KR20110026707A - Method for manufacturing recycled polyester chip and recycled polyester filament fiber manufactured therefrom - Google Patents

Abstract

PURPOSE: A method for manufacturing a recycled polyester chip is provided to secure the purity of generated polyester powder by sorting all kinds of foreign materials in polyester bottle waste. CONSTITUTION: Metal materials are removed by unpacking polyester bottle bale. A polyester bottle body is formed by removing a label and a cap. The polyester bottle body is pulverized. The residue of the label is removed by wind force. Plastic of a different material is separated by water. A polyester flake is pulverized. The residual foreign substance in the polyester flake is removed by wind force. Plastic of a different material in the polyester flake is separated by water. The polyester powder is molded in a pellet form through the melting.

Description

Method for manufacturing polyester recycled chip and recycled polyester filament manufactured therefrom {Method for manufacturing Recycled polyester chip and Recycled polyester filament fiber Manufactured Therefrom}

Embodiments of the present invention relates to a method for producing a recycled chip for polyester long fiber production using polyester bottle waste, and to a recycled polyester long fiber manufactured therefrom, and more particularly, to a low cost, The present invention relates to a method for producing a regenerated chip for producing polyester long fibers, which is fractionated by low energy and to ensuring the purity of a polyester regenerated chip, and a functional regenerated polyester long fiber produced therefrom.

With the recent acceleration of environmental pollution, gases such as carbon dioxide, methane, nitrous oxide (N ₂ O) and chlorofluorocarbons (CFCs) are increasingly surrounding the earth. The result is a global warming effect that prevents the release of radiant heat from the earth, which warms the earth. Due to the greenhouse effect, the earth's atmospheric temperature in 1990 was reported to be about 0.5 to 0.7 ° C higher than in 1880, causing secondary problems such as ecosystem changes, sea level rise, and ozone depletion. In order to cope with this global warming problem internationally, the international community signed a climate change agreement in Rio de Janeiro, Brazil in June 1992.In 1998, the Kyoto Protocol reduced the greenhouse gas emissions based on market principles and the binding force of each country. To reach a target, and the importance of recycling for waste has emerged.

Among the synthetic resins, the recycling method of polyester mainly used can be subdivided as follows.

First, chemical recycling is chemical decomposition of waste polyester bottles to be used as chemical raw materials. Semi-permanent recycling is possible, and it is an optimal method in a cyclical economic society, but it is difficult in terms of technology and cost.

Material recycling is the melting and regeneration of homogeneous or dissimilar materials, and is the best method in terms of cost, but there is a practical problem that thorough classification is required.

Thermal recycling is not recommended as a recycling method because it is reused as thermal energy and cannot repeatedly use resources and generates carbon dioxide by combustion.

Among polyester wastes, the problem of handling a bulky polyester bottle by weight is becoming more serious. Currently, the general recycling method of polyester bottles is material recycling, and the polyester bottles recovered after use are only melted and short-fiber (staple yarn) to be formed. It is impossible to use for polyester filament (filament yarn) due to deterioration of physical properties, color discoloration and dyeing unevenness. Moreover, discarded polyester bottles are often incorporated with labels and caps of different plastic materials, such as polypropylene, polyethylene, polyvinyl chloride, etc., derived from components of polyester bottle products, various adhesives, pigments, dyes and the like. Such material recycling is not suitable for polyester long fiber applications that require high purity because the recovered polyester resin has low purity.

Embodiments of the present invention is to produce a polyester recycled chip that can be used to produce a polyester long fiber by securing a high purity of the polyester recycled chip by separating all kinds of foreign matter contained in the polyester bottle waste at low cost, low energy It is about a method.

Embodiments of the present invention relates to a method for producing recycled polyester filaments using the polyester regenerated chip prepared by the above production method.

Embodiments of the present invention are directed to a functional polyester filament produced by the method for producing a recycled polyester filament.

One aspect of the present invention, unpacking the polyester bottle bale (Bale) to remove the metal material and removing the label, cap of the different material material other than polyester to form a polyester bottle body;

5 to 10 m / sec of wind is applied to the polyester flakes having a length of 30 to 30 mm formed by pulverizing the polyester bottle body to remove residues of the label first, and the specific gravity is selected by water to make the specific gravity smaller than that of water. A primary fractionation process step of primaryly separating the different material plastics;

The first fractionated polyester flakes were pulverized and applied to the polyester powder having a length of 0.01 to 0.5 mm to apply wind power of 1 to 2 m / sec to remove residual foreign matters secondly, and to perform specific gravity differentiation with water so that specific gravity is higher than water. A second fractionation process step of secondly separating the small different material plastics; And

It relates to a method for producing a polyester regenerated chip comprising melting the secondary fractionated polyester powder and molding into pellets.

Another aspect of the present invention relates to a method for producing regenerated polyester filaments which are spun by using a cross-section spinneret after remelting the prepared polyester regenerated chip.

Another aspect of the present invention relates to a functional regenerated polyester filament produced by the method for producing a polyester filament.

According to the method of manufacturing a polyester regenerated chip according to the embodiments of the present invention, it is possible to secure the purity of the polyester powder produced by separating all kinds of foreign substances contained in the polyester bottle waste as a raw material at low cost and low energy. In addition, it can not only produce high quality functional polyester filament but also reduce environmental pollution.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 schematically illustrates a process for manufacturing a polyester regenerated chip and yarn according to an embodiment of the present invention. Referring to FIG. 1, in the method of manufacturing a polyester recycling chip according to an embodiment of the present invention, an unpacking of the collected polyester bottle bale is performed, and the metal material of the polyester bottle is removed. And a pre-treatment step of forming a polyester bottle body by removing a label and a cap of a different material other than polyester from the polyester bottle from which the metal material is removed after removal using a detector.

Among various foreign substances included in the polyester bottle dismantled from the polyester bottle bale, metal components such as iron and aluminum serve as obstacles in forming a polyester regeneration chip. Therefore, metal detectors are used to find and remove metal components such as iron and aluminum contained in polyester bottles. The label and cap made of polypropylene, polyethylene, and polyvinyl chloride are separated and removed from the polyester bottle in which the metal component is removed by hand or a known technique.

Subsequently, the polyester bottle body in which the label and the cap of the different material material are separated and pulverized is pulverized to form a polyester flake of a predetermined size, and the first fractionation removes various foreign substances.

More specifically, the primary fractionation step includes wet grinding and drying the pretreated polyester bottle body to form a polyester flake having a length of 3 to 30 mm, by wind power of 5 to 10 m / sec from the polyester flake. Firstly removing the residue of the label, and the foreign matter and the residue of the contents of the polyester flakes from which the residue is removed are washed with water and subjected to specific gravity screening to remove foreign substances having a higher specific gravity than water, having a specific gravity greater than water. The first step is to separate the small different plastic material.

If the length of the polyester flakes subjected to the primary fractionation is less than 3 mm, not only foreign matters that are to be separated and removed but also the effective flakes of polyester flakes are blown away by wind, and when the length of the polyester flakes exceeds 30 mm, The flake's own weight interferes with the removal of debris.

From the polyester flakes, different materials and foreign substances including label residues such as polyethylene, polypropylene, polyvinyl chloride, and the like, which are different from polyesters used in the labels of polyester bottles and the like, are firstly removed by wind.

That is, an airflow of 5-10 m / sec wind speed is applied to the polyester flakes to blow off the label residues contained in the polyester flakes. At this time, if the air velocity of the polyester flakes is less than 5 m / s, the label residues contained in the polyester flakes are not properly screened and removed due to the lack of wind power, and the air velocity of the air stream applied to the polyester flakes is 10 If m / sec is exceeded, not only the label residue but also the active polyester flakes are blown away by the wind due to the excess wind, so it is applied to the polyester flake when the primary material and foreign matter including the label residue are removed first. Loss of wind must be properly controlled. Such wind screening can remove 99% or more of label residues of polyethylene, polypropylene, and polyvinyl chloride, which are different materials.

Subsequently, the polyester flakes are washed with water and fed into a specific gravity separator to remove the cap pulverized product containing polyethylene or polypropylene, which cannot be removed in wind sorting. The cap mill is separated off by specific gravity screening and the remaining polyester flakes are recovered and dried to obtain the first fractionally washed polyester flakes.

Conventional polyester bottle regeneration methods are first fractionally cleaned and immediately pelletized to produce chips of several hundred ppm of different material and foreign matter, which are suitable for producing ordinary polyester moldings or short fibers. Although it is pure, it is very poor in terms of purity to produce polyester long fibers. In the case of long fibers, fairness in a continuous process should be secured, and in terms of quality, post-processability, especially dyeability, should be secured. Hundreds of ppm of dissimilar materials and foreign substances included in the primary rinsed polyester flakes It acts as a serious drawback and significantly lowers fairness and stainability.

Therefore, in order to make the first fractionally washed polyester flakes long fibers, a secondary fractionation process for further improving the purity of the polyester flakes is essential.

In the method for manufacturing a polyester regenerated chip according to an embodiment of the present invention, the primary fractionally washed polyester flakes are wet pulverized and dried to form a polyester powder having a length of 0.01 to 0.5 mm, and the polyester powder Carry out a second fractionation.

That is, in the method for manufacturing a polyester regenerated chip according to an embodiment of the present invention, a polyester powder having a primary material separated from the primary flake is wet pulverized and dried to form a polyester powder having a length of 0.01 to 0.5 mm, and the formed poly After removing residual foreign matters secondary by 1 ~ 2 m / sec wind power from the ester powder, the foreign substances and contents residues of polyester powder from which residual foreign substances have been removed are washed with water, and the specific gravity difference is selected to remove foreign substances having a higher specific gravity than water. A secondary fractionation process involves the removal and secondary separation of the dissimilar plastics with less specific gravity than water.

When the length of the polyester powder subjected to the second fractionation is less than 0.01 mm, the not only foreign matter that is to be separated and removed, but also the polyester powder, which is an active ingredient, is blown away and removed together with the length of the polyester powder. In the differentiation process, the weight of the polyester powder is hampered by the removal of foreign substances.

If the air velocity applied to the polyester powder to remove the fine label residues is less than 1 m / sec, the fine label residues contained in the polyester powder may not be properly screened out due to the lack of wind power. If the wind speed of the air flow exceeds 2 m / sec, the excess wind blows away not only the fine label residue but also the active polyester powder due to the excess wind, so that the secondary materials and foreign substances including the fine label residue are secondary. When removed, wind power applied to the polyester powder must be controlled more precisely and properly than the first fractionation process. By such wind sorting, the content of label residues of polyethylene, polypropylene, and polyvinyl chloride, which are different materials included in the polyester powder, can be reduced to 10 ppm or less.

Subsequently, in order to remove the fine cap pulverized product mainly composed of polyethylene or polypropylene, which cannot be removed in wind power sorting, the polyester powder is washed with water, and put into a specific gravity separator, and the polyethylene or polypropylene material having a smaller specific gravity than water is used. After the fine cap pulverized product was separated off by specific gravity screening, the remaining polyester powder was recovered and dried to obtain a secondary fractionally washed polyester powder.

As described above, the second fractionally washed polyester powder has a level of 10 ppm or less of different materials and foreign substances, and thus has a purity enough to form polyester long fibers by melt spinning. The polyester powder is melted and molded into pellets to form a polyester recycling chip.

 In the method of manufacturing a polyester regenerated chip according to an embodiment of the present invention, the content of the titanium dioxide is 50 to 30,000 by melting the polyester powder in which the dissimilar material plastics are secondarily separated and side feeding the master batch chip containing titanium dioxide as a quencher. It may include a recycled chip forming process of forming a polyester melt of ppm and the polyester melt formed by extrusion molding and cooling and solidified to form a polyester recycled resin and then cut it into pellets.

More specifically, the secondary fractionally washed polyester powder is dried to a moisture content of 30 ppm or less using a dehumidifying dryer. The dried polyester powder is injected into an extruder equipped with a side feeder, melted and extruded, and titanium dioxide, a light-dispersing quencher, is added to the side feeder in the form of a master batch chip and mixed with the polyester powder to make a dioxide. A polyester melt with a titanium content of 30,000 ppm or less is formed. The master batch chip mixed with the polyester powder to form the polyester melt is configured to have a titanium dioxide content of 5-50% by weight. If the titanium dioxide content of the mixed master batch chip is less than 5% by weight, the titanium dioxide content is insufficient, which is disadvantageous in terms of the cost of the polyester recycled chip made from the polyester melt, and if the titanium dioxide content exceeds 50% by weight, the polyester melt It is difficult to secure the dispersibility of titanium dioxide in the polyester regenerated chip, which causes a decrease in processability and dyeing property in the production of long fibers.

As described above, the titanium powder-containing master batch chip is fed to the polyester powder, melted and extruded, and cooled in a cooling bath to form a recycled resin. The recycled resin is cut into pellets using a cutter to form a long fiber. Ester recycled chip is manufactured. At this time, the step of adding titanium dioxide may be omitted depending on the use of the final product.

The polyester recycled chip produced by the method for producing a polyester recycled chip is used alone, or mixed with a new polyester chip for fiber manufacturing, and melt-spun by a known general cooling method or a special central cooling spinning method to make polyester. Regenerated functional polyester filaments having a content of 10 to 100% by weight of the recycled chip component can be prepared.

Although it is technically possible to construct recycled polyester filaments with a content of polyester recycled chip components of less than 10% by weight (i.e., 90% by weight or more of the new polyester chip for fiber manufacturing), polyester bottle waste Loss of meaning of producing recycled polyester filaments using the polyester recycled chip produced by the material recycling of. Preferably the content of the regenerated chip component in the regenerated functional polyester filament may be 50 to 100% by weight.

The cross section of the regenerated polyester filament thus produced may be ○ type, Δ type or + type, but is not necessarily limited thereto.

Hereinafter, the configuration and effects of the present invention will be described in more detail with specific examples, but these examples are only intended to more clearly understand the present invention and are not intended to limit the scope of the present invention.

Example 1: Preparation of Recycled Polyester Yarn

1. Fractionation The polyester bottle bales were dissociated to disperse the polyester bottle.

2. Metallic material was removed from the polyester bottle using a metal detector.

3. The different materials such as labels and caps were manually removed from the polyester bottle from which the metal material was removed.

4. The pretreated polyester bottle was ground with a wet mill to form a polyester flake of average length 5 mm.

5. Different materials such as labels, caps, etc. were separated and removed from the polyester flakes by 5 m / sec wind power applied in the wind separator.

6. The polyester flakes from which the dissimilar materials and foreign substances were separated were washed with industrial water and separated by specific gravity with a specific gravity separator to separate the dissimilar materials and foreign substances having a smaller specific gravity than water, and washed and dried to complete the primary fractionation.

7. The first fractionated polyester flakes were ground with a wet mill to form polyester powder with an average length of 0.1 mm.

8. The residual dissimilar materials and foreign matters were separated from the polyester powder by the 1.5 m / sec wind power applied in the wind separator.

9. The polyester powder from which the dissimilar materials and foreign substances were separated was washed with industrial water and subjected to specific gravity difference separation using a specific gravity separator to separate the dissimilar materials and foreign substances having a smaller specific gravity than water, and then washed and dried for secondary separation.

10. The secondary fractionated polyester powder was melted in an extruder at 295 ° C., followed by extrusion molding and cooling to form a polyester recycled resin.

11. The polyester recycled resin was cut into pellets to form a polyester recycled chip.

12. The polyester regenerated chip was spun at a speed of 4,500 m / min at 290 ° C. in a conventional long fiber spinning device equipped with a Y-type spinneret to produce 150 denier / 48 filament triangular cross-sectional regenerated polyester yarns.

Example 2: Preparation of Recycled Polyester Yarn

The secondary fractionated polyester powder was melted at 295 ° C. in an extruder, and side fed a master batch chip containing 50% by weight of titanium dioxide as a quencher, and 99.4% by weight of polyester powder and 0.6% by weight of master batch chip were mixed. To form a polyester melt with a titanium dioxide content of 3,000 ppm and a polyester regenerated chip at a rate of 295 ° C. at 4,000 m / min in a centrally cooled long fiber spinning device equipped with a cross spinneret. A recycled polyester yarn was prepared in the same manner as in Example 1, except that the yarn was spun to form a 75 denier / 72 filament cross regenerated polyester yarn.

Example 3: Preparation of Recycled Polyester Yarn

The secondary fractionated polyester powder was melted in an extruder at 295 ° C., and side fed a master batch chip containing 30 wt% of titanium dioxide as a quencher, and 99.0 wt% of polyester powder and 1.0 wt% of the master batch chip were mixed. Forming a polyester melt with a titanium dioxide content of 3,000 ppm and spinning a polyester regenerated chip at a rate of 295 ° C. and 4,100 m / min in a centrally cooled long fiber spinning device equipped with a ○ spinneret. A recycled polyester yarn was prepared in the same manner as in Example 1 except that a recycled polyester yarn of denier / 192 filaments was prepared.

Comparative Example 1: Preparation of Recycled Polyester Yarn

1. A polyester bottle bale was decanted to disperse the polyester bottle.

2. Metallic material was removed from the polyester bottle using a metal detector.

3. Pretreatment was performed by manually removing different materials such as labels and caps from the polyester bottle from which the metal material was removed.

4. The pretreated polyester bottle was ground with a wet mill to form polyester flakes with an average length of 10 mm.

5. Dissimilar materials such as labels, caps and other foreign matter were removed from the polyester flakes by 7 m / s of wind power applied in the wind separator.

6. The polyester flakes from which the dissimilar materials and foreign substances were separated were washed with industrial water and separated by specific gravity with a specific gravity separator to separate the dissimilar materials and foreign substances having a smaller specific gravity than water, and washed and dried.

7. The fractionated polyester flakes were melted in an extruder at 295 ° C. and then extruded and cooled to solid to form a polyester recycled resin.

8. The polyester recycled resin was cut into pellets to form a polyester recycled chip.

9. The polyester regenerated chip was spun at a speed of 4,500 m / min at 290 ° C. in a conventional long fiber spinning device equipped with a Y-type spinneret to prepare a triangular cross-sectional regenerated polyester yarn of 150 denier / 48 filaments.

Comparative Example 2: Preparation of Recycled Polyester Yarn

The fractionated polyester flakes were melted in an extruder at 295 ° C., side fed a master batch chip containing 50 wt% titanium dioxide as a quencher, and 99.4 wt% polyester powder and 0.6 wt% master batch chip were mixed. A polyester melt with a titanium dioxide content of 3,000 ppm was formed and the polyester regenerated chip was spun at a rate of 295 ° C and 4,000 m / min in a centrally cooled long fiber spinning device equipped with a + -shaped spinneret at 75 denier / A recycled polyester yarn was prepared in the same manner as in Comparative Example 1 except that a 72 filament-shaped regenerated polyester yarn was produced.

Comparative Example 3: Preparation of Recycled Polyester Yarn

The fractionated polyester flakes were melted in an extruder at 295 ° C., side fed a master batch chip containing 30 wt% of titanium dioxide as a quencher, and 99.0 wt% polyester powder and 1.0 wt% master batch chip were mixed. Forming a polyester melt with a titanium dioxide content of 3,000 ppm and spinning a polyester regenerated chip at a rate of 295 ° C. at a rate of 4,100 m / min in a centrally cooled long fiber spinning device equipped with a conventional ○ spinneret. A recycled polyester yarn was prepared in the same manner as in Comparative Example 1 except that a recycled polyester yarn of denier / 192 filaments was prepared.

Evaluation of physical properties and processability of the polyester regenerated chip and the regenerated polyester filament prepared in Examples 1 to 3 and Comparative Examples 1 to 3 was carried out by the following method, and the results are shown in Table 1 below.

1. Color L, b value of polyester regenerated chip: Color L value and color b value of regenerated chip were measured by KS A 0067 color standard using Colorerview of Gardener.

2. Elongation of recycled polyester filament: The elongation of regenerated polyester filament was measured by using Instron 5565 of Instron.

3. Spinning operation: The end of the full tube was measured for 4 hours by operating the 4-end spinning machine for 48 hours.

4. Combustibility: 12 weight combustors were operated for 48 hours, and the ratio of full capacity to total production was measured using 3 kg volume basis.

5. Dyeability: 100 fabrics were prepared by dyeing the fabrics with sock paper, and visually evaluated and there was no dyeing difference at all. ◎, if there was at least one dyeing difference in the sample, X was indicated. The proportion of good samples without staining in the whole circular knitted fabric was measured by the M ratio (%).

<Table 1> Physical properties and processability of polyester recycled chip and recycled polyester filament

As shown in Table 1, it can be seen that the polyester regenerated chip and the regenerated polyester filament according to the embodiment are superior in various physical properties, processability, and dyeing properties to the polyester regenerated chip and the regenerated polyester filament according to the comparative example. .

Although the present invention has been described in detail with reference to preferred embodiments of the present invention, it will be apparent to those skilled in the art that the present invention may be variously changed or modified without departing from the spirit and scope of the present invention. Modifications and variations are also to be construed as being included in the scope of protection of the present invention.

The following drawings illustrate one embodiment of the present invention, and together with the detailed description of the present invention serve to assist in understanding the present invention, the present invention should not be construed as limited to the matters set forth in these drawings.

1 is a schematic process diagram of a method for manufacturing a polyester regenerated chip and yarn according to an embodiment of the present invention.

Claims (9)

Forming a polyester bottle body by unpacking a polyester bottle bale to remove a metal material and removing a label and a cap of a different material other than polyester; 5 to 10 m / sec of wind is applied to the polyester flakes having a length of 30 to 30 mm formed by pulverizing the polyester bottle body to remove residues of the label first, and the specific gravity is selected by water to make the specific gravity smaller than that of water. A primary fractionation process step of primaryly separating the different material plastics; The first fractionated polyester flakes were pulverized and applied to the polyester powder having a length of 0.01 to 0.5 mm to apply wind power of 1 to 2 m / sec to remove residual foreign matters secondly, and to perform specific gravity differentiation with water so that specific gravity is higher than water. A second fractionation process step of secondly separating the small different material plastics; And Melting of the secondary fractionated polyester powder and molding in a pellet form manufacturing method of a polyester regeneration chip. The method of claim 1, wherein the manufacturing method further comprises mixing a master batch chip containing titanium dioxide (TiO ₂ ) with the secondary fractionated polyester powder. The method of claim 2, wherein the master batch chip has a titanium dioxide content of 5 to 50% by weight. A polyester regenerated chip produced by the method of any one of claims 1 to 3. Forming a polyester bottle body by unpacking a polyester bottle bale to remove a metal material and removing a label and a cap of a different material other than polyester; 5 to 10 m / sec of wind is applied to the polyester flakes having a length of 30 to 30 mm formed by pulverizing the polyester bottle body to remove residues of the label first, and the specific gravity is selected by water to make the specific gravity smaller than that of water. A primary fractionation process step of primaryly separating the different material plastics; 1 to 2 m / sec of wind power is applied to the polyester powder having a length of 0.01 to 0.5 mm formed by pulverizing the first fractionated polyester flakes to remove residual foreign matter, and the specific gravity is differentiated by water. A second fractionation process step of secondly separating the small dissimilar plastics;   Melting the secondary fractionated polyester powder and molding the pellet into a pellet to form a polyester recycling chip; And And re-melting the polyester regenerated chip and spinning the yarn using spinnerets. The method of claim 5, further comprising mixing the polyester recycled chip and the fiber manufacturing polyester chip formed after the step of forming the polyester recycled chip.   Regenerated polyester filaments produced by the process according to claim 5 or 6. 8. The regenerated polyester filament according to claim 7, wherein the content of the polyester regenerated chip component in the regenerated polyester filament is 50 to 100% by weight. 8. The regenerated polyester filament according to claim 7, wherein a cross section of the regenerated polyester filament is ○, △ or +.

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