Hydrothermal Separation of Polyester-Cotton Textiles Using Organic Acid Catalysts

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Solution Overview

Problem

Current methods for recycling polyester-cotton textiles are inefficient and environmentally harmful due to the use of harmful chemicals and expensive solvents, which pose challenges in cost control and environmental protection.

Innovation Solution

A hydrothermal reaction catalyzed by a biodegradable organic acid, such as methanesulfonic acid or citric acid, is used to separate and recycle waste polyester-cotton textiles, involving fragmentation, dispersion in an aqueous solution, heating in a high-pressure reactor, and filtration to obtain pure polyester and cotton fibers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If chemical methods using harmful chemicals (hydrochloric acid, tetramethylene sulfone) are used to separate polyester-cotton textiles, then separation completeness is improved, but environmental pollution and cost increase

Engineering Contradiction:
Improveseparation completenessVSAvoidenvironmental pollution
Core Design Contradiction:
Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical parameters by using organic acids (acetic acid, formic acid, oxalic acid, citric acid) instead of traditional harmful chemicals like hydrochloric acid or tetramethylene sulfone. This parameter substitution maintains the chemical effectiveness for fiber separation while eliminating environmental pollution and reducing costs.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent employs inexpensive organic acids as catalysts that can be easily disposed of or degraded naturally, replacing expensive and environmentally harmful chemicals. The organic acids serve their purpose during the separation process and then decompose benignally, avoiding long-term environmental contamination.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

2Manufacturing precision

If chemical methods using harmful chemicals are used to separate polyester-cotton textiles, then separation completeness is improved, but production cost increases

Engineering Contradiction:
Improveseparation completenessVSAvoidproduction cost
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent uses inexpensive organic acids (acetic acid, formic acid, oxalic acid, citric acid) as catalysts that are significantly cheaper than traditional chemicals like hydrochloric acid or tetramethylene sulfone. These organic acids can be purchased at low cost and disposed of or degraded naturally after use, reducing both material costs and disposal costs.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

By changing the chemical parameters to use organic acids instead of traditional harmful chemicals, the patent maintains effective fiber separation while dramatically reducing production costs. The organic acids provide sufficient catalytic activity for complete separation at much lower prices.

Inventive Principle:
Principle #35Parameter changes

3Manufacturing precision

If large and expensive solvents (NMMO, ionic liquid, DMT) are used to dissolve fibers selectively, then separation completeness is improved, but production cost and environmental impact increase

Engineering Contradiction:
Improveseparation completenessVSAvoidproduction cost
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive solvents like NMMO, ionic liquid, and DMT with inexpensive organic acids that serve as catalysts for hydrothermal degradation. These organic acids are much cheaper, can be easily disposed of or degraded naturally, and still achieve complete fiber separation through catalytic action on the hydrothermal reaction.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent substitutes the mechanical/dissolution-based approach using large solvents with a chemical catalytic approach using organic acids. Instead of relying on bulk solvent dissolution, the organic acids catalyze hydrothermal reactions that selectively degrade cotton fibers while leaving polyester intact, achieving separation through catalytic chemistry rather than bulk solvent action.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If large and expensive solvents are used to dissolve fibers selectively, then separation completeness is improved, but environmental protection is compromised

Engineering Contradiction:
Improveseparation completenessVSAvoidenvironmental protection
Core Design Contradiction:
Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent uses organic acids that are environmentally benign and can be degraded naturally, replacing expensive and environmentally harmful solvents like NMMO, ionic liquid, and DMT. These organic acids pose no environmental threat after use and can be disposed of or decomposed without harming the environment.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces the solvent-based dissolution system with a catalytic hydrothermal reaction system using organic acids. This substitution eliminates the need for large volumes of expensive and environmentally harmful solvents, achieving the same separation completeness through a greener, more sustainable chemical process.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method effectively recycles waste polyester-cotton textiles with high recovery rates, reducing environmental impact and production costs by using a natural, non-polluting catalyst, achieving over 95% polyester and 80% cotton fiber recovery without harmful chemicals or solvents.

Implementation Method 1

heating the mixed system to 110 ̃180° C. in a high-pressure reactor so that cotton fibers in the waste polyester-cotton textile undergo a degradation reaction

Methodology Applied
Scientific EffectHydrothermal reaction: Hydrolysis

Implementation Method 2

a hydrothermal reaction catalyzed by an organic acid

Methodology Applied
Scientific EffectCatalysis: Catalysis

Data Source

PatentUS11396114B2Method for separating and recycling a waste polyester-cotton textile by means of a hydrothermal reaction catalyzed by an organic acid
Publication Date: 2022.07.26 THE HONG KONG RES INST OF TEXTILES & APPAREL
  • US11396114B2 patent drawing
  • US11396114B2 patent drawing
  • US11396114B2 patent drawing

AI summary

A method for separating and recycling a waste polyester-cotton textile by a hydrothermal reaction catalyzed by an organic acid, comprising the following steps: dividing a waste polyester-cotton textile into fragments and dispersing in an aqueous solution system of the organic acid catalyst to obtain a mixed system; in a high-pressure reactor, heating the mixed system to 110˜180° C. so that cotton fibers in the waste polyester-cotton textile undergo a degradation reaction for 0.5˜3 h to obtain a mixture; and filtering the mixture by a sieve, washing to obtain a polyester fiber aggregate, and then filtering the remaining portion by a filtration membrane in vacuum so as to obtain cotton fiber fragments after washing. Embodiments of the present disclosure may provide advantages for the separation, recycling and reuse of waste polyester-cotton textiles. For example, the catalyst used during processing is derived from nature and is biodegradable.