DELHI
FIG 2 LACTIDE FORMATION
JUNE 2,2001 IIT DELHI
PROPERTIES
The key properties of new synthetic fibre derived from corn are as follows:
Superior melt processability, can produce microfibres.
Low moisture absorption, rapid wicking, excellent hand drape and resilience.
Wrinkle resistance.
JUNE 2,2001 IIT DELHI
Qualities from silk-like to cotton-like.
Exceptional UV resistance.
Low flammability, stain resistance.
Can be washed,dry cleaned and commercially laundered.
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