EPA-600/2-77-023K
February 1977
Environmental Protection Technology Series
INDUSTRIAL PROCESS PROFILES FOR
ENVIRONMENTAL USE: Chapter 11.
The Synthetic Fiber Industry
Industrial Environmental Research Laboratmy
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-77-023k
February 1977
INDUSTRIAL PROCESS PROFILES
FUR ENVIRONMENTAL USE
CHAPTER 11
THE SYNTHETIC FIBER INDUSTRY
by
Jerry L. Parr
Radian Corporation
Austin, Texas 78766
Contract No. 68-02-1319
Project Officer
Alfred B. Craig
Metals and Inorganic Chemicals Branch
Industrial Environmental Research Laboratory
Cincinnati, Ohio 45268
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This report has been reviewed by the Industrial Environmental Research
Laboratory - Cincinnati, U.S. Environmental Protection Agency, and approved
for publication. Approval does not signify that the contents necessarily
reflect the views and policies of the U.S. Environmental Protection Agency,
nor does mention of trade names or commercial products constitute endorsement
or recommendation for use.
ii
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TABLE OF CONTENTS
CHAPTER 11
Page
INDUSTRY DESCRIPTION 1
Raw Materials 3
Products 4
Companies 6
Environmental Impact 6
Bibliography 9
INDUSTRY ANALYSIS 11
Synthetic Fiber Processing 11
Process No. 1. Mel t Spi nni ng 13
Process No. 2. Wet Spinning 16
Process No. 3. Dry Spinning 19
Process No. 4. Lubrication 21
Process No. 5. Drawing 23
Process No. 6. Fiber Modifications 25
APPENDIX A - Raw Materials Lists 27
APPENDIX B - Products 31
APPENDIX C - Producers 41
m
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LIST OF FIGURES
CHAPTER 11
Figure Page
1 SYNTHETIC FIBER INDUSTRY FLOW DIAGRAM 12
IV
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LIST OF TABLES
CHAPTER 11
Table Page
1 1975 PRODUCTION OF SYNTHETIC FIBERS 2
2 TEN LARGEST SYNTHETIC FIBER PRODUCERS 2
3 FUELS & ELECTRICAL ENERGY CONSUMED BY COMPANIES IN
SIC CODE 2824 IN 1971 3
4 RAW MATERIAL CONSUMPTION FOR PRODUCTION OF SYNTHETIC
FIBERS BY COMPANIES IN SIC CODE 2824 IN 1971 4
5 GENERIC NAMES OF SYNTHETIC FIBERS 5
6 END USES OF SYNTHETIC FIBERS, 1973 CONSUMPTION (Gg), 5
7 CAPACITY OF TEN LARGEST SYNTHETIC FIBER PRODUCERS 6
8 SUMMARY OF WASTEWATER DATA FOR SELECTED FIBERS 7
9 SOURCE CLASSIFICATION CODES FOR SYNTHETIC FIBERS 8
10 INPUT POLYMERS FOR MELT SPINNING 13
11 TYPICAL MELT SPINNING OPERATING PARAMETERS 14
12 INPUT MATERIALS FOR WET SPINNING 16
13 OPERATING SUMMARY OF PARAMETERS FOR PRODUCTION OF
ACRYLIC FIBERS BY WET SPINNING 17
14 INPUT MATERIALS FOR DRY SPINNING 19
15 OPERATING PARAMETERS FOR SYNTHETIC FIBER DRAWING 23
A-l FIBER RAW MATERIALS 28
A-2 TYPICAL ADDITIVES USED IN FIBER PRODUCTION 29
A-3 SOLVENTS USED IN FIBER PRODUCTION 30
B-l PRODUCTS OF THE SYNTHETIC FIBERS INDUSTRY 32
B-2 CHEMICAL AND PHYSICAL PROPERTIES OF SOME TEXTILE FIBERS .. 38
C-l SYNTHETIC FIBER PRODUCERS, PLANT LOCATIONS, PRODUCTS,
AND CAPACITIES 42
C-2 LOCATION OF U.S. SYNTHETIC FIBER PRODUCING PLANTS 49
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ACKNOWLEDGEMENTS
Some of the technical information used in preparing this catalog entry was
supplied to EPA by Monsanto Research Corporation, Dayton Laboratory, under
Contract No. 68-02-1320, Task 17. The contribution of Duane E. Earley is
gratefully acknowledged. Mr. William Medley was Project Leader.
This catalog entry was prepared for EPA by Radian Corporation under Contract
No. 68-02-1319, Task 52. The author was Jerry L. Parr, with contributions
made by Terry B. Parsons and Judith D. Whiting. Eugene C. Cavanaugh was the
Program Manager.
Helpful review comments from Robert W. Lenz were received and incorporated
in this chapter.
vi
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SYNTHETIC FIBER INDUSTRY
INDUSTRY DESCRIPTION
Synthetic*fibers are defined as noncellulosic fibers of synthetic origin.
The category includes manufactured fibers in which the fiber-forming substance
is a long-chain, organic synthetic polymer. Cellulosic fibers such as rayon
and acetate and the inorganic fibers such as boron, fiberglass, and graphite
are excluded. Synthetic fiber industry activities start with a synthetic, long-
chain polymer and terminate with the formation of a marketable filament or
threadlike material.
The major raw material for the synthetic fiber industry is bulk polymer
obtained from the plastics and resins industry. For descriptive purposes it
was assumed that the polymer is received by the synthetic fiber industry in
the form of polymer chips. In actuality, however, some processes use molten
or dissolved polymer directly from the polymerization vessel.
The processes involved in the manufacture of synthetic fibers are melt
spinning, dry-spinning, wet spinning, lubrication, drawing, and fiber modifi-
cation. A flow diagram has been prepared which illustrates the sequence in
which these processes are combined to produce a marketable product.
The synthetic fiber industry employs 97,000 people in 149 plants. Most
of the production is from a few large plants with capacities from 50 to 150 Gg x
per year. There are many small specialty plants in which products are cap- (Z^-H*?*^Tj
tively consumed. Capacities of these plants are from 0.5 to 5 Gg per year.
Capacities are approximate because equipment may be used to produce more
than one product and producers may shift product lines depending on market
conditions.
Synthetic fibers comprise about 43 percent of the total fiber production
in the United States with 2700 Gg produced in 1975. Of this total more than
99 percent was either acrylic, nylon, olefin, or polyester. Production data
for 1975 are summarized in Table 1.
Of the 149 plants in operation on January 1, 1976, 85 are located in the
states of North Carolina, South Carolina, Virginia, and Tennessee. Another
44 are located in seven adjoining mid-atlantic and southern states. The re-
maining 20 are scattered throughout 11 states and Puerto Rico. Table C-2
in the appendix shows the number of plants in each state and the fiber pro-
duced. Several of these plants are associated with polymerization processes
in the plastics and resins industry or with downstream industries such as the
textile or tire producing industries. Table 2 lists the ten largest producers
and their major products. These ten companies account for 85 percent of the
total production capacity.
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Table 1. 1975 PRODUCTION OF SYNTHETIC FIBERS
Fiber
Polyester
Nylon
Acrylic
Olefin
Other
TOTAL
Production
1360
843
238
226
5
2672
, Gg (106lbs)
(2995)
(1857)
( 525)
( 497)
( ID
(5885)
Source: C & EN's Top 50 Chemical Products and Producers. Chemical and Engin-
eering News, 54.09): 33-39, May 3, 1976.
Production Fell, Often Sharply, Last Year for Almost All Major Chemi-
cal Products. Chemical and Engineering News, 54J24): 35, June 7, 1976.
Table 2. TEN LARGEST SYNTHETIC FIBER PRODUCERS
Producer
Acrylic
Major Products
Nylon Olefin
Polyester
Akzona, Inc.
Allied Chemical Corporation
American Cyanamid Company x
American Hoechst Corporation
Celanese Corporation
Dow Badische Company x
E. I. duPont de Nemours &
Co., Inc. x
Eastman Kodak Company x
Monsanto Company x
Phillips Petroleum Company
x
x
x
x
x
x
x x
x
x
x
x
x
x
x
x
x
x
Source: Directory of Chemical Producers, 1976.
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A decline in production of synthetic fibers started in 1973 and resulted
in substantial losses for fiber producers during 1975. Despite increased
fiber demand production dropped to only 72 percent of existing capacity^be-
cause of stocks accumulated by textile companies as a hedge against antici-
pated shortages and price rises. Price increases in raw materials and util-
ities also affected producers, and many smaller companies were forced out of
business. However, by late 1975 production was almost back to full capacity
and the outlook for 1976 is optimistic, especially for polyester. Plant
capacities are expected to increase 22 percent to 4200 Gg by 1980, although
growth rates of per capita fiber consumption are expected to taper off.
Fiber demand is closely tied to a variety of complex market conditions
such as disposable income levels (apparel), housing starts (home furnishings)
and automobile sales (tire cord). Thus, the major influences on future fiber
growth are population increases and continued replacement of natural and cell-
ulosic fibers. Energy requirements for the synthetic fibers industry for 1971
are summarized in Table 3.
Table 3. FUELS & ELECTRICAL ENERGY CONSUMED BY COMPANIES IN SIC CODE
2824 in 1971
Purchased fuels
Coal (Gg) 2883
Fuel Oil (Mm3) 702
Natural Gas (Gm3) 1160
Purchased Electrical Energy (GWh) 4843
Generated Electrical Energy (GWh) 1528
Total Energy Consumed (TWh equiv.) 43.4
Source: U. S. Bureau of Census. Census of Manufacturers, 1972. Industries
Series: Plastics Materials, Synthetic Rubber, and Man-made Fibers.
MC72(2)-28B. Washington, D. C., GPO, 1974.
Raw Materials
Relatively pure materials are required in the fibers industry because
of the deleterious effect of impurities on the properties of the fiber. The
primary raw material used in the synthetic fiber industry is bulk polymer ob-
tained either directly from the polymerization process or indirectly in the
form of dried polymer chips. The polymers used and their chemical compositions
are summarized in Table A-l in the appendix. Table 4 gives 1974 industry con-
sumption figures for major raw materials.
Many additives are blended with the polymer before fiber production.
Examples are delustrants, pigments, dyeing assistants, dye receptors, optical
brighteners, heat stabilizers, antioxidant stabilizers, and light stabilizers.
Ordinarily, the total amount of additives does not exceed five percent. Mat-
erials added to the fiber to enhance product utility include lubricating agents,
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bacteriostats, humectants, anti-static agents, and other similar additives.
Both organic solvents and aqueous solutions of inorganic salts are used in
some processes. Tables A-2 and A-3 in the appendix list some of these raw
materials.
The synthetic fiber industry, like the plastics and resins industry, is
dependent on basic petrochemicals as feedstocks for production. The major
chemical feedstocks used directly to produce polymers for fiber raw materials
are benzene, butadiene, ethylene, propylene, and xylene. The shortage of
these raw materials has affected fiber producers in a variety of ways. At
present, feedstocks seem ample to meet demand.
Table 4. RAW MATERIAL CONSUMPTION FOR PRODUCTION OF SYNTHETIC FIBERS
BY COMPANIES IN SIC CODE 2824 in 1971.
Raw Material
Consumption, Gg
Acrylonitrile
Acrylates and methacrylates
Caprolactam
Glycols
290
12
347
518
Source: U. S. Bureau of Census. Census of Manufacturers, 1972.
Industries Series: Plastics Materials, Synthetic Rubber,
and Man-made Fibers. MC72(2)-28B. Washington, D. C. ,
GPO, 1974.
Products
Synthetic fibers have been grouped into nine classes by the Federal Trade
Commission. The accepted generic names for the synthetic fibers produced in
the United States are acrylic, modacrylic, nylon, aramid, olefin, polyester,
saran, spandex, and vinyon. Definitions of these classes are found in Table
5. Other fibers which are now being produced but have not yet been assigned
generic names are fluorocarbon, polycarbonate, and novoloid (phenolic) fibers.
Table B-l in Appendix B gives a complete product list and properties of major
products are given in Table B-2.
Fibers are generally marketed as yarn, staple, or tow. Other forms are
monofi lament, split film, fiberfill, and nonwoven fabrics. The major uses of
synthetic fibers are summarized in Table 6. Over 80 percent of the fiber used
in home furnishings is for rugs, carpets, and carpet backing. Most of the re-
mainder is used for draperies and upholstery. The major industrial use (70
percent) for synthetic fibers is for automobile tire cord. Other uses of syn-
thetic fibers are automobile seat covers; belting; electrical wire insulation;
hose; recreational surfaces (Astroturf); roofing; rope and twine; sewing thread;
tents, parachutes, sails, etc.; tarp; and webbing for outdoor furniture.
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Table 5. GENERIC NAMES OF SYNTHETIC FIBERS
Generic Name Definition
*Acrylic At least 85 percent acrylonitrile by weight
*Modacrylic 35-85 percent acrylonitrile by weight
*Nylon Polyamide with less than 85 percent of the amide linkages
attached to two aromatic rings.
Aramid Polyamide with at least 85 percent of amide linkages
attached to two aromatic rings.
*01efin At least 85 percent ethylene, propylene, or other olefin
units by weight.
*Polyester At least 85 percent by weight of an ester of a substituted
aromatic carboxylic acid, including but not limited to the
ester of a dihydric alcohol and terephthalic acid.
Saran At least 80 percent vinylidene chloride by weight.
Spandex At least 85 percent of a segmented polyurethane.
Vinyon At least 85 percent vinyl chloride
*
These classes account for 99 percent of production.
Table 6. END USES OF SYNTHETIC FIBERS, 19731 CONSUMPTION (Gg)
Home Industrial
Apparel Furnishings & Other Total
Acrylic and Modacrylic
Nylon
Olefin2
Polyester
TOTAL
165
192
< 1
898
1255
84
356
121
234
795
5
205
49
280
539
254
753
170
1412
2589
Includes imports
21972 figures
Sources: Harper, C. A. Handbook of Plastics and Elastomers. N.Y.,
McGraw-Hill, 1975.
Wallace, P. T. Fibers-Introduction, and Fibers-Synthetic.
In: Chemical and Economics Handbook. Menlo Park, California,
Stanford Research Inst., August and December 1974, 541.1000A-541
1000K; 543.1000-543.1400E; 543.3521J.
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Companies
As of 1 January 1976 there were 61 companies which comprised the synthetic
fibers industry. The companies operated 149 plants in 22 states and Puerto
Rico. Table 7 lists the 10 largest companies and the production capacity of
each along with the combined capacity of the other 51 companies. A complete
listing of all plants, by company, is given in Appendix C. Production capa-
cities were not available for some plants which produce low-volume specialty
items. As is evident from the company list, many of the fiber producers are
also major synthetic polymer producers. Fiber plants are generally not loca-
ted near polymer plants although the trend in newer plants is toward integra-
tion of these two industries.
Table 7. CAPACITY OF TEN LARGEST SYNTHETIC FIBER PRODUCERS
Company
E. I. duPont de Nemours & Co., Inc.
Celanese Corporation
Monsanto Company
Eastman Kodak Company
Akzona, Inc.
Allied Chemical Corporation
American Hoechst Corporation
Dow Badische Company
Phillips Petroleum Company
American Cyanamid Company
All Others
Number of
Plants
16
5
9
3
5
4
2
2
3
2
98
149
Capacity
(Gg/yr)
>1169 (1387)*
382
> 373 (433)*
195 (308)*
135
129 (143)*
116 (127)*
100
91
80
506
3276 (3748)*
*Planned increases for 1976
Environmental Impact
Relatively little data were available on the environmental impact of the
synthetic fibers industry. It can be assumed that the industry produces all
three types of waste (gaseous, solid, and liquid) in varying degrees. Aqueous
emissions appear to represent the largest potential source of pollution.
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In general, the polymer raw materials are not toxic or otherwise hazard-
ous unless heated to temperatures at which decomposition can occur. Emissions
from the fiber industry usually arise from mechanical treatment of the polymer
or are associated with solvents, additives, lubricants, or finishes used in
processing. Companies which use integrated polymerization spinning systems
produce waste which contains unreacted monomer.
The major sources of gaseous emissions are from cooling chambers, con-
ditioning chamber^.^l^ntYemQval chambers, and from solvent make-up. The
use~bTTiof^solvents in several processes results in the entrainment of solvent
by the fibers. Solvent may be subsequently emitted as vapor during processes
such as drawing or heat-setting. "~" '
Particulate emissions of the solid polymer are possible from most of the
processes but primarily from the Quitting, winding, crimping., and baling pro-
cess steps. Other solid wastes resuTt from disposal of sub-standard material,
filter solids, and water treatment sludge. Some four percent of fiber pro-
duced is of sub-standard quality. This waste fiber may be buried, incinerated,
reprocessed, or sold depending on supply and demand, __.
Liquid emissions generally are termed "spin-finish wastes." Included
in this category are water used for purging the spinning baths and washing
the filaments, lubricants used in finish applications, and solvent wastes
from dry and wet spinning. Other liquid effluents arise from wash water
in filtration steps, solvent spills, and drawing baths. Periodic cleaning
of process equipment also contributes significantly to the total wastewater
load. Sanitary wastes resulting from the large number of people employed
at fiber plants are a significant portion of the total effluent load. Cool-
ing water blowdown also contributes to the liquid effluent from melt spinn-
ing.
Wastewater emissions from some operations have been classified according
to waste load and treatability. This information is summarized in Table 8.
Analysis of samples from a settling pond at an acrylic fibers production
facility indicated the presence of acrylonitrile (100 mg/A), 2,3-dibromo-l-
propanol (0.5 mgl/£), an isomer of dibromopropene, and 2,4-dimethyldiphenyl-
sulfone.
Table 8. SUMMARY OF WASTEWATER DATA FOR SELECTED FIBERS
Fiber
Nylon
Olefin1
Spandex
Wastewater
Loading (mVkkg)
1.3-30.9
8.3-14.2
-
Raw Waste Loads (kg/kkg)
BOD5 COD SS
0.1-60 0.2-90 0.1-6
0.4-1.1 1.8-2.6 0.2-2.2
20Z 402
polypropylene
Estimated
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EPA Source Classification Codes for the synthetic fibers industry are
summarized in Table 9.
Table 9. SOURCE CLASSIFICATION CODES FOR SYNTHETIC FIBERS
Operation Code
Nylon General 3-01-024-01
Dacron General 3-01-024-01
Orion 3-01-024-03
Elastic 3-01-024-04
Teflon 3-01-024-05
Polyester 3-01-024-06
Nomex 3-01-024-08
Acrylic 3-01-024-12
Tynex 3-01-024-12
Olefins 3-01-024-14
Others 3-01-024-99
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Bibliography
(1) American Home Economics Association. Textile Handbook, 4th Ed. Washington,
D. C., 1970.
(2) Billmeyer, F. W., Jr. Fiber Technology. In: Textbook of Polymer Science.
N. Y., Interscience Publishers, 1962.
(3) C&EN's Top 50 Chemical Products and Producers. Chemical and Engineering
News, 54(19):33-39, May 3, 1976.
(4) Directory of Chemical Producers - U.S.A. Chemical Information Services,
Menlo Park, California, Stanford Research Institute, 1976.
(5) Environmental Protection Agency, Effluent Guidelines Division. Develop-
ment Document for Effluent Limitations Guidelines and New Source Per-
formance Standards for the Synthetic Polymers Segment of the Plastics
and Synthetic Materials Manufacturing Point Source Category. EPA 440/1-
75/036-b. Washington, D. C., Jan. 1975.
(6) Environmental Protection Agency, (Office of Air and Water Program, Eff-
luent Guidelines Div.). Development Document for Effluent Limitations
Guidelines and New Source Performance Standards for the Synthetic Resins
Segment of the Plastics and Synthetic Materials Manufacturing Point Source
Category.
(7) Federal Energy Administration, Office of Economic Empact. Report to
Congress on Petrochemicals. Public Law 93-275, Section 23, GPO, 1974.
(8) Fiber Makers Took a Beating in 1975. Chemical and Engineering News,
54_(6):12, Feb. 9, 1976.
(9) Harper, C. A. Handbook of Plastics and Elastomers. N.Y., McGraw-Hill,
1975.
(10) Man-Made Fiber Producers' Directory. Textile Organon, 65_(9), 1974.
(11) 1975 Man-Made Fiber Deskbook. Modern Textiles 1975 (March), 17.
(12) Polyester Raw Materials Allow Fiber Growth. Chemical and Engineering
News, 53J39): 11-13, Sept. 29, 1975.
(13) Production Fell, Often Sharply, Last Year for Almost All Major Chemical
Products. Chemical and Engineering News, 54_(24):35-38, June 7, 1976.
(14) Recession Clamped a Lid on Growth in Chemical Output Last Year, With
Production Down for Many Major Products. Chemical and Engineering News,
53_(22):31-38, June 2, 1975.
(15) Sorenson, W. R. and T. W. Campbell. Preparative Methods of Polymer
Chemistry, 2nd Ed. N.Y., Interscience Publishers, 1968.
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(16) Stanford Research Institute. 1975 Directory of Chemical Producers,
U.S.A. Menlo Park, California, 1975.
(17) U. S. Bureau of Census. Census of Manufacturers, 1972, Industry
Series: Plastics Materials, Synthetic Rubber, and Man-Made Fibers.
MC72(2)-28B. Washington, D. C., 6PO, 1974.
(18) U. S. Makes World's Lowest-Cost Fibers. Chemical and Engineering News,
53(48), 10-11, Dec. 1, 1975.
(19) Wallace, P. T. Fibers-Introduction, and Fibers-Synthetic. In: Chemi-
cal and Economics Handbook. Menlo Park, California, Stanford Research
Inst., August and December 1974, 541.1000A-541.1000K: 543.1000-543.1400E;
543.3521J.
(20) Work, R. W. Man-Made Textile Fibers. In: Riegel's Handbook of In-
dustrial Chemistry, 7th Ed. J. A. Kent, ed. N.Y., Van Nostrand Rein-
hold, 1974.
10
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INDUSTRY ANALYSIS
Data for the analysis of the fiber industry are presented in six process
modules. There are three processes describing filament formation and three
which describe fiber treatment. Variations on these processes occur both in
order of processing and in operating conditions. The processes are presented
graphically in Figure 1. They have been numbered consecutively from 1 to 6.
The numbers assigned to the modules on the flow sheet correspond to process
description numbers.
Some data were available on operating parameters for the spinning and
drawing processes, but not for all fibers. Waste stream data were available
mainly in the form of general comments about the production of a particular
fiber. Data on utilities were unavailable. The data given should be viewed
as being generally representative of industry and not descriptive of the var-
iation in waste management practices from company to company.
Synthetic Fiber Processing
Synthetic fibers are formed by three different processes: melt spinning
(Process No. 1), wet spinning (Process No. 2), and dry spinning (Process No. 3).
The choice of method depends primarily on several simple polymer characteris-
tics such as melting point, melt stability, and solubility in organic solvents.
The spinning processes accomplish the extrusion of the polymer in liquid form
through fine orifices called spinnerets. The processes differ in the manner
in which the polymer is liquefied, which in turn determines the manner in which
the extruded filaments are solidified.
Melt spinning uses heat to melt the polymer and then uses cool air to
solidify the extruded liquid stream. In dry spinning, solidification of the
fiber occurs by evaporation of the solvent used to dissolve and extrude the
polymer. In wet spinning, the liquid polymer is spun (extruded) into a liquid
coagulating bath. The essential feature of this process is the mass transfer
of the organic solvent or inorganic salt solution from the polymer to the co-
agulating bath. The fiber thus formed can be wound on a bobbin at either
constant speed or constant tension to give "continuous filament yarn" or it
can be cut into small pieces called "staple" which may be processed into
bundles called "tow."
The yarn, staple, or tow must be lubricated (Process No. 4) to reduce the
friction encountered in the processing machinery and to reduce the static
electric charge on the fiber. The lubricated fiber is then drawn (Process No.
5) to give orientation and increase strength and modified (Process No. 6) by
a variety of process steps to give a finished product.
11
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STEAM
AIR
ro
itasm
O GASEOUS EMISSIONS
QSOUO EMISSIONS
£ UQUB EMISSIONS
FIGURE 1. SYNTHETIC RBER INDUSTRY FLOW DIAGRAM
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SYNTHETIC FIBERS
PROCESS NO. 1
Melt Spinning
1. Function - Melt spinning is used to convert polymer chips into synthetic
fibers called filaments. This process is used for polymers which can be
melted under reasonable conditions without degradation of the polymer and
thus is used mainly for the production of nylon, polyester, olefin, and saran
filaments.
The polymer chips can be melted in a variety of ways. The trend is
towards extrusion of the polymer chips in an electrically heated screw extruder.
The molten polymer is processed in a nitrogen atmosphere and metered through
an accurately machined gear pump to a filter assembly consisting of either a
series of metal gauzes or layers of graded sand. The filtered molten polymer
is then extruded at a constant rate, under high pressure, through a nickel or
stainless steel spinneret. The extruded liquid polymer streams are cooled
using an air stream and the solid filaments thus formed converge at a guide
to give a "spun yarn." For fibers such as nylon 66 the filaments pass through
a steam conditioning tube before converging.
After the fiber is converged it is given further treatments which are
dictated by the end use. These treatments probably include drawing and lub-
rication. Crimping, heat-setting, winding, cutting, or twisting may also be
done.
2. Input Materials - The polymers treated in melt spinning and their chem-
ical composition are summarized in Table 10.
Table 10. INPUT POLYMERS FOR MELT SPINNING
Fiber
Generic Type
Input Polymer
Nylon 66
Nylon 6
Nylon 610
Dacron
Kodel
Nylon
Nylon
Nylon
Polyester
Polyester
Polypropylene Olefin
Polyethylene Olefin
Saran Saran
Poly(hexamethylene adipamide)
Polycaprolactam
Poly(hexamethylene sebacamide)
Poly(ethylene terephthai ate)
Poly(l,4 dimethyl dicyclohexyl
terephthai ate)
Polypropylene
Polyethylene
Poly(vinylidene chloride)
The input polymer may contain other copolymers, dyes, or additives as
listed in Table A-2 in the appendix. Other input materials in the process
include air, nitrogen and steam.
13
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3. Operating Parameters - Operating parameters for the melt spin processing
of major fibers are given in Table 11.
Table 11. TYPICAL MELT SPINNING OPERATING PARAMETERS
Fiber
Nylon
Polyester
Olefin
Saran
Spin Temperature
(°C)
270-290
280-300
250-360
175
Pressure
(MPa)
-
7-35
-
-
Spinneret
Hole Diam. (urn)
200-300
-
>100
-
Spin Speed
(m/min)
600-1200
500-1000
-
-
4. Utility Requirements - Quantitative data were not found in the sources
consulted for this study.
5. Waste Streams - Gaseous emissions resulting from the use of air to solid-
ify the filament and steam to condition nylon could contain unreacted monomer
or other volatile hydrocarbon species. Solid wastes resulting from filtering
the molten polymer are disposed of by landfill. Water used for rinsing the
spinneret and other process equipment contributes to the spin-finish wastes
which have high BOD and oil and grease contents. Large quantities of water
are used for cooling and air conditioning. Liquid effluents arise from cool-
ing tower blowdown.
6- EPA Source Classification Code - See industry description.
7. References -
(1) Billmeyer, F. W., Jr. Textbook of Polymer Science, 2nd Ed. N.Y.,
Wiley, 1971.
(2) Environmental Progection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.). Development Document for Effluent Limitations
Guidelines and New Source Performance Standards for the Synthetic Resins
Segment of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-74-010-a. Washington, D. C., 1974.
(3) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
(4) Erlich, Victor L. Olefin Fibers. In: Encyclopedia of Polymer
Science and Technology, Vol 9. H. F. Mark, ed. N.Y., Wiley, 1968,
p. 403-40.
14
-------
(5) Farrow, G. and E. S. Hill. Polyester Fibers. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Ed., Vol 16. Anthony
Standen, ed. N.Y., Wiley, 1968, p. 143-158.
(6) Farrow, G., et al. Polyester Fibers. In: Encyclopedia of Poly-
mer Science and Technology, Vol 11. H. F. Mark, ed. N.Y., Wiley,
1969, p. 1-41.
(7) Lewis, P. F. Polyolefin Fibers. In: Chemical and Economics Hand-
book, Menlo-Park, California, Stanford Research Institute, July 1969,
543.5520F.
(8) Mark, H. F., S. M. Atlas and E. Cernia, eds. Man-Made Fibers,
Science and Technology, Vol 1. N.Y., Wiley Interscience, 1967.
(9) Mark, H. F., S. M. Atlas and E. Cernia, eds. Man-Made Fibers, Science
and Technology, Vol 2. N. Y., Wiley Interscience, 1968.
(10) Mclntyre, J. E. Man-Made Fibers, Manufacture. In: Encyclopedia of
Polymer Science and Technology, Vol 8. H. F. Mark, ed. N.Y., Wiley,
1968, p. 374-404.
(11) Repka, Benjamin C., Jr. Olefin Polymers. In: Kirk-Othmer Encyclo-
pedia of Chemical Technology, 2nd Ed., Vol 16. Anthony Standen, ed.
N.Y., Wiley, 1968, p. 217-309.
(12) Snider, 0. E. and R. J. Richardson. Polyamides (Fibers). In: Kirk-
Othmer Encyclopedia of Chemical Technology, 2nd Ed., Vol 16. Anthony
Standen, ed. N.Y., Wiley, 1968, p. 46-87.
(13) Snider, 0. E. and J. Richardson. Polyamide Fibers. In: Encyclopedia
of Polymer Science and Technology, Vol 10. H. F. Mark, ed. N.Y.,
Wiley, 1969, p. 347-460.
(14) Wallace, P. T. Nylon Fibers. In: Chemical and Economics Handbook.
Menlo Park, California, Stanford Research Institute, April 1973,
453.4122E-F.
(15) Wallace, P. T. Polyester Fibers. In: Chemical and Economics Handbook.
Menlo Park, California, Stanford Research Institute, October 1974,
543.482E-F.
(16) Work, R. W. Man-Made Textile Fibers. In: ReigeTs Handbook of
Industrial Chemistry, 7th Ed. J. A. Kent, ed. N.Y., Van Nostrand
Reinhold, 1974, p. 323-330.
15
-------
SYNTHETIC FIBERS PROCESS NO. 2
Wet Spinning
1. Function - Wet spinning is also used to produce filaments from polymer
chips. This process is used for polymers which can be dissolved in solvents.
Wet spinning requires slower spinning speeds than either melt or dry spinning.
This production method is usually reserved for the manufacture of heavy tow,
which also requires slow speeds for downstream processing steps. This method
is used primarily to produce acrylic, modacrylic and spandex tow.
Equipment required for wet spinning includes a solution vessel, a metering
pump, a filter, a spinneret, and a coagulant tank. Products which require
"aging" of the polymer solution before spinning employ a holding tank and all
processes include a recovery system to separate the coagulant and solvent.
As in melt spinning, the extruded filaments are further processed in a
variety of ways depending on end use. Wet spinning requires a washing step
immediately after extrusion to remove solvent and other impurities. This wash-
ing step can occur either continuously or by a batch method.
2. Input Materials - The main input materials include polymer, solvent, and
coagulant. Some examples are summarized in Table 12. Although water is gen-
erally used to clean the fibers, aqueous ammonia is sometimes used for fil-
aments spun from inorganic salt solutions.
Table 12. INPUT MATERIALS FOR WET-SPINNING
Fiber
Acryl i c
Polymer
Polyacrylonitrile
Solvent
Dime thy! ace tamide
Coagulant
Aqueous DMAc
(DMAc)
Aqueous ZnCl2 Aqueous Zn€l2
Aqueous NaSCN Aqueous NaSCN
Modacrylic Polyacrylonitrile-
poly(vinyl chloride) Acetonitrile Aqueous Acetonitrile
copolymer . . .. ^
v Acetone Water
Spandex Polyurethane Dimethylformamide Water
(DMF)
16
-------
3- Operating Parameters - The important variables affecting fiber properties
are concentration and temperature of the polymer solution (dope) and spin-bath
composition, concentration, and temperature. The values for these variables
differ from fiber to fiber and solvent to solvent but should be within the range
given below.
Spinneret:
Coagulate Bath Temperature:
Concentration of Polymer:
Mind-Up Speed:
Spinning Speeds:
Spin Temperature:
1,000 to 12,000 holes, 50 to 100 ym diameter.
May be made of platinum or tantalum if corrosive
liquids are used.
-15 to 10°C
10 to 30 %
15 to 60 m/min
50 to 100 m/min
0 to 200°C
Specific operating parameters for wet-spinning of some acrylic fibers are
summarized in Table 13.
Table 13. OPERATING SUMMARY OF PARAMETERS FOR PRODUCTION OF ACRYLIC FIBERS BY
WET SPINNING
Fiber
Producer
Polymer
Solvent Concentration
Composition (wt. %)
Coagulent Bath
Temp. Composition
(°C) (wt %)
Acrilan-
16
Acrilan-1656
Creslan
Creslan
Zefran
Zefran
Zefran
61
58
Monsanto
Monsanto
American Cyanamid
^American Cyanamid
Dow Badische
Dow Badische
Dow Badische
DMAc
DMAc
45-50%
45-50%
NaSCN
NaSCN
60% ZnCl2
60% ZnCl2
54-60%
ZnCl2
25
19
10 to 13
10 to 13
10
10
10
20
20
-5
-5
10
15
15
to
to
to
to
to
to
32
+5
+5
25
30
30
45-65% DMAc
66% DMAc
10% NaSCN
10% NaSCN
43-47% ZnCl
32-39% ZnCl
32-39% ZnCl
2
2
2
4. Utilities - No data were found in the sources consulted for this study.
5- Waste Streams - Gaseous emissions may result from solvent evaporation.
Solid wastes resulting from filtration of the polymer solution and from the
solvent recovery unit may be incinerated or sent to landfill. Sub-standard
fiber, often termed spinning waste, is also either incinerated or sent to
landfill. Gaseous emissions are produced from polymer incineration. Liquid
effluents are produced from cooling water discharge and blowdown and a once
17
-------
through cooling system with discharge to a storm sewer is employed at one
plant. Regeneration wastes are generated by the deionizing unit used to pro-
vide spin bath make-up water. The spin-finish waste includes water used to
clean the fibers and rinse water used to clean out various pieces of equip-
ment.
A wet spinning process variation termed reaction or chemical spinning
is employed by one company to produce spandex fiber. Effluent from fiber
washing is a mixture of water, toluene, and ethylene/diamine. Toluene and
water are separated in a continuous decanter. The waste water has a faint
odor of toluene and is discharged to a municipal sewage system. The toluene
is purified by distillation. Still bottoms are drummed and sent to landfill.
Nitriles (acrylic fiber), cyanides (spandex fiber), vinyl chloride (modacrylic
fiber), or thiocyanates could be present in waste waters from other processes.
Wastes from the solvent purification and recycle process contains inorganic
salts or organic solvents which contribute significantly to the total waste
load.
6. EPA Source Classification Code - See Industry Description.
7. References -
(1) Billmeyer, F. W., Jr. Fiber Technology. In: Textbook of Polymer
Science. N.Y., Interscience Publishers, 1962,
(2) Chaney, David W. Acrylic and Modacrylic Fibers. In: Kirk«0thmer
Encyclopedia of Chemical Technology, 2nd Ed., Vol. I. Anthony Standen,
ed. N,Y., Wiley, 1968, p. 313-338,
(3) Davis, 0. W, and Paul Shapiro, Acrylic Fibers. In: Encyclopedia of
Polymer Science and Technology, Vol 1, H. F. Mark, ed. N.Y., Wiley,
1964, p. 342-73.
(4) Environmental Protection Agency, Effluent Guidelines Division. De-
velopment Document for Effluent Limitations Guidelines and New Source
Performance Standards for the Synthetic Polymers Segment of the Plastics
and Synthetic Materials Manufacturing Point Source Category. EPA 4407
1-75/036-b. Washington, D. C., Jan, 1975.
(5) Kennedy, R, K. Modacrylic Fibers. In: Encyclopedia of Polymer
Science and Technology, Vol 8. H. F. Mark, ed. N.Y., Wiley, 1968,
p. 812-39.
(6) Mclntyre, J. E. Man-Made Fibers, Manufacture. In: Encyclopedia of
Polymer Science and Technology, Vol 8, H. F, Mark, ed. N.Y., Wiley,
, 1968, p. 374-404.
(7) Wallace, P. T. Acrylic and Modacrylic Fibers. In: Chemical Economics
Handbook. Menlo Park, California, Stanford Research Institute, October
1975.
(8) Work, R. W. Man-Made Textile Fibers. In: Reigel's Handbook of Indus-
trial Chemistry, 7th Ed. J. A. Kent, ed. N.Y., Van Nostrand Reinhold,
1974, p. 323-330.
18
-------
SYNTHETIC FIBERS
PROCESS NO. 3
Dry Spinning
1. Function - Dry spinning is the third process used for converting polymer
chips into filaments. A polymer solution is extruded into a zone of heated
gas or vapor. The volatile solvent readily evaporates, leaving a solidified
filament which is then further processed. This process is used for easily
dissolved polymers such as acrylonitrile, poly(vinyl chloride), or polyure-
thane. Dry spinning is generally used to make continuous filament yarn be-
cause of the higher spinning speeds possible.
The equipment used for dry spinning is the same as that used for wet
spinning up to the spinneret. After leaving the spinneret the solution pass-
es through a spinning cell which consists of a cabinet about 25 feet long.
Hot, solvent-lean gas or vapor enters at one end and solvent-rich gas or va-
por emerges from the other.
The solidified filament is further treated by the processes listed in melt
spinning. An efficient solvent recovery system is required.
2. Input Materials - The two major input materials, polymer and solvent, are
summarized in Table 14 for the various fibers.
Table 14. INPUT MATERIALS FOR DRY SPINNING
Fi ber
Acryl i c
Modacryl i c
Spandex
Polymer
Polyacrylonitrile
Poly acrylonitrile/
poly (vinyl chloride)
polyu re thane
Solvent
DMF, DMAc
tetramethylene sulfone
acetone
DMF, DMAc
The gas used to evaporate the solvent may be air, inert gas (nitrogen or
carbon dioxide), superheated steam, or superheated solvent vapor.
3. Operating Parameters - The major operating parameters are summarized below:
Spinneret:
Gas temperature:
25 to 200 ym diameter holes
80 to 130°C for low boiling solvents
200 to 400°C for higher boiling solvents (DMF, DMAc)
The cell walls may be heated to 500°C
Polymer concentration: 10 to 30%
Yarn wind-up speed: 500 to 1200 m/min
19
-------
4. Utilities - No data were found in the sources consulted for this study.
5. Haste Streams - Gaseous emissions probably include solvent vapors. Fil-
tration of the polymer solution (dope) feed to spinning produces solid wastes
which are either incinerated or sent to landfill.
Liquid effluents include waste solution from the solution preparation
step, waste from solvent purification and cooling water discharge. The waste
stream from the solution preparation step is incinerated, while the waste from
solvent purification and equipment washing is sent to biological treatment.
Waste polymer and unrecovered solvent are termed "spinning wastes" and are
either incinerated or added to the spin-finish waste stream.
6. EPA Source Classification Code - See Industry Description
7. References -
(1) Billmeyer, F. W., Jr. Fiber Technology. In: Textbook of Polymer
Science. N.Y., Interscience Publishers, 1962.
(2) Chaney, David W. Acrylic and Modacrylic Fibers. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Ed., Vol. I. Anthony
Standen, ed. N.Y., Wiley, 1968, p. 313-338.
(3) Davis, C. W. and Paul Shapiro. Acrylic Fibers. In: Encyclopedia
of Polymer Science and Technology, Vol 1. H. F. Mark, ed. N.Y.,
Wiley, 1964, p. 342-73.
(4) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
(5) Environmental Protection Agency, (Office of Air and Water Program,
Effluent Guidelines Div,). Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthe-
tic Resins Segment of the Plastics and Synthetic Materials Manufactur-
ing Point Source Category. EPA 440/1-74-010-a. Washington, D. C.
1974.
(6) Kennedy, R. K. Modacrylic Fibers. In: Encyclopedia of Polymer
Science and Technology, Vol 8. H. F. Mark, ed. N.Y., Wiley, 1968,
p. 812-39.
(7) Mclntyre, J. E. Man-Made Fibers, Manufacture. In: Encyclopedia of
Polymer Science and Technology, Vol 8. H. F. Mark, ed, N.Y., Wiley,
1968, p. 374-404.
(8) Wallace, P. T. Acrylic and Modacrylic Fibers. In: Chemical Econ-
omics Handbook. Menlo Park, California, Stanford Research Institute,
October 1975, 543.3522G.
(9) Work, R. W. Man-Made Textile Fibers. In: Reigel's Handbook of
Industrial Chemistry, 7th Ed. J. A. Kent, ed. N.Y., Van Nostrand
Reinhold, 1974, p. 323-330.
20
-------
SYNTHETIC FIBERS PROCESS NO. 4
Lubrication
1. Function - The three main functions of lubrication (spin finishing) are
surface lubrication, plasticizing action and static protection. The applica-
tion of a lubricant immediately after filament formation improves subsequent
handling and processing.
For melt spun and dry spun yarns, the lubricant is applied before winding
on a spin bobbin. In staple finishing the lubricant may be applied by pass-
ing through a bath or by spraying. For wet spun fibers the lubricant is
usually added after the cleaning step.
Most applications occur at the spinning stage. The lubricant is contacted
with the filament immediately after spinning by means of a ceramic wheel. An
aqueous solution or emulsion of the lubricant is pumped to a holding or stor-
age tank. From this tank, the lubricant is circulated into feeding trays where
it contacts the ceramic applicator.
2. Input Materials - The input materials to the process are the spun filament
from Process 1, 2, or 3, the antistatic lubricant, and water. Typical anti-
static lubricants are polyoxyethylene attached to aliphatic hydrocarbon chains,
long-chain alkyl quarternary ammonium salts, hydroxyalkylamine salts of long-
chain fatty acids, high-boiling aliphatic esters, hydrocarbon oils, and fluid
silicones. The lubricant is applied as a solution or emulsion in water.
3. Operating Parameters - Both the composition of the lubricant and the
amount applied to the fiber depend on the chemical composition of the fiber
and on the end use. The application is made at ambient pressure and temper-
ature. The application speed is the same as the yarn wind-up speed.
4. Utilities - No data were found in the sources consulted for this study.
5. Waste Streams - Spent lubricant is the major contributor to spin-finish
waste streams. Occasional cleaning of spin finish tanks also adds to the
total plant waste load in the form of oil and grease. At one plant these
waste streams are sent to municipal sewage treatment plants. In-plant
biological treatment is employed at another plant.
6. EPA Source Classification Code - See Industry Description
7. References -
(1) Billmeyer, F. W., Jr. Textbook of Polymer Science, 2nd Ed. N.Y..
Wiley, 1971.
(2) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
21
-------
(3) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.). Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(4) Mclntyre, J. E. Man-Made Fibers, Manufacture. In: Encyclopedia of
Polymer Science and Technology, Vol 8. H. F. Mark, ed. N.Y., Wiley,
1968, p. 374-404.
22
-------
SYNTHETIC FIBERS PROCESS NO. 5
Drawing
1. Function - The function of drawing (stretching) is to introduce molecular
orientation to the spun fiber and thus produce a stronger fiber. An optimum
draw ratio exists for each type of fiber as shown in Table 15. Yarns and tows
are drawn by stretching between two rolls, one to feed the undrawn yarn and the
other, moving at a faster velocity, to collect the drawn yarn. The ratio of
the surface speeds of the feed and draw rolls is defined as the draw ratio.
Many fibers are drawn as an integral part of the spinning process. In
other cases it is preferable to store the fibers or carry out some other oper-
ation first. The drawing process may be aided by heating the fiber either
through direct metal-to-fiber contact or by passing the fiber through a bath
containing a heated plasticizing liguid or other solution. In these cases
drawing may be combined with other processes such as cleaning or lubrication.
The drawn fiber may be wound, cut into tow, or modified by further treatment
depending on end use.
2. Input Materials - The input material is the lubricated fiber or tow from
Process 4. Superheated steam, hot water, or hot inert liquids may be used
depending on drawing arrangement.
3. Operating Parameters - The operating parameters are summarized in Table 15.
Table 15. OPERATING PARAMETERS FOR SYNTHETIC FIBER DRAWING
Fiber
Modacrylic
Acryl i c
Polyester
Nylon
Polypropylene
Polyethylene
Draw
Ratio
-
-
3 to 6
3 to 6
5 to 8
4 to 10
Draw
Temperature
(°C)
-
70 to 110
75 to 100
15
100 to 120
-
Percent
Elongation
400 to 1400
300 to 1000
400
250 to 600
-
-
Yarn and tow are drawn at different speeds. Drawing speeds vary from 100 to
1500 m/min.
4. Utilities - No data were found in the sources consulted for this study.
5. Waste Streams - Possible emissions from drawing include vapors of solvents
entrained in the fiber or waste liquids used in drawing baths.
23
-------
6. EPA Source Classification Code - See Industry Description
7. References -
(1) Billmeyer, F. W., Jr. Textbook of Polymer Science, 2nd Ed. N.Y.,
Wiley, 1971.
(2) Davis, C. W. and Paul Shapiro. Acrylic Fibers. In: Encyclopedia of
Polymer Science and Technology, Vol 1. H. F. Mark, ed. N.Y., Wiley,
1964, p. 342-73.
(3) Erlich, Victor L. Olefin Fibers. In: Encyclopedia of Polymer Science
and Technology, Vol 9. H. F. Mark, ed. N.Y., Wiley, 1968, p. 403-40.
(4) Farrow, 6. and E. S. Hill. Polyester Fibers. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Ed., Vol 16. Anthony Standen,
ed. N.Y., Wiley, 1968, p. 143-58.
(5) Kennedy, R. K. Modacrylic Fibers. In: Encyclopedia of Polymer
Science and Technology, Vol 8. H. F. Mark, ed. N.Y., Wiley, 1968,
p. 812-39.
(6) Mark, H. F., S. M. Atlas and E. Cernia, eds. Man-Made Fibers, Science
and Technology, Vol 2. N.Y., Wiley Interscience, 1968.
(7) Snider, 0. E. and J. Richardson. Polyamide Fibers. In: Encyclopedia
of Polymer Science and Technology, Vol 10. H. F. Mark, ed. N.Y.,
Wiley, 1969, p. 347-460.
24
-------
SYNTHETIC FIBERS PROCESS NO. 6
Fiber Modifications
1. Function - The function of these process steps is to modify the fiber
into a marketable product. Modifications include twisting to produce inter-
filament cohesion, heat setting or heat relaxation to produce dimensional
stability, crimping to add bulk and resilience, and cutting to produce staple
products similar to natural fibers. Other processing steps such as dyeing;
sizing; treating with water-repellant, fire-retardant, or other finishes; or
blending different fibers may be done by the fiber manufacturer but are
usually performed after manufacture and sale of the fiber.
The procedure used by a particular plant to transform the drawn fiber
into a marketable product depends on the end use. The following processing
steps are those used most often.
False-twist Texturing: This method of adding twist to yarns has replaced
many of the other twisting procedures because of the high speed (300,000 to
700,000 rpm) of operation. In this procedure the yarn is heated close
to the melting point, twisted to 28 to 40 turns per centimeter and then
cooled and unwound.
Heat Treating: Heat treating procedures are carried out by passing the
fiber through an oven or over a heated roll. If the fiber is under
tension, the procedure is called heat setting; if the procedure is
carried out under little or no tension it is called heat relaxation.
Heat setting procedures are often combined with texturizing process steps
in order to "set" the crimp or twist.
Crimping: Staple or yarn is crimped by mechanically distorting the fiber.
Crimping may be done at various stages during fiber production but is
usually done during or immediately after the drawing process. Crimping
procedures include gear crimping, edge crimping, and stuffer-box crimping.
Gear crimping is accomplished by passing the yarn through a pair of
meshed gears. The permanency of the crimp depends on the yarn temper-
ature during crimping and the setting temperature thereafter. In edge
crimping the yarn is passed over a blunt knife edge. The distortions
and strains which develop are retained by passing the yarn over a cooling
roll. Stuffer-tube crimping of yarn or stuffer-box crimping of tow are
accomplished by forcing the yarn into an electrically-heated, thermo-
statically controlled tube or box. The yarn pushes up on a weighted in-
sert which is free to rise and fall in the vessel. The crimped yarn is
pulled from the tube at constant speed. The temperature of the oven and
the yarn residence time control the amount of crimp.
Cutting: Continuous filament or tow is chopped into staple using cutting
machines. The fiber can be cut by rotating knives as it advances on roll-
ers or it can be advanced by centrifugal force and cut by stationary knives
as it advances.
25
-------
2. Input Materials - Synthetic filament or tow is the only input material
to this process.
3. Operating Parameters - Roller speeds approximate the speeds used in
spinning and drawing. Heat setting temperatures are generally close to the
melting point of the fiber.
4. Utilities - No data were found in the sources consulted for this study.
5. Waste Streams - Emissions from fiber modification processes are primarily
particulate wastes resulting from physical manipulation of the fiber. Heat
treatment of fibers could release gaseous emissions of entrained solvent.
6. EPA Source Classification Code - See Industry Description
7. References -
(1) Kennedy, R. K. Modacrylic Fibers. In: Encyclopedia of Polymer
Science and Technology, Vol 8. H. F. Mark, ed. N.Y., Wiley, 1968,
p. 812-39.
(2) Mark, H. F., S. M. Atlas and E. Cernia, eds. Man-Made Fibers,
Science and Technology, Vol 1. N.Y., Wiley Interscience, 1967.
(3) Mclntyre, J. E. Man-Made Fibers, Manufacture. In: Encyclopedia of
Polymer Science and Technology, Vol 8. H. F. Mark, ed. N.Y., Wiley,
1968, p. 374-404.
(4) Snider, 0. E. and J. Richardson. Polyamide Fibers. In: Encyclopedia
of Polymer Science and Technology, Vol 10. H. F. Mark, ed. N.Y.,
Wiley, 1969, p. 347-460.
26
-------
APPENDIX A
RAW MATERIALS LISTS
27
-------
Table A-l. FIBER RAW MATERIALS
Generic Name and Trade Name
Polymer Raw Materials
Acryli c
' Aramid1
Nomex
Fiber B (Kevlar)
Qi ana
Tajmi r
Fluorocarbon
Modacrylic
Nylon
Nylon 62
Nylon 662
Nylon 610
Nylon 612
Olefin
Polyester
Dacron/Fortrel
Kodel
Saran1
Spandex1
Vinyon1
acrylonitrile with 7 to 8% neutral acrylate
comonomers
m-phenylene diamine and isophthaloyl chloride
p-phenylene diamine and terephthaloyl chloride
trans, trans-bis-(4 aminocyclohexyl)-methane
and dodecanoic acid
2-pyrrolidone
tetra fluoroethylene and fluorinated ethylene-
propylene copolymers
acrylonitrile and vinyl chloride or other
comonomers
hexamethylenediamine and adipic acid
caprolactam
hexamethylenediamine and sebacic acid
hexamethylene diamine and dodecanoic acid
ethylene, propylene, or other olefin
dimethyl terephthalate or terephthalic acid
and ethylene glycol
dimethylterephthalate and 1, 4 cyclo hexylene
diglycol
vinylidene chloride and vinyl chloride
diisocyanates, polyester, polyester glycols
diamines
vinyl chloride and vinyl acetate
1These fibers represent less than 2% of total fiber production
2Nylon 6 and 66 represent 99% of nylon production
Sources: Wallace, P. T. Fibers - Introduction, and Fibers - Synthetic.
In: Chemical and Economic Handbook. Menlo Park, California.
Stanford Research Inst., August and December 1974, 541.1000A-
541.1000K; 543.1000-543.1400E; 543.3521J.
28
-------
Table A-2. TYPICAL ADDITIVES USED IN FIBER PRODUCTION
Delustrants -
Optical Brighteners -
Antioxidant Stabilizers -
Light Stabilizers -
Dyeing assistants -
Lucricants and Other Finishes -
Usually titanium dioxide
Stiblene
Phenyl coumarin
derivatives
Alkylated phenols
p-cresols mixed with sulfides
Thio compounds such as dilauryl
or distearyl thio dipropionate
Long-chain alkyl
benzophenones
derivatives of hydroxy
2-methyl-5-vinyl pyridine
2-vinyl pyridine
p-vinyl-benzene sulfonic acid
Sulphocinamic acid
Polyoxyethylene attached to aliphatic
hydrocarbon chains
Long-chain alkyl quartenary
Hydroxyalkyl amine salts of
Aliphatic esters
Hydrocarbons
Fluid silicones
ammonium salts
fatty acids
29
-------
Table A-3. SOLVENTS USED IN FIBER PRODUCTION
Dimethyl acetanride
Dimethyl formamide
Acetonitrile
Acetone
Aqueous ZnCl2
Aqueous NaSCN
Tetrarnethylene sulfone
30
-------
APPENDIX B
PRODUCTS
31
-------
Table B-l. PRODUCTS OF THE SYNTHETIC FIBERS INDUSTRY
Trademark
A-Acrilan
Acrilan
Acrilan Plus
Acrilan 2000+
Acttonwear
Amco Polyethylene
Amco Polypropylene
American Polyethylene
American Polypropylene
Anso
Anso-X
Antron
AstroTurf
Autowine
Avlin (fiber 200)
Beaunit Nylon
Beaunit Polyester
Bi-Loft
Blue "C"
Cadon, C-Cadon
Camalon
Cantrece
Caprolan
Celanese Nylon
Chadolene
Chadolon
Cordura
Courtaulds Nylon
Crepeset
Crepeset Anti-Cling
Creslan
C-Cumuloft
Cumuloft
Generic Name
acrylic
acrylic
acrylic
acrylic
nylon
olefin
olefin
olefin
olefin
nylon
nylon
nylon
nylon
olefin
polyester
nylon
polyester
acrylic
nylon, polyester
nylon
nylon
nylon
nylon, polyester
nylon
olefin
nylon
nylon
nylon
nylon
nylon
acrylic
nylon
nylon
Producer
Monsanto
Monsanto
Monsanto
Monsanto
Monsanto
American Mfg.
American Mfg.
American Mfg.
American Mfg.
Allied Chemical
Allied Chemical
DuPont
Monsanto
Indian Head
IMC-
El Paso Natural Gas
El Paso Natural Gas
Monsanto
Monsanto
Monsanto
Camac Corp.
DuPont
Allied Chemical
Celanese
Diversified Ind.
Chadbourn Ind.
DuPont
Courtaulds
Akzona
Akzona
American Cyanamid
Monsanto
Monsanto
Types and Special
Characteristics1
FST
F (solution dyed)
S
F (solution dyed)
F (producer-textured)
M (incl. slit film)
M (incl. slit film)
M (incl. slit film)
M (inc. slit film)
F, S
F, S
FST
Ribbon
Slit Processed
high modulus
FS
F (multibobal) , S
FST
S (bi-component) T
FS
F (multilobal) S
F
FM (bi-component)
FMS
F
F (fibrillated)
FM
F
F
M (inherent crepe
effect built in
during manufac-
ture)
M (inherent crepe and
anti-ding proper-
ties built in dur-
ing manufacture
ST
F (textured)
F (textured)
End-Use
Areas2
AHI
AH
H
H
A
I
I
I
I
H
H
AH
I
R
AH
HITC
TCA
A
AHI, TC
H
AH
A
AHITC
AHITC
HIS
A
LI
A
A
A
AHI
H
H
32
-------
Table B-l. PRODUCTS OF THE SYNTHETIC FIBERS INDUSTRY (CONTINUED)
Trademark
Dacron
DLP 17 Polyethylene
DLP 21 Polyethylene
DLP 31 Polyethylene
DLP 40 Polypropylene
DLP 47 Polypropylene
DLP 50 Polypropylene
DLP 57 Polypropylene
DLP 61 Polypropylene
DLP 70 Polypropylene
DLP 77 Polypropylene
DLP 90 Polypropylene
DuPont nylon
Ektafill
Elura
Encron
Encron 8
Encron Golden Touch
Encron Plyloc
Enkaloft TWIX
Generic Name
polyester
olefin
olefin
olefin
olefin
olefin
olefin
olefin
olefin
olefin
olefin
olefin
nylon
polyester
modacrylic
polyester
polyester
polyester
polyester
nylon
Producer
DuPont
Thiokol
Thiokol
Thiokol
Thiokol
Thiokol
Thiokol
Thiokol
Thiokol
Thiokol
Thiokol
Thiokol
DuPont
Eastman
Monsanto
Akzona
Akzona
Akzona
Akzona
Akzona
Types and Special
Characteristics1
FST
M (round shrinker
yarn)
M (round)
M (ribbon)
M (round & flat)
M (round & flat)
M (round & flat)
M (round & flat)
M (round, hi-tenacity
M (ribbon)
M (ribbon)
F (round)
FSTM
S (fiberfill)
T
FS
F (multilobal cross
section, reduces
sparkle in outer- wear
fabrics)
F (high filament
count)
F (producer-textured
two-ply stretch)
F (bulked, multilobal;
End-Use
Areas2
AHITC
I
I
AHI
HI
HI
HI
HI
I
I
HI
HI
AHITC
H
Wigs
AHITC
A
A
A
H
Enkaloft Stria nylon
Enkaloft Super Bulk nylon
Enkaloft TWIX nylon
Enkalure nylon
Enkalure II nylon
Akzona
Akzona
Akzona
Akzona
Akzona
space differential,
normal, cationic,
light dyeing types)
S (crimpset or non-
crimpset, normal ca-
tionic, dyeing types)
F (bulked, modified
twist, plied; cation-
ic and light dyeing
types; random pattern
effect)
F (high bulk)
F (bulked, modified
twist, plied; cation-
ic, light dyeing types;
tweed pattern effect
F (multilobal, delayed
soiling) AH
F (bulked, multilobal,
soil hiding)
S (multilobal), crimpset
or non-crimpset)
H
H
H
33
-------
Table B-l. PRODUCTS OF THE SYNTHETIC FIBERS INDUSTRY (CONTINUED)
Trademark
Enkalure III
Enka Nylon
Enka Polyester
Enkasheer
Esterweld
Fib rl lawn
Fib ri Ion
Firestone nylon
Firestone polyester
FMC Vinyon
Fortrel
Fortrel 5
Fortrel 7
Fortrel PCP
Glospan/Cleerspan
Goldcres
Goodyear Polyester
Hamlon
Hanover Nylon
Hanover Polyester
Herculon
Herculon IV
Hoechst Polyester
Kevlar
Kevlar 29
Kevlar 49
Kodel
Kynar
Kynol
Lo-Pic
Generic Name
nylon
nylon
polyester
nylon
polyester
olefin
olefin
nylon
polyester
vinyon
polyester
polyester
polyester
polyester
spandex
olefin
polyester
olefin
nylon
polyester
olefin
olefin
polyester
araraid
aramid
aramid
polyester
fluorocarbon
novoloid
olefin
Producer
Akzona
Akzona
Akzona
Akzona
American Cyanamide
Fibron
Fib r on
Firestone
Firestone
IMC
Cleanese
Celanese
Celanese
Celanese
Globe
Shuford Mills
Goodyear Tire
ACS Industries
Falk Fibers &
Fabrics
Falk Fibers &
Fabrics
Hercules
Hercules
Amer. Hoechst
DuPont
DuPont
DuPont
Eastman
Monofilaments
Carborundum
Fibron
Types and Special End-Use
Characteristics1 Areas2
F (inherent anti-ding
properties built in
during manufacture)
MFS (type 6.)
FS
M (producer modified
torque yarn)
F (treated)
F (fibrillated)
F (fibrillated)
MF
F
F or S (modified)
FST
F
T
S (producer-colored)
F (fused)
M (flat)
F (fibrillated)
F
F
MF
MF
F (bulked) FST
FS
SF (high tenacity, low
pilling for cotton,
woolen & worsted
systems)
F
F
F
FS (several types avail-
able)
M
S
M (flat)
A
AHITC
AHITC
A
I
H, I
HI
ITC
TCI
AH
AHITC
A
AH
H
AHI
AHI
AHI
TC
HI
AI
AHI
AHI
H
AHI
TC
I
I
AHI
I
AHI
HI
34
-------
Table B-l. PRODUCTS OF THE SYNTHETIC FIBERS INDUSTRY (CONTINUED)
trademark
Lycra
Marvess
Marvess III
Marvess CG
Mont re 1
Monvelle
Multisheer
MX6020
MX6020-H
MX108
Newton Polyester
NM1000
NM1103
NM1200
NM1400
NM1500
Nomex
Numa
Nylon by Amtech
Nypel Halar
Nypel Nylon
Nypel Polyester
Nypel Polypro
Olefin
Olefin
Oletex
Orion
Parapro
Pat Ion
PE3100
Phillips 66 Nylon
PolarGuard •
Polycarbonate
Polyester
Generic Name
spandex
olefin
olefin
olefin
olefin
biconstituent nylon/
spandex
nylon
polyester
polyester
nylon
polyester
nylon
nylon
nylon
nylon
nylon
aramld
spandex
nylon
fluoro carbon
nylon
polyester
olefin
olefin
olefin
olefin
acrylic, modacryllc
olefia
olefin
polyester
nylon
polyester
polycarbonate
polyester
Producer
DuPont
Phillips
Phillips
Phillips
Wellington
Monsanto
Akzona
Shakespeare
Shakespeare
Shakespeare
Albany Inter.
Monofilaments
Monofilaments
Monofilaments
Monofilaments
Monofilaments
DuPont
Ameliotex
Amtech
Allied Chetn.
Allied Chem-
Allied Chem.
Allied Chem.
Waltrich
Indian Head
Poncar
DuPont
Wall
Standard Oil Co.
(Ind.)
Monofilaments
Phillips
Celanese Corp.
Monofilaments Inc.
American Cyanamide
Types and Special End-Use
Characteristics1 Areas2
F
FS
F (BCF, modified cross-
section, high luster,
solution dyed.)
S (heavy-denier sol. dyed)
(low shrinkage, very high
modulus)
M,F
F (stretch yarns)
M-Round, reg. , med. & low
shrink
M-Round, hydrolysis re-
sistant, Reg., med. & low
shrink
M-Round opaque, HM
F
M (clear melt-dyed)
M (clear melt-dyed)
M (clear melt-dyed)
M (clear melt-dyed)
M (clear melt-dyed)
FS
F
M (round)
M
M
M
M
M
Slit-film, high mod.
M
ST
F
F
M (clear melt-dyed)
F
F,T
M
F
A
AHI
AH
H
HI
A (Hosiery)
A
I
I
I
I
AHI
AHI
AHI
AHI
A
AHI
AHI
I
I
I
I
I
AHI
I
IR
AH
H
H
AHI
AHI
AI
AI
TC
35
-------
Table B-l. PRODUCTS OF THE SYNTHETIC FIBERS INDUSTRY (CONTINUED)
Trademark
Polyester by Amtech
Polyethylene by Amtech
Polyloom I
Polyloom II
Polypropylene by Amtech
Polywrap
Poncar
Pro-Tuft
Qlana
Quintess
Random-set
Random-tone
Ruvea
S-3
Saran by Amtech
SEF
Shakespeare Nylon
Shakespeare Polyester
Shareen
Shoeflex
Shurti
Sooflex
Spectran
Starbrite
Strialine
Stryton
Synflex-N
Synthetic Ind
Tango
Teflon
Textura
Travira
TW 6208
Ty EZ
Generic Name
polyester
olefin
olefin
olefin
olefin
olefin
olefin
olefin
nylon
polyester
nylon
nylon
nylon
nylon
saran
modacrylic
nylon
polyester
nylon
nylon
olefin
nylon
polyester
nylon
polyester
nylon
nylon
olefin
nylon
fluorocarbon
polyester
polyester
olefin
olefin
Producer
Amtech
Amtech
Standard Oil Co.
(Calif.)
Standard Oil Co.
(Calif.)
Amtech
Indian Head
Poncar
Bemis
DuPont
Phillips
Rohm and Haas
Rohm and Haas
DuPont
Shakespeare
Amtech
Monsanto
Shakespeare
Shakespeare
Court aulds
Shakespeare
Shuford Mills
Shakespeare
Monsanto
Star Fibers
Akzona
Phillips
Wall Industries
Diversified Ind.
Allied Chemical
DuPont
Rohm and Haas
Amer. Hoechst
Fib r on
Indian Head
Types and Special End-Use
Characteristics1 Areas2
M (round)
M (round)
F (fibr illated)
F (fibrillated)
M (round and flat)
Slit processed high
modulus
M
P (ribbon)
M
F
Twisted and heat-set
Heat-set and dyed
" M (ribbon)
M (clear, melt-dyed)
M (round and flat)
S (flame retardant)
M (round)
M
M, F
M (clear, melt-dyed)
F (fibrillated)
M (clear, melt-dyad)
S
S
F (thick & thin,
color contrast dyeing)
F (undulating variable
cross-section)
M
Slit Film
F
FM
Producer textured
FS (high tenacity)
F
Slit processed high
IH
I
HI
HI
IH
R
IR
HIT
AH
AH
H
H
AHI
I
IH
AH
I
I
A (Hosiery)
I
R
I
A
AHI
AH
AH
H
IH
A
I
A
AHI
R
R
modulus
36
-------
Table B-l. PRODUCTS OF THE SYNTHETIC FIBERS INDUSTRY (CONTINUED)
Trademark
Tytite
Ultron
Unifil
Vectra
Verel
Voplex
Voplex
Vylor
Wall Polypropylene
Waltrich Polypropylene
Wellene
Wellon
Wellstrand
WSF PE
WSF PP
X-static
Zefran
Zefran
Zefran
Generic Name
olefin
nylon
olefin
olefin
modacrylic
olefin
vinyon
nylon
olefin
olefin
polyester
nylon
nylon & polyester
(heavy den.)
olefin
olefin
nylon
acrylic
nylon
polyester
Producer
Indian Head
Monsanto
Wall
Vectra
Eastman
Voplex
Voplex
DuPont
Wall
Waltrich
Wellman
Wellman
Wellman
Wellington
Wellington
Rohm and Haas
Dow
Dow
Dow
Types and Special
Characteristics1
Slit processed high
modulus
F
M
FS
S (assorted types for
specialized uses)
M (round or flat
polypropylene and
polyethylene)
M (flat)
M
M
M and ribbon
S
S (monofil)
M (round, high tenacity
(slit film)
M (round, high tenacity)
(slit)
F (fibrillated)
F (anti-static modified)
S (dyeable copolymer,
producer - colored
homopolymer)
FS
F
End-Use
Areas2
R
A
H
AIH
AHI
I
I
I
I
IH
HI
AHI
HI
I
I
AH
AHI
AH
A
IType: M=monofilament: F=multifilament; S=staple fiber; T=tow.
Identification of end-use areas: A»apparel; H»carpets, home furnishings; l«industrial fabrics:
TC»tire cord: R=twine
Source: Directory of Chemical Producers - U.S.A. Directory Information Services,
Menlo Park, California, Stanford Research Institute, 1976.
1975 Man-made Fiber Deskbook. Modern Textiles 1975 (March), 17.
37
-------
Table B-2. CHEMICAL AND PHYSICAL PROPERTIES OF SOME TEXTILE FIBERS1
Fiber
Acryl i c
Acrilan
Creslan
Orion
Modacryl i c
Dynel
Verel
Nylon 6
regular monofi lament
staple
Nylon 66
regular monofi lament
staple and tow
Nomex
Olefin
Polypropylene- isotatic
monofi lament
staple and tow
Polyesters, regular tenacity
Avlin, staple
Blue C, staple
Dacron, staple
Encron, filament
Fortrel, staple
Kodel, staple
Quintess, staple
Trevira, staple
Vycron, staple
Specific
Gravity
1.17
1.18
1.16
1.3
1.33-1.37
1.14
1.14
1.14
1.14
1.38
0.9-0.91
0.9-0.91
1.38
1.39
1.38
1.38
1.38
1.38
1.38
1.38
1.38
Tenacity2
(grams per
denier)
2-2.7
2-3
2.2-2.6
3.5-4.2
2-2.8
4-7
3.8-5.5
3-6
3.5-7.2
4-5.3
3.5-7
3-6.5
3.5-5
4.6
2.2-6
4.4-5
4.8
4.5-5.5
4.5-5.5
3.1-6.6
3.8-5.8
Tenacity (Wet)2
(grams per
denier)
1.6-2.2
1.6-2.7
1.8-2.1
3.5-4.2
2-2.7
3.7-6.2
-
2.6-5.2
3-6.1
3-4.1
3.5-7
3-6.5
3.5-5
4.5
2.2-6
4.4-5
4.8
4.5-5.5
4.5-5.5
3.1-6.6
3.8-5.8
Moisture
Regain
(percent)
1.5
1-1.5
1.5
0.4
3-4.25
2.8-5
2.8-5
4.2-4.5
4.2-4.5
6.5
0.01-0.1
0.01-0.1
0.4
0.4
0.4-0.8
0.4
0.4
0.4
0.4
0.4
0.6
Extensibility3
(percent)
34-50
35-45
20-28
14-34
25-43
17-45
37-50
25-65
16-66
22-32
14-30
20-80
35-50
40-50
12-55
27-36
45-55
35-45
40-50
18-55
22-67
Elasticity1*
(percent)
99(2) 89(5)
55-65(3) 40-60(5)
-
100(2) 98(5)
88(4) 55(10)
99-100(2-100)
100(2)
100(5) 99-100(10)
-
-
98(5) 95(10)
97-100(2) 94-100(5)
90-95(2) 55-65(5)
92(2) 75(5)
100(1)
55-65(5)
75-80(5)
75-85(2) 35-45(5)
67-86(2) 57-74(5)
44(5) 33(10)
-------
Table B-2. CHEMICAL AND PHYSICAL PROPERTIES OF SOME TEXTILE FIBERS1 (CONTINUED)
CO
Fiber
Saran
Spandex
Fulflex
Glospan
Lycra
Numa
Unel
Vyrene
Fluorocarbon
Teflon, staple
Teflon, monofi lament
Biconstituent Fiber
Source-ACOOOl
Specific
Gravity
1.7
1.41
1.2
1.21
1.2
1.2
1.2
2.1
2.1
1.22
Tenacity2
(grams per
denier
up to 1.5
0.34
0.7
0.7-0.9
0.6-0.9
0.55-0.85
-
1.2-1.4
0.5
up to 9
Tenacity (Wet)2
(grams per
denier
up to 1.5
_
0.6-0.9
-
-
-
-
1.2-1.4
0.5
—
Moisture
Regain
(percent)
None
<0.5
<1
1.3
1
1.3
0.3
_
-
2.7
Extensibility3
(percent)
15-25
600-625
600-700
444-555
500-600
500-700
650-700
15-33
52
45 maximum
Elasticity1*
(percent)
-
97(50)
99(50) 98(200)
97(50)
98(300)
96-98.5(50)
98(600)
_
-
100(4)
Because natural fibers inevitably vary in properties and man-made fibers may be produced in various forms, values
given should be interpreted as indicating order of magnitude of the fibers as used in textile applications.
2Tested at 21 °C (70°F) with relative humidity 65 percent.
Percentage of elongation at 65 percent relative humidity.
"Percentage of recovery from strain indicated.
Source: American Home Economics Association. Textile Handbook, 4th Ed., Washington, D. C., 1970.
-------
APPENDIX C
PRODUCERS
41
-------
Table C-l. SYNTHETIC FIBER PRODUCERS, PLANT LOCATIONS, PRODUCTS, AND CAPACITIES
Company
ACS Industries
Akzona Inc.
American Enka Co., Div
Albany International Corp.
Albany Felt Co., Div.
Newton Line Co., Inc.
Allied Chem. Corp.
Fibers Div.
-pa
ro
Nypel, Inc., Subsid.
Alrac Corp.
Aroeliotex, Inc.
American Cyanamid Co.
Fibers Div.
IRC Fibers Co. Subsid.
American Hoechst Corp.
Film Div.
Hoechst Fibers Indust. Div.
American Mfg. Co. Inc.
St. Loin's Cordage Mills Div.
AMTECH, Inc.
Location
Walthourville, Ga.
Woonsocket, R.I.
Central, S.C.
Enka, N.C.
Lowland, Tenn.
Central, S.C.
Lowland, Tenn.
Homer, N.Y.
Homer, N.Y.
Homer, N.Y.
Homer, N.Y.
Chesterfield, Va.
Irmo, S.C.
Irmo, S.C.
Moncure, N.C.
West Conshohocken, Pa.
Stamford, Conn.
Rocky Hill, N.J.
Milton, Fla.
Painesville, Ohio
Delaware City, Del.
Spartanburg, S.C.
Homesdale, PA
St. Louis, MO
Odenton, Md.
Odenton, Md.
Odenton, Md.
Odenton, Md.
Products5
Olefin (P)
Olefin
Nylon
Nylon
Nylon
Polyester
Polyester
Fluorocarbon
Nylon
Polyester
Olefin (E&P)
Nylon
Nylon
Polyester
Polyester
Nylon
Nylon
Spandex
Acrylic and modacrylic
Polyester
Polyester
Polyester
Olefin (E&P)
Olefin (E&P)
Nylon
Olefin (E&P)
Polyester
Saran
Form5 Capacity (Gg/Yr)1 Remarks
Y,F
Y,F
Y.F.S
Y.F.S
Y,F,S
Y,S
Y,S
F
F
F
F
Y.F.S
Y.F.S
Y.S
Y,S
F
Y,S
F
S.T
Y
Y.F.S.T
Y.F.S.T
F,0
F,0
F
F,0
F
F
na
na
7
34
45
"I
j
na
1
<.5
na
59
45
9 Experimental Capacity
16 (14)2
na
>1(23)2 Pilot
<.5
57
23
2
114 (II)2
na
na
5
na
0.5
na
-------
Table C-l. SYNTHETIC FIBER PRODUCERS, PLANT LOCATIONS, PRODUCTS, AND CAPACITIES (CONTINUED)
CO
Company
Arlln Mfg. Co., Inc.
Benris Co., Inc.
Berkley & Co., Inc.
Camac Corp.
The Carborundum Co.
Polymers Venture
Celanese Corp.
Fiber Industries, Inc., Subsid.
»
Chadboum, Inc.
Chadbourn Indus t. Div.
Chadol Div.
Columbian, Rope Co.
The Cordage Group Div.
Courtalds North America, Inc.
Andrew Crowe & Sons, Inc.
Crowe Rope Co. , Div.
Deering Mil liken, Inc.
Indust. Div.
Dow Badische Co.
Location
Lowell, Mass.
St. Louis, Mo.
Talladega, Ala.
Spirit Lake, Iowa
Spirit Lake, Iowa
Bristol , Va.
Bristol, Va.
Niagra Falls, N.Y.
Greenville, S.C.
Florence, S.C.
Greenville, S.C.
Salisbury, N.C.
Shelby, N.C.
Gainesville, Ga.
Auburn, N.Y.
LeMoyne, Ala.
Warren, Me.
Laurens, S.C.
Laurens, S.C.
Spartanburg, S.C.
Williamsburg, Va.
Anderson, S.C.
Anderson, S.C.
Products 5
Olefin (E&P)
Olefin (P)
Olefin (P)
Olefin (E&P)
Nylon
Nylon
Olefin
Novoloid
Nylon
Polyester
Polyester
Polyester
Polyester
Nylon
Olefin (E&P)
Nylon
Olefin (P)
Nylon
Olefin
Olefin
Acrylic and modacrylic
Nylon
Polyester
Form5
F,0
F,0
F,0
F
F
Y
Y.S
Y,S,T
Y,S,T
Y.S.T
Y.S.T
Y,F
F.O
Y.F
F
F
F
S,T
Y.S
Y
Capacity (Gg/Yr)1 Remarks
na
na
na
na Captive Use
0.5
5
na
na
40
45
30
57
210
2
na
2
na
0.5 Captive Use
na
na
33
39
28
-------
Table C-l. SYNTHETIC FIBER PRODUCERS, PLANT LOCATIONS, PRODUCTS, AND CAPACITIES (CONTINUED)
Company
Diversified Indust. Inc.
Synthetic Indust. Inc., Subsid.
Tennessee Fibers, Subsid.
E.I. duPont de Nemours & Co., Inc.
Textile Fibers Dept.
Plastic Products & Resins Dept.
Eastman Kodak Co.
Eastman Chem. Products, Inc., Subsid.
Carolina Eastman Co. Div.
Tennessee Eastman Co., Div.
El Paso Natural Gas Co.
Beaunit Corp., Subsid.
Beaunit Fibers Div.
Falk Fibers & Fabrics Inc.
Hanover Mills, Inc., Subsid.
Universal Polymer Products, Co.
Subsid.
FIBRON, Inc.
The Firestone Tire & Rubber Co.
Firestone Synthetic Fibers Co., Div.
Location
Chickamauga, Ga.
Pecatur, Tenn.
Camden, S.C.
Waynesboro, Va.
Richmond, Va.
Richmond, Va. —
Camden, S.C.
Chattanooga, Tenn.
Marti nsville, Va.
Richmond, Va.
Seaford, Del.
Camden, S.C.
Cape Fear, N.C.
Chatanooga, Tenn.
Kinston, N.C.
Old Hickory, Tenn.
Waynesboro, Va.
Parkersburg, W. Va.
Columbia, S.C.
Kings port, Tenn.
Elizabethton, Tenn.
Etowah, Tenn.
Elizabethton, Tenn.
Yanceyville, N.C.
Fuquay-Varina, N.C.
Chatanooga, Tenn.
Hopewell , Va.
Products5
Olefin (P)
Olefin (P)
Acrylic and Modacrylic
Acryl i c
Flurocarbon
- Arami d
Nylon
Nylon
Nylon
Nylon
Nylon
Polyester
Polyester
Polyester
Polyester
Polyester
Spandex
Nylon
Polyester
Polyester, Acrylic
& Modacrylic
Nylon
Nylon
Polyester
Olefin (P)
Nylon
Polyester
Olefin (P)
Nylon
Polyester
Form5
0
0
S.T
S,T
Y.F.S.T
Y.F.S.T
Y,F,S.T
Y.F.S.T
Y.F.S.T
Y,F,S,T
V.S.T
Y,S,T
Y.S.T
Y.S.T
Y,S,T
F
F
Y,S
S
S.T
Y,S
Y,T
Y.F
Y,F
Y,F
Y
Capacity (Gg/Yr)1
na
na
Il38
J
na
, (23)2;)
>450 (70)2
" 570 (115)2
. 5
11
Il77 (113)3
18
4
33
29
/ A % O / «« *• \ Q
(9)2 (27)3
2
5
na
25
14
Remarks
Captive Use
Captive Use
Captive Use
-------
Table C-l. SYNTHETIC FIBER PRODUCERS, PLANT LOCATIONS, PRODUCTS, AND CAPACITIES (CONTINUED)
01
Company
FMC Corp.
Chem. Group
Fiber Div.
FNT Indust. Inc.
Georgia Synthetics, Inc.
Globe Mfg. Co.
The Goodyear Tire & Rubber Co.
Chem. Div.
Hercules Inc.
Polymers Dept.
Fibers Div.
Film Div.
Indian Head, Inc.
Indian Head Yarn & Thread, Div.
Kay ser- Roth Corp.
Yarn Processing Div.
Lambeth Corp.
Clarence L. Meyer & Co.
Meyers Fibers, Inc.
Monofi laments, Inc.
Location
Front Royal, Va.
Lew is town, Pa.
Meadville, Pa.
Menominee, Mich.
Elberton, Ga.
Fall River Mass.
Gas torn' a, N.C.
Point Pleasant, W. Va.
Scottsboro, Ala.
Covington, Va.
Oxford, Ga.
Covington, Va.
Blue Mountain, Ala.
Creedmoor, N.C.
New Bedford, Mass.
Ansonville, N.C.
Waynes bo ro, Va.
Waynesboro, Va.
Waynes bo ro, Va.
Products5
Polyester
Polyester
Vi nyon
Olefin (E)
Olefin (P)
Spandex
Spandex
Polyester
Olefin (P)
Olefin (P)
Olefin (P)
Nylon
Olefin (P)
Polyester
Nylon
Polyester
Polycarbonate
Form5
Y,S
Y,S
S
F
0
F
F
F.Y
Y.S.T
0
0
Y,F
F
F
F
F
Capacity (Gg/Yr)1 Remarks
1 20
23
2
na
na
0.7
0.9
6.5 Captive Use
14
45"
na
na
5 Captive Use
na
5
<.5
<.5
na
-------
Table C-l. SYNTHETIC FIBER PRODUCERS, PLANT LOCATIONS, PRODUCTS, AND CAPACITIES (CONTINUED)
en
Company
Monsanto Co.
Monsanto Textiles Co.
The Osterneck Co. .
Phillips Petroleum Co.
Phillips Fibers Corp., Subsid.
Fibers International Corp., Subsid.
PI atari 1 Co.
Poncar Plastic Corp.
Rohm and Haas Co.
Rohm and Haas N.C. Inc., Subsid.
Shakespeare Co.
Monofi lament Oiv.
Shuford Mills, Inc.
Standard Oil Co. of California
Chevron Chem. Co., Subsid.
Location
Decatur, Ala.
Pensacola, Fla.
Decatur, Ala.
Greenwood, S.C.
Pensacola, Fla.
Sand Mountain
Decatur, Ala.
Sand Mountain, Ala.
Lumberton, N.C.
Rocky Mount, N.C.
Spartanburg, S.C.
Guayama, P.R.
Guayama, P.R.
Birdsboro, Pa.
Mi ami , Fl a .
Fayetteville, N.C.
Fayetteville, N.C.
Columbia, S.C.
Columbia, S.C.
Hickory, N.C.
Dayton, Tenn.
Products s
Acrylic and Modacrylic
Nylon-Spandex
Nylon
Nylon
Nylon
Nylon
Polyester
Polyester
Olefin (P)
Polyester
Olefin (P)
Nylon
Polyester
Nylon
Olefin (P)
Nylon
Polyester
Nylon
Polyester
Olefin (P)
Olefin (P)
Form5
SJ
Y
Y.F.S
Y.F.S
Y.F.S
Y,F,S
Y,S
Y,S
0
Y
Y,S,T
Y
Y
F
F
Y,F,T
Y,T
F
F
F
0
Capacity (Gg/Yr)1 Remarks
120 (30)2
Bi constituent fiber,
pilot
11
91
68
10
43
30 (30)2
Captive Use
23
25*
29
14
1
na
18
30 (3D)2
2
1
na
«• *•
5*
-------
Table C-l. SYNTHETIC FIBER PRODUCERS, PLANT LOCATIONS, PRODUCTS, AND CAPACITIES (CONTINUED)
Company
Standard 011 Co. (Indiana)
Amoco Chems. Corp. Subsid.
Amoco Fabrics Co., Subsid.
Patchogue Plymouth Co. Div.
Star Fibers, Inc.
Texfl Indust., Inc.
Texfi Yarn and Fibers Group
Thiokol Corp.
Fibers Div.
Tubbs Cordage Co.
Uni royal, Inc.
Unlroyal Fiber & Textile Div.
Voplex Corp.
Canadaigua Plastics Div.
Well Indust., Inc.
Maltrich Plastic Corp.
Wellington Computer Graphics, Inc.
Wellington Synthetic Fibers, Inc.
subsid._
Montair Div.
Plastic Woven Products Div.
Poly Fibers Div.
Location
Bainbridge Ga.
Hazelhurst, Ga.
Nashville, Ga.
Edgefield, S.C.
Asheboro, N.C.
New Bern, N.C.
Waynesboro, Va.
Orange, Calif.
Winnsboro, S.C.
Winnsboro, S.C.
Canadaigua, N.Y.
Canadaigua, N.Y.
Beverly, N.J.
Tennet, N.J.
Pilot Mountain, N.C.
Lees vi lie, S.C.
Trusville, Ala.
Products b
Olefin (P)
Olefin (P)
Olefin (P)
Nylon
Polyester
Polyester
Olefin (E&P)
Olefin (P)
Nylon
Olefin
Olefin (E&P)
Vinyon
Olefin (E&P)
Olefin (P)
Olefin (E&P)
Olefin (P)
Olefin (P)
Form5
0
0
0
S
Y
Y
Y,F,0
F
F
F.S
F
F
F
F
F.O
F
F,0
Capacity (Gg/Yr)1 Remarks
na
18"
na
6
8
11
14"
na
<.5
9"
na
0.5
na
na
na
na
na
-------
Table C-l SYNTHETIC FIBER PRODUCERS, PLANT LOCATIONS, PRODUCTS, AND CAPACITIES (CONTINUED)
Company Location Products5 Form5 Capacity (Gg/Yr)1 Remarks
Wellman, Inc.
Wellman Indust., Inc., Subsid.
Man-Made Fiber Div. Johnsonville, S.C. Nylon S,T 14
Johnsonville, S.C. Polyester S,T 16
'On-line 1 January 1976 unless otherwise noted. Capacity data from 1976 Directory of Chemical Producers unless otherwise noted.
2Capacity increase scheduled in 1976
'Capacity increase under construction or planning
''Capacity data from 1975 Directory of Chemical Producers
ABBREVIATIONS.: P-polypropylene, E-polyethylene, Y-yarn, F-filament, mono or raulti, S-staple, T-tow, 0-other, na-not available
Sources: Man-Made Fiber Producers' Directory. Textile Organon, 65(9), 1974.
Directory of Chemical Producers, 1976.
oo
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TABLE C-2
LOCATION OF U.S. SYNTHETIC FIBER PRODUCING PLANTS
STATES AND AREA ACRYLIC
New England
Connecticut
Maine
Massachusetts
Rhode Island
Mid-Atlantic
Del aware
Maryl and
New Jersey
New York
Pennsylvania
Piedmont 3
N. Carolina
S. Carolina 1
Virginia 2
W. Virginia
South 3
Alabama 1
Florida 1
Georgia
Tennessee 1
Puerto Rico
Midwest & West
California
Iowa
Michigan
Missouri
Ohio
TOTAL 6
NYLON
1
1
5
1
1
1
2
23
4
11
7
1
13
3
2
1
6
1
1
1
43
OLEFIN
4
1
2
1
8
2
2
3
1
12
3
5
4
16
3
1
7
5
5
1
1
1
2
45
POLYESTER
4
1
1
1
1
28
11
11
4
2
9
3
5
1
1
1
42
OTHER
1
1
6
1
1
3
1
5
1
4
1
1
13
TOTAL
6
1
1
3
1
23
2
5
3
8
5
71
19
28
21
3
42
10
5
8
17
2
7
1
2
1
2
1
149
Sources: Textile Organon
1976 Ch. P.O.
49
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TECHNICAL REPORT DATA
(Please read Inunctions on ilie reverse before completing}
1. REPORT NO.
EPA-600/2-77-023k
2.
4. TITLE AND SUBTITLE
Industrial Process Profiles for Environmental Use:
Chapter 11. The Synthetic Fiber Industry
3. RECIPIENT'S ACCESSION-NO.
5. REPORT DATE
February 1977
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Jerry L. Parr
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Radian Corporation
8500 Shoal Creek Boulevard
P.O. Box 99U8
Austin, Texas 78766
10. PROGRAM ELEMENT NO.
1AB015
11. CONTRACT/GRANT NO.
68-02-1319, Task 31*
12. SPONSORING AGENCY NAME AND ADDRESS
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. ENVIRONMENTAL PROTECTION AGENCY
Cincinnati. Ohio, 1*5268
13. TYPE OF REPORT AND PERIOD COVERED
Initial: 8/75-11/76
14. SPONSORING AGENCY CODE
EPA/600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The catalog of Industrial Process Profiles for Environmental Use was developed as an
aid in defining the environmental impacts of industrial activity in the United States.
Entries for each industry are in consistent format and form separate chapters of the
study. Synthetic fibers are defined as noncellulosic fiber of synthetic origin. The
category includes manufactured fibers in which the fiber-forming substances is a Icng-
chain, organic synthetic polymer. Cellulosic fibers such as rayon and acetate arid
the inorganic fibers such as boron, fiberglass, and graphite are excluded. Syn-
thetic fiber industry activities start with a synthetic, long-chain polymer and
terminate with the formation of a marketable filament or thread-like material. One
process flow sheet and six process descriptions have been prepared to characterize
the industry. Three of the process descriptions are involved with filament formation
and three describe fiber treatment. Within each process description available data
have been presented on input materials, operating parameters, utility requirements
and waste streams. Data related to the subject matter, including company and product
data, are included as appendices.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
Pollution
Synthetic Fibers
Organic Synthetic Polymer
Polymerization
Process Description
19. DISTRIBUTION STATEMENT
Release to Public
b.lDENTIFIERS/OPEN ENDED TERMS
Air Pollution Control
Water Pollution Control
Solid Waste Control
Textile Industry
Synthetic Fibers
19. SECURITY CLASS (This Jit-port)
Unclassified
20. SECURITY CLASS (Tins page)
Unclassified
0. COSATI I ;iclii/Group
07C
HE
13C
21. NO. OF RAGfcS
56
22. PRICE
EPA Form 2220-1 (9-73)
50
iHJSGPO: 1978 — 757-086/0807
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