Recycled Polyester Resin Dye Extraction from Colored PET Fabric
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Solution Overview
Problem
Existing chemical recycling techniques for polyester fibers fail to adequately extract dyes from colored fibers, leading to inferior color tone and requiring advanced purification methods.
Innovation Solution
A method involving the use of colored PET fabric as a raw material, where a heated ethylene glycol (EG) is used to extract the coloring component before depolymerization, followed by simple purification steps like filtration, crystallization, and activated-carbon treatment to obtain a recycled polyester resin with excellent heat resistance and color tone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If advanced purification methods are used to extract dyes from colored fibers, then the color tone of the recycled resin is improved, but the process complexity and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by performing dye extraction from colored PET fibers before depolymerization. This pre-treatment removes coloring components in advance, preventing them from interfering with subsequent purification steps and final resin quality. The extraction is conducted using organic solvents or oxidizing agents prior to breaking down the polymer, thereby simplifying the overall purification process while maintaining excellent color tone in the recycled resin.
Solution Approach 2:
The patent directly extracts and removes dye components from colored PET fibers using extraction methods with organic solvents or oxidizing agents. By taking out the harmful coloring components before depolymerization, the process achieves high-quality color tone in the final resin without requiring complex multi-stage purification systems, thus resolving the contradiction between quality and complexity.
2Manufacturing precision
If molecular distillation is performed to purify BHET monomer, then the purity of the monomer is improved, but the energy consumption and processing time increase
Solution Approach 1:
The patent performs dye extraction as a preliminary action before depolymerization, removing coloring components that would otherwise require energy-intensive removal during monomer purification. This pre-removal of impurities reduces the burden on subsequent purification steps, allowing simpler and less energy-consuming methods to achieve the required monomer purity.
Solution Approach 2:
The patent employs disposable activated carbon during the purification process to adsorb remaining impurities from the BHET monomer solution. This simple, inexpensive material provides effective purification without requiring complex distillation equipment or high energy input, replacing energy-intensive molecular distillation with a more efficient and economical approach.
3Ease of manufacture
If simple purification steps are used after depolymerization, then the process complexity is reduced, but the color tone quality of the final resin deteriorates
Solution Approach 1:
The patent performs dye extraction as a preliminary action before depolymerization, removing the majority of coloring components in advance. This pre-treatment enables the use of simple purification steps afterward (such as activated carbon treatment and filtration) while still achieving excellent color tone quality in the final resin, as the bulk of color contaminants have already been removed.
Solution Approach 2:
The patent uses organic solvents or oxidizing agents as intermediaries to extract dyes from colored PET fibers before depolymerization. These intermediary substances facilitate the removal of coloring components, enabling subsequent simple purification steps to produce high-quality resin with excellent color tone that would otherwise require complex purification processes.
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
The method achieves a recycled polyester resin with heat resistance and dry properties comparable to those made from virgin materials, while maintaining an equivalent color tone through efficient dye extraction and simple purification processes.
Implementation Method 1
a step of bringing a heated EG into contact with the colored PET fabric to extract a coloring component
Implementation Method 2
a step of bringing EG vapor into contact with the colored PET fabric
Implementation Method 3
a step of depolymerizing the PET fabric after extracting the coloring component to obtain an EG solution containing the ester monomer
Implementation Method 4
a step of performing an activated-carbon treatment or an ion-exchange treatment
Implementation Method 5
a step of cooling a filtration solution of 85°C or more and 100°C or less to 30°C or less, and crystallizing and recovering the ester monomer
Data Source
AI summary
A recycled polyester resin obtained by using colored PET fabric as a material, the recycled polyester resin being a polyethylene terephthalate resin comprising 88-100 mol% of a terephthalic acid residue with respect to all acid components, and 88-100 mol% of an ethylene glycol residue with respect to all diol components, wherein the polyethylene terephthalate resin has (1) a diethylene glycol percentage content of not less than 0.1 mass% but less than 0.8 mass%, (2) a nitrogen atom percentage content of 0.5-15.0 mass ppm, and (3) a b-value in the Hunter color tone of not less than -10.0 but less than 5.0.

