Method for regeneration of polyester and recycling of polyester textile waste using an organic liquid
A thermal treatment and organic liquid-based process effectively recycles polyester textiles by removing textile chemicals, enhancing the quality and yield of recycled PET products for dyeing and spinning applications.
Patent Information
- Application Number
- PCT/EP2025/055074
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-02-27
- Filing Date
- 2025-02-25
- Publication Date
- 2025-09-04
AI Technical Summary
Existing chemical recycling methods for polyethylene terephthalate (PET) are energy inefficient, ecologically unfriendly, and produce low-quality recycled PET due to long depolymerisation times and the need for mixing with virgin PET, while recycling polyester textiles with textile chemicals is challenging.
A process involving thermal treatment and contact with organic liquids to remove textile chemicals, resulting in polyester solids with improved color quality, purity, size uniformity, and melt spinnability, suitable for producing yarn.
The process enhances the yield and uniformity of recycled polyester products, improving their suitability for dyeing and spinning processes.
Smart Images

Figure EP2025055074_04092025_PF_FP_ABST
Abstract
Description
[0001] METHOD FOR REGENERATION OF POLYESTER AND RECYCLING OF POLYESTER TEXTILE WASTE USING AN ORGANIC LIQUID
[0002] FIELD OF THE INVENTION
[0003] The invention relates generally to a recycling of polyesters such as polyethylene terephthalate (PET). The invention also relates to a process for producing a polyester the process comprising the following steps: a. providing a first polyester fragment; b. optionally subjecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. contacting the first polyester fragment or the second polyester fragment with one or more organic liquids to obtain a further polyester fragment; converting the further polyester fragment into a plurality of polyester solids. The first polyester fragment comprises a polyester polymer and a textile chemical. The further polyester fragment comprises less textile chemical than the first polyester fragment. The invention further relates to a polyester product obtainable by aforementioned process, a device for treating a polyester fragment and a use of polyester solids for a purpose such as a de-esterification, an esterification, a fibre, a textile, a container, a film, or a combination of at least two thereof.
[0004] BACKGROUND
[0005] Polyethylene terephthalate (PET) is one of the most widely used and economically important thermoplastic polymers. PET is used for, e.g., fibres for clothing, containers for food and beverages, such as bottles, and for films. As a result of the wide usage of PET and its nonbiodegradability, PET-containing products have created serious ecological concerns. Methods for recycling PET are thus very important in order to reduce the amount of PET waste. One method of recycling is the reduction of PET into the chemical components that are used to produce PET, followed by the polymerisation of the chemical components to obtain recycled PET. This is known as chemical recycling. Disadvantages of the chemical recycling process include the following: the recycling process is generally very energy inefficient, is ecologically unfriendly, and has a low through-put. In particular, if the PET is depolymerised to monomers, this requires long depolymerisation times, and leads to the production of large amounts of degradation products that can’t be removed from the recycled PET. Very often it is also required to mix the PET that is chemically recycled with virgin PET in order to obtain a recycled PET product of sufficiently high quality.
[0006] The chemical recycling of polyethylene terephthalate is described by, e.g., Bartolome et al. (2012), Recent Developments in the Chemical Recycling of PET, Material Recycling - Trends and Perspectives. EP3778744 Al discloses a method for recycling PET that includes mixing virgin PET liquid starting material with the recycled PET (virgin PET liquid starting material is defined as the chemical components required to produce virgin PET, i.e., PET that is not obtained using a recycling method). CN109134244 A discloses a method for recycling PET that uses both glycol and methanol to depolymerise PET. CN108395373 A discloses a method for recycling PET that uses ethylene glycol and propylene glycol.
[0007] In addition to selecting an appropriate method for recycling of polyesters and in particular PET, it is a further challenge to subject sufficiently pure and clean PET feed to the further steps of recycling. This holds in particular for polyester textiles such as PET fabrics which have been dyed and in particular those which have been treated with other textile chemicals. Attempts to provide a solution to this challenge are known for example from US 2022 / 0169786 Al and JP 7177449 B2. These two references focus on the use of a particular solvent.
[0008] OBJECTS
[0009] An object of the present invention is to at least partially overcome at least one of the disadvantages encountered in the state of the art.
[0010] It is a further object of the invention to provide a further intermediate product that has an improved colour quality.
[0011] It is a further object of the invention to provide a further intermediate product that has an improved purity.
[0012] It is a further object of the invention to provide a further intermediate product that has an improved uniformity of size and shape. It is a further object of the invention to provide a process for recycling polyester textiles with improved melt spinnability to produce yam.
[0013] It is a further object of the invention to provide a process for recycling polyester textiles with improved yield.
[0014] It is a further object of the invention to provide a process for recycling polyester textiles with improved uniformity for a dying process.
[0015] SUMMARY OF THE INVENTION
[0016] The invention provides a process in which a first polyester fragment is optionally subjected to a thermal treatment to obtain a second polyester fragment. The first polyester fragment or the second polyester fragment, as appropriate, is then contacted with an organic liquid to obtain a further polyester fragment, which in turn is converted into a plurality of polyester solids. One or more textile chemicals present in the first polyester fragment are at least partially removed by these steps, so that the further polyester fragment comprises less textile chemicals than the first polyester fragment. The invention further includes a polyester product obtainable by this process, a device for treating a polyester fragment with the process and a use of polyester solids or products obtained by this process for a variety of purposes.
[0017] BRIEF DESCRIPTION
[0018] A contribution to the at least partial achievement of at least one of the aforementioned objectives is provided by the subject-matter of the independent claims. The features disclosed in the claims, the specification, and the drawings may be essential for different embodiments of the claimed invention, both separately and in any combination with each other.
[0019] A contribution to the at least partial achievement of at least one of the aforementioned objectives is provided by the subject-matter of the following embodiments labelled |1| etc.. 111 A process for producing a polyester product, the process comprising the following steps: a. Providing a first polyester fragment; b . Optionally subj ecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. Contacting the first or second polyester fragment with a sequence S of one or more organic liquids to obtain a further polyester fragment; d. Converting the further polyester fragment into a plurality of polyester solids; wherein the first polyester fragment comprises at least 50 wt.-% of a polyester polymer, preferably at least 80 wt. %, more preferably at least 90 wt. %; wherein the first polyester fragment comprises a textile chemical different from the polyester polymer; wherein the further polyester fragment comprises less of the textile chemical than does the first polyester fragment; wherein, for the following organic liquid criteria i. to iv., criterion i. is satisfied by at least one member of S, criterion ii. is satisfied by at least one member of S, and criteria iii. and iv. are both satisfied by all members of S: i. Capacity to dissolve silicone at 130 °C according to the test method herein; ii. Capacity to dissolve a dye at 130 °C characterised by a maximum absorption Amaxof at least 2, preferably at least 2.3, more preferably at least 2.5, more preferably still at least 2.8 according to the test method herein; iii. A polyester dissolving ability at 130 °C, determined according to the test method herein, of not more than 8 mg / ml, preferably not more than 5 mg / ml, more preferably not more than 2 mg / ml, more preferably still not more than 1 mg / ml, more preferably still not more than 0.5 mg / ml, more preferably still not more than 0.1 mg / ml, values perhaps being as low as 0.001 mg / ml; iv. A boiling point not less than 130 °C.
[0020] In one aspect of this embodiment, the set S comprises a member satisfying criteria i.-iv.. In one aspect of this embodiment, the set S has a single member satisfying criteria i.-iv.. In one aspect of this embodiment, the set S comprises a first member satisfying criteria i., iii. and iv. and a second member satisfying criteria ii., iii. and iv.. In one aspect of this embodiment, the set S has two members, the first member satisfying criteria i., iii. and iv. and the second member satisfying criteria ii., iii. and iv..
[0021] |2| The process according to embodiment |1|, wherein the polyester polymer of has a glass transition temperature Tgand one or more of the members of S, preferably each member of S, has a boiling point above Tg, preferably by at least 5 K, more preferably by at least 10 K In one aspect of this embodiment, Tgis the highest glass transition temperature for the first polyester fragment or second polyester fragment.
[0022] |3| The process according to embodiment |1| or |2|, wherein one or more of the members of S comprises two or more liquid organic components, each in an amount of at least 10 wt. %, preferably at least 20 wt. %, more preferably at least 30 wt. %, and each liquid organic component satisfying criteria iii. and iv..
[0023] In one aspect of this embodiment, the two or more liquid organic components are present as a mixture.
[0024] |4| A process for producing a polyester product, the process comprising at least the following process steps: a. Providing a first polyester fragment; b. Optionally subjecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. Contacting the second polyester fragment with an organic liquid, the organic liquid comprising a group C of organic liquid components, to obtain a further polyester fragment; d. Converting the further polyester fragment into a plurality of polyester solids; wherein the first polyester fragment comprises at least 50 wt.-% of a polyester polymer, preferably at least 80 wt. %, more preferably at least 90 wt. %; wherein the first polyester fragment comprises a textile chemical different from the polyester polymer; wherein the further polyester fragment comprises less of the textile chemical than does the first polyester fragment; wherein, for the following organic liquid criteria i. to iv., criterion i. is satisfied by at least one member of C, criterion ii. is satisfied by at least one member of C, and criteria iii. and iv. are both satisfied by all members of C: i. Capacity to dissolve silicone at 130 °C according to the test method herein; ii. Capacity to dissolve a dye at 130 °C characterised by a maximum absorption Amaxof at least 2, preferably at least 2.3, more preferably at least 2.5, more preferably still at least 2.8 according to the test method herein; iii. A polyester dissolving ability at 130 °C, determined according to the test method herein, not more than 8 mg / ml, preferably not more than 5 mg / ml, more preferably not more than 2 mg / ml, more preferably still not more than 1 mg / ml, more preferably still not more than 0.5 mg / ml, more preferably still not more than 0.1 mg / ml, values perhaps being as low as 0.001 mg / ml; iv. A boiling point not less than 130 °C, preferably not less than 140 °C, more preferably not less than 150 °C.
[0025] In one aspect of this embodiment, the set C comprises a member satisfying criteria i.-iv.. In one aspect of this embodiment, the set C has a single member satisfying criteria i.-iv.. In one aspect of this embodiment, the set C comprises a first member satisfying criteria i., iii. and iv. and a second member satisfying criteria ii., iii. and iv.. In one aspect of this embodiment, the set C has two members, the first member satisfying criteria i., iii. and iv. and the second member satisfying criteria ii., iii. and iv.. In one aspect of this embodiment, one or more, preferably all, of the organic liquid components is each an organic compound.
[0026] |5| The process according to embodiment |4|, wherein the polyester polymer has a glass transition temperature Tgand one or more of the members of C, preferably each member of C, has a boiling point above Tg, preferably by at least 5 K, more preferably by at least 10 K. In one aspect of this embodiment, Tgis the highest glass transition temperature for the first polyester fragment or second polyester fragment.
[0027] |6| A process for producing a polyester product, the process comprising the following process steps: a. Providing a first polyester fragment; b. Optionally subjecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. Contacting the first or second polyester fragment with an organic liquid to obtain a further polyester fragment; d. Converting the further polyester fragment into a plurality of polyester solids; wherein the first polyester fragment comprises at least 50 wt.-% of a polyester polymer, preferably at least 80 wt. %, more preferably at least 90 wt. %; wherein the first polyester fragment comprises a textile chemical different from the polyester polymer; wherein the further polyester fragment comprises less of the textile chemical than does the first polyester fragment wherein the organic liquid comprises a first organic component having one or more rings, each ring comprising at least one C atom. In one aspect of this embodiment, the organic liquid has the features laid out in one of the preceding embodiments.
[0028] |7| The process according to embodiment |6|, wherein the first organic liquid component has: a. One or more rings of C atoms; b. One or more rings of C atoms with one or more, but not all, of the C atoms in the ring each replaced by an atom independently selected from the group consisting of O, N, S & P; or c. both a. and b..
[0029] |8| The process according to embodiment |6| or |7|, wherein the first organic liquid component comprises: a. An optionally substituted cycloaliphatic ring, b. An optionally substituted aromatic ring, c. An optionally substituted heteroarene ring, d. An optionally substituted hetero cycloaliphatic ring, or e. Two or more independently selected from a. to d; the optional substitution being of non-ring atoms. |9| The process according to any of the embodiments |6| to |8|, wherein at least half of the atoms in the first organic liquid component are independently selected from the group consisting of C and H, any remainder being heteroatoms independently selected from the group consisting of: F, Cl, Br, I, S, O, N, and P.
[0030] 110| The process according to any of the embodiments |6| to |9|, wherein the first organic liquid component is a cycloaliphatic compound, aromatic compound, heteroarene compound or hetero cycloaliphatic compound, optionally functionalised with one or more groups independently selected from the group consisting of: an alkyl group, a halogen group, an ester group, a phenolic group, a hydroxyl group, an ether group, a ketone group, an aldehyde group, an amine group, an amide group, a carboxyl group, a sulfonic acid group, a phosphate group, a phosphoric acid group and a sulfoxide group.
[0031] 1111 The process according to any of the embodiments |6| to 110|, wherein the first organic liquid component comprises an optionally substituted benzene ring, the substitution being of nonring atoms.
[0032] 112| The process according to any of the embodiments |6| to 1111, wherein the first organic liquid component is benzene, optionally functionalised with one or more items independently selected from the group consisting of: an alkyl group, a halogen group, an ester group, a phenolic group, a hydroxyl group, an ether group, a ketone group, an aldehyde group, an amine group, an amide group, a carboxyl group, a sulfonic acid group, a phosphate group, a phosphoric acid group and a sulfoxide group. Preferred functionalised benzenes are o- xylene, m-xylene, p-xylene, chlorobenzene, bromobenzene and iodobenzene. In one aspect of this embodiment, the organic liquid comprises two or more xylene isomers.
[0033] |13| The process according to any of the embodiments |6| to |12|, wherein the first organic liquid compound is a hydrocarbon which is once or more halogenated. The halogen is preferably F, Cl, Br or I, preferably Cl, Br or I, more preferably Cl or Br, most preferably Cl. A preferred halogenated hydrocarbon is chlorobenzene. 114| The process according to any of the preceding embodiments, wherein the first polyester fragment comprises the textile chemical in an amount in the range of 0.01 to 20 wt.-%, based on the total weight of the first polyester fragment, preferably in the range from 0.5 to 10 wt. %, more preferably in the range from 1 to 8 wt. %.
[0034] 115| The process according to any of the preceding embodiments, wherein the textile chemical is selected from the group consisting of a dye, a finisher, a softener, or a combination of at least two thereof.
[0035] |16| The process according to any of the preceding embodiments, wherein the first polyester fragment is one of a plurality of two or more polyester fragments, the plurality of polyester fragments meeting one or more of the following criteria: a. A d50maximum length in the range of 300 to 600 mm, preferably in the range from 325 to 575 mm, more preferably in the range from 350 to 550 mm; b. A GSM in the range of 30 to 400 g / m2, more preferably in the range of 50 to 350 g / m2, and even more preferably in the range of 100 to 250 g / m2; c. Comprises two or more fibres; d. An intrinsic viscosity (IV) in the range of 0.4 to 1.4, more preferably in the range of 0.5 to 1.2, and even more preferably in the range of 0.6 to 1.1; e. Bulk density in the range of 0.01 to 0.75 g / cm3, preferably in the range from 0.15 to 0.7 g / cm3, more preferably in the range from 0.2 to 0.6 g / cm3.
[0036] These criteria may be satisfied in various combinations, preferably selected from the group consisting of: a., b., a.+b., c., a.+c., b.+c., a.+b.+c., d., a.+d., b.+d., a.+b.+d., c.+d., a.+c.+d., b.+c.+d., a.+b.+c.+d., e., a.+e., b.+e., a.+b.+e., c.+e., a.+c.+e., b.+c.+e., a.+b.+c.+e., d.+e., a.+d.+e., b.+d.+e., a.+b.+d.+e., c.+d.+e., a.+c.+d.+e., b.+c.+d.+e. and a.+b.+c.+d.+e.
[0037] |17| The process according to any of the preceding embodiments, wherein the polyester polymer comprises an amorphous domain; wherein the polyester polymer attains a temperature as high as or exceeding its glass transition temperature Ts, preferably by at least 5 K, more preferably by at least 10 K. |18| The process according to embodiment |17|, wherein the polyester polymer attains a temperature exceeding its glass transition temperature 7g by not more than 90 K, preferably not more than 85 K, more preferably not more than 80 K.
[0038] |19| The process according to any of the preceding embodiments, wherein the polyester polymer comprises a crystalline domain; wherein the polyester polymer attains a temperature not as high as its crystallization temperature Tc.
[0039] |20| The process according to any of the preceding embodiments, wherein the polyester polymer has not exceeded its melting temperature Tm.
[0040] |211 The process according to any of the preceding embodiments, wherein the heat treatment is performed in a heat treatment zone, and wherein the Contacting in step c. is performed in a contacting zone downstream to the heating zone.
[0041] |22| The process according to embodiment |21|, wherein the contacting zone has an at least 2 times higher concentration of organic liquid than the heating zone.
[0042] |23| The process according to any of the preceding embodiments, wherein the heat treatment meets least one or all of the following criteria:
[0043] (A) Involves a gas flow;
[0044] (B) Involves relative moving the first polyester fragments to each other, preferably by tumbling, mixing or turning;
[0045] (C) Requires a residence time of the first polyester fragment in the range of 1 to 6000 s, preferably in the range from 10 to 5000 s, more preferably in the range from 50 to 3000 s;
[0046] (D) Requires a temperature in the range of 80 to 260 °C, preferably in the range from 100 to 200 °C, more preferably in the range from 110 to 155 °C.
[0047] In one aspect of this embodiment, the above criteria are satisfied in one of the following combinations: (A), (B), (A)+(B), (C), (A)+(C), (B)+(C), (A)+(B)+(C), (D), (A)+(D), (B)+(D), (A)+(B)+(D), (C)+(D), (A)+(C)+(D), (B)+(C)+(D) and (A)+(B)+(C)+(D). |24| The process according to any of the preceding embodiments, wherein one or more of the organic liquids employed in step c. meets at least one or all of the following criteria:
[0048] (I) Has a boiling point at least 1 K above Tgof the polyester polymer; or
[0049] (II) Has a boiling point below the melting temperature of the polyester polymer.
[0050] |251 The process according to any of the preceding embodiments, wherein at least a part of one or more of the organic liquids employed in step c. is recovered after the contacting and returned into the contacting.
[0051] |26| The process according to any of the preceding embodiments, wherein one or more of the organic liquids employed in step c. comprises at least 30 wt. %, based on the total mass of the organic liquid, an organic molecule having a ring with at least one C atom, preferably at least 40 wt. %, more preferably at least 50 wt. %.
[0052] |27| The process according to any of the preceding embodiments, wherein the concentration of the textile chemical is increased in one or more of the organic liquids employed in step c. is increased by the contacting.
[0053] |28| The process according to any of the preceding embodiments, wherein the concentration of the textile chemical in one or more of the organic liquids employed in step c. is decreased.
[0054] |29| The process according to the preceding embodiment, wherein the decrease is obtained by an absorption means.
[0055] |30| The process according to the preceding embodiment, wherein the absorption means is selected from the group consisting of a carbon particle, a silicon oxide particle, an ion exchange resin or at least two thereof.
[0056] |311 The process according to any of the preceding embodiments, wherein one or more of the organic liquids employed in step c. is at least partly removed prior to the conversion. |32| The process according to any of the preceding embodiments, wherein shear or heat or both is applied in the conversion.
[0057] |33| The process according to any of the preceding embodiments, wherein the plurality of polyester solids is selected from the group consisting of chips, beads, flakes, pellets, fibres or a combination of at least two thereof.
[0058] |34| The process according to any of the preceding embodiments, wherein the process comprises as additional process steps: e. Subjecting the polyester solids to a de-esterification reaction to obtain a deesterification product; f. Optionally, subjecting the de-esterification product to a purification to obtain a purified de-esterification product; g. Subjecting the de-esterification product, or the purified de-esterification product, to an esterification reaction or other chemical modification or keeping the de- esterification product.
[0059] |351 The process according to the embodiment 35, wherein the de-esterification product has an
[0060] IV in the range of 1.3 to 0.005, for example of 0.6 to 0.05, or of 0.2 to 0.01.
[0061] |36| The process according to any of the preceding embodiments, wherein the polyester product has an IV in the range of more than 0.6 to 1.4, for example from 0.4 to 1.0 mPa s, or from 0.6. to 0.9. mPa s.
[0062] |37| The process according to any of the preceding embodiments, wherein the polyester product is a homo polymer, a co-polymer or both.
[0063] |38| The process according to any of the preceding embodiments, wherein the polyester product is selected from the group consisting of a flake, a pellet, a chip, a container, a yam, a fibre, a textile, a film or at least two thereof. |39| The process according to any of the preceding embodiments, wherein at least 20 wt.-% of the textile chemical is a dye, preferably at least 25 wt.-%, more preferably at least 30 wt.- %.
[0064] |40| The process according to the preceding embodiments, wherein the dye is selected from the group consisting of: an azo dye, an anthraquinone dye, a phthalocyanine dye, a reactive dye, a disperse dye, a direct dye, a vat dye, a sulphur dye, a cationic / basic dye, an acid dye, a solvent dye and a mordant dye, preferably a disperse dye.
[0065] |411 The process according to any of the preceding embodiments, wherein at least 50 wt.-% of the textile chemical is a finisher, wherein the finisher is a polymer comprising at least one repeating unit which has no ester group.
[0066] |42| The process according to the preceding embodiment, wherein the finisher is one or more selected from the group consisting of: a silicone, a polyacrylate, a polyurethane, a fluorochemical, a spin finish oil, a coning oil and a surfactant.
[0067] |431 A use of an organic liquid or a sequence of organic liquids S recited in any of the preceding embodiments for improving the recycling of a polyester polymer textile.
[0068] |44| A device for treating a polyester fragment, comprising a moving means adapted and arranged i. to move two or more limp textile fragments, ii. to pass a gas and a liquid through the two or more limp textile fragments; wherein the moving means connects at least the following zones: iii. A feeder zone, adapted and arranged to receive the two or more polyester fragments, iv. A heat treatment zone, adapted and arranged to heat the two or more limp textile fragments, v. A contacting zone, adapted and arranged to contact the two or more limp textile fragments with one or more organic liquids, each comprising an organic compound having a ring with at least one C atom, vi. Optionally a drying zone, adapted and arranged to remove at least a part of the organic liquid from the two or more polyester fragments, and vii. A converting zone, adapted and arranged to shear the two or more limp textile fragments.
[0069] |45| The device according to embodiment |44|, wherein a de-esterification zone is arranged downstream to the converting zone, which is adapted and arranged to reduce the molecular weight of a polyester.
[0070] |46| The device according to the embodiment |45|, wherein an esterification zone is arranged downstream to the de-esterification zone, which is adapted and arranged to increase the molecular weight of a polyester.
[0071] |47| The process according to any of the embodiments |1| to |42|, wherein the process is performed in a device according to any of the embodiments |44| to |46|.
[0072] |48| A polyester product, obtainable by a process according to any of the embodiments |1| to |42| or |47|.
[0073] |49| A use of a plurality of polyester solids obtainable by a process comprising the following process steps: a. Providing a first polyester fragment; b. Optionally subjecting the first polyester fragment to a heat treatment to obtain a second polyester fragment; c. Contacting the first or second polyester fragment or second polyester fragment with one or more organic liquids, each comprising an organic compound having a ring with at least one C atom to obtain a further polyester fragment; d. Converting the further polyester fragment into the plurality of polyester solids; for a purpose selected from the group consisting of: a chemical modification or a forming or both. Preferred chemical modifications are one or more selected from the group consisting of: a functionalization, a de-esterification, an esterification. Preferred formed bodies are one or more selected from the group consisting of: a fibre, a textile, a container and a film. DETAILED DESCRIPTION
[0074] A first embodiment of the invention is a process for producing a polyester product, the process comprising the following process steps: a. Providing a first polyester fragment; b. Optionally subjecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. Contacting the first polyester fragment or the second polyester fragment with one or more organic liquids to obtain a further polyester fragment; d. Converting the further polyester fragment into a plurality of polyester solids; wherein the first polyester fragment comprises at least 50 wt.-% of a polyester polymer; wherein the first polyester fragment comprises a textile chemical different from the polyester polymer; wherein the further polyester fragment comprises less of the textile chemical than does the first or the second polyester fragment.
[0075] A preferred organic liquid comprises one or more organic compounds, preferably a total of at least 50 wt. % of organic compounds, more preferably at least 80 wt. %, more preferably still at least 90 wt. %, more preferably still at least 99 wt. %. One embodiment of an organic liquid is a single organic compound, preferably present in an amount of at least 50 wt. %, more preferably at least 80 wt. %, more preferably still at least 90 wt. %, more preferably still at least 99 wt. %. One embodiment of an organic liquid comprises 2 organic compounds, preferably present in an total amount of at least 50 wt. %, more preferably at least 80 wt. %, more preferably still at least 90 wt. %, more preferably still at least 99 wt. %. A preferred organic liquid may comprise non-organic compounds, preferably in an amount less than 50 wt. %, more preferably less than 20 wt. %, more preferably still less than 10 wt. %, more preferably still less than 1 wt. %
[0076] In one embodiment, the contacting step c. is performed with a single organic liquid. In another embodiment, the contacting step c. is performed with two or more organic liquids, preferably 2 to 5 organic liquids, more preferably 2 to 4 organic liquids, more preferably still 3 or 4 organic liquids, more preferably 2 organic liquids. In the case that more than 1 organic liquid is employed they are preferably employed sequentially.
[0077] In the present context, the term “fragments” refers to pieces which are obtained by fragmenting an item. The item can be any item known to and considered useful for the present invention by a skilled person. The item can be any material, such as textiles, fabrics, fleeces, sheets, films, flakes and yams, preferably textiles, fabrics, fleeces, sheets, films, and yams. In another aspect flakes are preferred. Preferably, the item is a limp material. A limp item in the present context is an item which is dimensionally unstable when low forces are applied, which has a low stiffness and thus, large deformations result from low forces or loads. Often, limp is associated as a property of an item having an overall bending rigidity of less than 0.2 gf cm2 / cm (less than or equal to 3.5 10'5J). Bending rigidity is preferably determined according to the heart loop method laid out in Kara, S. Tekstil ve Konfeksiyon, 31(2), Year 2021, 82-90. A preferred item has a bulk density below 200 kg / m3. Bulk density is preferably determined according to DIN EN ISO 60 (1999). A preferred item is shape conformable, preferably conforming to the shape of a supporting solid under its own weight.
[0078] When referring to a “fragment”, not necessarily a one and only fragment is meant. Moreover, this term may include pluralities of fragments. Fragment refers to a piece and implies that this piece is result of an action which makes many pieces out of a single one. Some examples of such actions are shredding, chopping, slicing, cutting, milling and breaking.
[0079] A first polyester fragment is provided as a feed material. The feed may include material from any source known by a skilled person and considered suited to be used in the present invention. For example, the polyester fragment can be a polyester used before by a consumer or commercial, so- called waste. It can also be composed of a share of used polyester fragments and another share of virgin polyester fragments. “Virgin” in the present context refers to material which has been manufactured but not yet used. E.g., such a product has been manufactured from starting materials which do not commence from recycling, and converted into a fabric, which again has been converted into a cloth. The cloth, however, has not been worn or used otherwise by a consumer.
[0080] A “fragment” of a first polyester preferably has physical dimensions (e.g., length, width, thickness) that are all below an upper value. It is preferred that this upper value is less than 50 cm, more preferably less than 30 cm, and further preferably less than 20 cm. An example of a plurality of “fragments” are PET textile fragments of PET flakes, which are well-known to the skilled person employed in the technical field of recycling, preferably textile fragments.
[0081] A “first dimension” of a fragment should preferably be understood to mean either the width, the length, or both, of the fragment. A “length” of a fragment should preferably be understood as referring to the largest dimension of the fragment. A “width” of a fragment should preferably be understood as referring to the second largest dimension of the fragment. A “thickness” of a fragment should preferably be understood as referring to the smallest dimension of a fragment.
[0082] In a preferred aspect of the invention, the geometric shape of the fragments is not limited. A preferred shape is a lamella shape. A preferred lamella shape has a length, width and thickness, the length and width each being at least 2 times the thickness, preferably at least 5 times, more preferably at least 10 times. A preferred lamella can be based on a polygonal 2-dimensional shape or a non-polygonal 2-dimensional shape. The preferred polygonal 2-dimensional shape is foursided.
[0083] In an embodiment, the first polyester fragment may comprise at most 90 wt.-% of waste polyester and at least 10 wt.-% of virgin polyester, for example from 40 to 90 wt.-%, or from 50 to 90 wt.- %, or from 50 to 80 wt.-%, or from 40 to 85 wt.-% of waste polyester, while the remainder to 100% is virgin polyester, the wt.-% always based on the total amount of first polyester fragment provided. Further, the composition of first polyester fragment provided in step a. may vary over time, in particular when referring to a continuous process, or from batch to batch for discontinuous processing.
[0084] The polyester be any polyester known to and considered useful for the present invention by a skilled person. Examples of suited polyester are aliphatic, cycloaliphatic, and aromatic polyesters, as well as co-poly esters, polyester-co-polymers and any other kind of feed comprising polyester.
[0085] Examples of aliphatic polyesters are polylactide or polyglycolic acid, or both. Examples of cycloaliphatic polyesters are based on cyclohexanedimethanol.
[0086] Examples of aromatic polyester are polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate; polyethylene naphthalate; polycarbonate; polyester carbonate; polyester resin. Examples of aromatic co-polyesters are polyesters containing co-monomers selected from the group consisting of cyclohexanedimethanol (CHDM), diethylene glycol (DEG), oligo ethylene glycol (OEG), isophthalic acid (IP A), or a combination of at least two thereof.
[0087] Examples of aromatic polyester-copolymers are poly(ester-amide), poly(ester-ether), or both.
[0088] In a preferred embodiment of the process, the first polyester has a density in the range of 1.25 g / cm3to 1.55 g / cm3, more preferably in the range of 1.28 g / cm3to 1.50 g / cm3, and further preferably in the range of 1.31 g / cm3to 1.47 g / cm3. Densities of the first polyester are well-known in the art, and can be found, e.g., C. A. Harper, Modern Plastics Handbook: Handbook, McGraw- Hill Professional, New York, 2000, and at https: / / en.wikipedia.org / wiki / Polyethylene_terephthalate.
[0089] In an aspect of this embodiment, examples of the first polyester are amorphous PET with a density in the range of 1.33 g / cm3to of 1.39 g / cm3, and single crystal PET with a density of 1.455 g / cm3. In a preferred embodiment of the process, the first polyester, in particular in form of a plurality of fragments, has a bulk density in the range of 0.01 g / cm3to 0.75 g / cm3, more preferably in the range of 0.15 g / cm3to 0.65 g / cm3, even more preferably in the range of 0.18 g / cm3to 0.50 g / cm3, further preferably in the range of 0.20 g / cm3to 0.40 g / cm3and even further preferably in the range of 0.22 g / cm3to 0.37 g / cm3.
[0090] Further, the first polyester fragment may comprise two or more different polyester, as well as up to 20 wt.-%, for example 15 wt.-% or less, for example 10 wt.-% or less, for example 5 wt.-% or less, or 2 wt.-% or less of plastics different from the polyester.
[0091] In any way, the first polyester fragment comprises at least 50 wt.-%, for example 55, 60, 65, 70, 75, 80, 85, 90 or at least 95 wt.-% of polyester polymer, the wt.-% based on the total amount of first polyester fragment. Often, the first polyester fragment comprises less than 5, for example 3 or 1 wt.-% of non-polyester, the wt.-% based on the total amount of first polyester fragment. Nonpolyester can be any material which is not a polyester.
[0092] In an embodiment of the process, the first polyester fragment may meet at least one, preferably two or more, or even all of the following criteria: (a) A d50maximum length in the range of 300 to 600 mm;
[0093] (b) A GSM in the range of 30 to 400 g / m2, more preferably in the range of 50 to 350 g / m2, and even more preferably in the range of 100 to 250 g / m2;
[0094] (c) Comprises two or more fibres;
[0095] (d) An intrinsic viscosity (IV) in the range of 0.4 to 1.4, more preferably in the range of 0.5 to
[0096] 1.2, and even more preferably in the range of 0.6 to 1.1;
[0097] (e) Bulk density in the range of 0.01 to 0.75 g / cm3.
[0098] The d50maximum length is the d50value for the largest extension of the fragment.
[0099] From the above list, the first polymer fragment may be characterized by a combination of any one of these list elements: (a), (b), (a)+(b), (c), (a)+(c), (b)+(c), (a)+(b)+(c), (d), (a)+(d), (b)+(d), (a)+(b)+(d), (c)+(d), (a)+(c)+(d), (b)+(c)+(d), (a)+(b)+(c)+(d), (e), (a)+(e), (b)+(e), (a)+(b)+(e), (c)+(e), (a)+(c)+(e), (b)+(c)+(e), (a)+(b)+(c)+(e), (d)+(e), (a)+(d)+(e), (b)+(d)+(e),
[0100] (a)+(b)+(d)+(e), (c)+(d)+(e), (a)+(c)+(d)+(e), (b)+(c)+(d)+(e) or (a)+(b)+(c)+(d)+(e).
[0101] The first polyester fragment can be of any physical constitution, for example at least one selected from the group consisting of films, fibers, yarns, fabric, textiles, sheet, or a combination of two or more thereof.
[0102] The polyester constituting the first, second and further polyester fragment is a semicrystalline polymer. Semicrystalline means that a fragment of the polyester has crystalline regions and other which are not crystalline, i.e. amorphous. Crystalline regions are characterized in that the polymer is arranged in a parallel, structured packing. Amorphous regions are those in which no structural organization is observed. This is schematically shown in Fig. 2. It can be determined by DSC analysis, as detailed in the test method herein. The extent of crystallinity and / or amorphousness of a sample of polyester can be determined by various analytical methods.
[0103] DSC analysis is preferably performed according to the test method described herein. When using a DSC, the so-called thermogram of a sample delivers useful information. To record a thermogram, a sample is put in a special crucible and heated at a given heating rate from a low temperature to above its melting temperature, while difference in temperature measured for this sample is compared against an empty crucible. The DSC produces an Enthalpy in J / g vs. Temperature plot. An exemplary plot for polyethylene terephthalate is shown in Fig. 3. Typically, a glass transition temperature Tgis found in a range of 70 to 90 °C, a crystallization temperature Tcin the range of 120 to 200 °C, and a melting temperature Tmin the range of 240 to 260 °C. AHmois the standard heat of melting of 100% crystalline PET and is typically in the range from about 120 to about 140 J / g, as is known from the literature (see Panowicz, R.; Konarzewski, M.; Durejko, T.; Szala, M.; Lazinska, M.; Czerwinska, M.; Prasula, P. Materials, 2021, 14, 3833-3848). The melting enthalpy AHmis obtained by calculating the area under the melt signal and a baseline fit from onset to onset. Similarly, the heat of crystallization AHCis calculated. The degree of crystallinity, expressed as % crystallinity can be calculated this way:
[0104] The glass transition temperature Tgis the temperature at which a softening of a solid semicrystalline or an amorphous polymer occurs. By definition, a Tgis by a step in the baseline of the measurement curve (Fig. l). It is characterized by its onset, peak, inflection and end temperature. Tgis defined at the intersection between the curve and half height of the step. The evaluation procedure is described in e.g., ISO 11357.
[0105] The crystallization temperature Tcis the temperature at which some polymers re-crystallize. With PET, this is where amorphous regions organize to crystals. The temperature is defined as the maximum of an exothermic peak.
[0106] The melt temperature Tmin the context of the present invention is the temperature at the maximum of an endothermic peak. This is, where the whole sample is in melt form and no crystalline or other solids remain.
[0107] In an embodiment of the process, the first polyester fragment comprises at least one textile chemical in an amount in the range of 0.01 to 20 wt.-%, based on the total weight of the first polyester fragment. For example, the amount of textile chemical can be from 0.5 to 15, or 2 to 14, or 2.5 to 9 wt.-%.
[0108] In an embodiment of the process, the textile chemical may be at least one element selected from the group consisting of a dye, a finishing, such as a softener, a coating, a print, a pigment, adhesives, or a combination of at least two thereof. Preferably the textile chemical may be a dye, or a finisher or both, more preferably a dye. This includes two or more elements of the same group, but may as well refer to elements from different groups. Often, the textile chemical is a package comprising several elements from different groups, for example three dyes, a finisher and two softeners.
[0109] Each of these group of the above elements may include a variety of different kinds of chemical compounds. It is understood by a skilled person that the above indications are for exemplary purposes, since the number of possible variations is unlimited. However, a skilled person knows when evaluating a polyester waste as a feed material, whether this waste and its components are suited to be processed.
[0110] In an embodiment of the process, at least 50 wt.-%, for example 55, 60, 65, 70, 75, 80 or at least 85 wt.-% of the textile chemical is one or more finishers, wherein the one or more finishers are polymers, each comprising at least one repeating unit which has no ester group. The wt.-% are based with regard to the total amount of the textile chemical. Typically, finishers are applied or are present on the fibre used in or to prepare a fabric. Accordingly, it is preferred that the concentration of the finisher is higher on the fibre than on the fabric made out or using a plurality of the fibres comprising the finisher. Also, typically, coatings are applied or are present on the fabric or textile but not in or on the fibre used in or to prepare a fabric. Thus, it is preferred that the concentration of the coating is higher on the fabric than on or in the fibre used to make the fabric.
[0111] Usually, prints are understood to comprise a colorant, like a dye or a pigment or both, and a matrix, preferably an organic matrix, more preferably a resin. It is preferred that the matrix contains the dye or the pigment or both. Prints are present in the first polyester fragment, wherein the concentration of the print on polyester fragment and thus preferably on the fabric or textile, is higher than in the polyester fragment and preferably higher than in the fibres of the polyester fragment and in particular the fabric or textile. It is quite often observed that the print is present as a colorant coating on the surface of the polyester fragment and preferably on the fabric or textile. In many cases, prints are applied on a polyester fragment, preferably a fabric or a textile, in form of a liquid or paste and then cured, by heat treatment, IR treatment, UV treatment, or the like, in order to harden the precursor of the matrix to form the matrix. Often, a pigment is present on the polyester fragment in form of particles. A typical d50particle size of these pigment particles is in the range of 0.01 to 15 pm. Usually, pigments are applied on a textile fragment, in particular on a fabric or textile, in a dispersion. In this context it is preferred that the pigments are dispersed in a matrix, preferably the above-mentioned matrix.
[0112] This finisher can be any which is known by and considered suited as a finisher for a polyester polymer by skilled person. Examples of finishers are molecules comprising at least one repeating unit which has no ester group. Typically, a finisher is selected from the group consisting of silicones, polyacrylates, polyurethanes (each of these polymers independently of each other, with or without any pendant groups such as amino, amido or epoxy, or at least two thereof), fluorochemicals (preferably fluorosurfactants, fluoropolymers, or both), spin finish oil, coning oil, surfactants, or a combination of at least two thereof. The previously mentioned polymer classes could be also on out of more sections or branches of a copolymer. The finish typically imparts certain functionality or added property to or onto the polyester fragment, such as the fibre or fabric. Preferably, such functionality or property is selected from the group consisting of water repellency, moisture management, flame retardancy, anti-slip, anti-static, wrinkle-free, softening, moth protection, or a combination of at least two thereof.
[0113] In the context of this invention, adhesives are organic compounds capable of connecting parts, such as fibres, present in the polyester fragments or on the polyester fragment. In the latter case, the adhesive may serve to connect two or more polyester fragments to a polyester fragment agglomerate. Examples of adhesives are selected from the group selected from the group of hot melts, preferably based on polyolefins, polyurethanes, polyacrylates, polyesters or a combination of at least two thereof, glues, limes, or a combination of at least two thereof. Typically, the Tmof an adhesive is at least 20 °C, more preferably at least 40 °C, and most preferably at least 60 °C, less than the Tmof the polyester fragment.
[0114] In an embodiment of the process, at least 10 wt.-%, for example 20, 30, 40, 50, 60, 70, 80 or at least 85 wt.-% of the textile chemical is one or more dyes, the wt.-% based with regard to the total amount of the textile chemical.
[0115] The dyes can be any which are known by and considered suited as dyes for a polyester polymer by a skilled person. Examples of suited dyes include, without being limited, azo dyes, anthraquinone dyes, phthalocyanine dyes, reactive dyes, disperse dyes, direct dyes, vat dyes, sulphur dyes, cationic / basic dyes, acid dyes, solvent dyes, mordant dyes, etc; preferably disperse dyes. In general dyes, in particular disperse dyes, are typically identified by their colour index (C.I.) nomenclature and include C.I. Compounds classified according to the colour they impart such as C.I. Disperse Black, C.I. Disperse Red, C.I. Disperse Blue, C.I. Disperse Orange, C.I. Disperse Yellow, C.I. Disperse Green, C.I. Disperse Violet, C.I. Disperse Brown, or a combination of two or more thereof. A textile may contain either one or more than one of the above mentioned disperse dyes. Similarly, the pigments which may act as colorants include compounds identified by C.I. nomenclature and include compounds classified according to the colour, they impart such as C.I. Pigment Black, C.I. Pigment Red, C.I. Pigment Blue, C.I. Pigment Orange, C.I. Pigment Yellow, C.I. Pigment Violet, C.I. Pigment Green, C.I. Pigment Brown, or a combination of two or more thereof. A textile may contain either one or more than one of the above-mentioned pigments. Further details regarding dyes can be obtained from the text book of Klaus Hunger, Industrial Dyes - Chemistry, Properties and Applications, 2003, Wiley VCH.
[0116] It can be often found in polyester fragments that either dye(s) or pigments(s) as such or a mixture of at least one dye and at least one pigment are employed in an amount in the range of 0.5 to 8 wt.- %, preferably in the range of 1.5 to 6 wt.-% and more preferably in a range of 2 to 5.5 wt.-%, each based on the total weight of the polyester fragment. It is also quite often observed in polyester fragments that either finisher(s) or coating(s) as such or a mixture of at least one finisher and at least one coating are employed in an amount in the range of 0.1 to 18 wt.-%, preferably in the range of 1.5 to 16 wt.-% and more preferably in a range of 6 to 14 wt.-%, each based on the total weight of the polyester fragment.
[0117] In an embodiment of the process, at least 20 wt.-%, for example 30, 40, 50, 60, 70, 80 or at least 85 wt.-% of the textile chemical is one or more softeners, the wt.-% based with regard to the total amount of the textile chemical.
[0118] The softener can be any which is known by and considered suited as softener for a polyester material by skilled person. With regard to typical examples of suited softeners reference is made to the materials and chemicals as well as formulation used as finishers, as disclosed herein above.
[0119] In an embodiment of the process, the polyester polymer comprises at least one, preferably two or more amorphous domains. In an embodiment of the process, the polyester polymer comprises at least one, preferably two or more amorphous domains, and the polyester polymer has a glass transition temperature Tgat a temperature in the range from 60 to 90 °C, for example from 65 to 85 °C, or from 70 to 80 °C.
[0120] In an embodiment of the process, the polyester polymer comprises at least one, preferably two or more crystalline domains, and the polyester polymer has a crystallization temperature Tcat a temperature in the range from 120 to 200 °C, for example from 140 to 190 °C, or from 160 to 185 °C.
[0121] In an embodiment of the process, the polyester polymer comprises at least one, preferably two or more amorphous domains and at least one, preferably two or more crystalline domains. The polyester polymer may have both,
[0122] {a} a glass transition temperature Tgat a temperature in the range from 65 to 95 °C, for example from 67 to 93 °C, or from 70 to 90 °C; and
[0123] {b}a crystallization temperature Tcat a temperature in the range from 120 to 200 °C, for example from 140 to 190 °C, or from 160 to 185 °C.
[0124] In an embodiment of the process, the polyester polymer a melting temperature Tmin the range from 230 to 270 °C, or from 240 to 260 °C.
[0125] The providing in step a. may be accomplished by any means known to and considered suited by a skilled person for the process of the invention. Usually, the providing is a disposing of a first polymer fragment into a device, in which at least a part of the process is performed.
[0126] In step b., which is optional, the first polyester fragment is subjected to a thermal treatment to obtain a second polyester fragment. The thermal treatment transfers heat to the first polyester fragment. This can be achieved by virtually any means of heat and transfer of heat known to a skilled person and considered suited, which does not cause any one or more of destruction, decomposition, degradation, side reactions, or depolymerization to the polyester fragment.
[0127] In an embodiment of the process the first polyester fragment is heated to obtain the second polyester fragment, wherein the polyester fragment attains a temperature as high as or exceeding the glass transition temperature of the polyester polymer in the polyester fragment. In an embodiment of the process the first polyester fragment is heated to obtain the second polyester fragment wherein the polyester polymer attains a temperature exceeding its glass transition temperature Tgby not more than 90 K, for example not more than 60 or 50 K. According to one aspect, it is preferred that said temperature remains below the boiling temperature Tbof the organic liquid, preferably at least 5 K, or 10 K or 15 K below said boiling temperature.
[0128] In an embodiment of the process the first polyester fragment is heated to obtain the second polyester fragment wherein the polyester polymer has not exceeded its melting temperature Tm.
[0129] In an embodiment of the process the heat treatment in step b. meets at least one, preferably two or more or even all of the following criteria:
[0130] (A) it involves a gas flow;
[0131] (B) it involves relative moving the first polyester fragments to each other;
[0132] (C) it requires a residence time of the first polyester fragments in the range of 1 to 6000 s, preferably 60 to 3000 s, and more preferably 300 to 900 s;
[0133] (D)it requires a temperature in the range of 80 to 260 °C.
[0134] The gas flow as in (A) may comprise one or more of the following gases: nitrogen, or ambient air. The gas flow my also employ compressed gas such as nitrogen, or nitrogen or ambient air.
[0135] Relative moving of the first polyester fragments to each other can be realized by any means known to and considered suited by a skilled person, such as, e.g. by conducting step (B) a tumbler, a rotary kiln, a screw, or a combination of two or more thereof. The first polyester fragments may be subjected to the heat treatment of step b. in the range from 1 to 6000 s, or from 60 to 3000 s, or from 300 to 900 s. The heat treatment in step b. may be conducted at a temperature in the range from 80 to 260 °C, or from 90 to 230 °C, or from 100 to 200 °C.
[0136] From the above list, heat treatment in step b. may be characterized by a combination of any one of these list elements: (A), (B), (C), (D); (A), (B), (C); (A), (B), (C); (A), (C), (D); (A), (B), (D); (A), (B); (C), (D); (A), (D); (B), (D); (A), (C).
[0137] According to the invention, the further polyester fragment comprises less of the textile chemical than does the first polyester fragment or second polyester fragment. In other words, step c. aims to reduce the amount of textile chemical in the polyester fragment. Without being bound to a theory or mechanism, it is assumed that this occurs due to evaporation, degradation, chemical conversion, reaction, extraction, washing out or any other process known to and considered possible by a skilled person.
[0138] In an embodiment of the invention, the amount of textile chemical in the second polyester fragment, preferably before contact of organic liquid, is in the range from 1 to 99 %, or from 15 to 85 %, or from 30 to 60 %, with regard to the amount of textile chemical in the first polyester fragment.
[0139] In step c., the first polyester fragment or the second polyester fragment is contacted with an organic liquid. Thereby a further polyester fragment is obtained. In general, the contacting in step c. can be performed by any means and technique, known to a skilled person and considered suited in the present invention. In an embodiment of the process, the contacting in step c. may comprise one or more of the following techniques: spraying, soaking, flushing, emerging or a combination of two or more thereof.
[0140] Upon contact, the organic liquid dissolves at least a part of the textile chemical of the first polyester fragment or the second polyester fragment thereby forming a further polyester fragment.. It is preferred that, if any, only small amounts of the polyester are lost in step c.. The total weight of polyester in the further polyester fragment is preferably not reduced by more than 10 %, more preferably not more than 5 %, most preferably not more than 1.5 % below that of the first or second polyester fragment in the contacting step.
[0141] According to one aspect of the invention it is preferred that concentration of polyester dissolved in the organic liquid when the contacting in step c. is finished is less than 20 wt.-%, preferably less than 15 wt.-%, more preferably less than 10 wt.-%, further preferred less than 7 wt.-%, moreover preferred less than 4 wt.-% and in particular preferred less than 1 wt.-%, each based on the total weight of organic liquid. It is preferred that the beforementioned soluble content of the polyester in the organic liquid is determined at 20°C.
[0142] According to one aspect of the invention it is preferred that the amount of organic liquid in step b. is lower than in step c. In this context it is preferred that the amount of organic liquid present in step b. is at least 2 times, preferably at least 10 times and more preferably at least 20 times lower than the amount of organic liquid present in step c. It is preferred that step b. is substantially or totally free of the organic liquid.
[0143] The boiling point of the organic liquid is at least 1 K, for example 2, 3, 4, 5 or 6 K above the Tgof the polyester polymer. The boiling point of the organic liquid may be as high as perhaps 350 K, for example 10, 40, 80, 100 or 200 K above the Tgof the polyester polymer.
[0144] The maximal solubility of the polyester in the organic liquid may be less than 4 %, preferably 3 % and more preferably less than 2 %, and most preferably less than 1 %, or less than 0.5 %.
[0145] In a further embodiment of the process, the contacting in step c. is performed at or below the boiling point of the organic liquid, for example at a temperature which is at least 1, 2, 3, 4, 5, 10 or 20 K below the boiling point of the organic liquid.
[0146] In an embodiment of the process at least a part of the organic liquid is recovered after the contacting and returned into the contacting, preferably following purification, such as absorption, distillation or a combination of both. A preferred distillation is performed at atmospheric pressure (0.101325 MPa) or at a reduced pressure. Preferably, the recovery can be achieved in subsequent step d., or independent from that.
[0147] In one embodiment, one or more organic liquids, or one or more components of one or more organic liquids, or a combination of both, satisfies the following criteria: i. A capacity to dissolve silicone at 130 °C according to the test method herein; ii. A dye dissolving ability at 130°C, determined according to the test method herein, characterised by a value of Amaxof at least 2, preferably at least 2.3, more preferably at least 2.5, most preferably at least 2.8.; iii. A polyester dissolving ability at 130°C, determined according to the test method herein, not more than 8 mg / ml, preferably not more than 5 mg / ml, more preferably not more than 2 mg / ml, more preferably still not more than 1 mg / ml, more preferably still not more than 0.5 mg / ml, more preferably still not more than 0.1 mg / ml, values perhaps being as low as 0.001 mg / ml; iv. A boiling point of at least 130 °C. The species to be tested in the criteria i. to iv. are test species defining the dissolving power of the organic liquid and are not necessarily present in the recited process.
[0148] Where the organic liquid has more than one boiling point, the boiling point in criterion iv. is one of the boiling points, preferably the lowest thereof.
[0149] In one embodiment, the organic liquid comprises an organic compound having one or more rings, each ring comprising at least one C atom. The organic liquid may comprise one such organic compound or two or more such organic compounds. The content of each such organic compound is preferably at least 25 wt. %, more preferably at least 50 wt. %, more preferably still at least 90 wt. %. The organic liquid may substantially or fully consist of such an organic compound. Where more than one such organic compound is present in the organic liquid, the total content of such organic compounds is preferably at least 25 wt. %, more preferably at least 50 wt. %, more preferably still at least 90 wt. %. The organic liquid may substantially or fully consist of such organic compounds.
[0150] One preferred class of organic compounds is cycloaliphatic compounds. Preferred rings in cycloaliphatic compounds are cyclobutane, cyclopentane, cyclohexane, cycloheptane and cyclooctane rings. A preferred unsubstituted cycloaliphatic compound is cyclooctane. Cycloaliphatic compounds may have one or more non-ring substitutions. Preferred substituted cycloaliphatic compounds are substituted cyclobutane, substituted cyclopentane, substituted cyclohexane, substituted cycloheptane and substituted cyclooctane. Preferred non-ring substitutions are one or more selected from an alkyl group, a halogen group, an ester group, a phenolic group, a hydroxyl group, an ether group, a ketone group, an aldehyde group, an amine group, an amide group, a carboxyl group, a sulfonic acid group, a phosphate group, a phosphoric acid group and a sulfoxide group. A preferred substitution is a hydroxyl group, an ether group, a ketone group or an aldehyde group. Preferred halogen groups are fluoro, chloro, bromo and iodo, more preferably fluoro or chloro. Non-ring substitutions can be spaced from the ring by a hydrocarbon section, such as an alkyl chain, which may be saturated or unsaturated. Non-ring substitutions are substitutions of species connected to the ring as opposed to substitution of atoms constituting the ring. Multiple non-ring substitutions can be present on the same ring atom or on different ring atoms in the same ring. One preferred cycloaliphatic compound is a cycloketone, preferably cyclohexanone. One preferred class of organic compounds is cycloaliphatic compounds in which one or more C atoms in the ring has / have been substituted with a heteroatom, preferably independently selected from the group consisting of O, S, N or P. Preferred hetero-aliphatic rings are based on cyclopropane, cyclobutane, cyclopentane, cyclohexane, cycloheptane and cyclooctane. Heterocycloaliphatic compounds may have one or more non-ring substitutions. Preferred non-ring substitutions are one or more selected from an alkyl group, a halogen group, an ester group, a phenolic group, a hydroxyl group, an ether group, a ketone group, an aldehyde group, an amine group, an amide group, a carboxyl group, a sulfonic acid group, a phosphate group, a phosphoric acid group and a sulfoxide group. A preferred substitution is a hydroxyl group, an ether group, a ketone group or an aldehyde group. Preferred halogen groups are fluoro, chloro, bromo and iodo, more preferably fluoro or chloro. Non-ring substitutions can be spaced from the ring by a hydrocarbon section, such as an alkyl chain. Non-ring substitutions are substitutions of species connected to the ring as opposed to substitution of atoms constituting the ring. Multiple non-ring substitutions can be present on the same ring atom or on different ring atoms in the same ring.
[0151] One preferred class of organic compounds is aromatic compounds. Preferred aromatic rings are benzene, anthracene and naphthalene. Aromatic compounds may have one or more non-ring substitutions. Preferred non-ring substitutions are one or more selected from an alkyl group, a halogen group, an ester group, a phenolic group, a hydroxyl group, an ether group, a ketone group, an aldehyde group, an amine group, an amide group, a carboxyl group, a sulfonic acid group, a phosphate group, a phosphoric acid group and a sulfoxide group. Non-ring substitutions can be spaced from the ring by a hydrocarbon section, such as an alkyl chain. Non-ring substitutions are substitutions of species connected to the ring as opposed to substitution of atoms constituting the ring. Multiple non-ring substitutions can be present on the same ring atom or on different ring atoms in the same ring. A preferred substitution is a chloride. One preferred set of aromatic compounds are those which are once or multiply substituted with a halogen. Preferred halogen groups are fluoro, chloro, bromo and iodo, more preferably fluoro or chloro. A preferred compound of this type is chlorobenzene. Another preferred set of aromatic compounds are those which have one or more small alkyl moieties, preferably one or more methyl moieties. One preferred compound of this type is xylene. Another preferred set of aromatic compounds are those with one or more ether groups. One preferred compound of this type is Anisole. One preferred class of organic compounds is hetero-arenes. Preferred hetero-arene rings have one or more hetero-atoms, preferably independently selected from the group consisting of O, S, N or P. Some preferred hetero-arenes are benzofuran, isobenzofuran, pyrrole, indole, isoindole, benzothiophene, benzo[c]thiophene, imidazole, benzimidazole, purine, pyrazole, indazole, benzoxazole, benzisoxazole, benzothiazole, quinoline, isoquinoline, quinoxaline, acridine, quinazoline, pyridazine, cinnoline, phthalazine, 1,2, 3 -triazine and 1,2,4-triazine. Hetero-aromatic compounds may have one or more non-ring substitutions. Preferred non-ring substitutions are one or more selected from an alkyl group a halogen group, an ester group, a phenolic group, a hydroxyl group, an ether group, a ketone group, an aldehyde group, an amine group, an amide group, a carboxyl group, a sulfonic acid group, a phosphate group, a phosphoric acid group and a sulfoxide group. Non-ring substitutions are substitutions of species connected to the ring as opposed to substitution of atoms constituting the ring. Multiple non-ring substitutions can be present on the same ring atom or on different ring atoms in the same ring. A preferred substitution is a hydroxyl group, a ketone group, an ether group or an aldehyde group. Preferred halogen groups are fluoro, chloro, bromo and iodo, more preferably fluoro or chloro. Non-ring substitutions can be spaced from the ring by a hydrocarbon section, such as an alkyl chain. Preferred organic compounds in this context preferably have a boiling point of at least 130 °C.
[0152] A further preferred class of organic compounds consists of combinations of rings from the preceding four classes. Rings can be fused together, linked directly through a single non-ring bond, or spaced by an intervening species, for instance by an alkyl spacer. An example of such a mixed compound is benzocyclobutene, which is an example of an aromatic ring fused to a cycloaliphatic ring. Another example is 2-benzyl cyclohexanone, in which an aromatic ring and a cycloaliphatic ring are spaced by a methylene spacer.
[0153] The organic liquid may further comprise an amount of a non-solvent with regard to the textile chemicals, for example water.
[0154] In an embodiment of the process the organic liquid comprises at least 30 vol.-%, for example at least 40, 50, 60 or at least 70 vol.%, based on the total volume of the organic liquid, an aromatic molecule, preferably a methyl substituted or halogenated aromatic molecule. A preferred halogenated aromatic molecule is chlorobenzene. Preferred methyl substituted aromatic molecules are mono-substituted or di-substituted. A preferred methyl substituted aromatic molecules is xylene.
[0155] In one embodiment, a preferred organic compound is one or more selected from the group consisting of: xylene, chlorobenzene, anisole and cyclohexanone. In one aspect of this embodiment, a preferred organic compound is xylene. In another aspect of this embodiment, a preferred organic compound is chlorobenzene. In another aspect of this embodiment, a preferred organic compound is anisole. In another aspect of this embodiment, a preferred organic compound is cyclohexanone.
[0156] In an embodiment of the process the concentration of the textile chemical is increased in the organic liquid by the contacting. For example, the concentration of the textile chemical in the organic liquid can be over 3000 grams of textile chemical / kg of organic liquid, for example more than 0.01 ppm (milligrams of textile chemical / kg of organic liquid) and up to 2000 grams of textile chemical / kg of organic liquid
[0157] In an embodiment of the process the concentration of the textile chemical in the further polyester fragment is less than in the second polyester fragment or the first polyester fragment. For example, the concentration of textile chemical is 50 % or less, e.g. 40, 30, 20, 10, or 5 % or less in the further polyester fragment based on the amount of textile chemical in the second polyester fragment or in the first polyester fragment.
[0158] In a further embodiment of the process the decrease in the concentration of textile chemicals is obtained by a certain purification technique. This purification technique can be selected from the group consisting of adsorption, absorption, precipitation, gravimetric separation, centrifugation, etc. preferably, an adsorption means. In a further embodiment of the process the adsorption means is selected from the group consisting of a carbon particle, an activated carbon, a bentonite, a silicon oxide particle, an ion exchange resin, a polymeric adsorbent, or at least two thereof.
[0159] In an embodiment of the process the organic liquid is at least partly removed prior to the conversion, for example at least 10, 20, 30, 40 or 50 vol.% of the organic liquid are removed from the further polyester fragment prior to conversion of the further polyester fragment, the vol.% with reference to the amount of organic liquid in the moment of contacting.
[0160] In an embodiment of the process, the thermal treatment of step b. is performed in a thermal treatment zone and the contacting of step c. with the organic liquid is performed in a contacting zone downstream of the thermal treatment zone. Preferably, the contacting zone has an at least 2 times higher concentration of the organic liquid than the thermal treatment zone.
[0161] In an embodiment of the process, converting the further polyester fragment into a plurality of polyester solids in step d. can be achieved by any means and techniques known to a skilled person and considered suited in the present invention. Converting may be performed by a technique selected from the group consisting of: solvent removal (evaporation), extrusion, dry blowing, granulation, flaking or any other technique involving melting of further polyester fragments, feeding of the melt to a die or a form of desired shape and size, quenching of an outlet coming after die or a form to below melting temperature to obtain solid polyester, or a combination of two or more thereof.
[0162] In an embodiment of the process, shear or heat or both is applied in the conversion in step d.
[0163] For example, step d. may be performed at a temperature in the range of 80 to 400 °C, or of 130 to 300 °C, or of 200 to 280 °C. For the extrusion, a pressure across a filter or screen is preferably in the range from 30- 105to 35 - 105Pa. For the extrusion, a pressure across a die head is preferably not above 40- 105Pa.
[0164] An extruder is a device useful for realizing this embodiment. A skilled person is able to select a suited extruder from the variations of extruder commercially available. Here, the skilled person in particular considers to avoid damage to the material to be extruded.
[0165] In an embodiment of the process, the plurality of polyester solids formed in step d. is selected from the group consisting of chips, beads, flakes, pellets, granules, blocks, fibres, or a combination of at least two thereof.
[0166] Optionally, a step of drying the further polyester fragment may be included. This step may be performed after completion of step c. and prior to step d. Drying can be achieved by any means and techniques known to a skilled person and considered suited in the present invention. Drying may be performed by a technique selected from the group consisting of: applying heat, applying a reduced pressure, circulation of dry and hot gas, or a combination of at least two thereof.
[0167] In an embodiment of the process, the process comprises these additional process steps: e. Subjecting the plurality of polyester solids to a de-esterification reaction to obtain a de- esterification product; f. Optionally, subjecting the de-esterification product to a purification to obtain a purified de-esterification product; g. Subjecting the de-esterification product, or the purified de-esterification product, to an esterification reaction or other chemical modification or keeping the de-esterification product, preferably by stopping the process after de-esterified product has been obtained.
[0168] In an embodiment of the process the de-esterification product has an intrinsic viscosity (IV) in the range of 1.3 to 0.005, for example of 0.6 to 0.05, or of 0.2 to .0.01.
[0169] In an embodiment of the process the polyester product after esterification has an intrinsic viscosity in the range from0.4 to 1.4 mPa s, for example from 0.4 to 1.0 mPa s, or from 0.6 to 0.9 mPa s.
[0170] The de-esterification product is preferably subjected to a purification to obtain a purified de- esterification product. Any purification methods and aids can be applied. Amongst these those are preferred which allow a depletion of colour, particles, or other impurities. In this context a filtration is preferred. Many suitable filtration aids may be employed. Amongst these, membranes, preferably based on polymers, such as ion exchange resins, and particulated filter aids are preferred. Preferred particulated filter aids are inorganic filter aids, like bentonite, clay, activated carbon, silicate, or a combination of two or more thereof.
[0171] In an embodiment of the process the polyester product is characterized by one or both of the following features:
[0172] [I] a melting temperature Tmin the range from 245 to 251 °C;
[0173] [II] a di ethylene glycol content of at least 1.5 wt. %, preferably at least 2 wt. %, more preferably at least 2.4 wt. %. The diethylene glycol content might be as high as 4 wt. %.
[0174] In an embodiment of the process the first polyester fragment, or the polyester product, or both is a homopolymer or a copolymer.
[0175] In an embodiment of the process the polyester product is selected from the group consisting of a flake, a pellet, a chip, a container, a yarn, a fiber, a textile, a film or at least two thereof. Another embodiment of the invention is a device for treating a polyester fragment, comprising a moving means, at least a feeder zone, a heat treatment zone, a contacting zone and a converting zone, and optionally a drying zone, wherein the moving means is adapted and arranged i. to move two or more polyester fragments; ii. to pass a gas and a liquid through the two or more polyester fragments; wherein the moving means connects at least the following zones: iii. A feeder zone, adapted and arranged to receive the two or more polyester fragments, iv. A heat treatment zone, adapted and arranged to heat the two or more polyester fragments, v. A contacting zone, adapted and arranged to contact the two or more polyester fragments with an organic liquid, vi. Optionally a drying zone, adapted and arranged to remove at least a part of the organic liquid from the two or more polyester fragments, and vii. A converting zone, adapted and arranged to shear the two or more fragments.
[0176] In an embodiment of the device, the device comprises these further zones: viii. A de-esterification zone, preferably downstream of the converting zone, adapted and arranged to obtain a de-esterification product from the two or more sheared fragments, ix. Optionally a filtration zone, adapted and arranged to remove at least some impurities from the two or more de-esterified fragments, and x. An esterification zone, adapted and arranged to obtain an esterification product from the de-esterified fragments.
[0177] The moving means can be of any kind or apparatus known to a skilled person and considered suited to host sections i. - v. and vii., and optionally section vi. of the above embodiment. The zones iii. To vii. are arranged in the above order, by preference.
[0178] In an embodiment of the device, the device is suited and configured to perform the process of the invention in the device, the process as defined in any of the above embodiments. For example, step a. of the 1stembodiment of the process of the invention can be performed in step iii. Of the device. For example, step b. of the 1stembodiment of the process of the invention can be performed in step iv. Of the device. For example, step c. of the 1stembodiment of the process of the invention can be performed in step v. of the device. For example, step d. of the 1stembodiment of the process of the invention can be performed in step vii. Of the device. For example, an optional further step of drying the polyester fragment as described with regard to the 1stembodiment of the process of the invention can be performed in optional step vi. of the device.
[0179] In an embodiment of the device, the feeder zone is adapted and arranged to receive two or more polyester fragments. Moreover, the feeder zone is adapted and arranged to provide the two or more polyester fragments to the moving means. The feeder zone may comprise a hopper, a flap, a dosing device capable of measuring volume or weight of feed, sensors and sorters capable of detecting and sorting feed materials outside of set specifications such as based on size, colour, chemical composition, or a combination of two or more thereof.
[0180] In an embodiment of the device, the device is adapted and arranged to move polyester fragments which are limp.
[0181] In an embodiment of the device, moving means may comprise one or more screws, belts, plurality of moving beakers, or a combination of two or more thereof.
[0182] The moving means may include a housing which is suited and configured to connect the zones forming the device.
[0183] In an embodiment of the device, the device is suited and configured to pass a gas through the moving means and at least one, preferably two or more, or even all zones forming the device.
[0184] In an embodiment of the device, the heating zone is at least one element selected from the list consisting of a rotary kiln, a pre-oven, a tumbler, a screw conveyor, or a combination of two or more thereof.
[0185] In an aspect of the device, the heating zone may comprise at least one element selected from the list consisting of a conveyor belt having a plurality of holes, a conveyor net, screw conveyor with holes or mesh, or a combination of two or more thereof. In an embodiment of the device, the contacting zone is at least one element selected from the list consisting of a tank, a device capable of converting volume of liquid into plurality of drops, an adsorbent bed, temperature sensor, flame arrestors, or a combination of two or more thereof.
[0186] In an aspect of this embodiment of the device, the moving means is configured to pass through the contacting zone. Further, an insert may be positioned between the moving means and the bottom of the contacting zone, which contains at least one adsorbent, e.g. selected from charcoal, activated carbon, bentonite, ion exchange resins, polymeric absorbents or a combination of two or more thereof.
[0187] In an aspect of the above embodiment of the device, the contacting zone may comprise a providing means suited and configured to provide an organic liquid to polyester fragments being conveyed by and / or on the moving means. The providing means may be selected from the group consisting of a nozzle, a sprayer, a hose, a pipe, a faucet, or a combination of two or more thereof.
[0188] In a further aspect of the above embodiment of the device, the contacting zone may comprise collecting and circulation means suited and configured to collect organic liquid at the bottom of the contacting zone and to circulate it to the providing means of the contacting zone. For example, the organic liquid may be collected at the bottom of the providing means through an outlet and pumped to the providing means using a pump. In a further aspect, the circulation means useful for circulating the organic liquid may comprise further means for regeneration of the organic liquid prior to re-using it. For example, the organic liquid may be evaporated and condensed during regeneration to purify the liquid and to separate it from any impurities, for example from any textile chemicals, such as dyes, finishers and so on, coming from the polyester fragments. In an alternative or even additional configuration, the contacting zone is configured so that at least some of the organic liquid collected at the bottom of the contacting zone may, optionally regenerated, be provided to the feeding zone or the heating zone, or both, to contact with the polyester fragments.
[0189] In an embodiment of the device, the drying zone is at least one element selected from the list consisting of mesh with a hot air supply, a rotary oven, a vessel with heating coils, a vessel with heating jackets, or a combination of at least two thereof. In an embodiment of the device, the converting zone comprises at least one element selected from the list consisting of an extruder, a kneader vessel, a vessel with heating coils, a vessel with heating jackets, a die or form, both preferably to pass a melt under pressure, each followed by a quenching section, or a combination of at least two thereof.
[0190] In an embodiment of the device, a recipient is arranged downstream of the converting zone. This could be a vessel or tank, both of which could be heated.
[0191] In another embodiment of the device, a de-esterification zone is arranged downstream to the converting zone, which is adapted and arranged to reduce the molecular weight of a polyester.
[0192] In an embodiment of the device, a filtration zone is arranged downstream to the de-esterification zone, which is adapted and arranged to remove at least some impurities from the de-esterification product. The filtration zone may comprise at least one or more elements selected from the list consisting of membranes, preferably based on polymers, such as ion exchange resins, and particulated filter aids. Preferred particulated filter aids are inorganic filter aids, like bentonite, clay, activated carbon, silicate, or a combination of two or more thereof.
[0193] In an embodiment of the device, an esterification zone is arranged downstream to the de- esterification zone, which is adapted and arranged to increase the molecular weight of a polyester. In an embodiment of the device, a chemical modification zone is arranged downstream to the de- esterification zone, which is adapted and arranged to perform any chemical reaction different to a polymerization reaction. Thus, it is preferred that this chemical modification zone differs from the esterification zone.
[0194] For example, step e. of the process of the invention can be performed in a zone viii., the de- esterification zone of the device. For example, optional step f. of the process of the invention can be performed in a zone ix., the filtration zone of the device. For example, step g. of the process of the invention can be performed in a zone x., the esterification or chemical reaction zone of the device. In a further embodiment, the process of the invention described above is performed in a device according to any one of the above embodiments.
[0195] A further embodiment is a polyester product obtainable by a process according to any one of the above embodiments.
[0196] A further embodiment is a use of a plurality of polyester solids obtainable by a process comprising the following process steps: a. Providing a first polyester fragment; b. Subjecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. Contacting the second polyester fragment with an organic liquid to obtain a further polyester fragment; d. Converting the further polyester fragment into the plurality of polyester solids; for a purpose selected from the group consisting of a chemical modification, preferably, a functionalization, de-esterification, esterification, formation of a body, preferably a fibre, a textile, a container, a film, or a combination of at two or more thereof.
[0197] BRIEF DESCRIPTION OF THE DRAWINGS
[0198] The following schematic drawings show aspects of the invention for improving the understanding of the invention in connection with some exemplary illustrations. The drawings are solely for the purpose of illustration. Accordingly, it is not intended to limit the invention to the extent shown in the drawings, nor are the drawings meant to be on scale if not explicitly stated.
[0199] Figure 1 shows a schematic presentation of the process according to claim 1.
[0200] Figure 2 shows a schematic view on a polyester fragment having crystalline and amorphous regions.
[0201] Figures 3a and 3b show characteristic DSC graphs for a polymer material.
[0202] Figure 4 shows a schematic presentation of optional further steps.
[0203] Figure 5 shows a schematic design of a device as claimed. Figure 6 shows a gel permeation chromatograph for the silicone employed in the silicone solubility test method.
[0204] Figure 7 shows an 'H NMR spectrum for the silicone employed in the silicone solubility test method.
[0205] DETAILED DESCRIPTION OF THE DRAWINGS
[0206] Figure 1 shows a flow diagram of the process according to this disclosure. A first step, labelled a. is the provision of a first polyester fragment. A first polyester fragment has a polyester polymer as its major constituent and is preferably a textile. The first polyester fragment is contaminated with textile chemical, which can be a single chemical or a combination of more than one chemicals. The textile chemical typically comprises dye, finisher and ink as major constituents. A second step, labelled b. is an optional thermal treatment. Where the thermal treatment is performed, the first polyester fragment is converted into a second polyester fragment. A third step, labelled c., is the contacting step which constitutes the focus of this disclosure. If no thermal treatment b. was performed, step c. is performed on a first polyester fragment. If a step b. was performed, step c. is performed on a second polyester fragment. In step c., the first or second polyester fragment is contacted with an organic liquid. At least some of the textile chemical is dissolved in the organic liquid, thus reducing the content of textile chemical in the polyester fragment and increasing the content in the organic liquid. Step c. thus results in a further polyester fragment. In a further step d., the further polyester fragment is converted into a plurality of polyester solids. Step d. may include for example an extrusion step to produce pellets as feed-stock for further de-esterification processes.
[0207] Figure 2 shows a sketch of a partially crystallised polymer material. Regions of ordered crystalline polymer can be observed amongst regions of disordered amorphous polymer.
[0208] Figures 3a and 3b show graphs for a thermal heating profile for a PET textile. Two melting temperatures are seen at 245.6 °C and 256.4 °C. A crystallisation temperature at 184 °C is observed in the first cooling cycle. In the second heating cycle, a glass transition temperature is observed at around 80 °C and a melting temperature is observed at 253.8 °C. Figure 4 shows further downstream processes which could follow the process of the invention. A de-esterification step e., an optional purification step f. of the de-esterified product and an esterification step g. can be performed on the plurality of polyester solids produced by the process of this invention.
[0209] Figure 5 shows a schematic for a device according to the invention. Part i. is a moving means for moving textile fragments. The moving means connects at least the zones i. to v.. i. is a feeder zone, adapted and arranged to receive the two or more polyester fragments, ii. is a heat treatment zone, adapted and arranged to heat the two or more limp textile fragments, iii. is a contacting zone, adapted and arranged to contact the two or more limp textile fragments with one or more organic liquids, each comprising an organic compound having a ring with at least one C atom. iv. is an optional drying zone, adapted and arranged to remove at least a part of the organic liquid from the two or more polyester fragments, vi. is a converting zone, adapted and arranged to shear the two or more limp textile fragments.
[0210] Figure 6 shows a gel permeation chromatograph (GPC) for the silicone employed in the silicone solubility test method. A silicone polymer (commercially available from Modem Industries, Nashik, India (product code: S02050500M)); of poly(dimethyl siloxane) [CAS No.: 63148-62-9] is employed. The gel permeation chromatograph shows a single monomodal distribution with peak molecular weight (Mp) = 7058 g / mol, number average molecular weight (Mn) = 4980 g / mol; and poly dispersity index (Mw / Mn) = 1.5. For GPC analysis 60 mg of poly(dimethyl siloxane) was dissolved in 5 ml THF (CAS no.: 109-99-9) to prepare solution. This solution was injected in a GPC system where chromatography column (Part No.: PLgel Mixed-B; 10 microns; 7.5 mm x 300 mm; commercially available from Agilent Technologies Inc., USA) and system temperature was maintained at 30 °C and flow rate for analysis was maintained at 1 ml / min with THF as eluent. Other important details regarding GPC system: Detector: Refractive Index (RI); Standards used for calibration: Polystyrene - narrow molecular weight distribution standards; Mw range = 1000 to 275000 g / mol.
[0211] Figure 7 shows an 'H NMR spectrum for the silicone employed in the silicone solubility test method. The spectrum shows a strong signal at chemical shifts 0.110 ppm and 0.093 ppm, characteristic of a silicone; implying the poly(dimethyl siloxane) used in solubility test was of high purity. For 'H NMR analysis: 20 mg of silicone oil was dissolved in 0.6 ml of deuterated chloroform (CDCI3; CAS No.: 865-49-6) and analyzed on 400 MHz FT-NMR Spectrometer (commercially available from Bruker, Germany; Model: Avance III).
[0212] Test Methods
[0213] A. Bulk density
[0214] When a feedstock comprises a plurality of fragments, the bulk density of the feedstock is calculated according to the standard ASTM DI 895- 17 (Method C). The method is performed using a feedstock of PET textile fabrics in the form of 2 cm x 2 cm squares as the sample. In the event that 60 g of material used for the test does not fit into a 1000 cm3container without compression, a larger container is used. The bulk density of the feedstock, e.g. polyester fragments, is measured prior to contacting the feedstock with the first amount of the first organic compound.
[0215] B. Intrinsic viscosity
[0216] The intrinsic viscosity IV of a polymer, e.g. the first polyester, is measured according to the standard ASTM D4603:2018, with the following change: the flow time of the solution in a capillary viscometer is determined at 25 °C, instead of 30 °C (as given in the standard).
[0217] C. Residence time
[0218] The residence time ZRESis determined by the following equation:
[0219] ?RES=^REACTOR / ^PRODUCT VOLUME RATE, where PREACTOR is the volume of a volume space, e.g., a reactor volume, and FPRODUCT VOLUME RATE is the volume rate of a mixture exiting (e.g., the first intermediate mixture, the further intermediate mixture) the volume section.
[0220] D. GSM
[0221] The test method provided below applies to all the fabrics (griege, dyed and coated) which were used in this study. Mass per unit area of PET textile fabric (Gram per Square Meter) was measured as per ASTM D-3776 (Option C). PET textile fabric samples were hand-cut using a scissor (commercially available from Fiskars®, Finland; Grade: Fiskars 8-inch Original Orange Handled- Scissor) in 10 cm * 10 cm (total area = 100 cm2) area (measured using a scale with a precision of 0.1 mm) and conditioned at 30 °C and 50 % Relative Humidity for 1 hour. Mass of conditioned samples of PET textile fabrics were weighed on an analytical balance (commercially available from Citizen Scale Incorporated, USA; Model: CX 220). Following equation was used for calculating GSM as reported in ASTM D-3776. g / m2= 106G / Lw
[0222] Where, G = mass of specimen, g
[0223] L = length of specimen, mm
[0224] W = width of specimen, mm
[0225] This test method is also applicable for determining the GSM of polyester fabrics other than PET.
[0226] E. DSC analysis
[0227] The polymer material is analysed using a differential scanning calorimeter (DSC) instrument (Perkin Elmer DSC-8000). The sample is first held at 40 °C for 1 minute, then heated from 40 °C to 300 °C (1stHeating), then cooled from 300 °C to 40 °C (1stCooling), then held at 40 °C for 1 minute, then heated from 40 °C to 300 °C (2ndHeating) under nitrogen stream, at a standard heating / cooling rate of 30 °C / min. The crystallization temperature (Tc) is determined from DSC curve of the first cooling run. The glass transition temperature Tgis determined from the second heating run, as the midpoint temperature and the melting temperature (Tm) was calculated as the peak of the melting endotherm.
[0228] F. Polyester dissolving ability:
[0229] An undyed and uncoated (griege) PET textile fabric (GSM = 90) was used for solubility studies. This fabric was manufactured by a knitting process using a polyester PET draw textured yarn (DTY) [composing of polyethylene terephthalate [CAS No.: 25038-59-9] as the major component and 0.30 wt.% of titanium dioxide [CAS No.: 13463-67-7] (determined as an ash content of 0.30 wt.%; ash content is measured by burning a known weight of sample at 800 °C for 4 hours and measuring the residual weight; wt.% being based on total weight of the PET fabric)] was used for solubility studies. Key specifications of griege PET draw textured yarn (DTY) are intrinsic viscosity = 0.65; melting point = 249 °C - 251 °C; diethylene glycol content = 2.6 wt.%; isophthalic acid content = 1.6 wt.%; denier / filament = 75 / 72; type = low intermingle [LIM]), The knitting of DTY to prepare fabric was carried out on a circular knitting machine (commercially available from Bharat Machines,, Ludhiana, India; Model: H.K.M.) with the setting of gauge = 24. The fabric sample was subjected to following pre-treatment before using for solubility studies: The sample washed with petroleum ether [CAS No. 8032-32-4] (2 times) to remove any remnants of spin finish oil and / or coning oil. It was dried to a constant weight in an oven (commercially available from EIE Instruments Pvt. Ltd., Ahmedabad, India; Model No. EIE-101) at 130 °C. In a 20 ml glass test tube (commercially available from BOROSIL® in India; length = 15 cm; circular diameter = 1.6 cm) were added: 0.2 grams of PET textile fabric and 3 ml of the organic liquid to be tested at 30 °C. It was made sure that PET textile fabric was completely immersed in organic liquid. The glass test tube was immersed in a thermal bath (silicone oil) maintained at 130 °C and kept for a total of 30 minutes after which the test tube and its contents were removed from the bath. Upon removal, the contents of the glass test tube were immediately filtered over Whatman® filter paper (No. 41; circular shape) and the filtrate collected in a glass petri dish (commercially available from BOROSIL® in India; diameter = 9.0 cm; height = 1.5 cm). For the filtration, the circular filter paper was folded to obtain a semicircle and again to obtain a quarter circle, which was opened up to obtain a conical shape. The cone of filter paper was introduced into a conical glass funnel held in a tripod stand above a glass petri dish and left for 30 minutes for the liquid filtrate to drip into the glass petri dish. The contents of the glass petri dish were then dried to a constant weight at a temperature at least 10 °C above the boiling point of the organic liquid (in the case of a mixture of organic liquids, above the highest boiling point of the organic liquid) in an oven (commercially available from EIE Instruments Pvt. Ltd., India; Model No. EIE-101) to evaporate organic liquid until constant mass. Upon removal from oven, the glass petri-dish was immediately placed inside a glass desiccator (commercially available from BOROSIL®, India; product code: 3082042) filled with desiccant (commercially available from W. A. Hammond Drierite Co. Ltd., USA; product number: 22001) for 30 minutes at 30 °C to avoid absorption of moisture during cooling. Upon removal from desiccator, the mass of PET polyester polymer left on a glass petri dish was measured using an analytical balance (commercially available from Citizen Scale Incorporated, USA; Model: CX 220) and reported as the mass of PET polyester polymer soluble in organic liquid. The solubility data (mg of PET polyester polymer soluble in 3 ml organic liquid when solubilized at 130 °C for 30 minutes) is compiled in the table of the examples section. Some amount of solution was absorbed by Whatman® filter paper (No. 41) during filtration in all the cases. For the purposes of this study this amount is not taken into consideration.
[0230] G. Silicone dissolving ability A silicone polymer (commercially available from Modern Industries, Nashik, India (product code: S02050500M); of poly(dimethyl siloxane) [CAS No.: 63148-62-9]; viscosity of silicone polymer as measured by Brookfield viscometer = 100 cSt (using spindle number 4; RPM = 30 at 25 °C); molecular weight of silicone polymer as analysed by Gel Permeation Chromatography (GPC): a single monomodal distribution with peak molecular weight (Mp) = 7058 g / mol, number average molecular weight (Mn) = 4980 g / mol; poly dispersity index (Mw / Mn) = 1.5; For GPC analysis 60 mg of poly(dimethyl siloxane) was dissolved in 5 ml THF (CAS no. : 109-99-9) to prepare solution. This solution was injected in a GPC system where chromatography column (Part No.: PLgel Mixed-B; 10 microns; 7.5 mm x 300 mm; commercially available from Agilent Technologies Inc., USA) and system temperature was maintained at 30 °C and flow rate for analysis was maintained at 1 ml / min with THF as eluent. Other important details regarding GPC system: Detector: Refractive Index (RI); Standards used for calibration: Polystyrene - narrow molecular weight distribution standards; Mw range = 1000 to 275000 g / mol) was used for solubility studies. In a 20 ml glass test tube (commercially available from BOROSIL®; length = 15 cm; diameter = 1.6 cm) were added in sequence: 1 gram of silicone polymer (weighing measurements performed on Citizen Scale Incorporated, USA; Model: CX 220; least count = 0.001 gm), 4 ml of organic liquid and a magnetic stir-bar (made of Teflon®; cylindrical in shape; diameter = 5 mm; length = 10 mm; commercially available from Modern Science Apparatus Pvt. Ltd., Nashik, India; Model No.: M202). The test tube with the above contents was immersed in a thermal bath at 130 °C (silicone oil; contents in bath agitated for uniform mixing). The contents in the test tube were stirred using a magnetic stir-plate (commercially available from IKA ® Model No. : C-MAG HS7 digital) at motor speed on setting 1 for a period of 20 minutes at 130 °C. After 20 minutes, the stirring was stopped, and the test tube was left in the thermal bath at 130 °C for an additional 10 minutes. After a total of 30 minutes of the test (20 minutes with stirring + 10 minutes without stirring), the test tube was removed from thermal bath and solubility was immediately determined by visual observation: If no phase boundary was observed, the organic liquid was classified as capable of dissolving the silicone. If a phase boundary was observed, the organic liquid was classified as incapable of dissolving the silicone. In either case, small droplets of one liquid suspended in another liquid, as a cloudy emulsion, is classified as a single phase, which does not constitute a phase boundary. H. Dye dissolving ability
[0231] 1,2-dihydroxyanthraquinone (CAS Number: 72-48-0) (commercially available from TCI Co., Ltd., Japan; product number: D0242; purity: > 95% [HPLC]) was used as a dye / chromophore molecule for solubility studies. In a 20 ml glass test tube (commercially available from BOROSIL®; length = 15 cm; diameter = 1.6 cm) were added in sequence: 0.2 grams of the dye / chromophore (weighing measurements performed on Citizen Scale Incorporated, USA; Model: CX 220; least count = 0.001 gm), a magnetic stir-bar (made of Teflon®; cylindrical in shape; diameter = 5 mm; length = 10 mm; commercially available from Modern Science Apparatus Pvt. Ltd., Nashik, India; Model No.: M202) and 6 ml of the organic liquid to be tested (measured using a 10 ml glass pipette; commercially available from BOROSIL®; part number: 7059P06; graduation interval = 0.1 ml) at 25 °C (temperature of the lab maintained in the range from 24 to 26 °C using a mercury thermometer with scale having 0.5 °C graduations). The test tube with the above contents was mounted vertically above a magnetic stir-plate (commercially available from IKA ® Model No.: C-MAG HS7 digital). The contents were stirred for 30 minutes with motor speed on setting 4 on the magnetic stir-plate. After 30 minutes, stirring was stopped and the contents were immediately filtered over Whatman™ filter paper no. 42 and liquid filtrate was collected in a glass vial. For the filtration, the circular filter paper was folded to obtain a semicircle and again to obtain a quarter circle, which was opened up to obtain a conical shape. The cone of filter paper was introduced into a conical glass funnel held in a tripod stand above the glass vial and left for 15 minutes for the liquid filtrate to drip into the glass vial. In all the cases filtration was complete within 15 minutes. During filtration it was made sure that additional air movement in the room (such as fan and air conditioner) were turned off. Following filtration, the contents in the glass vial were transferred to a cuvette for measurement of UV-Visible absorbance spectrum (quartz square cuvette; volume = 3 ml; light path = 10 mm; range = 190 nm to 1400 nm; commercially available from Labindia Analytical Instruments Pvt. Ltd., India; Part No. 82600001). UV-Visible spectroscopy was performed at 25 °C on a UV-Visible spectrophotometer (commercially available from Labindia Analytical Instruments Pvt. Ltd., India; Model No.: UV 3200; double beam hollow graphic monochromator with 1200 lines / mm). The UV-Visible spectrum was recorded in absorbance mode over a range of 200 nm to 800 nm using scan step of 0.1 nm and precision value set at 50. In each case, a baseline correction was performed using a cuvette of the pure organic liquid without contact with the dye / chromophore. The point of maximum absorbance (Amax) and corresponding wavelength (denoted as max) were determined and the dye solubility is quoted as Amax.
[0232] Examples
[0233] Some examples are described in this section to demonstrate the invention. The examples are merely illustrative, and not intended to limit the scope of the invention.
[0234] Example 1 : Dissolving Ability
[0235] The dissolving ability of a range of organic vehicles was determined according to the test methods described herein. Dissolving ability at 130°C is shown in table 1.
[0236] Example 2a: Contacting with Organic liquid
[0237] A PET piece of green dyed (commercially available from Colourtex Industries Pvt. Ltd., India; Grade: Coral ene Green XF) fabric was cut into a 2 cm * 2 cm square and immersed in the test organic liquid in a round bottom flask and mixed gently at the test temperature for 2 minutes. After 2 minutes, the fabric was removed. This example was performed for the test temperatures and the aforementioned organic liquid and mixtures thereof.
[0238] Example 2b: Contacting with Organic liquid
[0239] Example 2a was repeated except that the fabric was not immersed. It was kept on a ceramic mesh and organic liquid was poured onto it from above.
[0240] Example 3 : Recycling
[0241] A multitude of contacted fabrics from examples 2a and 2b were further processed according to the remaining steps d., e. and f. of figures 1 and 4. Drying was performed for 10 minutes at a temperature 10 °C above the boiling point, in the case of a mixture of organic liquids, above the highest boiling point of the organic liquid, in an oven (commercially available from EIE Instruments Pvt. Ltd., India; Model No. EIE-101). Granule formation was performed by melting at 280°C and passing through an extruder (commercially available from Labtech Engineering, Thailand; Setup: Extruder [Table Top Micro Scientific 16 mm twin screw extruder] + Benchtop water bath with strand suction and quick lock strand guide + Benchtop mini pelletizer LZ-80) at a temperature of 280 °C. De-esterification was performed by glycolysis method wherein granules were reacted with Monoethylene Glycol (CAS No.: 107-21-1) in 70:30 (weight basis) at 196 °C for 4 hours under atmospheric conditions in a glassware-based setup (a 500 ml round bottom flask + water condenser + heating mantle) which generated a homogeneous free flowing liquid (glycolyzed product) at 196 °C. Esterification was performed by using the glycolyzed product obtained above as the starting material. Mixture of glycolyzed product, catalyst (antimony tri oxide; CAS No.: 1309-64-4; 150 ppm) and ortho-phosphoric acid (CAS No.: 7664-38-2; 20 ppm) were reacted together under vacuum (2 mbar) at 280 °C for 4 hours to produce a viscous polymer at 280 °C which was subsequently pelletized by underwater granulation process to produce cylindershaped granules / chips (typically, 40 chips weighed together to 1 gram). The entire process of esterification (polymerization) and subsequent generation of polyester granules was carried out using a 150-litre pilot-scale reactor (commercially available from TongHui Chemical Technology and Engineering Co. Ltd., Jiangsu, China). Spinning was performed by using polyester granules generated above and using a commercially available pilot-scale spinning machine from VB Soluzioni & Tecnologie srl, Italy (Model No.: EASYSPIN-LAB2) using T = 275 °C - 290 °C and winding speed of 2800 m / min. to produce partially oriented yarn (POY) with specification of deni er / filam ent = 130 / 48. The quality of yam (yarn defects) produced was assessed by uniformity in dyeing and colour imparted on a fabric after the dyeing process. For this purpose, POY obtained was converted into Draw Textured Yarn (DTY) which was subsequently knitted into a fabric that was subjected to dyeing process followed by visual inspection. The details of these steps are as follows. The POY obtained was subsequently converted into Draw Textured Yarn (DTY) with specification of deni er / filam ent = 75 / 48 by using a DTY machine (commercially available from Aalidhra Textile Engineers Ltd., Surat, India; Model No.: ATE-12-4S) at 700 m / min speed and at 200 °C texturing heater temperature. The DTY obtained was knitted into a fabric using circular knitting machine (commercially available from Bharat Machines, Ludhiana, India; Model: H.K.M.) with the settings of gauge = 24. The fabric produced at this stage was subjected to scouring process wherein fabric was dipped in a hot (90 °C) mixture of demineralized water (ratio of fabric: demineralized water = 1 :25 by weight), sodium carbonate (CAS No.: 497-19-8; 2 gm / liter based on demineralized water) & Sera® wash-C-NEC (commercially available from DyStar India Pvt. Ltd., India; 2 gm / liter based on demineralized water) under stirring for 30 minutes. After 30 minutes, fabric was removed from the mixture and washed with an excess of demineralized water at room temperature. The scoured fabric was subsequently dyed with a disperse dye using following process: 75 gms of scoured fabric, 1.50 litres of demineralized water, 24.75 ml of dye solution (prepared separately as 1 gm of disperse dye [commercially available from DyStar India Pvt. Ltd., India; grade name: Dianix® Blue S-BG] diluted with 100 ml of demineralized water), 15 ml of sodium acetate solution (prepared separately as 10 gms of sodium acetate trihydrate [CAS No.: 6131-90-4] diluted with 100 ml of demineralized water), 15 ml of Sera® Gal P-LP solution (prepared separately as 10 gms of Sera® Gal P-LP [commercially available from DyStar India Pvt. Ltd.] diluted with 100 ml demineralized water) were added in a beaker. To this mixture, 3% aqueous solution of acetic acid (CAS No.: 64-19-7) was added drop- by-crop to bring the pH to 5.0. This entire mixture was dyed using a typical high temperature high pressure [HTHP] method in a dyeing machine (commercially available from R.B. Electronic and Engineering Pvt. Ltd., Mumbai, India; Capacity = 2.5 kg; Type = Soft Overflow (SOF); temperature range = 1 °C - 145 °C). The dyeing program used is [in sequence]: ramp from room temperature to 50 °C in 8.33 minutes, hold at 50 °C for 5 minutes, ramp from 50 °C to 70 °C in 6.67 minutes, further ramp from 70 °C to 90 °C in 10 minutes, further ramp from 90 °C to 130 °C in 40 minutes, hold at 130 °C for 30 minutes, ramp from 130 °C to 70 °C in 12 minutes. Upon dyeing the fabric was removed from dyeing machine, washed with excess of water, dried in washing machine to remove excess of water with spinning mode (commercially available from Haier India Appliances Pvt. Ltd., Delhi, India; Model No.: HTW65-187BO; setting for spinning used = 1) followed by thorough drying in oven at 120 °C for 20 minutes. The dyed fabric was then visually checked for uniformity in dyeing and colour under light (commercially available from Philips Lifemax; Part No.: 36W / 54 6500K) in a dark room.
[0242] Performance in the steps following a contacting process at 130°C is presented in table 3.
[0243] Table 3.
[0244] Table 3 shows advantages connected to the organic liquids favoured according to the invention. A first advantage is an improved yield of recycled polymer material. A second advantage is an improved uniformity of shape and size of polyester solids following the extruder step. A third advantage is greater uniformity and reliability in the spinning step. A fourth advantage is in increased uniformity of dyability and colouring in the final coloured yarn product.
Claims
Claims1. A process for producing a polyester product, the process comprising the following steps: a. Providing a first polyester fragment; b . Optionally subj ecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. Contacting the first or second polyester fragment with a sequence S of one or more organic liquids to obtain a further polyester fragment; d. Converting the further polyester fragment into a plurality of polyester solids; wherein the first polyester fragment comprises at least 50 wt.-% of a polyester polymer; wherein the first polyester fragment comprises a textile chemical different from the polyester polymer; wherein the further polyester fragment comprises less of the textile chemical than does the first polyester fragment; wherein, for the following organic liquid criteria i. to iv., criterion i. is satisfied by at least one member of S, criterion ii. is satisfied by at least one member of S, and criteria iii. and iv. are both satisfied by all members of S: i. Capacity to dissolve silicone at 130 °C according to the test method herein; ii. Capacity to dissolve a dye at 130 °C characterised by a maximum absorption Amaxof at least 2, preferably at least 2.3, more preferably at least 2.5, more preferably still at least 2.8 according to the test method herein; iii. A polyester dissolving ability at 130 °C, determined according to the test method herein, of not more than 8 mg / ml, preferably not more than 5 mg / ml, more preferably not more than 2 mg / ml, more preferably still not more than 1 mg / ml, more preferably still not more than 0.5 mg / ml, more preferably still not more than 0.1 mg / ml, values perhaps being as low as 0.001 mg / ml; iv. A boiling point not less than 130 °C.
2. The process according to claim 1, wherein the polyester polymer of has a glass transition temperature Tgand one or more of the members of S, preferably each member of S, has a boiling point above Tg.
3. The process according to claim 1 or 2, wherein one or more of the members of S comprises two or more liquid organic components, each in an amount of at least 10 wt. % and each liquid organic component satisfying criteria iii. and iv..
4. A process for producing a polyester product, the process comprising at least the following process steps: a. Providing a first polyester fragment; b. Optionally subjecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. Contacting the first or second polyester fragment with an organic liquid, the organic liquid comprising a group C of organic liquid components, to obtain a further polyester fragment; d. Converting the further polyester fragment into a plurality of polyester solids; wherein the first polyester fragment comprises at least 50 wt.-% of a polyester polymer; wherein the first polyester fragment comprises a textile chemical different from the polyester polymer; wherein the further polyester fragment comprises less of the textile chemical than does the first polyester fragment wherein, for the following organic liquid criteria i. to iv., criterion i. is satisfied by at least one member of C, criterion ii. is satisfied by at least one member of C, and criteria iii. and iv. are both satisfied by all members of C: i. Capacity to dissolve silicone at 130 °C according to the test method herein; ii. Capacity to dissolve a dye at 130 °C characterised by a maximum absorption Amaxof at least 2 according to the test method herein; iii. A polyester dissolving ability at 130 °C, determined according to the test method herein, not more than 8 mg / ml; iv. A boiling point not less than 130 °C.
5. The process according to claim 4, wherein the polyester polymer has a glass transition temperature Tgand one or more of the members of C, preferably each member of C, has a boiling point above Tg.
6. A process for producing a polyester product, the process comprising the following process steps: a. Providing a first polyester fragment; b. Optionally subjecting the first polyester fragment to a thermal treatment to obtain a second polyester fragment; c. Contacting the first or second polyester fragment with an organic liquid to obtain a further polyester fragment; d. Converting the further polyester fragment into a plurality of polyester solids; wherein the first polyester fragment comprises at least 50 wt.-% of a polyester polymer; wherein the first polyester fragment comprises a textile chemical different from the polyester polymer; wherein the further polyester fragment comprises less of the textile chemical than does the first polyester fragment; wherein the organic liquid comprises a first organic component having one or more rings, each ring comprising at least one C atom.
7. The process according to claim 6, wherein the first organic liquid component has: a. One or more rings of C atoms; b. One or more rings of C atoms with one or more, but not all, of the C atoms in the ring each replaced by an atom independently selected from the group consisting of O, N, S & P; or c. both a. and b..
8. The process according to claim 6 or 7, wherein the first organic liquid component comprises: a. An optionally substituted cycloaliphatic ring, b. An optionally substituted aromatic ring, c. An optionally substituted heteroarene ring,d. An optionally substituted hetero cycloaliphatic ring, or e. Two or more independently selected from a. to d; the optional substitution being of non-ring atoms.
9. The process according to any of the claims 6 to 8, wherein the first organic liquid component is a cycloaliphatic compound, aromatic compound, heteroarene compound or hetero cycloaliphatic compound, optionally functionalised with one or more groups independently selected from the group consisting of: an alkyl group, a halogen group, an ester group, a phenolic group, a hydroxyl group, an ether group, a ketone group, an aldehyde group, an amine group, an amide group, a carboxyl group, a sulfonic acid group, a phosphate group, a phosphoric acid group and a sulfoxide group.
10. The process according to any of the preceding claims, wherein the first polyester fragment comprises the textile chemical in an amount in the range of 0.01 to 20 wt.-%, based on the total weight of the first polyester fragment.
11. The process according to any of the preceding claims, wherein the textile chemical is selected from the group consisting of a dye, a finisher, a softener, or a combination of at least two thereof.
12. The process according to any of the preceding claims, wherein the first polyester fragment is one of a plurality of two or more polyester fragments, the plurality of polyester fragments meeting one or more of the following criteria:(a) A dso maximum length in the range of 300 to 600 mm;(b) A GSM in the range of 30 to 400 g / m2;(c) Comprises two or more fibres;(d) An intrinsic viscosity (IV) in the range of 0.4 to 1.4;(e) Bulk density in the range of 0.01 to 0.75 g / cm3.
13. The process according to any of the preceding claims, wherein one or more of the organic liquids employed in step c. meets at least one or all of the following criteria:(I) Has a boiling point at least 1 K above Tgof the polyester polymer; or(II) Has a boiling point below the melting temperature of the polyester polymer.
14. The process according to any of the preceding claims, wherein the plurality of polyester solids is selected from the group consisting of chips, beads, flakes, pellets, fibres or a combination of at least two thereof.
15. The process according to any of the preceding claims, wherein the process comprises as additional process steps: e. Subjecting the polyester solids to a de-esterification reaction to obtain a deesterification product; f. Optionally, subjecting the de-esterification product to a purification to obtain a purified de-esterification product; g. Subjecting the de-esterification product, or the purified de-esterification product, to an esterification reaction or other chemical modification or keeping the de- esterification product.
16. The process according to any of the preceding claims, wherein the polyester product is selected from the group consisting of a flake, a pellet, a chip, a container, a yam, a fibre, a textile, a film or at least two thereof.
17. The process according to any of the preceding claims, wherein at least 20 wt.-% of the textile chemical is a dye.
18. A use of an organic liquid or a sequence of organic liquids S recited in any of the preceding claims for improving the recycling of a polyester polymer textile.
19. A device for treating a polyester fragment, comprising a moving means adapted and arranged i. to move two or more limp textile fragments, ii. to pass a gas and a liquid through the two or more limp textile fragments; wherein the moving means connects at least the following zones:iii. A feeder zone, adapted and arranged to receive the two or more polyester fragments, iv. A heat treatment zone, adapted and arranged to heat the two or more limp textile fragments, v. A contacting zone, adapted and arranged to contact the two or more limp textile fragments with one or more organic liquids, each comprising an organic compound having a ring with at least one C atom, vi. Optionally a drying zone, adapted and arranged to remove at least a part of the organic liquid from the two or more polyester fragments, and vii. A converting zone, adapted and arranged to shear the two or more limp textile fragments.
20. A polyester product, obtainable by a process according to any of the claims 1 to 17.
21. A use of a plurality of polyester solids obtainable by a process comprising the following process steps: a. Providing a first polyester fragment; b. Optionally subjecting the first polyester fragment to a heat treatment to obtain a second polyester fragment; c. Contacting the first polyester fragment or second polyester fragment with one or more organic liquids, each comprising an organic compound having a ring with at least one C atom to obtain a further polyester fragment; d. Converting the further polyester fragment into the plurality of polyester solids; for a purpose selected from the group consisting of: a chemical modification or a forming or both.
Citation Information
Patent Citations
Waste polyester recovering method
CN108395373A
Waste polyester degradation method
CN109134244A
Processes for recycling polyethylene terephthalate
EP3778744A1
Method for producing bleached polyester, bleaching agent, and method for producing recycled polyethylene terephthalate
JP7177449B2
Method for producing decolored polyester, decolored polyester, and decoloring agent
US20220169786A1