Process for preparing a granular material
The process of using recycled waste materials to produce granular polyamide 6 addresses the challenge of reducing new raw material usage, enhancing sustainability in polymer manufacturing by effectively recycling textile and engineering plastics waste.
Patent Information
- Application Number
- PCT/EP2024/074959
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-04-25
- Filing Date
- 2024-09-06
- Publication Date
- 2025-03-13
AI Technical Summary
The manufacturing of granules comprising polyamide 6 faces challenges in reducing or eliminating the use of new raw materials, with a growing emphasis on sustainability and environmental neutrality.
A process involving the use of recycling materials, specifically waste materials like textile and engineering plastics waste, is employed to produce granular polyamide 6. This process includes melting the recycled polyamide 6 in a melt extrusion apparatus, removing gas phases, and shaping the material into strands before granulating it.
The process effectively utilizes recycled materials to produce granular polyamide 6, reducing the demand for new raw materials and promoting sustainability in polymer product manufacturing.
Smart Images
Figure EP2024074959_13032025_PF_FP_ABST
Abstract
Description
[0001] Process for preparing a granular material
[0002] The present invention relates to a process for preparing a granular material comprising polyamide 6. Further, the present invention relates to a granular material comprising polyamide 6. Furthermore, the present invention relates to an apparatus for preparing a granular material comprising polyamide 6. In addition, the present invention relates to a use of the granular material comprising polyamide 6 for preparing a stream SCPL comprising purified e-caprolactam, or to a method for preparing a stream SCPL comprising purified e-caprolactam from the granular material MG. Furthermore, the present invention relates to a use of SCPL for preparing one or more of a polymer and a polymer product, or to a method for preparing one or more of a polymer and a polymer product by employing SCPL. Processes and apparatuses according to the present invention may be used, for example, in the field of granule manufacturing, such as for manufacturing a granule as an intermediate product for further preparing polymer and / or polymer products.
[0003] In polymer product manufacturing, and thus also in the manufacturing of intermediate products, such as granules comprising polyamide 6, the usage and generation of sustainable materials that are as environmentally neutral as possible is becoming increasingly important. In general, therefore, a reduction or even elimination of raw, new polyamide 6 material is desirable in the manufacture of granules comprising polyamide 6.
[0004] Thus, it was an object of the present invention to provide processes and apparatuses, which address the above-mentioned challenges. Specifically, processes and apparatuses shall be disclosed, which allow the usage of recycling material for preparing a granular material comprising polyamide 6.
[0005] Therefore, the present invention relates to a process for preparing a granular material MG comprising polyamide 6. The process comprises the steps as given in the independent claims and as listed as follows. The process steps may be performed in the given order. However, other orders of the process steps are feasible. Further, one or more of the process steps may be performed in parallel and / or on a timely overlapping fashion. Further, one or more of the process steps may be performed repeatedly. The process may include additional process steps beyond those mentioned.
[0006] The process for preparing a granular material MG comprising polyamide 6 comprises the following steps:
[0007] (i) providing a solid particulate material MP comprising polyamide 6;
[0008] (ii) feeding material MP provided according to (i) via at least one material feeding device Fi into a melt extrusion apparatus E, wherein E comprises
[0009] (a) at least one material receiving means RE for receiving material MP from the at least one feeding device Fi and for providing MP into a melting and conveying space SE; (b) the melting and conveying space SE for melting polyamide 6 comprised in MP and conveying a mixture ME comprising melted polyamide 6 via preferably rotating conveying means CM to at least one shaping orifice OE, wherein SE has a length LSE;
[0010] (c) the at least one shaping orifice OE for forming at least one strand from ME;
[0011] (d) at least one degassing means GE for removing at least a part of a gas phase present in SE;
[0012] (e) heating means HE for providing polyamide 6 melting conditions in SE;
[0013] (iii) subjecting material MP in SE to polyamide 6 melting conditions, obtaining in SE the mixture ME comprising melted polyamide 6, and further obtaining in SE a gas phase comprising one or more gaseous decomposition products of the material MP, said melting conditions comprising a melting temperature TM;
[0014] (iv) removing at least a part of the gas phase obtained according to (iii) from SE via the at least one degassing means GE;
[0015] (v) removing the at least one strand from E via the at least one shaping orifice OE, said at least one strand having a temperature Ts with Ts TM;
[0016] (vi) optionally subjecting the at least one strand removed from E according to (v) to cooling, obtaining at least one cooled strand having a temperature Tc with Tc < Ts;
[0017] (vii) subjecting the at least one optionally cooled strand to granulation, obtaining the granular material MG.
[0018] Preferably, MP comprises a waste material. More preferably, MP comprises one or more of a textile waste material and an engineering plastics waste material. More preferably, MP comprises a textile waste material. More preferably, MP consists of a waste material. Waste material preferably is a post-consumer material or a post-industrial material. For example, fishing nets and carpet waste.
[0019] Preferably, MP is in the form of one or more of fibers, filaments, granules, and shredded pieces. More preferably, MP exhibits a popcorn-like shape.
[0020] Preferably, the particles of MP, independently of each other, have a volume in the range of from 1 to 20000 mm3. More preferably, the particles of MP, independently of each other, are fitting into a cuboid having side lengths of 2, 100 and 100 mm. More preferably, the particles of MP, independently of each other, have a volume in the range of from 1 to 10000 mm3. More preferably, the particles of MP, independently of each other, are fitting into a cuboid having side lengths of 1 , 100 and 100 mm. More preferably, the particles of MP, independently of each other, have a volume in the range of from 1 to 6000 mm3. More preferably, the particles of MP, independently of each other, are fitting into a cuboid having side lengths of 1 , 50 and 120 mm. More preferably, the particles of MP, independently of each other, have a volume in the range of from 1 to 1200 mm3. More preferably, the particles of MP, independently of each other, are fitting into a cuboid having side lengths of 1 , 20 and 60 mm More preferably, the particles of MP, independently of each other, have a volume in the range of from 1 to 800 mm3. More preferably, the particles of MR, independently of each other, are fitting into a cuboid having side lengths of 1 , 10 and 80 mm More preferably, the particles of MR, independently of each other, have a volume in the range of from 1 to 600 mm3. More preferably, the particles of MR, independently of each other, are fitting into a cuboid having side lengths of 1 , 5, and 120 mm. More preferably, the particles of MR, independently of each other, have a volume in the range of from 1 to 400 mm3. More preferably, the particles of MR, independently of each other, are fitting into a cuboid having side lengths of 1 , 20 and 20 mm or into a cuboid having side lengths of 1 , 10 and 40 mm More preferably, the particles of MR, independently of each other, have a volume in the range of from 1 to 120 mm3. More preferably, the particles of MR, independently of each other, are fitting into a cuboid having side lengths of 1 , 2 and 60 mm or into a cuboid having side lengths of 2, 2 and 30 mm. More preferably, the particles of MR, independently of each other, have a volume in the range of from 1 to 80 mm3. More preferably, the particles of MR, independently of each other, are fitting into a cuboid having side lengths of 1 , 1 and 80 mm or into a cuboid having side lengths of 1 , 2 and 40 mm. More preferably, the particles of MR, independently of each other, have a volume in the range of from 1 to 40 mm3. More preferably, the particles of MR, independently of each other, are fitting into a cuboid having side lengths of 1 , 2 and 20 mm or into a cuboid having side lengths of 1 , 1 and 40 mm.
[0021] Preferably, MP has a water content in the range of from 0 to 10 weight- % based on the total weight of Mp. More preferably, MP has a water content in the range of from 0 to 8 weight-% based on the total weight of Mp. More preferably, MP has a water content in the range of from 0 to 6 weight-% based on the total weight of Mp.
[0022] Preferably, from 30 to 100 weight-% of MP consist of polyamide 6. More preferably, from 50 to 100 weight-% of MP consist of polyamide 6. More preferably from 60 to 100 weight-% of MP consist of polyamide 6.
[0023] Preferably, in addition to polyamide 6, MP further comprises at least one further polymeric material. More preferably, in addition to polyamide 6, MP further comprises one or more of a polyamide 6.6, a polyurethane, a polyester, acrylic, a cellulosicmaterial preferably including cotton, a rubber material comprising one or more of a natural rubber material and a synthetic rubber material, a protein fiber material preferably including one or more of silk and wool. More preferably, MP optionally further comprises one or more of a pigment material, a glass fiber material and a carbon fiber material.
[0024] Preferably, the at least one feeding device Fi comprises at least one dosing apparatus. More preferably, the at least one feeding device Fi comprises one or both of a gravimetrical dosing apparatus and a volumetric dosing apparatus. More preferably, the at least one feeding device Fi comprisesat least one dosing apparatus selected from the group consisting of a scale, a belt, a stuffing screw, such as a single or a twin screw, a vibration feed, and a cell wheel. More preferably, the stuffing screw is a single screw or a twin screw. Alternatively and more preferably, a manual feed is possible.
[0025] Preferably, the at least one feeding device Fi is arranged so that MP is fed into SE in the downstream-most nine tenths of LSE. More preferably, the at least one feeding device Fi is arranged so that MP is fed into SE in the downstream-most five sixths of LSE. More preferably, the at least one feeding device Fi is arranged so that MP is fed into SE in the downstream-most four fifths of LSE. More preferably, the at least one feeding device Fi is arranged so that MP is fed into SE in the downstream-most three fourths of LSE. More preferably, the at least one feeding device Fi is arranged so that MP is fed into SE in the downstream-most two thirds, of LSE.
[0026] Preferably, from 50 to 100 weight-% of MP are fed into E according to (ii) via the at least one feeding device Fi arranged in the downstream-most nine tenths, preferably five sixths, more preferably four fifths, more preferably three fourths, more preferably two thirds, of LSE, wherein preferably the rest is fed into E via at least one further feeding device Fi arranged in the upstream-most first third, preferably first fourth, more preferably first fifth, more preferably first sixth, more preferably first tenth, of LSE. More preferably, from 60 to 100 weight-% of MP are fed into E according to (ii) via the at least one feeding device Fi arranged in the downstream-most nine tenths, preferably five sixths, more preferably four fifths, more preferably three fourths, more preferably two thirds, of LSE, wherein preferably the rest is fed into E via at least one further feeding device Fi arranged in the upstream-most first third, preferably first fourth, more preferably first fifth, more preferably first sixth, more preferably first tenth, of LSE. More preferably, from 70 to 100 weight-% of MP are fed into E according to (ii) via the at least one feeding device Fi arranged in the downstream-most nine tenths, preferably five sixths, more preferably four fifths, more preferably three fourths, more preferably two thirds, of LSE, wherein preferably the rest is fed into E via at least one further feeding device Fi arranged in the upstream-most first third, preferably first fourth, more preferably first fifth, more preferably first sixth, more preferably first tenth, of LSE. More preferably, from 80 to 100 weight-% of MP are fed into E according to (ii) via the at least one feeding device Fi arranged in the downstream-most nine tenths, preferably five sixths, more preferably four fifths, more preferably three fourths, more preferably two thirds, of LSE, wherein preferably the rest is fed into E via at least one further feeding device Fi arranged in the upstream-most first third, preferably first fourth, more preferably first fifth, more preferably first sixth, more preferably first tenth, of LSE.
[0027] As an example, a reason for a feeding distribution according to the previous paragraph may be that preferably a diameter of the feeding device Fi when arranged in the downstream-most nine tenths, preferably five sixths, more preferably four fifths, more preferably three fourths, more preferably two thirds, of LSE, i.e. as a side dosing, is bigger than a diameter of the feeding device Fi when arranged in the upstream-most first third, preferably first fourth, more preferably first fifth, more preferably first sixth, more preferably first tenth, of LSE, i.e. as a main feed, of the extrusion apparatus E. Preferably, step (i) further comprises providing a solid particulate material MPX, wherein step (ii) comprises feeding material MPX provided according to step (i) into the melt extrusion apparatus E, and wherein step (iii) further comprises subjecting material MPX in SE to polyamide 6 melting conditions, obtaining in SE the mixture ME comprising melted polyamide 6, and further obtaining in SE a gas phase comprising one or more gaseous decomposition products of the materials MP and MPX, said melting conditions comprising a melting temperature TM and a melting pressure pM. Preferably, E optionally further comprises:
[0028] (f) at least one material receiving means REX for receiving material MPX from the at least one feeding device and for providing MPX into the melting and conveying space SE.
[0029] Preferably, from 80 to 100 weight-% of MPX consist of polyamide 6. More preferably, from 90 to 100 weight-% of MPX consist of polyamide 6. More preferably, from 94 to 100 weight-% of MPX consist of polyamide 6. More preferably, from 95 to 100 weight-% of MPX consist of polyamide 6. More preferably, from 98 to 100 weight-% of MPX consist of polyamide 6. More preferably, from 99 to 100 weight-% of MPX consist of polyamide 6.
[0030] Preferably, MPX is fed according to (ii) via the at least one material feeding device Fi and / or via at least one material feeding device F2 into the melt extrusion apparatus E.
[0031] Preferably, MPX is fed according to (ii) via the at least one feeding device F1 , wherein F1 comprises at least two dosing apparatuses selected from the group consisting of a scale, a belt, a stuffing screw, such as a single or a twin screw, a vibration feed, and a cell wheel. More preferably, F1 comprises one first dosing apparatus for MP and one second dosing apparatus for MPX, preferably one first scale for MP and one second scale for MPX. More preferably, MPX is fed into SE via RE and / orvia REX. More preferably, RE is further configured for receiving material Mx from F2 and for providing Mx into SE.
[0032] Preferably, the at least one feeding device F2 is arranged so that MPX is fed into SE in the upstream-most third of LSE. More preferably, the at least one feeding device F2 is arranged so that MPX is fed into SE in the upstream-most sixth of LSE. More preferably, the at least one feeding device F2 is arranged so that MPX is fed into SE in the upstream-most tenth of LSE. More preferably, the at least one feeding device F2 is arranged so that MPX is fed into SE in the upstream-most eleventh of LSE.
[0033] Preferably, the at least one feeding device F2 comprises at least one dosing apparatus selected from the group consisting of a scale, a belt, a stuffing screw, such as a single or a twin screw, a vibration feed, and a cell wheel. More preferably, the at least one feeding device F2 comprises at least two dosing apparatuses selected from the group consisting of a scale, a belt, a stuffing screw, such as a single or a twin screw, a vibration feed, and a cell wheel. More preferably, the stuffing screw is a single screw or a twin screw. Alternatively and more preferably, a manual feed is possible.
[0034] Preferably, according to step (ii), MP and MPX are fed into the extrusion apparatus E at a weight ratio MP / (MP+MPX) in the range of from 0.01 :1 to 0.99:1. More preferably, according to step (ii), MP and MPX are fed into the extrusion apparatus E at a weight ratio MP / (MP+MPX) in the range of from 0.01 :1 to 0.5:1 . More preferably, according to step (ii), MP and MPX are fed into the extrusion apparatus E at a weight ratio MP / (MP+MPX) in the range of from 0.01 :1 to 0.3:1 . More preferably, according to step (ii), MP and MPX are fed into the extrusion apparatus E at a weight ratio MP / (MP+M PX) in the range of from 0.01 :1 to 0.2:1. More preferably, according to step (ii), MP and MPX are fed into the extrusion apparatus E at a weight ratio MP / (MP+MPX) in the range of from 0.01 :1 to 0.15:1. More preferably, according to step (ii), MP and MPX are fed into the extrusion apparatus E at a weight ratio MP / (MP+MPX) in the range of from 0.01 :1 to 0.133:1.
[0035] Preferably, SE has a diameter DSE, wherein the ratio LSE / DSE is in the range of from 20:1 to 80:1. More preferably, the ratio LSE / DSE is in the range of from 25:1 to 70:1. More preferably the ratio LSE / DSE is in the range of from 30:1 to 60:1. More preferably the ratio LSE / DSE is in the range of from 32:1 to 48:1 . Alternatively, and more preferably, the ratio LSE / DSE is in the range of from 24:1 to 40:1.
[0036] Preferably, E is an extruder or a kneader. More preferably, E is an extruder. More preferably, E is one of a single-screw extruder, a twin screw extruder and a planetary roller extruder. More preferably E is a single-screw extruder or a twin screw extruder.
[0037] Preferably, E further comprises:
[0038] (g) at least one mixing element, preferably at least two mixing elements, more preferably at least three mixing elements, preferably kneading elements, and at least three, preferably at least four, conveying elements.
[0039] Preferably, said at least two or said at least three or said at least four elements are serially arranged.
[0040] Preferably, E comprises at least two feeding devices Fi, wherein the total number of feeding devices equals the number of the mixing elements according to step (g). More preferably, E comprises at least two feeding devices Fi and at least one feeding device F2, wherein the total number of feeding devices equals the number of the mixing elements according to step (g).
[0041] Preferably, the conveying space SE has at least two different zones. More preferably, the conveying space SE has at least three different zones. More preferably, the conveying space SE has at least four different zones. More preferably, SE has one or more material receiving zones ZER, one or more melting zones ZEM, one or more degassing zones ZEG, and at least one outputting zone ZOUT. Preferably, E comprises at least 2 orifices OE. More preferably, E comprises at least 3 orifices OE. More preferably, E comprises at least 5 orifices OE. More preferably, the at least one orifice OE has a cross-section in the form of a square, a rectangle, a circle, an oval, a triangle, or a star. More preferably, the number of orifices is in the range of from 2 to 500. More preferably, the number of orifices is in the range of from 3 to 400. More preferably, the number of orifices is in the range of from 5 to 390. More preferably, the number of orifices is in the range of from 10 to 330. More preferably, the number of orifices is in the range of from 10 to 300. More preferably, the number of orifices is in the range of from 10 to 250. It is further also conceivable that the at least one orifice OE has a cross-section in the form of a suitable letter.
[0042] Preferably, E further comprises:
[0043] (h) at least one melt pump.
[0044] Preferably, the process further comprises applying pressure onto ME via the at least one melt pump in the direction of movement of ME in SE.
[0045] As an example, a reason for E comprising the at least one melt pump may be in order to support removal of the at least one strand according to step (v), which may otherwise be restricted due to the viscosity of ME.
[0046] Preferably, E further comprises:
[0047] (j) at least one melt filter arranged in SE upstream of OE.
[0048] Preferably, said at least one the melt filter comprises one or more of a sieve, a perforated plate, and a fabric, wherein the mesh size of the at least one melt filter is preferably in the range of from 0.02 to 3 mm. More preferably, the mesh size of the at least one melt filter is in the range of from 0.025 to 2 mm. More preferably, the mesh size of the at least one melt filter is in the range of from 0.035 to 1 mm. More preferably, the mesh size of the at least one melt filter is in the range of from 0.1 to 0.8 mm. More preferably, the mesh size of the at least one melt filter is in the range of from 0.1 to 0.11 mm.
[0049] Preferably, the process further comprises feeding at least one processing aid into SE. More preferably, the processing aid comprises, preferably consists of, a liquefying medium. Preferably the processing aid, more preferably the liquefying medium, includes one or more of a liquid medium and a solid medium. The processing aid, preferably the liquefying medium, preferably comprises at least one mono-, oligo., and / or polyhydric alcohol including one or more a polyethylene glycols, and water. Further, the processing aid, preferably the liquefying medium, is fed into SE preferably by one or more of admixing the processing aid, preferably the liquefying medium, with the material MP prior to (ii); and feeding the processing aid, preferably the liquefying medium, into SE via at least one feeding device F3, and at least one receiving means REL. Preferably, said at least one receiving means REL is arranged so that the processing aid, preferably the liquefying, medium is fed into SE in the downstream-most nine tenths of LSE. More preferably, said at least one receiving means REL is arranged so that the processing aid, preferably the liquefying medium, is fed into SE in the downstream-most five sixths of LSE. More preferably, said at least one receiving means REL is arranged so that the processing aid, preferably the liquefying medium, is fed into SE in the downstream-most four fifths of LSE. More preferably, said at least one receiving means REL is arranged so that the processing aid, preferably the liquefying medium, is fed into SE in the downstream-most three fourths of LSE. More preferably two thirds of LSE.
[0050] Preferably, the processing aid is one or more of a fluid medium, preferably a liquid medium, and a solid medium. More preferably, the liquefying medium is one or more of a fluid medium, preferably a liquid medium, and a solid medium. More preferably, the processing aid is a gas. More preferably, the liquefying medium is a gas. More preferably, the processing aid is a liquid. More preferably, the liquefying medium is a liquid.
[0051] Preferably, the weight ratio of processing aid, preferably of liquefying medium, to MP is in the range of from 0.05:1 to 2:1 . More preferably, the weight ratio of processing aid, preferably of liquefying medium, to MP is in the range of from 0.1 :1 to 2:1 . More preferably, the weight ratio of processing aid, preferably of liquefying medium, to MP is in the range of from 0.2:1 to 2:1 . More preferably, the weight ratio of processing aid, preferably of liquefying medium, to MP is in the range of from 0.3:1 to 1.5:1. More preferably, the weight ratio of processing aid, preferably of liquefying medium, to MP is in the range of from 0.5:1 to 1 :1.
[0052] Preferably, it is also possible that the processing aid, preferably the liquid medium, more preferred the liquid medium, is admixed with the material MPX prior to step (ii). Preferably, the processing aid, preferably the liquefying medium, allows to decrease the melting temperature TM, wherein TM preferably is about 200°C.
[0053] Preferably, the gas phase obtained according to step (iii) comprises at least one of a decomposition product of polymer and water. More preferably, the gas phase obtained according to step (iii) comprises gas or vapour of decomposed elastin. Preferably, the water content of the gas phase is in the range of from 0.01 to 10 volume-% based on the total volume of the gas phase. More preferably, the water content of the gas phase is in the range of from 0.01 to 8 volume-% based on the total volume of the gas phase. More preferably, the water content of the gas phase is in the range of from 0.01 to 5 volume-% based on the total volume of the gas phase.
[0054] Preferably, removing at least a part of the gas phase from SE according to step (iv) is carried out either actively, or passively, or actively and passively. The at least one degassing means GE is preferably selected from the group consisting of a hole in a sidewall of the extrusion apparatus E, a degassing screw arranged in a hole in a sidewall of the extrusion apparatus E, an atmospheric dome arranged on a hole in a sidewall of the extrusion apparatus E, a vacuum dome arranged on a hole in a sidewall of the extrusion apparatus E, and a combination of two or more thereof.
[0055] Preferably, the hole in the sidewall is arranged in the upper half of the extrusion apparatus E, preferably of the barrel of the extrusion apparatus E. More preferably, the hole in the sidewall is arranged in the upper third of the extrusion apparatus E, preferably of the barrel of the extrusion apparatus E. More preferably, the hole in the sidewall is arranged in the upper fifth of the extrusion apparatus E, preferably of the barrel of the extrusion apparatus E.
[0056] Preferably, the atmospheric dome and / or the vacuum dome are arranged on a hole positioned in the upmost fifth of the extrusion apparatus E. More preferably, the atmospheric dome and / or the vacuum dome are arranged on a hole positioned in the upmost fifth of the barrel of the extrusion apparatus E.
[0057] Preferably, according to step (iii), TM is in the range of from 150 to 350 °C. More preferably, according to step (iii), TM is in the range of from 180 to 280 °C. More preferably, according to step (iii), TM is in the range of from 200 to 250 °C.
[0058] Preferably, according to step (iii), the polyamide 6 melting conditions further comprise a melting pressure pM. PM is preferably in the range of from 0 to 350 bar. More preferably, PM is in the range of from 0 to 150 bar. More preferably, PM is in the range of from 0 to 130 bar. More preferably, PM is in the range of from 0 to 100 bar. More preferably, 0 < PM 350 bar. More preferably, 0 < PM 150 bar. More preferably 0 < PM 130 bar. More preferably 0 < PM 100 bar. More preferably 5 < PM 45 bar.
[0059] Preferably, according to step (iii), the polyamide 6 melting conditions further comprise a throughput HM through SE. HM is preferably in the range of from 100 to 12000 kg / h. More preferably, HM is in the range of from 150 to 8000 kg / h. More preferably, HM is in the range of from 250 to 6,000 kg / h.
[0060] Preferably, according to step (iii), the polyamide 6 melting conditions further comprise a rotating speed RM of the conveying means CM. The rotational speed is preferably in the range of from 20 to 2000 rpm. More preferably, the rotational speed is in the range of from 50 to 1200 rpm. More preferably, the rotational speed is in the range of from 60 to 800 rpm. More preferably, the rotational speed is in the range of from 200 to 700 rpm. More preferably, the rotational speed is in the range of from 400 to 500 rpm.
[0061] Preferably, according to step (iii), the polyamide 6 melting conditions further comprise a torque QM of the conveying means CM. QM is preferably in the range of from 0 to 30,000 Nm. More preferably, QM is in the range of from 250 to 20,000 Nm. More preferably, QM is in the range of from 300 to 15,000 Nm. Preferably, QM is the torque per screw, such as the torque exerted by one screw.
[0062] Preferably, E comprises at least one melt pump. Preferably, the polyamide 6 melting conditions according to step (iii) preferably further comprise a melt pump pressure in the range of from 1 to 350 bar. More preferably, the melt pump pressure is in the range of from 2 to 150 bar. More preferably, the melt pump pressure is in the range of from 5 to 140 bar. Additionally or alternatively, the polyamide 6 melting conditions according to step (iii) preferably further comprise a melt pump rotation in the range of from 1 to 1 ,000 rpm. More preferably, the melt pump rotation is in the range of from 10 to 500 rpm. More preferably, the melt pump rotation is in the range of from 50 to 300rpm. Alternatively, and more preferably, the melt pump rotation is in the range of from 34 to 47 rpm
[0063] Preferably, the process further comprises one or more of controlling, adjusting and maintaining at least one of the polyamide 6 melting conditions according to step (iii).
[0064] Preferably, according to step (vi), the at least one strand is cooled using a cooling medium selected from a gaseous cooling medium, a liquid cooling medium and a mixture thereof. The gaseous cooling medium is preferably one or more of air, lean air and nitrogen. The liquid cooling medium preferably comprises water. More preferably, the liquid cooling medium consists of water.
[0065] Preferably, for cooling according to step (vi), a strand cooling conveyor is used. Said strand cooling conveyor preferably is comprised in a strand cooling tray. Said strand cooling tray preferably comprises one or more of strand guiding means for guiding the at least one strand through the tray and strand feeding means for feeding the at least one strand removed according to step (v) to the strand cooling tray. Alternatively, and more preferably, for one or both of cooling according to step (iv) and for granulation according to step (v), an underwater pelletizer is used.
[0066] Preferably, Ts is in the range of from 350 to 180 °C. More preferably, Ts is in the range of from 320 to 200 °C. More preferably, Ts is in the range of from 300 to 200 °C. More preferably, Ts is in the range of from 280 to 180°C.
[0067] Preferably, Tc is in the range of from 25 to 350°C. More preferably, Tc is in the range of from 50°C to 320°C. More preferably, Tc is in the range of from 50°C to 280°C. More preferably, Tc is in the range of from 150 to 220 °C. More preferably, Tc is in the range of from 160 to 200 °C. More preferably, Tc is in the range of from 170 to 180 °C. Alternatively, and more preferably, Tc is in the range of from 25°C to 170°C. More preferably, Tc is in the range of from 25°C to 150°C.
[0068] Preferably, according to step (vi), the at least one strand is cooled from Ts to Tc at a cooling rate in the range of from 1 to 2700 K / min. More preferably, according to step (vi), the at least one strand is cooled from Ts to Tc at a cooling rate in the range of from 1 to 2000 K / min. More preferably, according to step (vi), the at least one strand is cooled from Ts to Tc at a cooling rate in the range of from 1 to 1000 K / min. More preferably, according to step (vi), the at least one strand is cooled from Ts to Tc at a cooling rate in the range of from 5 to 400 K / min. More preferably, according to step (vi), the at least one strand is cooled from Ts to Tc at a cooling rate in the range of from 5 to 350 K / min. More preferably, according to step (vi), the at least one strand is cooled from Ts to Tc at a cooling rate in the range of from 50 to 300 K / min.
[0069] Preferably, according to step (vii), the granulation of the at least one strand comprises cutting the at least one strand, wherein for said cutting, one or more of an under water pelletizer, a hot-cut pelletizer, a pressurized air pelletizer, and a strand pelletizer are used. In case the under water pelletizer is used, preferably an under water granulation, also referred to as “UWG”, is used in the granulation according to step (vii), wherein preferably water is used as cooling medium in the tray and / or box.
[0070] Preferably, the granular material MG obtained according to step (vii) has a bulk density in the range of from 500 to 1200 g / l determined according to DIN ISO 697:1982. More preferably, the granular material MG obtained according to step (vii) has a bulk density in the range of from 600 to 1000 g / l determined according to DIN ISO 697:1982. More preferably, the granular material MG obtained according to step (vii) has a bulk density in the range of from 600 to 900 g / l determined according to DIN ISO 697:1982. Alternatively and more preferably, the granular material MG obtained according to step (vii) has a bulk density in the range of from 450 to 1200 g / l determined according to DIN ISO 697:1982. More preferably, the granular material MG obtained according to step (vii) has a bulk density in the range of from 500 to 750 g / l determined according to DIN ISO 697:1982. More preferably, the granular material MG obtained according to step (vii) has a bulk density in the range of from 570 to 690 g / l determined according to DIN ISO 697:1982.
[0071] Preferably, the granular material MG obtained according to step (vii) is characterized by a particle mass in the range of from 0.2 to 70 mg. More preferably, the granular material MG obtained according to step (vii) is characterized by a particle mass in the range of from 0.2 to 60 mg. More preferably, the granular material MG obtained according to step (vii) is characterized by a particle mass in the range of from 0.2 to 50 mg. Alternatively and more preferably, the granular material MG obtained according to step (vii) is characterized by a particle mass in the range of from 0.2 to 100 mg. More preferably, the granular material MG obtained according to step (vii) is characterized by a particle mass in the range of from 0.5 to 70 mg. More preferably, the granular material MG obtained according to step (vii) is characterized by a particle mass in the range of from 0.7 to 60 mg.
[0072] Preferably, the granular material MG obtained according to step (vii) has a maximum particle length in the range of from 0.5 to 10 mm. More preferably, the granular material MG obtained according to step (vii) has a maximum particle length in the range of from 1 .5 to 8 mm. More preferably, the granular material MG obtained according to step (vii) has a maximum particle length in the range of from 2 to 6 mm. In case an under water granulation, also referred to as “UWG”, is used in the granulation according to step (vii), the granular material MG obtained according to (vii) preferably has a diameter in the range of from 0.5 to 10 mm. More preferably, in case of UWG being used in the granulation according to step (vii), the granular material MG obtained according to (vii) has a diameter in the range of from 0.5 to 8 mm. More preferably, in case of UWG being used in the granulation according to step (vii), the granular material MG obtained according to (vii) has a diameter in the range of from 0.5 to 6 mm.
[0073] The present invention further relates to a granular material MG, obtainable or obtained by a process according to the present invention. Preferably, the present invention further relates to a granular material MG, obtainable or obtained by a process as described herein.
[0074] Preferably, from 30 to 100 weight-% of MG consist of polyamide 6. More preferably, from 50 to 100 weight-% of MG consist of polyamide 6. More preferably, from 60 to 100 weight-% of MG consist of polyamide 6.
[0075] Further, the present invention relates to an apparatus for preparing a granular material MG, preferably by a process according to the present invention. Preferably, the present invention further relates to an apparatus for preparing a granular material MG as described herein. Said apparatus comprises:
[0076] (A) a melt extrusion apparatus E comprising
[0077] (a) at least one material receiving means RE for receiving a solid particulate material MP comprising polyamide 6 from at least one feeding device Fi and for providing MP into a melting and conveying space SE;
[0078] (b) the melting and conveying space SE for melting polyamide 6 comprised in MP and conveying a mixture ME comprising melted polyamide 6 via preferably rotating conveying means CM to at least one shaping orifice OE, wherein SE has a length LSE;
[0079] (c) the at least one shaping orifice OE for forming at least one strand from ME;
[0080] (d) at least one degassing means GE for removing at least a part of a gas phase present in SE;
[0081] (e) heating means HE for providing polyamide 6 melting conditions in SE;
[0082] (f) optionally at least one material receiving means REX for receiving material MPX comprising polyamide 6 from at least one feeding decive F2 and for providing MPX into the melting and conveying space SE;
[0083] (g) optionally at least three mixing elements and at least three, preferably at least four, conveying elements;
[0084] (h) optionally at least one melt pump;
[0085] (j) optionally at least one melt filter arranged in SE upstream of OE;
[0086] (B) at least one feeding device comprising (a) at least one material feeding device Fi for feeding material MR, and optionally material MPX, into E;
[0087] (b) optionally at least one material feeding device F2 for feeding material MPX, preferably additionally or alternatively to the feeding of MPX according to (B)(a), into E and further optionally at least one material receiving means REX for receiving material MPX from the at least one feeding device F2 and for providing MPX into the melting and conveying space SE;
[0088] (c) optionally at least one feeding device F3 for feeding a liquid medium into E and further optionally at least one material receiving means REL for receiving the liquid medium from the at least one feeding device F3 and for providing the liquid medium into the melting and conveying space SE;
[0089] (C) optionally cooling means Me arranged downstream of E for cooling the at least one strand obtained from E;
[0090] (D) granulation means MG arranged downstream of OE, and preferably downstream of the cooling means Me, for preparing the granular material MG from the at least one strand shaped by the at least one shaping orifice OE, preferably from the at least one cooled strand obtained by the cooling means Me.
[0091] Furthermore, the present invention relates to a use of the granular material MG according to the present invention, e.g. as described herein, for preparing a stream SCPL comprising purified c- caprolactam. Additionally or alternatively, the present invention relates to a method for preparing a stream SCPL comprising purified c-caprolactam from the granular material MG according to the present invention, e.g. as described herein.
[0092] Preparing the stream SCPL preferably comprises:
[0093] (a) providing a stream SM comprising the solid material M;
[0094] (P) preparing an aqueous depolymerization mixture based on SM;
[0095] (y) subjecting the aqueous depolymerization mixture to polyamide 6 depolymerization conditions in a reaction unit UR, obtaining a liquid aqueous stream SR comprising c- caprolactam dissolved in water at a concentration CSR, the stream SR further comprising one or more impurities;
[0096] (5) passing the liquid aqueous stream SR into an evaporation unit UE, obtaining from SR a liquid aqueous stream SL comprising c-caprolactam dissolved in water at a concentration CSL with CSL > CSR, and further obtaining from SR one or more aqueous vapor streams Sv;
[0097] (c) passing the aqueous stream SL into a heat-consuming purification unit UP, obtaining from SL a stream SCPL comprising c-caprolactam at a concentration CSCPL with
[0098] CSCPL » CSL, and further obtaining from SL one or more aqueous streams SRW, wherein at least part of the heat consumed in UP is provided by at least one of the one or more streams Sv, thereby obtaining from the at least one stream Sv at least one at least partially condensed aqueous stream Svw; ( ) recycling at least one stream Svw at least partially to the reaction unit UR and at least one stream SRW at least partially to the reaction unit UR.
[0099] Further, the present invention relates to a use of SCPL obtainable or obtained according to step (E) as described herein for preparing one or more of a polymer and a polymer product. Additionally or alternatively, the present invention relates to a method for preparing one or more of a polymer and a polymer product, said method comprising employing SCPL according to step (E) as described herein as a starting material.
[0100] Preferably, the polymer, or the polymer product, or the polymer and the polymer product is or are in the form of at least one of a granulate, a strand, a rod, a plate, a pipe, a foil, a layer, a film, a sheet, a fiber, a filament, a coating, an extruded article, a molded article, a soft foam, a half-rigid foam and a rigid foam.
[0101] Preferably, the polymer, or the polymer product, or the polymer and the polymer product comprises or comprise polyamide 6 and optionally at least one further polymeric compound. Said polyamide 6 preferably being at least partially obtainable or obtained from SCPL obtainable or obtained according to step (E) as described herein. The at least one further polymeric compound preferably comprises one or more of at least one polyamide 6.6, at least one polyethylene terephthalate, at least one polyurethane, at least one polyester, at least one cellulose material, and at least one rubber material comprising one or more of at least one natural rubber material and at least one synthetic rubber material.
[0102] Preferably, the polymer, or the polymer product, or the polymer and the polymer product is or are one of the following or a part of one of the following: a part of a car, preferably a cylinder head cover, an engine cover, a housing for a charge air cooler, a charge air cooler flap, an intake pipe, an intake manifold, a connector, a gear wheel, a fan wheel, a cooling water box, a housing or a housing part for a heat exchanger, a coolant cooler, a charge air cooler, a thermostat, a water pump, a radiator, a fastening part or a part of a battery system for electromobility, a dashboard, a steering column switch, a seat, a headrest, a center console, a transmission component, a door module, a car exterior for an A, a B, a C or a D pillar cover, a spoiler, a door handle, an exterior mirror, a windscreen wiper, a windscreen wiper protection housing, a decorative grill, a cover strip, a roof rail, a window frame, a sunroof frame, an antenna panel, a headlight, a taillight, an airbag, and / or a cushion; a cloth, an apparel, preferably a shirt, trousers, a pullover, a boot, a shoe, a shoe sole, a tight and / or or jacket; an electrical part, preferably an electrical component, an electronic passive component, an electronic active component, a printed circuit board, a housing component, a foil, a line, a switch such as a microswitch, a plug, a socket, a distributor, a relay, a resistor, a capacitor, an inductor, a bobbin, a lamp, a diode such as an LED, a transistor, a connector, a regulator, an integrated circuit (IC), a processor, a controller, a memory, a sensor, a microbutton, a semiconductor, a reflector housing for example for light-emitting diodes, a fastener for an electrical and / or an electronic component, a spacer, a bolt, a strip, a slide-in guide, a screw, a nut, a film hinge, a snap hook (snap-in), and / or a spring tongue; a consumer and / or a pharmaceutical product, preferably a tennis string, a climbing rope, a bristle, a brush, an artificial grass, a 3D printing filament, a grass trimmer, a zipper, a hook and loop fastener, a paper machine clothing, an extrusion coating, a fishing line, a fishing net, an offshore line and rope, a vial, a syringe, an ampoule, a bottle, a sliding element, a spindle nut, a chain conveyor, a plain bearing, a roller, a wheel, a gear, a roller, a ring gear, a screw and spring damper, a hose, a pipeline, a cable sheathing, a socket, a switch, a cable tie, a fan wheel, a carpet, a box and / or a bottle for cosmetics, a mattress, a cushion, an insulation; a packaging for the food industry, preferably a mono- and / or multi-layer blown film, a cast film (mono- and / or multi-layer), a biaxially stretched film, a laminating film.
[0103] Preferably, the polymer, or the polymer product, or the polymer and the polymer product contains or contain polyamide 6, obtainable or obtained from SCPL obtainable or obtained according to step (E) as described herein, in an amount of 1 weight-% or more, preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight-% or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight-% or more, more preferably 95 weight-% or more; and / or in an amount of 100 weight-% or less, preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less.
[0104] The present invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the dependencies and back-references as indicated. In particular, it is noted that in each instance where a range of embodiments is mentioned, for example in the context of a term such as "The process of any one of embodiments 1 to 4", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The process of any one of embodiments 1 , 2, 3 and 4". Further, it is explicitly noted that the following set of embodiments represents a suitably structured part of the general description directed to preferred aspects of the present invention, and, thus, suitably supports, but does not represent the claims of the present invention.
[0105] 1 . A process for preparing a granular material MG comprising polyamide 6, the process comprising
[0106] (i) providing a solid particulate material MP comprising polyamide 6;
[0107] (ii) feeding material MP provided according to (i) via at least one material feeding device Fi into a melt extrusion apparatus E, wherein E comprises (a) at least one material receiving means RE for receiving material MP from the at least one feeding device Fi and for providing MP into a melting and conveying space SE;
[0108] (b) the melting and conveying space SE for melting polyamide 6 comprised in MP and conveying a mixture ME comprising melted polyamide 6 via preferably rotating conveying means CM to at least one shaping orifice OE, wherein SE has a length LSE;
[0109] (c) the at least one shaping orifice OE for forming at least one strand from ME;
[0110] (d) at least one degassing means GE for removing at least a part of a gas phase present in SE;
[0111] (e) heating means HE for providing polyamide 6 melting conditions in SE;
[0112] (iii) subjecting material MP in SE to polyamide 6 melting conditions, obtaining in SE the mixture ME comprising melted polyamide 6, and further obtaining in SE a gas phase comprising one or more gaseous decomposition products of the material MP, said melting conditions comprising a melting temperature TM;
[0113] (iv) removing at least a part of the gas phase obtained according to (iii) from SE via the at least one degassing means GE;
[0114] (v) removing the at least one strand from E via the at least one shaping orifice OE, said at least one strand having a temperature Ts with Ts TM;
[0115] (vi) optionally subjecting the at least one strand removed from E according to (v) to cooling, obtaining at least one cooled strand having a temperature Tc with Tc < Ts;
[0116] (vii) subjecting the at least one optionally cooled strand to granulation, obtaining the granular material MG.
[0117] 2. The process of embodiment 1 , wherein MP comprises, preferably consists of, a waste material, preferably one or more of a textile waste material and an engineering plastics waste material, more preferably a textile waste material.
[0118] 3. The process of embodiment 1 or 2, wherein MP is in the form of one or more of fibers, filaments, granules, and shredded pieces.
[0119] 4. The process of any one of embodiments 1 to 3, wherein the particles of MP, independently of each other, have a volume in the range of from 1 to 20000 mm3, preferably fitting into a cuboid having side lengths of 2, 100 and 100 mm; preferably a volume in the range of from 1 to 10000 mm3, preferably fitting into a cuboid having side lengths of 1 , 100 and 100 mm; more preferably a volume in the range of from 1 to 6000 mm3, preferably fitting into a cuboid having side lengths of 1 , 50 and 120 mm; more preferably a volume in the range of from 1 to 1200 mm3, preferably fitting into a cuboid having side lengths of 1 , 20 and 60 mm; more preferably a volume in the range of from 1 to 800 mm3, preferably fitting into a cuboid having side lengths of 1 , 10 and 80 mm; more preferably a volume in the range of from 1 to 600 mm3, preferably fitting into a cuboid having side lengths of 1 , 5, and 120 mm; more preferably a volume in the range of from 1 to 400 mm3, preferably fitting into a cuboid having side lengths of 1 , 20 and 20 mm or into a cuboid having side lengths of
[0120] 1 , 10 and 40 mm; more preferably a volume in the range of from 1 to 120 mm3, preferably fitting into a cuboid having side lengths of 1 , 2 and 60 mm or into a cuboid having side lengths of
[0121] 2, 2 and 30 mm; more preferably a volume in the range of from 1 to 80 mm3, preferably fitting into a cuboid having side lengths of 1 , 1 and 80 mm or into a cuboid having side lengths of 1 , 2 and 40 mm; more preferably a volume in the range of from 1 to 40 mm3, preferably fitting into a cuboid having side lengths of 1 , 2 and 20 mm or into a cuboid having side lengths of 1 , 1 and 40 mm.
[0122] 5. The process of any one of embodiments 1 to 4, wherein MP has a water content in the range of from 0 to 10 weight-%, preferably from 0 to 8 weight-%, more preferably from 0 to 6 weight-%, based on the total weight of Mp.
[0123] 6. The process of any one of embodiments 1 to 5, wherein from 30 to 100 weight-%, preferably from 50 to 100 weight-%, more preferably from 60 to 100 weight-% of MP consist of polyamide 6.
[0124] 7. The process of embodiment 6, wherein in addition to polyamide 6, MP further comprises at least one further polymeric material, preferably one or more of a polyamide 6.6, a polyurethane, a polyester, acrylic, a cellulosicmaterial preferably including cotton, a rubber material comprising one or more of a natural rubber material and a synthetic rubber material, a protein fiber material preferably including one or more of silk and wool, and optionally further comprises one or more of a pigment material, a glass fiber material and a carbon fiber material.
[0125] 8. The process of any one of embodiments 1 to 7, wherein the at least one feeding device Fi comprises at least one dosing apparatus, preferably one or both of a gravimetrical dosing apparatus and a volumetric dosing apparatus, more preferably selected from the group consisting of a scale, a belt, a stuffing screw, such as a single or a twin screw, a vibration feed, and a cell wheel.
[0126] 9. The process of any one of embodiments 1 to 8, wherein the at least one feeding device Fi is arranged so that MP is fed into SE in the downstream-most nine tenths, preferably five sixths, more preferably four fifths, more preferably three fourths, more preferably two thirds, of LSE-
[0127] 10. The process of any one of embodiments 1 to 9, wherein from 50 to 100 weight-% preferably from 60 to 100 weight-%, more preferably from 70 to 100 weight-%, more preferably from 80 to 100 weight-% of MP are fed into E according to (ii) via the at least one feeding device Fi arranged in the downstream-most nine tenths, preferably five sixths, more preferably four fifths, more preferably three fourths, more preferably two thirds, of LSE, wherein preferably the rest is fed into E via at least one further feeding device Fi arranged in the upstream-most first third, preferably first fourth, more preferably first fifth, more preferably first sixth, more preferably first tenth, of LSE
[0128] 11 . The process of any one of embodiments 1 to 10, wherein (i) further comprises providing a solid particulate material MPX, wherein (ii) comprises feeding material MPX provided according to (i) into the melt extrusion apparatus E, and wherein (iii) further comprises subjecting material MPX in SE to polyamide 6 melting conditions, obtaining in SE the mixture ME comprising melted polyamide 6, and further obtaining in SE a gas phase comprising one or more gaseous decomposition products of the materials MP and MPX, said melting conditions comprising a melting temperature TM and a melting pressure PM; wherein E optionally further comprises
[0129] (f) at least one material receiving means REX for receiving material MPX from the at least one feeding device and for providing MPX into the melting and conveying space SE; wherein from 80 to 100 weight-%, preferably from 90 to 100 weight-%, more preferably from 94 to 100 weight-%, more preferably from 95 to 100 weight-%, more preferably from 98 to 100 weight-%, more preferably from 99 to 100 weight-% of MPX consist of polyamide 6.
[0130] 12. The process of embodiment 11 , wherein MPX is fed according to (ii) via the at least one material feeding device Fi and / or via at least one material feeding device F2 into the melt extrusion apparatus E.
[0131] 13. The process of embodiment 11 or 12, wherein MPX is fed according to (ii) via the at least one feeding device Fi , wherein Fi comprises at least two dosing apparatuses selected from the group consisting of a scale, a belt, a stuffing screw, such as a single or a twin screw, a vibration feed, and a cell wheel.
[0132] 14. The process of embodiment 13, wherein the at least one feeding device F2 is arranged so that MPX is fed into SE in the upstream-most third, preferably sixth, more preferably tenth, more preferably eleventh of LSE.
[0133] 15. The process of embodiment 13 or 14, wherein the at least one feeding device F2 comprises at least one dosing apparatus, preferably at least two dosing apparatuses, selected from the group consisting of a scale, a belt, a stuffing screw, such as a single or a twin screw, a vibration feed, and a cell wheel.
[0134] 16. The process of any one of embodiments 11 to 15, wherein according to (ii), MP and MPX are fed into the extrusion apparatus E at a weight ratio MP / (MP+MPX) in the range of from 0.01 :1 to 0.99:1 , preferably from 0.01 :1 to 0.5:1 , more preferably from 0.01 :1 to 0.3:1 , more preferably from 0.01 :1 to 0.2:1 , more preferably from 0.01 :1 to 0.15:1 , more preferably from 0.01 :1 to 0.133:1.
[0135] 17. The process of any one of embodiments 1 to 16, wherein SE has a diameter DSE, wherein the ratio LSE / DSE is in the range of from 20:1 to 80:1 , preferably from 25:1 to 70:1 , more preferably from 30:1 to 60:1 , more preferably from 32:1 to 48:1 ; or wherein the ratio LSE / DSE is in the range of from 24:1 to 40:1.
[0136] 18. The process of any one of embodiments 1 to 17, wherein E is an extruder or a kneader, preferably an extruder, more preferably a single-screw extruder, a twin screw extruder or a planetary roller extruder, more preferably a single-screw extruder or a twin screw extruder.
[0137] 19. The process of any one of embodiments 1 to 18, wherein E further comprises
[0138] (g) at least one mixing element, preferably at least two mixing elements, more preferably at least three mixing elements, preferably kneading elements, and at least three, preferably at least four, conveying elements; wherein said at least two or said at least three or said at least four elements are preferably serially arranged.
[0139] 20. The process of embodiment 19, wherein E comprises at least two feeding devices Fi , and optionally at least one feeding device F2 as defined in embodiment 12, wherein the total number of feeding devices equals the number of the mixing elements according to (g).
[0140] 21 . The process of any one of embodiments 1 to 20, wherein the conveying space SE has at least two, preferably at least three, more preferably at least four different zones, wherein more preferably, SE has one or more material receiving zones ZER, one or more melting zones ZEM, one or more degassing zones ZEG, and at least one outputting zone ZOUT.
[0141] 22. The process of any one of embodiments 1 to 21 , wherein E comprises at least 2, preferably at least 3, more preferably at least 5 orifices OE, wherein the at least one orifice OE preferably has a cross-section in the form of a square, a rectangle, a circle, an oval, a triangle, or a star.
[0142] 23. The process of any one of embodiments 1 to 22, wherein E further comprises
[0143] (h) at least one melt pump; the process further comprising applying pressure onto ME via the at least one melt pump in the direction of movement of ME in SE. The process of any one of embodiments 1 to 23, wherein E further comprises
[0144] (j) at least one melt filter arranged in SE upstream of OE; wherein said at least one the melt filter preferably comprises one or more of a sieve, a perforated plate, and a fabric, wherein the mesh size of the at least one melt filter is preferably in the range of from 0.02 to 3 mm, preferably from 0.025 to 2 mm, more preferably from 0.035 to 1 mm, more preferably in the range of 0.1 to 0.8 mm, more preferably in the range of from 0.1 to 0.11 mm. The process of any one of embodiments 1 to 24, further comprising feeding at least oneprocessing aid, preferably a liquefying medium, including one or more of a liquid medium and a solid medium, into SE, wherein the processing aid, preferably the liquefying medium, preferably comprises at least one mono-, oligo-, and / or polyhydric alcohol including one or more polyethylene glycols, and water, wherein the processing aid, preferably the liquefying medium, is fed into SE preferably by one or more of admixing the processing aid, preferably the liquefying medium, with the material MP prior to (ii); feeding the processing aid, preferably the liquefying medium, into SE via at least one feeding device F3, and at least one receiving means REL, said at least one receiving means REL preferably being arranged so that the processing aid, preferably the liquefying medium, is fed into SE in the downstream-most nine tenths, preferably five sixths, more preferably four fifths, more preferably three fourths, more preferably two thirds of LSE. The process of any one of embodiments 1 to 25, wherein the gas phase obtained according to (iii) comprises at least one of a decomposition product of polymer, preferably gas or vapour of decomposed elastan, and water, wherein the water content of the gas phase is preferably in the range of from 0.01 to 10 volume-%, more preferably from 0.01 to 8 volume-%, more preferably from 0.01 to 5 volume-%, based on the total volume of the gas phase. The process of any one of embodiments 1 to 26, wherein removing at least a part of the gas phase from SE according to (iv) is carried out either actively, or passively, or actively and passively, wherein the at least one degassing means GE is preferably selected from the group consisting of a hole in a sidewall of the extrusion apparatus E, a degassing screw arranged in a hole in a sidewall of the extrusion apparatus E, an atmospheric dome arranged on a hole in a sidewall of the extrusion apparatus E, a vacuum dome arranged on a hole in a sidewall of the extrusion apparatus E, and a combination of two or more thereof. 28. The process of any one of embodiments 1 to 27, wherein according to (iii), TM is in the range of from 150 to 350 °C, preferably from 180 to 280 °C, more preferably from 200 to 250 °C.
[0145] 29. The process of any one of embodiments 1 to 28, wherein according to (iii), the polyamide 6 melting conditions further comprise a melting pressure pM, wherein PM is preferably in the range of from 0 to 350 bar, more preferably from 0 to 150 bar, more preferably from 0 to 130 bar, more preferably from 0 to 100 bar, more preferably from 5 to 45 bar.
[0146] 30. The process of any one of embodiments 1 to 29, wherein according to (iii), the polyamide 6 melting conditions further comprise a throughput HM through SE, wherein HM is preferably in the range of from 100 to 12000 kg / h, preferably from 150 to 8000 kg / h, more preferably from 250 to 6,000 kg / h.
[0147] 31 . The process of any one of embodiments 1 to 30, wherein according to (iii), the polyamide 6 melting conditions further comprise a rotating speed RM of the conveying means CM, wherein the rotational speed is preferably in the range of from 20 to 2000 rpm, more preferably from 50 to 1200 rpm, more preferably from 60 to 800 rpm, more preferably from 200 to 700 rpm, more preferably from 400 to 500 rpm.
[0148] 32. The process of any one of embodiments 1 to 31 , wherein according to (iii), the polyamide 6 melting conditions further comprise a torque QM of the conveying means CM, wherein QM is preferably in the range of from 0 to 30,000 Nm, preferably from 250 to 20,000 Nm, more preferably from 300 to 15,000 Nm.
[0149] 33. The process of any one of embodiments 1 to 32, wherein E comprises at least one melt pump as defined in embodiment 23, wherein according to (iii), the polyamide 6 melting conditions further comprise a melt pump pressure in the range of from 1 to 350 bar, preferably from 2 to 150 bar, more preferably from 5 to 140 bar.
[0150] 34. The process according to claim 33, wherein E comprises at least one melt pump as defined in embodiment 23, wherein according to (iii), the polyamide 6 melting conditions further comprise a melt pump rotation in the range of from 1 to 1 ,000 rpm, preferably from 10 to 500 rpm, more preferably from 50 to 300rpm, or a melt pump rotation in the range of from 34 to 47rpm.
[0151] 35. The process of any one of embodiments 1 to 34, comprising one or more of controlling, adjusting and maintaining at least one of the polyamide 6 melting conditions according to (iii)- 36. The process of any one of embodiments 1 to 35, wherein according to (vi), the at least one strand is cooled using a cooling medium selected from a gaseous cooling medium, a liquid cooling medium and a mixture thereof, wherein the gaseous cooling medium is preferably one or more of air, lean air and nitrogen, and wherein the liquid cooling medium preferably comprises, more preferably consists of, water.
[0152] 37. The process of any one of embodiments 1 to 36, wherein for cooling according to (vi), a strand cooling conveyor is used, said strand cooling conveyor preferably being comprised in a strand cooling tray, wherein said strand cooling tray preferably comprises one or more of strand guiding means for guiding the at least one strand through the tray and strand feeding means for feeding the at least one strand removed according to (v) to the strand cooling tray; or for cooling according to (vi) and for granulation according to (vii), an under water pelletizer is used.
[0153] 38. The process of any one of embodiments 1 to 37, wherein Ts is in the range of from 350 to 180 °C, preferably from 320 to 200 °C, more preferably from 300 to 200 °C, more preferably from 280 to 180°C.
[0154] 39. The process of any one of embodiments 1 to 38, wherein Tc is in the range of from 25 to 350°C, preferably from 50°C to 320°C, more preferably from 50°C to 280°C, more preferably from 150 to 220 °C, more preferably from 160 to 200 °C, more preferably from 170 to 180 °C; or Tc is in the range of from 25°C to 170°C, more preferably from 25°C to 150°C.
[0155] 40. The process of to any one of embodiments 1 to 39, wherein according to (vi), the at least one strand is cooled from Ts to Tc at a cooling rate in the range of from 1 to 2700 K / min, preferably from 1 to 2000 K / min, more preferably from 1 to 1000K / min; more preferably from 5 to 400 K / min, more preferably from 5 to 350 K / min, more preferably from 50 to 300 K / min.
[0156] 41 . The process of any one of embodiments 1 to 40, wherein according to (vii), the granulation of the at least one strand comprises cutting the at least one strand, wherein for said cutting, one or more of an under water pelletizer, a hot-cut pelletizer, a pressurized air pelletizer, and a strand pelletizer are used.
[0157] 42. The process of any one of embodiments 1 to 41 , wherein the granular material MG obtained according to (vii) has a bulk density in the range of from 500 to 1200 g / l, preferably from 600 to 1000 g / l, more preferably from 600 to 900 g / l, determined according to DIN ISO 697:1982; or the granular material MG obtained according to (vii) has a bulk density in the range of from 450 to 1200 g / l, preferably from 500 to 750 g / l, more preferably from 570 to 690 g / l, determined according to DIN ISO 697:1982. 43. The process of any one of embodiments 1 to 42, wherein the granular material MG obtained according to (vii) is characterized by a particle mass in the range of from 0.2 to 70 mg, preferably from 0.2 to 60 mg, more preferably from 0.2 to 50 mg; or the granular material MG obtained according to (vii) is characterized by a particle mass in the range of from 0.2 to 100 mg, preferably from 0.5 to 70 mg, more preferably from 0.7 to 60 mg.
[0158] 44. The process of any one of embodiments 1 to 43, wherein the granular material MG obtained according to (vii) has a maximum particle length in the range of from 0.5 to 10 mm, preferably from 1 .5 to 8 mm, more preferably from 2 to 6 mm.
[0159] 45. A granular material MG, obtainable or obtained by a process according to any one of embodiments 1 to 44.
[0160] 46. The granular material MG according to embodiment 45, wherein from 30 to 100 weight-%, preferably from 50 to 100 weight-%, more preferably from 60 to 100 weight-% of MG consist of polyamide 6.
[0161] 47. An apparatus for preparing a granular material MG, preferably by a process according to any one of embodiments 1 to 44, said apparatus comprising
[0162] (A) a melt extrusion apparatus E comprising
[0163] (a) at least one material receiving means RE for receiving a solid particulate material MP comprising polyamide 6 from at least one feeding device Fi and for providing MP into a melting and conveying space SE;
[0164] (b) the melting and conveying space SE for melting polyamide 6 comprised in MP and conveying a mixture ME comprising melted polyamide 6 via preferably rotating conveying means CM to at least one shaping orifice OE, wherein SE has a length LSE;
[0165] (c) the at least one shaping orifice OE for forming at least one strand from ME;
[0166] (d) at least one degassing means GE for removing at least a part of a gas phase present in SE;
[0167] (e) heating means HE for providing polyamide 6 melting conditions in SE;
[0168] (f) optionally at least one material receiving means REX for receiving material MPX comprising polyamide 6 from at least one feeding device F2 and for providing MPX into the melting and conveying space SE;
[0169] (g) optionally at least three mixing elements and at least three, preferably at least four, conveying elements;
[0170] (h) optionally at least one melt pump;
[0171] (j) optionally at least one melt filter arranged in SE upstream of OE;
[0172] (B) at least one feeding device comprising (a) at least one material feeding device Fi for feeding material MR, and optionally material MPX, into E;
[0173] (b) optionally at least one material feeding device F2 for feeding material MPX, preferably additionally or alternatively to the feeding of MPX according to (B)(a), into E and further optionally at least one material receiving means REX for receiving material MPX from the at least one feeding device F2 and for providing MPX into the melting and conveying space SE;
[0174] (c) optionally at least one feeding device F3 for feeding a liquid medium into E and further optionally at least one material receiving means REL for receiving the liquid medium from the at least one feeding device F3 and for providing the liquid medium into the melting and conveying space SE;
[0175] (C) optionally cooling means Me arranged downstream of E for cooling the at least one strand obtained from E;
[0176] (D) granulation means MG arranged downstream of OE, and preferably downstream of the cooling means Me, for preparing the granular material MG from the at least one strand shaped by the at least one shaping orifice OE, preferably from the at least one cooled strand obtained by the cooling means Me. Use of the granular material MG according to embodiment 45 or 46 for preparing a stream SCPL comprising purified c-caprolactam, or a method for preparing a stream SCPL comprising purified c-caprolactam from the granular material MG according to embodiment 43, wherein preparing the stream SCPL preferably comprises
[0177] (a) providing a stream SM comprising the solid material MG (112);
[0178] (P) preparing an aqueous depolymerization mixture based on SM;
[0179] (y) subjecting the aqueous depolymerization mixture to polyamide 6 depolymerization conditions in a reaction unit UR, obtaining a liquid aqueous stream SR comprising c- caprolactam dissolved in water at a concentration CSR, the stream SR further comprising one or more impurities;
[0180] (5) passing the liquid aqueous stream SR into an evaporation unit UE, obtaining from SR a liquid aqueous stream SL comprising c-caprolactam dissolved in water at a concentration CSL with CSL > CSR, and further obtaining from SR one or more aqueous vapor streams Sv;
[0181] (c) passing the aqueous stream SL into a heat-consuming purification unit UP, obtaining from SL a stream SCPL comprising c-caprolactam at a concentration CSCPL with CSCPL » CSL, and further obtaining from SL one or more aqueous streams SRW, wherein at least part of the heat consumed in UP is provided by at least one of the one or more streams Sv, thereby obtaining from the at least one stream Sv at least one at least partially condensed aqueous stream Svw;
[0182] «) recycling at least one stream Svw at least partially to the reaction unit UR and at least one stream SR at least partially to the reaction unit UR. Use of SCPL obtainable or obtained according to step (E) according to embodiment 48 for preparing one or more of a polymer and a polymer product; or a method for preparing one or more of a polymer and a polymer product, said method comprising employing SCPL according to step
[0183] (E) according to embodiment 45 as a starting material. The use or the method of embodiment 49, wherein the polymer, or the polymer product, or the polymer and the polymer product is or are in the form of at least one of a granulate, a strand, a rod, a plate, a pipe, a foil, a layer, a film, a sheet, a fiber, a filament, a coating, an extruded article, a molded article, a soft foam, a half-rigid foam and a rigid foam. The use or the method of embodiment 49 or 50, wherein the polymer, or the polymer product, or the polymer and the polymer product comprises or comprise polyamide 6 and optionally at least one further polymeric compound, said polyamide 6 being at least partially obtainable or obtained from SCPL obtainable or obtained according to step (E) according to embodiment 45, wherein the at least one further polymeric compound preferably comprises one or more of at least one polyamide 6.6, at least one polyethylene terephthalate, at least one polyurethane, at least one polyester, at least one cellulose material, and at least one rubber material comprising one or more of at least one natural rubber material and at least one synthetic rubber material. The use or the method of any one of embodiments 49 to 51 , wherein the polymer, or the polymer product, or the polymer and the polymer product is or are one of the following or a part of one of the following: a part of a car, preferably a cylinder head cover, an engine cover, a housing for a charge air cooler, a charge air cooler flap, an intake pipe, an intake manifold, a connector, a gear wheel, a fan wheel, a cooling water box, a housing or a housing part for a heat exchanger, a coolant cooler, a charge air cooler, a thermostat, a water pump, a radiator, a fastening part or a part of a battery system for electromobility, a dashboard, a steering column switch, a seat, a headrest, a center console, a transmission component, a door module, a car exterior for an A, a B, a C or a D pillar cover, a spoiler, a door handle, an exterior mirror, a windscreen wiper, a windscreen wiper protection housing, a decorative grill, a cover strip, a roof rail, a window frame, a sunroof frame, an antenna panel, a headlight, a taillight, an airbag, and / or a cushion; a cloth, an apparel, preferably a shirt, trousers, a pullover, a boot, a shoe, a shoe sole, a tight and / or or jacket; an electrical part, preferably an electrical component, an electronic passive component, an electronic active component, a printed circuit board, a housing component, a foil, a line, a switch such as a microswitch, a plug, a socket, a distributor, a relay, a resistor, a capacitor, an inductor, a bobbin, a lamp, a diode such as an LED, a transistor, a connector, a regulator, an integrated circuit (IC), a processor, a controller, a memory, a sensor, a microbutton, a semiconductor, a reflector housing for example for light-emitting diodes, a fastener for an electrical and / or an electronic component, a spacer, a bolt, a strip, a slide-in guide, a screw, a nut, a film hinge, a snap hook (snap-in), and / or a spring tongue; a consumer and / or a pharmaceutical product, preferably a tennis string, a climbing rope, a bristle, a brush, an artificial grass, a 3D printing filament, a grass trimmer, a zipper, a hook and loop fastener, a paper machine clothing, an extrusion coating, a fishing line, a fishing net, an offshore line and rope, a vial, a syringe, an ampoule, a bottle, a sliding element, a spindle nut, a chain conveyor, a plain bearing, a roller, a wheel, a gear, a roller, a ring gear, a screw and spring damper, a hose, a pipeline, a cable sheathing, a socket, a switch, a cable tie, a fan wheel, a carpet, a box and / or a bottle for cosmetics, a mattress, a cushion, an insulation; a packaging for the food industry, preferably a mono- and / or multi-layer blown film, a cast film (mono- and / or multi-layer), a biaxially stretched film, a laminating film.
[0184] 53. The use or the method of any one of embodiments 49 to 52, wherein the polymer, or the polymer product, or the polymer and the polymer product contains or contain polyamide 6, obtainable or obtained from SCPL obtainable or obtained according to step (E) according to embodiment 45, in an amount of 1 weight-% or more, preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight-% or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight-% or more, more preferably 95 weight-% or more; and / or in an amount of 100 weight-% or less, preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less.
[0185] As far as the embodiment 53 is concerned, the respective amounts are preferably determined based on identity preservation and / or segregation and / or mass balance and / or book and claim chain of custody models, more preferably based on mass balance, more preferably the International Sustainability and Carbon Certification (ISCC) standard. Additionally or alternatively, other methods, preferably analytical methods, are used to determine the respective amounts of embodiment 53. Preferably, the respective amounts of embodiment 53 are determined using one or more of an analytical method, such as NMR method and a red certification. More preferably, the respective amounts of embodiment 53 are determined using the NMR method.
[0186] As far as the embodiments 49 to 53 are concerned, preparing the polymer, the polymer product, or the polymer and the polymer product may comprise one or more synthesis steps and can be performed by conventional synthesis and technics well known to the person skilled in the art. Examples of the synthesis steps are described in “Industrial Organic Chemistry”, 3rdvolume, Wiley-VCH, 1997; ISBN: 978-3-527-28838-0; „Kunststoffhandbuch“, 11 volumes in 17 sub- volumes, Carl HanserVerlag, especially volume 6, „Polyamide“, 1stedition, 1966; “Injection Molding Reference Guide, 4thedition, CreateSpace Independent Publishing Platform, 2011 , ISBN: 978-1466407824; WO 2008 / 155271 A1 and WO 2013 / 139827 A1 , each of which is incorporated herein by reference.
[0187] The term „bar“ as used in the context of the present invention refers to “bar(g)”, i.e. pressure (gauge) , sometimes also referred to as “barg”, “gauge pressure” or “relative pressure”.
[0188] The term “textile material” covers textile raw materials and non-textile raw materials that are processed by various methods into linear, planar and spatial structures. It concerns the linear textile structures produced from them, such as yarns, twisted yarns and ropes, the sheet-like textile structures, such as woven fabrics, knitted fabrics, braids, stitch-bonded fabrics, nonwovens and felts, and the three-dimensional textile structures, i.e. body structures, such as textile hoses, stockings or textile semi-finished products; and it further concerns those finished products which, using the aforementioned products, are brought into a saleable condition by making up, opening up and / or other operations for onward transmission to the processor, the trade or the end consumer. Preferably, the textile material comprises at least one composite material and / or a prepreg material, such as a material comprising pre-impregnated fibers, preferably glass fibers and / or carbon fibers, and a polymer matrix, preferably a partially cured polymer matrix, more preferably a partially cured thermoset matrix. More preferably, the textile material comprises woven and / or knitted fibers, preferably woven and / or knitted glass fibers and / or carbon fibers, impregnated with at least one polymer matrix material, preferably a thermoset resin material, more preferably at least one material comprising, preferably besides PA6, one or more of an epoxy resin and a phenolic resin.
[0189] The term “textile waste material” covers a textile material as defined above, the inherent value of which has been consumed from the perspective of its current holder and, thus, is an end-of-life material for said holder.
[0190] Preferred aspects of the present invention are further illustrated in the Figures 1 to 6 as described hereinunder.
[0191] Description of the figures
[0192] Fig. 1 illustrates an embodiment of an apparatus for preparing a granular material MG performing a process for preparing a granular material MG;
[0193] Fig. 2 and 3 illustrate different embodiments of an apparatus for preparing a granular material MG;
[0194] Fig. 4 to 6 illustrate different embodiments of an extrusion apparatus E; Fig. 7 and 8 illustrate different embodiments of an apparatus for preparing a granular material MG.
[0195] In Figure 1, an embodiment of an apparatus 110 for preparing a granular material 112 comprising polyamide 6 is illustrated. Further, different embodiments of an apparatus 110 for preparing a granular material 112 are illustrated in Figures 2 and 3. The apparatus 110 comprises a melt extrusion apparatus 114, at least one feeding device 116 and granulation means 118. Optionally, the apparatus 110 further comprises cooling means 119 arranged downstream of the melt extrusion apparatus 114.
[0196] Figures 1 , 2, 3, 7 and 8, by showing different embodiments of the apparatus 110, also illustrate different embodiments of the melt extrusion apparatus 114. Further, different embodiments of the melt extrusion apparatus 114 are illustrated in Figures 4, 5 and 6. The melt extrusion apparatus 114 comprises at least one material receiving means 120 for receiving a solid particulate material MP 122 comprising polyamide 6 from at least one feeding device 116 and for providing material MP 122 into a melting and conveying space 124. Further, the melt extrusion apparatus 114 comprises the melting and conveying space 124 for melting polyamide 6 comprised in material MP 122 and conveying a mixture ME 126 comprising melted polyamide 6 via conveying means 128 to at least one shaping orifice 130, wherein the melting and conveying space 124 has a length LSE 132. Preferably, the conveying means 128 are rotating conveying means. Furthermore, the melt extrusion apparatus 114 comprises the at least one shaping orifice 130 for forming at least one strand 134 from the mixture ME 126. In addition, the melt extrusion apparatus 114 comprises at least one degassing means 136, preferably atmospheric degassing means 133 or vacuum degassing means 135, for removing at least a part of a gas phase present in the melting and conveying space 124. Further, the melt extrusion apparatus 114 comprises heating means 138 for providing polyamide 6 melting conditions in the melting and conveying space 124. The at least one feeding device 116 comprises at least one first material feeding device 140 for feeding MP, and optionally material MPX 142, into the extrusion apparatus 114. The granulation means 118 are arranged downstream of the shaping orifice 130 and are configured for preparing the granular material 112 from the at least one strand 134 shaped by the at least one shaping orifice 130. Optionally, the melt extrusion apparatus 114 comprises at least one melt filter 137 arranged in the melting and conveying space 124 upstream of the shaping orifice 130. Further optionally, the melt extrusion apparatus 114, preferably as conveying means 128, comprises at least one mixing element 139, preferably at least three mixing elements 139, and at least three, preferably at least four, conveying elements 141 . Optionally, the extrusion apparatus 114 further comprises at least one melt pump 143 configured for applying pressure onto the mixture 126 in the direction of movement of the mixture 126 in the melting and conveying space 124. Optionally, the extrusion apparatus 114 comprises further elements for further controlling the process, such as for example one or more valves, e.g. starting valves 145. Optionally, the at least one feeding device 116 comprises at least one second material feeding device 146 for feeding the material Mpxinto the extrusion apparatus 114, preferably additionally or alternatively to the feeding of MPX via the first material feeding device 140. Further optionally, the melt extrusion apparatus 114 comprises at least one material receiving means 144 for receiving the material MPX 142 comprising polyamide 6 from the at least one second feeding device 146 and for providing the material MPX 142 into the melting and conveying space 124. Further optionally, the at least one feeding device 116 comprises at least one third feeding device 148 for feeding a liquid medium into the extrusion apparatus 114, wherein the extrusion apparatus 114 further optionally comprises at least one material receiving means 150 for receiving the liquid medium from the at least one third feeding device 148 and for providing the liquid medium into the melting and conveying space 124. Further optionally, the feeding device 116 comprises at least one dosing apparatus 149, preferably at least two dosing apparatuses 149.
[0197] The optional cooling means 119 are preferably arranged downstream of the extrusion apparatus 114 and are configured for cooling, preferably by using a cooling medium, the at least one strand 134 obtained from the extrusion apparatus 114. The granulation means 118 are preferably arranged downstream of the cooling means 119, for preparing the granular material 112 from the at least one cooled strand 134 obtained by the cooling means 119. Further optionally, the granulation means 118 and the cooling means 119 are jointly realized in at least one under water pelletizer 151 .
[0198] Further, in Figure 1 , a flow chart of a process for preparing the granular material 112 comprising polyamide 6 is illustrated, performed by the exemplarily illustrated apparatus 110. The process comprises at least the following steps:
[0199] (i) (denoted by reference number 152) providing a solid particulate material MP 122 comprising polyamide 6;
[0200] (ii) (denoted by reference number 154) feeding material MP 122 provided according to step (i) 152 via at least one material feeding device 116 into a melt extrusion apparatus 114, wherein E comprises
[0201] (a) at least one material receiving means 120 for receiving material MP 122 from the at least one feeding device 116 and for providing MP 122 into a melting and conveying space 124;
[0202] (b) the melting and conveying space 124 for melting polyamide 6 comprised in MP 122 and conveying a mixture ME 126 comprising melted polyamide 6 via preferably rotating conveying means 128 to at least one shaping orifice 130, wherein the melting and conveying space 124 has a length LSE 132;
[0203] (c) the at least one shaping orifice 130 for forming at least one strand 134 from ME 126;
[0204] (d) at least one degassing means 136 for removing at least a part of a gas phase present in the melting and conveying space 124; (e) heating means 138 for providing polyamide 6 melting conditions in the melting and conveying space 124;
[0205] (iii) (denoted by reference number 156) subjecting material MP 122 in the melting and conveying space 124 to polyamide 6 melting conditions, obtaining in the melting and conveying space 124 the mixture ME 126 comprising melted polyamide 6, and further obtaining in the melting and conveying space 124 a gas phase comprising one or more gaseous decomposition products of the material MP 122, said melting conditions comprising a melting temperature TM;
[0206] (iv) (denoted by reference number 158) removing at least a part of the gas phase obtained according to step (iii) 156 from the melting and conveying space 124 via the at least one degassing means 136;
[0207] (v) (denoted by reference number 160) removing at least one strand 134 from the extrusion apparatus 114 via the at least one shaping orifice 130, said at least one strand 134 having a temperature Ts with Ts TM;
[0208] (vi) (not illustrated in Figure 1) optionally subjecting the at least one strand 134 removed from the extrusion apparatus 114 according to step (v) 160 to cooling, obtaining at least one cooled strand 134 having a temperature Tc with Tc < Ts;
[0209] (vii) (denoted by reference number 162) subjecting the at least one optionally cooled strand 134 to granulation, obtaining the granular material 112.
[0210] List of reference numbers
[0211] 110 apparatus
[0212] 112 granular material MG
[0213] 114 extrusion apparatus E
[0214] 116 feeding device
[0215] 118 granulation means MG
[0216] 119 cooling means Me
[0217] 120 material receiving means RE
[0218] 122 solid particulate material MP
[0219] 124 melting and conveying space SE
[0220] 126 mixture ME
[0221] 128 conveying means CM
[0222] 130 shaping orifice OE
[0223] 132 length LSE
[0224] 133 atmospheric degassing means
[0225] 134 strand
[0226] 135 vacuum degassing means
[0227] 136 degassing means GE
[0228] 137 melt filter
[0229] 138 heating means HE
[0230] 139 mixing elements
[0231] 140 material feeding device Fi
[0232] 141 conveying elements
[0233] 142 material MPX
[0234] 143 melt pump
[0235] 144 material receiving means REX
[0236] 145 starting valve
[0237] 146 material feeding device F2
[0238] 148 material feeding device F3
[0239] 149 dosing apparatus
[0240] 150 material receiving means REL
[0241] 151 under water pelletizer
[0242] 152 step (i)
[0243] 154 step (ii)
[0244] 156 step (iii)
[0245] 158 step (iv)
[0246] 160 step (v)
[0247] 162 (step (vi)
Claims
Claims1 . A process for preparing a granular material MG (112) comprising polyamide 6, the process comprising(i) providing a solid particulate material MP (122) comprising polyamide 6, wherein MP (122) comprises a waste material, wherein MP (122) is in the form of one or more of fibers, filaments, granules, and shredded pieces;(ii) feeding material MP (122) provided according to (i) via at least one material feeding device Fi (116, 140) into a melt extrusion apparatus E (114), wherein E (114) comprises(a) at least one material receiving means RE (120) for receiving material MP (122) from the at least one feeding device Fi (116, 140) and for providing MP (122) into a melting and conveying space SE (124);(b) the melting and conveying space SE (124) for melting polyamide 6 comprised in MP (122) and conveying a mixture ME (126) comprising melted polyamide 6 via conveying means CM (128) to at least one shaping orifice OE (130), wherein SE (124) has a length LSE (132);(c) the at least one shaping orifice OE (130) for forming at least one strand (134) from ME (126);(d) at least one degassing means GE (136) for removing at least a part of a gas phase present in SE (124);(e) heating means HE (138) for providing polyamide 6 melting conditions in SE (124);(iii) subjecting material MP (122) in SE (124) to polyamide 6 melting conditions, obtaining in SE (124) the mixture ME (126) comprising melted polyamide 6, and further obtaining in SE (124) a gas phase comprising one or more gaseous decomposition products of the material MP (122), said melting conditions comprising a melting temperature TM;(iv) removing at least a part of the gas phase obtained according to (iii) from SE (124) via the at least one degassing means GE (136);(v) removing the at least one strand (134) from E (114) via the at least one shaping orifice OE (130), said at least one strand (134) having a temperature Ts with Ts TM;(vii) subjecting the at least one strand (134) to granulation, obtaining the granular material MG(112).
2. The process of claim 1 , wherein the particles of MP (122), independently of each other, have a volume in the range of from 1 to 20000 mm3and fit into a cuboid having side lengths of 2 mm, 100 mm, and 100 mm.
3. The process of any one of embodiments 1 to 2, wherein MP (122) has a water content in the range of from 0 to 10 weight- % based on the total weight of MP (122), and additionally or alternatively from 30 to 100 weight-% of MP (122) consist of polyamide 6.
4. The process of any one of claims 1 to 3, wherein from 50 to 100 weight-% of MP (122) are fed into E (114) according to (ii) via the at least one feeding device Fi (116) arranged in the downstream-most nine tenths of LSE (132), wherein the rest is fed into E (114) via at least one further feeding device Fi (116) arranged in the upstream-most first third of LSE.
5. The process of any one of claims 1 to 4, wherein (i) further comprises providing a solid particulate material MPX (142), wherein (ii) comprises feeding material MPX (142) provided according to (i) into the melt extrusion apparatus E (114), and wherein (iii) further comprises subjecting material MPX (142) in SE (124) to polyamide 6 melting conditions, obtaining in SE (124) the mixture ME (126) comprising melted polyamide 6, and further obtaining in SE (124) a gas phase comprising one or more gaseous decomposition products of the materials MP (122) and MPX (142), said melting conditions comprising a melting temperature TM and a melting pressure PM; wherein E (114) further comprises(f) at least one material receiving means REX (144) for receiving material MPX (142) from the at least one feeding device (116) and for providing MPX into the melting and conveying space SE; wherein from 80 to 100 weight-% of MPX consist of polyamide 6.
6. The process of claim 5, wherein MPX is fed according to (ii) via the at least one material feeding device Fi (140) and additionally or alternatively via at least one material feeding device F2 (146) into the melt extrusion apparatus E.
7. The process of claims 5 or 6, wherein according to (ii), MP (122) and MPX (142) are fed into the extrusion apparatus E (114) at a weight ratio MP / (MP+M PX) in the range of from 0.01 :1 to 0.99:1.
8. The process of any one of claims 1 to 7, wherein E (114) further comprises(g) at least one mixing element (139) and at least three conveying elements (141); wherein said elements are serially arranged.
9. The process of claim 8, wherein E (114) comprises at least two feeding devices Fi (140), and at least one feeding device F2 (146) as defined in claim 7, wherein the total number of feeding devices (116) equals the number of the mixing elements (139) according to (g).
10. The process of any one of claims 1 to 9, wherein the granular material MG (112) obtained according to (vii) has one or more of a bulk density in the range of from 500 to 1200 g / l determined according to DIN ISO 697:1982 or a bulk density in the range of from 450 to 1200 g / l determined according to DIN ISO 697:1982,a particle mass in the range of from 0.2 to 70 mg or a particle mass in the range of from 0.2 to 100 mg; and a maximum particle length in the range of from 0.5 to 10 mm.
11. A granular material MG (112), obtainable or obtained by a process according to any one of claims 1 to 10, wherein from 30 to 100 weight-% of MG (112) consist of polyamide 6.
12. An apparatus (110) for preparing a granular material MG (112) by a process according to any one of claim 1 to 10, said apparatus (110) comprising(A) a melt extrusion apparatus E (114) comprising(a) at least one material receiving means RE (120) for receiving a solid particulate material MP (122) comprising polyamide 6 from at least one feeding device Fi (116, 140) and for providing MP (122) into a melting and conveying space SE (124);(b) the melting and conveying space SE (124) for melting polyamide 6 comprised in MP (122) and conveying a mixture ME (126) comprising melted polyamide 6 via conveying means CM (128) to at least one shaping orifice OE (130), wherein SE (124) has a length LSE (132);(c) the at least one shaping orifice OE (130) for forming at least one strand (134) from ME (126);(d) at least one degassing means GE (136) for removing at least a part of a gas phase present in SE (124);(e) heating means HE (138) for providing polyamide 6 melting conditions in SE (124);(B) at least one feeding device (116) comprising(a) at least one material feeding device Fi (140) for feeding material MP (122) into E (114);(D) granulation means MG (118) arranged downstream of OE (130) for preparing the granular material MG (112) from the at least one strand (134) shaped by the at least one shaping orifice OE (130).
13. A method for preparing a stream SCPL comprising purified c-caprolactam from the granular material MG (112) according to claim 11 , wherein preparing the stream SCPL comprises (a) providing a stream SM comprising the solid material MG (112);(P) preparing an aqueous depolymerization mixture based on SM;(y) subjecting the aqueous depolymerization mixture to polyamide 6 depolymerization conditions in a reaction unit UR, obtaining a liquid aqueous stream SR comprising E- caprolactam dissolved in water at a concentration CSR, the stream SR further comprising one or more impurities;(5) passing the liquid aqueous stream SR into an evaporation unit UE, obtaining from SR a liquid aqueous stream SL comprising c-caprolactam dissolved in water at aconcentration CSL with CSL > CSR, and further obtaining from SR one or more aqueous vapor streams Sv;(E) passing the aqueous stream SL into a heat-consuming purification unit UP, obtaining from SL a stream SCPL comprising c-caprolactam at a concentration CSCPL with CSCPL » CSL, and further obtaining from SL one or more aqueous streams SRW, wherein at least part of the heat consumed in UP is provided by at least one of the one or more streams Sv, thereby obtaining from the at least one stream Sv at least one at least partially condensed aqueous stream Svw;«) recycling at least one stream Svw at least partially to the reaction unit UR and at least one stream SR at least partially to the reaction unit UR.
14. A method for preparing one or more of a polymer and a polymer product, said method comprising employing SCPL according to step (E) according to claim 13 as a starting material.
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