Development of a Process for Recycling of Blended Fabrics Institut für Textiltechnik der RWTH Aachen University, Germany

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1 Development of a Process for Recycling of Blended Fabrics Institut für Textiltechnik der RWTH Aachen University, Germany

2 Development of a Process for Recycling of Blended Fabrics ITMA 2015 Milan, Italy

3 Overview About ITA Facts and project goal Method Results Conclusion Acknowledgements 3 von 17

4 About ITA Established in 1934 Part of the Faculty for Mechanical Engineering of RWTH Aachen University 100 research staff, 60 service personnel, 200 student research assistants Focus of research is the development of innovative textile machines, processes and products 4 von 17

personnel, 200 student research assistants Focus of research is the

5 Facts and project goal Facts Worldwide waste production of mio tons of PET/cotton per year PET is made of fossil resources and for each kilogram 80 MJ are needed For 1 kg cotton more than 10,000 l water are needed Goals A new recycling method Staple fibre yarns of fully recycled PET staple fibres References: Natureworks, WWF 5 von 17

needed For 1 kg cotton more than 10,000 l water are needed Goals A new recycling

6 Method 6 von 17

7 Method Preparation blended fabrics to fibres Enzymatic hydrolyse Fermentation to ethanol Wastewater treatment Acidic hydrolyse Fermentation to ethanol Wastewater treatment Further processing of PET fibre residue Opening of the fibres by f. e. carding Sliver production and rotor spinning Dyeing with dispersion dye Fabric production on laboratory knitting unit 7 von 17

processing of PET fibre residue Opening of the fibres by f. e.

8 Opening of the fibres Carding Laboratory carding unit by Anton Guillot KG, Aachen, Germany Feeding unit Material exit Worker and clearer pair Take-off roller Winding Feeding unit Tambour 20 cm 8 von 17

9 Sliver production Uster MDTA3 by Textechno Herbert Stein GmbH & Co. KG, Mönchengladbach, Germany Rotor Opener roll Feeding unit Rotor Feeding unit Opener roll 20 cm 9 von 17

10 Spinning Rotor spinning machine by Saurer.Schlafhorst, Übach-Palenberg, Germany Rotor groove with ring of fibres draw-off nozzle Yarn take-off Yarn liftoff point drawoff roll Rotor Sliver Twist zone 10 cm 10 von 17

with ring of fibres draw-off nozzle Yarn take-off

11 Results 1/4 Enzymatic hydrolyse not economical due to low extraction of ethanol Acidic hydrolyse highly economical due to catalytic process and only dilute acid Recoverd PET staple fibres with yarn and fabric remains Farbics Yarns 2 cm 11 von 17

to catalytic process and only dilute acid Recoverd PET staple

12 Results 2/4 Fabric remains can be opened easily by different methods Yarn remains are still a challenge and could not be opened completely using e. g. carding, fine opener or gradually cleaner Yarns in a sliver 2 cm 12 von 17

could not be opened completely using e. g.

13 Results 3/4 Yarn remains are in the rotor spun yarn as well Due to yarn remains average tenacity of 5 cn/tex of yarn of 100 % recycled PET But: Fibre tenacity of recycled PET of 45 cn/tex 13 von 17

Unevenness in colouring due to yarn remains Elaborate post-treatments

14 Results 4/4 Alkaline fastness to perspiration: grade 4 Washing at 50 C: grade 4-5 Rub fastness, dry: grade 4-5 Rub fastness, wet: grade 4 Unevenness in colouring due to yarn remains Elaborate post-treatments not needed Yarn remains of recycled PES 1 cm Before dyeing After dyeing 14 von 17

15 Conclusion An economic recycling process for blended fabrics is developed using acidic hydrolyse with dilute acid Yarn remains could not be opened completely At present only low tenacity of yarns achievable due to yarn remains Recycled PET staple fibres have high tenacity and posses potential for high tenacity yarns of 100 % recycled PET A twofold pin licker-in and a connected fourfold sawtooth licker-in bear the potential of opening the yarns 15 von 17

Recycled PET staple fibres have high tenacity and posses potential for high tenacity yarns of 100 % recycled PET A

16 Acknowledgements This project is in collaborated by RVN Textilrecycling GmbH, Neuenmarkt, Germany, and Forschung Umwelt Farbe, Hennef, Germany. The project No is funded by research association, Deutsche Bundestiftung Umwelt (DBU). 16 von 17

Umwelt Farbe, Hennef, Germany. The project No.

17 Thank you for your kind attention Institut für Textiltechnik der RWTH Aachen University Marie-Isabel Popzyk Otto-Blumenthal-Str. 1, Aachen, Germany Tel.: +49 (0) 241/

Popzyk Otto-Blumenthal-Str. 1, 52074 Aachen, Germany Tel.

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