The Techtextil Launch of Courtaulds Lyocell (1995)

Here's a photograph of the stand  built for the launch of lyocell into nonwovens, technical textiles and special papers at Techtextil 95. "Courtaulds Lyocell" was a name chosen to suggest that this lower priced matt version of Tencel was not really Tencel and not to be used in fashion textiles.  Lenzing were using the "Lenzing Lyocell" brand at this time.

Susan Conrad then MD of CMT International and Leslie Millard MD of the Design Distillery were responsible for developing the concept, construction and delivery of the stand.  Trevor Maggs, a freelancer working for CMT wrote much of the copy for the brochures.

Solvent Spun Rayon: Prof Turbak's view of the early history (Part 2)

The second extract of Prof. Alban Turbak's chapter on dissolution of cellulose:

Other Cellulose Solvent Systems
In each and every instance of dissolution of cellulose ... thermodynamic factors can be delineated and shown to have a significant and controlling effect on the success of the dissolution process.  In each case the solvent system swells the cellulose and then modifies the molecule either by derivatizing, proton weakening or removal, or by  complexing, to give  a new intermediate specie that can more readily react with the liquid solvent system.

Thus, all cellulose solvent systems can be categorized under 4 mechanisms:

a)    Cellulose as an acid

b)    Cellulose as a base

c)    Cellulose unstable derivative

d)    Cellulose stable derivatives

                                                                                                                

This chapter will review selected solvent systems involving  areas a, b, and c. Stable derivatives (d) will not be discussed.  All compounds can be considered to be acids or bases relative to some other stronger specie. For example;

       (A) is an Acid      relative to       Base  (B)

       HCl, ­­­H₂SO₄                              Carboxylic Acids

       Phosphoric                              Acetic, Cellulose

       Phenol                                     NaOH, Sodium Carbonate

       Alcohol                                   NaOH, sodium Metal

       Cellulose                                NMMO, N₂N₄

       Li⁽⁺⁾/DMAc                              Cellulose

      Cellulose-OH                           Unsolvated  anhydrous Cl^(-)

      Hydrocarbons,(isobutane)           NaNH₂

It may seem odd to realize that cellulose can act either as an acid or a base, yet this is exactly the case; especially in anhydrous or limited aqueous systems .

Water is an excellent swelling liquid for cellulose and opens millions of internal pores  in the cellulose  microfibrillar structure .  However, H₂O is itself both an acid or a base depending on the other molecular specie. Therefore, water normally reacts more rapidly than the cellulose with incoming molecules and this totally disrupts the effectiveness of the incoming potential dissolving moiety.

See Also  "Solvent Spun Rayon" and "Regenerated Cellulose Fibres"

Tencel Sales by Region 92-98 (1998)

This graph of actual Tencel sales prepared in 1998 illustrates the collapse referred to in an earlier post .

At a time when the Mobile plant capacity was said to be 55000 tpy, and the new Grimsby plant was due to add a further 42000 tpy, actual sales in the first quarter of 98 were only 5800 tons/quarter or at a 23,200 tonne/year rate.  Lenzing had 12,000 tonnes capacity and had postponed starting up the other stream at Heiligenkreuz.

First quarter 1995 caused consternation also with an annual sales rate of less than 3200 tonnes.  

However taking the long view (which was hard at the time!) smoothing out the noise gives a nice upward trend suggesting 60,000 tpy sales by 2004/5.

Solvent Spun Rayon: Prof Turbak's view of the early history (Part 1)

Prof. Alban Turbak did ground-breaking work on the dissolution of cellulose during the 1970's while with ITT Rayonier.  As he mentions in this extract of his introduction to non-NMMO cellulose dissolution methods in Regenerated Cellulose Fibres, his 1977 "Solvent Spun Rayon" book  provided one of the stimulii for research work to begin at Courtaulds.  His definition of these fibres as "reconstituted" rather than "regenerated" no longer figures in the nomenclature.

Ever since the discovery of the xanthate process by Cross and Bevan in 1892 and its commercialization in the early 1900’s there have been many efforts to dissolve cellulose directly in non-aqueous solvents which would be both easy to use and readily recoverable. The viscose process produces good quality films and fibers. However, by the mid 1970’s pollution problems and price competition from synthetic films and fibers had seriously eroded the cellophane and rayon markets. In order to remain commercially competitive it was necessary for rayon and cellophane producers to seek simpler less polluting processes.

In the mid 1970’s I.T.T. Rayonier decided that to preserve their pulp markets it would be in their best interest to take the lead in trying to find new ways to make rayon. To their credit, Rayonier’s management authorized a multi-million dollar research effort which ran for a period of 7 years at the I.T.T. Rayonier Eastern Research Division Laboratories. The overall goals were to develop new direct cellulose solvent systems which would require lower investment costs and be readily recovered and recycled in closed loop non-polluting systems.

In order to identify potential previously examined solvent candidates an extensive literature search was made covering 80 years of cellulose solvent reports A close examination and evaluation of these reports from a physical organic viewpoint led to a review paper which, for the first time, delineated all cellulose solvent systems into four simple categories.(1) Subsequently, several other solvent system reviews have been reported (2,3) Rayonier reported some of their preliminary results at an American Chemical Society symposium in New Orleans in 1977.(4) As a result of Rayonier’s stimulus other companies and research universities undertook cellulose solvent research projects.

Concurrently, Franks, McCorsley and Varga at the American Enka Corp were deeply involved in evaluating N-Methyl Morpholine-N- Oxide (NMMO).(5). The Enka NMMO technology was subsequently pursued by Courtaulds in England. As is now well known, Courtaulds’ Tencel® NMMO solvent spun cellulose fiber technology is now a major commercial success and solvent spun cellulose films for food packaging are currently under intense investigation. Tencel® lyocell is actually not a regenerated cellulose fiber but, rather, is a reconstituted cellulose fiber since it was never derivatized.


1. Turbak, A.F., Hammer. R.B., et al, Cellulose Solvents, CHEMTECH, 10,51-57, Jan. 1980
2. Hudson, S.M., and Cuculo, J.A., The Solubility of Unmodified cellulose: A Critique of the Literature, J. Macromol. Sci.,18, (1) 1-82,1980
3. Johnson, D.C., Solvents for Cellulose, Cellulose Chemistry and its Applications, Ellis Harwood, Ltd., Chinchester, 1985
4. Turbak, A.F., Solvent Spun Rayon, Modified Fibers and Derivatives, ACS Symposium # 58, Amer. Chem. Soc., Washington, D.C., 1977
5. Franks, N.E., McCorsley, C.C., and Varga, J.K., U, S. Patent 4,142,913 March, 1979; U.S. Patent4,196,282 April, 1980

Lenzing: Outlook for 2013

Lenzing will have 920,000 tonnes of man-made cellulosics capacity in 2013 and will sell off the plastics business.  Viscose plus Tencel capacity will rise to 1,000,000 tonnes in 2014. The megatrends driving growth will continue uninterrupted.

The additional production capacities which will be available to the Lenzing Group for an entire year for the first time will serve as the basis for an increase in sales volumes by about 13.5% to 920,000 tons. As a result, sales are expected to climb to a range between EUR 2.15 bn and EUR 2.25 bn. This includes the decline in the external sales of the Business Unit Pulp totalling a further EUR 50 mn, which in turn is the consequence of the full-scale conversion of the Paskov pulp plant to manufacturing dissolving wood pulp for the Group’s internal requirements.

The anticipated decrease in average fiber selling prices in a year-on-year comparison to EUR 1.80 to EUR 1.90 per kilogram (2012: EUR 1.96/kg) will impact earnings directly. The earnings contribution achieved by the additional sales volumes is expected to be largely offset by cost increases for personnel, chemicals and other input factors.

For this reason, in the light of the assumed development of fiber prices, EBITDA of the Lenzing Group should range between EUR 260 mn and EUR 290 mn in 2013, and EBIT is expected to be in the range of EUR 140 - EUR 170 mn from today’s perspective. This corresponds to an expected EBITDA margin of about 12% - 13% and an expected EBIT margin of approximately 6% - 8% in the 2013 financial year.

Investments (CAPEX) are likely to total approx. EUR 260 mn, significantly below the comparable level of EUR 346 mn in 2012. Sales negotiations focusing on the divestment of the Business Unit Plastics, which is not part of Lenzing’s core business, are already at an advanced stage. Binding offers were submitted.

Lenzing will respond to the low market visibility in 2013 by optimizations of market activities, cost structures as well as replacement and maintenance investments. The targeted volume growth of the Lenzing Group reaching the threshold of about one million tons of annual fiber capacity by the year 2014 remains unchanged. However, new investment projects will be subject to scrutiny with respect to the planned timeline. In the medium- and long-term, all three megatrends on the fiber market (population growth, increasing wealth and sustainability) driving growth of the man-made cellulose fiber industry will continue uninterrupted. “However, we intend to flexibly adapt our pace of growth to current market conditions and place additional emphasis on cash management”, says Lenzing CEO Peter Untersperger.

Source: Lenzing Press Release