Production method for Rayon:
Cellulose: Production begins with processed cellulose
Immersion: The cellulose is dissolved in caustic soda: (C6H10O5)n + nNaOH → (C6H9O4ONa)n + nH2O
Pressing: The solution is then pressed between rollers to remove excess liquid
White Crumb: The pressed sheets are crumbled or shredded to produce what is known as "white crumb"
Aging: The "white crumb" is aged through exposure to oxygen
Xanthation: The aged "white crumb" is mixed with carbon disulfide in a process known as Xanthation, the aged alkali cellulose crumbs are placed in vats and are allowed to react with carbon disulfide under controlled temperature (20 to 30 °C) to form cellulose xanthate: (C6H9O4ONa)n + nCS2 → (C6H9O4O-SC-SNa)n
Yellow Crumb: Xanthation changes the chemical makeup of the cellulose mixture and the resulting product is now called "yellow crumb"
Viscose: The "yellow crumb" is dissolved in a caustic solution to form viscose
Ripening: The viscose is set to stand for a period of time, allowing it to ripen: (C6H9O4O-SC-SNa)n + nH2O → (C6H10O5)n + nCS2 + nNaOH
Filtering: After ripening, the viscose is filtered to remove any undissolved particles
Degassing: Any bubbles of air are pressed from the viscose in a degassing process
Extruding: The viscose solution is extruded through a spinneret, which resembles a shower head with many small holes
Acid Bath: As the viscose exits the spinneret, it lands in a bath of sulfuric acid, resulting in the formation of rayon filaments: (C6H9O4O-SC-SNa)n + ½nH2SO4 → (C6H10O5)n + nCS2 + ½nNa2SO4
Drawing: The rayon filaments are stretched, known as drawing, to straighten out the fibers
Washing: The fibers are then washed to remove any residual chemicals
Cutting: If filament fibers are desired the process ends here. The filaments are cut down when producing staple fibers
Here is how cotton is produced:
Raw Materials
The materials required to take cotton bolls to spun cotton include cottonseeds for planting;
pesticides, such as insecticides, fungicides, and herbicides, to battle disease and harmful insects; and
fertilizers to enrich the soil.
Cotton growing is a long, involved process and growers must understand the requirements of the plant and keep vigilant lookout for potential problems. Pests must be managed in order to yield high-quality crops; however, growers must use chemicals very carefully in order to prevent damage to the environment. Defoliants are often used to maximize yield and control fiber color. Farmers must carefully monitor moisture levels at harvesting so bales will not be ruined by excess water during storage. Soil tests are imperative, since too much nitrogen in the soil may attract certain pests to the cotton.
There is much discussion regarding the amount of chemicals used in cotton cultivation. Currently, it is estimated that growers use, on average, 5.3 oz (151 g) of chemicals to produce one pound of processed cotton. Cotton cultivation is responsible for 25% of all chemical pesticides used on American crops. Unfortunately, cotton attracts many pests (most notably the boll weevil) and is prone to a number of rots and spotting, and chemicals are used to keep these under control. There are concerns about wildlife poisoning and poisons that remain in the soil long after cotton is no longer grown (although no heavy metals are used in the chemicals). As a result, some farmers have turned to organic cotton growing. Organic farming utilizes biological control to rid cotton of pests and alters planting patterns in specific ways to reduce fungicide use. While this method of cultivation is possible, an organically grown crop generally yields less usable cotton. This means an organic farmer must purchase, plant, and harvest more acreage to yield enough processed cotton to make the crop lucrative, or reduce costs in other ways to turn a profit. Increasingly, state university extension services are working with cotton farmers to reduce chemical use by employing certain aspects of biological control in order to reduce toxins that remain in the land and flow into water systems.
Here is a list of 16 pesticides used on cotton:
http://www.toxicfreenc.org/informed/pdfs/Cotton_chems.pdf
Cotton is one of the most chemical-intensive crops in the world, because it requires so many applications of insect-killers, weed-killers, plant growth regulators.
Worldwide, cotton covers 2.5% of the cultivated land and
cotton growers use 16% of the world’s pesticides. Eight of the top 10 pesticides most commonly used on U.S. conventionally produced cotton were classified as moderately to highly hazardous by the World Health Organization. The Environmental Justice Foundation elaborates more on the world wide negative effects of pesticide use in cotton.
Cotton (83%) is one of the top four GMO crops produced in the world which includes soy (89%), canola (75%) and corn (61%). GMO cotton production ranks ninth in global crop production.
On an average, 90 percent of U.S. cotton in 2010 was genetically engineered, according to a USDA survey. However 95 to 98% of all cotton is now genetically engineered in nine of the eleven cotton producing states surveyed. (Source USDA Economic Research Service, July 1, 2011.) The Huffington Post recently posted an excellent blog with more information and commentary on the issue.
If you think organic cotton has no chemicals in it either, think again.