PET-Recycling/Upcycling with the new LSP-Process (Liquid ... · PET-Recycling/Upcycling with the...

Next Generation Recyclingmaschinen

PET-Recycling/Upcycling with the new LSP-Process (Liquid State Polycondensation)

12th Annual CARE Conference May 6 - 8, 2014 Seattle Renaissance, Seattle, WA Thomas Pichler

Next Generation Group in brief

PET properties and forces describing material

decomposition and reversible composition

PET Reactor – basic functions

Handling of various different input materials (bottle flakes, wovens, etc.)

Results from test Runs

Outlook on commercial availability

Contents

PET-Recycling/Upcycling with the new LSP-Process (Liquid State Polycondensation)

2/28 May 2014 - 12th Annual CARE Conference

Profile

Competence for the Plastic Industry

3/22

Employees 2013: 226

Total Sales 2013: € 51,5 Mio.

Next Generation Group

May 2014 - 12th Annual CARE Conference

Members

4/22

RECYCLING-SOLUTIONS for industrial plastic converters and end-of-life plastics > Headquarter Feldkirchen, AUSTRIA > Customer Care Center for NAFTA/USA > Customer Care Center for ASIA/CHINA www.ngr.at

FILTRATION-SYSTEMS for heavy contaminated end-of-life plastics > Hanau, GERMANY www.britas-recycling.de

PILOT PLANTS + LAB EQUIPMENT for optimizing plastic materials and converting technologies > Ebersberg, GERMANY www.drcollin.de



5/11



Global Spread

6/11

Next Generation Equipment in Operation

Sales & Customer Care Center AMERICA

Representative Office MALAYSIA

Sales & Customer Care Center CHINA

Representative Office TAIWAN

Headquarter Feldkirchen, AUSTRIA

BritAS GmbH Hanau, GERMANY

Dr. Collin GmbH Ebersberg, GERMANY



LSP Technology


L S P

=

Liquid State Polycondensation

long polymer chain = high viscosity = high molecular weight = high iV- value = high price

cleaved

PET properties and forces describing material decomposition and reversible composition

8/18

Terephthalic acid Ethylene glycol

Polyethylene terephthalate



Intrinsic Viscosity (IV; dl/g)

Fiber, Textile 0,40 – 0,70 (0,62)

Film Grade 0,60 – 0,70 (BOPET)

0,70 – 1,00 (Thermoforming Sheets)

Bottle Grade 0,78 – 0,85 (Carbonated)

0,70 – 0,78 (Water flat)



AA-Value (Acetaldehyde) + others

Less than 1,5 ppm

Color value (L,a,b)

Food Contact non objection letters (FDA, EFSA, etc.)


Thermal decomposition

Thermal/ oxidative decomposition

Hydrolytic decomposition

Reason

Influence of too high temperature + too long exposure time

High Temperature+ Aerial oxygen

Moisture in the material

Comparison Decomposition-speed

1 10 10.000



SSP (Solid State Polycondensation)

LSP (Liquid State Polycondensation)

State of PET Solid / crystalline Liquid (melt)

Environment Vacuum or inert gas vacuum

Typical Temperature (200-240) °C (270-280) °C

IV – Lift – Speed (0,01 – 0,02) dl/g per hour

(0,01) dl/g per minute



PET-Reactor Basic Functions

May 2014 - 12th Annual CARE Conference 13/22

PET Upcycling unit for PET - fibers

Strand-Pelletizer

Shredder-Feeder-Extruder-

Combination

PET-Reactor

Handling of various different Input-Materials

May 2014 - 12th Annual CARE Conference 14/22

Input condition (clean in any case)

PET-fibre production waste textured and uncut

Material data Parameter Unity

Moisture Average 3368 ppm

iV-Average 0,62 dl/g

Spin finish ~ 0,5 %

Output 350 kg/h

Result iV-Average 0,665 dl/g

Results from test run


LSP Test runs

iV-Measuring points

After Extruder

Before Reactor

Pellet

LSP Testresults

0.630

0.570 0.563

0.641

0.663 0.658

0.655 0.660

0.666 0.665

0.550

0.560

0.570

0.580

0.590

0.600

0.610

0.620

0.630

0.640

0.650

0.660

0.670

0.680

Fibre after Extruder beforeReaktor

Pellets 60min.after Start

Pellets 90min.after Start

Pellets120min after

Start

Pellets180min. after

Start


Start


Start


Start

iV [d

l/g]

LSP –Testresults PET Fiber

LSP-Technology Laboratory facility / Prototype

New Laboratory facility Production capacity of 400 kg/h (tests @ 250 kg/h)

Results Test Run “Challenge Test” Fraunhofer

19/18

FDA non-objection Letter # 171 from Nov. 2013 under

http://www.fda.gov/food/ingredientspackaginglabeling/ packagingfcs/recycledplastics/ucm376377.htm

Outlook on commercial availability

Test program @ NGR Preforms Bottle flakes Fibres / woven / non-wovens Sheets

Technical implementation Up scaling Results long term tests

Test program in field Long term performance PET-properties

Colouring Energy consumption monitoring Operation parameters (controls)

11 2013

02 2014

01 2015

09 2014

Lab testing @ NGR

Beta + Market Testing (Field tests)

11 2014

Technical Implementation

Commercialization

20/18

Post Consumer Fiber Trials

21/18

Input Material:

Output Material:

Summary

22/18

LSP – Liquid State Polycondensation –

shifts IV-increase and decontamination into the molten phase

of PET (ideal for recycling-purposes)

Lab tests and pilote plant show encouraging results

Challenge tests have been very successful in terms

of decontamination (FDA non objection-letter received in Nov.2013)

Commercial availability to be expected early 2015

WE TAKE CARE OF YOUR PLASTIC WASTE

Next Generation Recycling Machines, Inc. Sales & Customer Care Center America 3000 Center Place, Suite 100 Norcross, GA 30093, USA Phone +1-678-720-9861, Fax -9863

Next Generation Recycling Machines Representative Office Malaysia D-12-08, Bl.D, PJ 8, No. 23, Jalan Barat, Seksyen 8 46050 Petaling Jaya, Selangor, Malaysia Phone +60 3 79588795, Fax: +60 3 79587795

Next Generation Recycling Machines Representative Office Taiwan 5F-7, No. 316, Wenchang Street Taipei 110, Taiwan Phone +886 2 8780 9346

[email protected], www.ngr.at

Next Generation Recyclingmaschinen GmbH HQ, Production and Customer Care Center Europe Gewerbepark 22 4101 Feldkirchen, Austria Phone +43 (0) 7233 70 1 07-0, Fax -2

Next Generation Recyclingmachines, Co., Ltd. Sales & Customer Care Center China No.6, Wuxi Road, Taicang Economic Development Zone, Taicang, Jiangsu 215400, China

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