Process and plant for recycling fabrics

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Solution Overview

Problem

Existing methods for recycling elastomeric fibers from waste textiles often result in partial degradation of the material, making it unsuitable for reuse with the required mechanical characteristics.

Innovation Solution

A process involving the use of a solvent recirculation method where elastomeric material is extracted from waste textiles in a static extraction chamber, with the solvent being repeatedly circulated and evaporated under reduced pressure to minimize degradation, using solvents like dimethylacetamide (DMAC) at controlled temperatures to dissolve and recover elastomeric fibers without significant physical or chemical alteration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional methods (thermal degradation, solvent extraction) are used to separate elastomeric fibers from waste textiles, then the elastomeric material can be recovered, but the material undergoes partial degradation and loses its mechanical characteristics

Engineering Contradiction:

Improveamount of elastomeric material recoveredVSAvoidmechanical characteristics of recovered elastomeric material

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent changes the extraction parameters by using supercritical or subcritical water instead of conventional solvents, operating at controlled temperatures and pressures. This allows extraction of elastomeric material while preserving its mechanical properties, as the extreme conditions of supercritical water extraction prevent degradation that occurs with conventional thermal or chemical methods

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transitions of water (liquid-steam) in a controlled manner during extraction. By transitioning water to supercritical or subcritical states and then back to liquid, the system achieves efficient extraction of elastomeric material without the degrading effects of conventional high-temperature thermal methods, thus maintaining the recovered material's mechanical characteristics

Inventive Principle:

Principle #36Phase transitions

2Productivity

If high temperatures are used to extract elastomeric material from waste textiles, then the extraction efficiency increases, but the elastomeric material degrades and loses elasticity

Engineering Contradiction:

Improveextraction efficiencyVSAvoidelasticity of elastomeric material

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent changes the temperature and pressure parameters to achieve supercritical or subcritical states of water. This allows extraction to occur at lower temperatures than conventional methods would require, preventing thermal degradation of the elastomeric material while maintaining high extraction efficiency through the enhanced solvating power of supercritical or subcritical water

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If multiple batches of fabric are processed in smaller amounts, then control over process parameters improves and quality increases, but the processing time and equipment complexity increase

Engineering Contradiction:

Improvecontrol over process parametersVSAvoidnumber of reactors required

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the extraction process into multiple batches, processing fabric in smaller quantities sequentially. This segmentation allows precise control over process parameters for each batch, improving quality and consistency. The system uses a single reactor that processes material in staged batches rather than requiring multiple reactors, balancing control precision with equipment simplicity

Inventive Principle:

Principle #1Segmentation

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 recovers elastomeric material with minimal degradation, achieving a yield of 90-99% and maintaining the material's elasticity and chemical stability, allowing for its reuse with reduced post-treatment needs.

Implementation Method 1

circulating a solvent through said extraction chamber and said waste textile to dissolve and remove the elastomeric material from the waste textile

Methodology Applied

Scientific EffectSolvation: Solvation

Implementation Method 2

condensing the evaporated solvent in at least one condensation chamber

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 3

evaporating at least part of the solvent obtained in step c) in an evaporation chamber to increase the amount of elastomeric material in the solvent

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20230392297A1Process and plant for recycling fabrics

Publication Date: 2023.12.07 SANKO TEKSTIL ISLETMELERI SANAYI VE TICARET AS

AI summary

In a process for recycling waste fabric comprising elastomeric material a polar solvent is flowed through the waste fabric in an extraction chamber to dissolve and remove the elastomeric material; the solvent is evaporated in an evaporation chamber and condensed to be sent to a solvent collection tank or back to the extraction chamber; the dissolved elastomeric material is eventually recovered from the concentrated polar solvent.