WO2023044699A1 - Textile seperation methods - Google Patents
Textile seperation methods Download PDFInfo
- Publication number
- WO2023044699A1 WO2023044699A1 PCT/CN2021/120092 CN2021120092W WO2023044699A1 WO 2023044699 A1 WO2023044699 A1 WO 2023044699A1 CN 2021120092 W CN2021120092 W CN 2021120092W WO 2023044699 A1 WO2023044699 A1 WO 2023044699A1
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- WO
- WIPO (PCT)
- Prior art keywords
- biosolvent
- textile substrate
- textile
- spandex
- blended
- Prior art date
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- 239000004753 textile Substances 0.000 title claims abstract description 124
- 238000000034 method Methods 0.000 title claims abstract description 57
- 229920002334 Spandex Polymers 0.000 claims abstract description 59
- 239000004759 spandex Substances 0.000 claims abstract description 58
- 239000000203 mixture Substances 0.000 claims abstract description 29
- 239000000758 substrate Substances 0.000 claims description 82
- 229920000642 polymer Polymers 0.000 claims description 26
- GAEKPEKOJKCEMS-UHFFFAOYSA-N gamma-valerolactone Chemical compound CC1CCC(=O)O1 GAEKPEKOJKCEMS-UHFFFAOYSA-N 0.000 claims description 18
- 239000004677 Nylon Substances 0.000 claims description 15
- 229920001778 nylon Polymers 0.000 claims description 15
- 229920000728 polyester Polymers 0.000 claims description 15
- 229920000742 Cotton Polymers 0.000 claims description 13
- 125000004432 carbon atom Chemical group C* 0.000 claims description 12
- WHIRALQRTSITMI-UJURSFKZSA-N (1s,5r)-6,8-dioxabicyclo[3.2.1]octan-4-one Chemical group O1[C@@]2([H])OC[C@]1([H])CCC2=O WHIRALQRTSITMI-UJURSFKZSA-N 0.000 claims description 9
- GMEONFUTDYJSNV-UHFFFAOYSA-N Ethyl levulinate Chemical compound CCOC(=O)CCC(C)=O GMEONFUTDYJSNV-UHFFFAOYSA-N 0.000 claims description 9
- XPFVYQJUAUNWIW-UHFFFAOYSA-N furfuryl alcohol Chemical compound OCC1=CC=CO1 XPFVYQJUAUNWIW-UHFFFAOYSA-N 0.000 claims description 9
- JOOXCMJARBKPKM-UHFFFAOYSA-N 4-oxopentanoic acid Chemical compound CC(=O)CCC(O)=O JOOXCMJARBKPKM-UHFFFAOYSA-N 0.000 claims description 6
- LZCLXQDLBQLTDK-UHFFFAOYSA-N ethyl 2-hydroxypropanoate Chemical compound CCOC(=O)C(C)O LZCLXQDLBQLTDK-UHFFFAOYSA-N 0.000 claims description 6
- HYBBIBNJHNGZAN-UHFFFAOYSA-N furfural Chemical compound O=CC1=CC=CO1 HYBBIBNJHNGZAN-UHFFFAOYSA-N 0.000 claims description 6
- 229920000433 Lyocell Polymers 0.000 claims description 4
- 229920000297 Rayon Polymers 0.000 claims description 4
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 3
- 150000001299 aldehydes Chemical class 0.000 claims description 3
- 150000001732 carboxylic acid derivatives Chemical class 0.000 claims description 3
- 150000002148 esters Chemical class 0.000 claims description 3
- 229940116333 ethyl lactate Drugs 0.000 claims description 3
- 150000002576 ketones Chemical group 0.000 claims description 3
- 229940040102 levulinic acid Drugs 0.000 claims description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 11
- 239000000126 substance Substances 0.000 abstract description 6
- 239000000243 solution Substances 0.000 description 11
- 239000002904 solvent Substances 0.000 description 9
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 6
- 238000000926 separation method Methods 0.000 description 5
- 238000005033 Fourier transform infrared spectroscopy Methods 0.000 description 4
- 239000000470 constituent Substances 0.000 description 4
- 238000004090 dissolution Methods 0.000 description 4
- 238000000605 extraction Methods 0.000 description 4
- 239000002028 Biomass Substances 0.000 description 3
- 238000001914 filtration Methods 0.000 description 3
- -1 modal Polymers 0.000 description 3
- 239000003208 petroleum Substances 0.000 description 3
- 238000011084 recovery Methods 0.000 description 3
- 238000004064 recycling Methods 0.000 description 3
- 239000010784 textile waste Substances 0.000 description 3
- 239000002699 waste material Substances 0.000 description 3
- FXHOOIRPVKKKFG-UHFFFAOYSA-N N,N-Dimethylacetamide Chemical compound CN(C)C(C)=O FXHOOIRPVKKKFG-UHFFFAOYSA-N 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 238000001311 chemical methods and process Methods 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 230000007717 exclusion Effects 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 238000005227 gel permeation chromatography Methods 0.000 description 2
- 239000004519 grease Substances 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- JOOXCMJARBKPKM-UHFFFAOYSA-M 4-oxopentanoate Chemical compound CC(=O)CCC([O-])=O JOOXCMJARBKPKM-UHFFFAOYSA-M 0.000 description 1
- LPEKGGXMPWTOCB-UHFFFAOYSA-N 8beta-(2,3-epoxy-2-methylbutyryloxy)-14-acetoxytithifolin Natural products COC(=O)C(C)O LPEKGGXMPWTOCB-UHFFFAOYSA-N 0.000 description 1
- 244000198134 Agave sisalana Species 0.000 description 1
- 244000303258 Annona diversifolia Species 0.000 description 1
- 235000002198 Annona diversifolia Nutrition 0.000 description 1
- 235000017166 Bambusa arundinacea Nutrition 0.000 description 1
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- 240000008564 Boehmeria nivea Species 0.000 description 1
- 241000282836 Camelus dromedarius Species 0.000 description 1
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 1
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 1
- 229920002284 Cellulose triacetate Polymers 0.000 description 1
- JVTAAEKCZFNVCJ-UHFFFAOYSA-M Lactate Chemical compound CC(O)C([O-])=O JVTAAEKCZFNVCJ-UHFFFAOYSA-M 0.000 description 1
- UAGJVSRUFNSIHR-UHFFFAOYSA-N Methyl levulinate Chemical compound COC(=O)CCC(C)=O UAGJVSRUFNSIHR-UHFFFAOYSA-N 0.000 description 1
- 240000003433 Miscanthus floridulus Species 0.000 description 1
- SECXISVLQFMRJM-UHFFFAOYSA-N N-Methylpyrrolidone Chemical compound CN1CCCC1=O SECXISVLQFMRJM-UHFFFAOYSA-N 0.000 description 1
- 244000082204 Phyllostachys viridis Species 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- QOSMNYMQXIVWKY-UHFFFAOYSA-N Propyl levulinate Chemical compound CCCOC(=O)CCC(C)=O QOSMNYMQXIVWKY-UHFFFAOYSA-N 0.000 description 1
- 241001416177 Vicugna pacos Species 0.000 description 1
- 241000282840 Vicugna vicugna Species 0.000 description 1
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- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- NNLVGZFZQQXQNW-ADJNRHBOSA-N [(2r,3r,4s,5r,6s)-4,5-diacetyloxy-3-[(2s,3r,4s,5r,6r)-3,4,5-triacetyloxy-6-(acetyloxymethyl)oxan-2-yl]oxy-6-[(2r,3r,4s,5r,6s)-4,5,6-triacetyloxy-2-(acetyloxymethyl)oxan-3-yl]oxyoxan-2-yl]methyl acetate Chemical compound O([C@@H]1O[C@@H]([C@H]([C@H](OC(C)=O)[C@H]1OC(C)=O)O[C@H]1[C@@H]([C@@H](OC(C)=O)[C@H](OC(C)=O)[C@@H](COC(C)=O)O1)OC(C)=O)COC(=O)C)[C@@H]1[C@@H](COC(C)=O)O[C@@H](OC(C)=O)[C@H](OC(C)=O)[C@H]1OC(C)=O NNLVGZFZQQXQNW-ADJNRHBOSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000006136 alcoholysis reaction Methods 0.000 description 1
- 210000000077 angora Anatomy 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000011425 bamboo Substances 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 231100000357 carcinogen Toxicity 0.000 description 1
- 239000003183 carcinogenic agent Substances 0.000 description 1
- 210000000085 cashmere Anatomy 0.000 description 1
- 235000005607 chanvre indien Nutrition 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- ODQWQRRAPPTVAG-GZTJUZNOSA-N doxepin Chemical compound C1OC2=CC=CC=C2C(=C/CCN(C)C)/C2=CC=CC=C21 ODQWQRRAPPTVAG-GZTJUZNOSA-N 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 210000004209 hair Anatomy 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 229940058352 levulinate Drugs 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229940057867 methyl lactate Drugs 0.000 description 1
- 210000000050 mohair Anatomy 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000003880 polar aprotic solvent Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 229920003226 polyurethane urea Polymers 0.000 description 1
- 238000002203 pretreatment Methods 0.000 description 1
- ILVGAIQLOCKNQA-UHFFFAOYSA-N propyl 2-hydroxypropanoate Chemical compound CCCOC(=O)C(C)O ILVGAIQLOCKNQA-UHFFFAOYSA-N 0.000 description 1
- 210000000075 qiviut Anatomy 0.000 description 1
- 238000005549 size reduction Methods 0.000 description 1
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- 231100000331 toxic Toxicity 0.000 description 1
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- 238000001291 vacuum drying Methods 0.000 description 1
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J11/00—Recovery or working-up of waste materials
- C08J11/04—Recovery or working-up of waste materials of polymers
- C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
- C08J11/08—Recovery or working-up of waste materials of polymers without chemical reactions using selective solvents for polymer components
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/02—Separating plastics from other materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/02—Separating plastics from other materials
- B29B2017/0203—Separating plastics from plastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/02—Separating plastics from other materials
- B29B2017/0213—Specific separating techniques
- B29B2017/0293—Dissolving the materials in gases or liquids
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
Definitions
- the present disclosure relates to a method of separating spandex from blended textile substrates, facilitating the recycling and reuse of textile materials from pre-and post-consumer textile waste.
- Textile waste is discharged in landfills or incinerated unless its constituents can be effectively separated for recycling and reuse.
- Spandex containing textile blends cannot be directly processed by existing textile recycling technology at a commercial or industrial scale.
- BR 9301022 Three of them (BR 9301022, WO 2013032408 and JP 2011088943) are related to the separation of spandex from polyamide (nylon) .
- the other two patents CN 106279755 and WO 2018150028 are related to the separation of spandex and polyester.
- BR 9301022 provides a method for the removal and recovery of nylon by dissolution in 5%formic acid.
- removal of spandex from nylon is achieved by thermal degradation at 150-260°C, and in JP 2011088943 by the dissolution of spandex in 85%N-methylpyrrolidone aqueous solution.
- polyester-spandex blends provides method of the removal of spandex by alcoholysis at high temperature and pressure (285°C and 5 MPa) and by depolymerisation of polyester at 165°C as in CN 106279755 and WO 2018150028, respectively.
- the present disclosure relates to the separation of spandex from other textile materials, particularly polyester (PET) , nylon, and cotton (and their blends) . It is the aim of this study to develop a more environmentally friendly method to remove spandex from the blended textile substrate by using biosolvents, while keeping the other constituent materials intact.
- Biosolvents are derived from renewable biomass and are being studied as safer and more sustainable alternatives than petroleum-based solvents.
- a method of separating spandex from a blended textile substrate comprising spandex and at least one other textile polymer comprising: contacting the blended textile substrate with a biosolvent at a temperature between 80°C to 150°C thereby forming a treated textile substrate comprising the at least one other textile polymer and a biosolvent extract solution comprising the biosolvent and at least a portion of the spandex in the blended textile substrate; and separating the biosolvent extract solution and the treated textile substrate.
- the at least one other textile polymer is selected from the group consisting of cotton, viscose, lyocell, nylon, polyester and blends thereof.
- the at least one other textile polymer comprises cotton.
- the blended textile substrate is a woven textile substrate, non-woven textile substrate, a knitted textile substrate, or a mixture thereof.
- the biosolvent is a ketone, an ester, a carboxylic acid, an alcohol, an aldehyde, or a mixture thereof.
- the biosolvent comprises between 5-7 carbon atoms.
- the biosolvent is dihydrolevoglucosenone, ethyl levulinate, gamma-valerolactone, ethyl lactate, furfural, furfuryl alcohol, levulinic acid, or a mixture thereof.
- the biosolvent is dihydrolevoglucosenone, ethyl levulinate and gamma-valerolactone, or a mixture thereof.
- the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 20 to about 1: 100, respectively.
- the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 50, respectively.
- the temperature is 120°C to 140°C and the step of contacting the blended textile substrate with the biosolvent occurs at atmospheric pressure.
- the treated textile substrate contains less than 1%by weight of spandex.
- the method further comprises the step of separating the spandex from the biosolvent extract solution thereby forming a recovered biosolvent and a recovered spandex.
- the recovered biosolvent is reused in the method.
- the average molecular weight of the at least one other textile polymer in the treated textile substrate is substantially unchanged from the average molecular weight of the at least one other textile polymer in the blended textile substrate.
- the method comprises: contacting the blended textile substrate with a biosolvent selected from the group consisting of dihydrolevoglucosenone, ethyl levulinate, gamma-valerolactone and mixtures thereof, wherein the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 50, respectively; at a temperature between 120°C to 140°C thereby forming a treated textile substrate and a biosolvent extract solution comprising the biosolvent and at least a portion of the spandex in the blended textile substrate; and separating the biosolvent extract solution and the treated textile substrate.
- a biosolvent selected from the group consisting of dihydrolevoglucosenone, ethyl levulinate, gamma-valerolactone and mixtures thereof, wherein the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 50, respectively; at a temperature between 120°C to 140°C thereby forming a treated textile substrate and a biosolvent extract
- the step of contacting the blended textile substrate with the biosolvent is conducted for 1-3 hours.
- the at least one other textile polymer is PET, nylon, cotton, or blends thereof.
- the method further comprises the step of separating the spandex from the biosolvent extract solution thereby forming a recovered biosolvent and a recovered spandex; and optionally reusing the recovered biosolvent in the method.
- the molecular weight of at least one other textile polymer in the treated textile substrate is substantially unchanged from the molecular weight of the at least one other textile polymer in the blended textile substrate.
- Figure 1 depicts a flow diagram for the spandex separating process according to certain embodiments of the methods described herein
- Figure 2 depicts a Fourier-transform infrared spectroscopy (FTIR) spectrum of untreated and treated samples of (A) polyester, (B) nylon, and (C) cotton samples.
- FTIR Fourier-transform infrared spectroscopy
- Patent law e.g., they can mean “includes” , “included” , “including” , and the like; and that terms such as “consisting essentially of” and “consists essentially of” have the meaning ascribed to them in U.S. Patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the present invention.
- the present disclosure provides a method of separating spandex from a blended textile substrate comprising spandex and at least one other textile polymer, the method comprising: contacting the blended textile substrate with a biosolvent at a temperature between 80°C to 150°C thereby forming a treated textile substrate comprising the at least one other textile polymer and a biosolvent extract solution comprising the biosolvent and at least a portion of the spandex in the blended textile substrate; and separating the biosolvent extract solution and the treated textile substrate.
- the blended textile substrate can comprise spandex and at least one textile polymer.
- the at least one textile polymer can be any textile polymer known in the art.
- Exemplary textile polymers include, but are not limited to, cotton, viscose, lyocell, modal, cellulose triacetate, cupro, linen, hemp, ramie, bamboo, sisal, polyester [such as polyethylene terephthalate (PET) ] , nylon, cashmere, merino wool, mohair, qiviut, angora, alpaca, llama, camel hair, vicuna, aralac, silk, acrylic, and elastolefin.
- PET polyethylene terephthalate
- the at least one textile polymer is selected from the group consisting of cotton, viscose, lyocell, nylon, polyester, and blends thereof.
- the blended textile substrate comprises nylon and at least one textile polymer selected from the group consisting of PET, cotton, and nylon.
- the blended textile substrate may comprise spandex in the amount between about 0.1%and about 30%, about 0.1%and about 25%, about 0.1%and about 20%, about 1%and about 20%, about 1%and about 15%, about 1%and about 10%, or about 1%and about 5%by weight.
- the blended textile substrate is a woven textile substrate, non-woven textile substrate, a knitted textile substrate, or a mixture thereof.
- the size of the blended textile substrate may also be optionally reduced prior to being subjected to the method described herein.
- the size of the blended textile substrate can be mechanically reduced using any method known in the art, such as by cutting, tearing, breaking, shredding, and/or other mechanical size reduction techniques.
- the reduction of the size of the blended textile substrate can increase the surface area of the blended textile substrate and assist in the isolation of spandex.
- the size of the blended textile substrate is reduced by using a textile opening machine.
- the blended textile substrate is cleaned prior to being subjected to the methods described herein.
- the blended textile substrate can be cleaned using any method known in the art, such as by washing in a solvent and/or directed air flow to remove, e.g., non-fibrous material.
- Biosolvents are derived from biomass, typically from cellulosic biomass, such as corn stover, saw grass or wood dust by different chemical processes. This emerging class of solvents is often investigated as alternative and replacement to traditional petroleum-based solvents as they offer advantages, such as being renewable and biodegradable. Because of the excellent solvating power of biosolvents for a wide range of chemicals, more applications for biosolvents in chemical processes are emerging.
- the biosolvent comprises an organic solvent having or more functional groups selected from a ketone, an ester, a carboxylic acid, an alcohol, an aldehyde, and a mixture of biosolvents thereof.
- the biosolvent comprises at least 3 carbon atoms, at least 4 carbon atoms, or at least 5 carbon atoms.
- the biosolvent can comprise between 3-30 carbon atoms, 3-20 carbon atoms, 3-10 carbon atoms, 5-10 carbon atoms, 5-7 carbon atoms, 5-6 carbon atoms, or 6-7 carbon atoms.
- biosolvents include, but are not limited to dihydrolevoglucosenone, a levulinate C 1 -C 6 alkyl ester, such as methyl levulinate, ethyl levulinate, or propyl levulinate, gamma-valerolactone, a lactate C 1 -C 6 alkyl ester, such as methyl lactate, ethyl lactate, and propyl lactate, furfural, furfuryl alcohol, levulinic acid, or a mixture thereof.
- the biosolvent is selected from the group consisting of dihydrolevoglucosenone, ethyl levulinate and gamma-valerolactone, and mixtures thereof.
- the blended textile substrate and the biosolvent can be present in a ratio of about 1: 10 to about 1: 100; about 4: 50 to about 1: 100; about 3: 50 to about 1: 100; about 2: 50 to about 1: 100; about 3: 100 to about 1: 100; or about 1: 50, respectively.
- the step of contacting the blended textile substrate with a biosolvent can occur at a temperature between about 80°C to about 150°C, about 90°C to about 150°C, about 100°C to about 150°C, about 110°C to about 150°C, about 120°C to about 150°C, about 120°C to about 140°C, about 120°C, or about 140°C.
- the amount of time that the blended textile substrate and the biosolvent are allowed to remain in contact for can depend on a number of parameters, such as the composition of the blended textile substrate, the surface area of the blended textile substrate, the choice of biosolvent, the temperature that the biosolvent extraction step is conducted at, and the mass ratio of the blended textile substrate to the biosolvent.
- the selection of the appropriate time that the blended textile substrate and the biosolvent are allowed to remain in contact is well within the skill of a person of ordinary skill in the art.
- the blended textile substrate and the biosolvent are allowed to remain in contact for about 30 minutes to about 5 hours, about 1 hour to about 5 hours, about 1 hour to about 4 hours, about 1 hour to about 3 hours, about 1.5 hour to about 3 hours, about 2.5 hour to about 3 hours, about 1.5 hours, about 2.5 hours, or about 2.9 hours.
- the treated textile substrate can be separated from the biosolvent extraction solution by filtration.
- the treated textile substrate can then be optionally washed water and dried.
- the treated textile substrate can comprise less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, less than about 0.5%, less than about 0.1%by weight of spandex.
- the spandex can be recovered from the biosolvent extraction solution by any number of methods, such as by distilling the biosolvent from the biosolvent extraction solution thereby yielding the recovered spandex.
- Blended textile substrates such as reclaimed garments and textiles typically incorporate a variety of dyes and/or chemical finishes and may be contaminated with other materials, such as dirt, grease, and the like.
- the blended textile substrate can optionally be processed in one or more pre-treatment stage (s) to remove dyes, finishes, contaminants (oils, grease, etc. ) and the like from blended textile substrate. Processing to remove non-textile components, such as buttons, zippers, fasteners, and the like may take place, if desired, prior to the methods described herein.
- the method described herein advantageously produces recovered textile materials from the blended textile substrate with relatively unchanged molecular weights and the FTIR data of the recovered textile materials (Figure 2) show no substantial decomposition products.
- the process flow diagram is presented in Figure 1.
- the dissolution temperature can be kept below the respective boiling point of the biosolvent.
- the treated solid material will be collected by filtration and drying. Used solvent can be recovered by vacuum evaporation for re-use.
- Spandex typically constitutes less than 25%by mass of textile blends, and in many cases lower than 5%by mass, it is therefore more logical to focus on the recovery of the higher volume (and hence higher value) among the constituent materials (e.g. PET, nylon and cotton) .
- the dissolution of spandex with some degree of degradation of spandex can be accepted. Residual spandex collected during the solvent recovery process can be potentially used as adhesive. Zero waste is generated by this treatment process.
- spandex can be dissolved in polar aprotic solvents, such as dimethylformamide (DMF) and dimethylacetamide (DMAc) , which are both potential carcinogens.
- polar aprotic biosolvents used in the methods described herein include Cyrene TM (dihydrolevoglucosenone) , ethyl levulinate and gamma-valerolactone,
- Fabric was first opened by fabric opening machine. Solid to liquid ratio was kept at 1: 50. After treatment, rinsing of samples with the same solvent at room temperature during the filtration step is performed to remove surface residue. Recovered material is dried by vacuum drying at 100°C for 1.5 hours. Composition of the original sample and recovered sample are determined according to AATCC 20A-2018. Molecular weight of the recovered material is by gel permeation chromatography (GPC) .
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Abstract
Provided herein is a method of separating spandex from textile blends using biosolvents. The recovered material is of high purity while the chemical structure and molecular weight remain substantially unaffected by the treatment.
Description
TECHNICHAL FIELD
The present disclosure relates to a method of separating spandex from blended textile substrates, facilitating the recycling and reuse of textile materials from pre-and post-consumer textile waste.
Textile waste is discharged in landfills or incinerated unless its constituents can be effectively separated for recycling and reuse. Spandex containing textile blends cannot be directly processed by existing textile recycling technology at a commercial or industrial scale.
There are four major types of elastomeric textile fibers and it is widely accepted that spandex is dominates the overall stretch yarn market with a reported market share of about 67%. Spandex was first invented in 1959 and its popularity has grown rapidly since then. The name ‘spandex’ is commonly used in the US and many other countries, while the term ‘elastane’ is preferred in Europe. Spandex is defined as a long chain synthetic polymer containing at least 85 wt%of segmented polyurethane that includes alternating soft polyester segments and hard polyurethane-urea segments. Spandex is well known by its exceptionally high elasticity (typically up to 500-600%) , lightweight and good abrasion resistance. These superior performances have resulted in its wide applications in different apparel products. Typically, the addition of 1-25%spandex in apparel is sufficient to bring comfort and stretch. The popularity of spandex in apparel and increasing amount of spandex containing apparel waste has created a need to develop methods for recovering spandex from waste apparel.
To meet this need, a number of methods for separating spandex from textile blends have been developed. Three of them (BR 9301022, WO 2013032408 and JP 2011088943) are related to the separation of spandex from polyamide (nylon) . The other two patents CN 106279755 and WO 2018150028 are related to the separation of spandex and polyester. BR 9301022 provides a method for the removal and recovery of nylon by dissolution in 5%formic acid. In WO 2013032408, removal of spandex from nylon is achieved by thermal degradation at 150-260℃, and in JP 2011088943 by the dissolution of spandex in 85%N-methylpyrrolidone aqueous solution. The two patents for polyester-spandex blends provides method of the removal of spandex by alcoholysis at high temperature and pressure (285℃ and 5 MPa) and by depolymerisation of polyester at 165℃ as in CN 106279755 and WO 2018150028, respectively.
None of the patents mentioned teach methods for separating spandex from cotton-spandex blends, which is one of the most common blends used in apparel, in some cases rely on toxic solvents for separation, and/or involve the depolymerisation of certain constituents.
There is thus a need to develop effective and environmentally friendly methods for separating spandex from pre-and post-consumer textile waste.
SUMMARY
The present disclosure relates to the separation of spandex from other textile materials, particularly polyester (PET) , nylon, and cotton (and their blends) . It is the aim of this study to develop a more environmentally friendly method to remove spandex from the blended textile substrate by using biosolvents, while keeping the other constituent materials intact. Biosolvents are derived from renewable biomass and are being studied as safer and more sustainable alternatives than petroleum-based solvents.
In a first aspect, provided herein is a method of separating spandex from a blended textile substrate comprising spandex and at least one other textile polymer, the method comprising: contacting the blended textile substrate with a biosolvent at a temperature between 80℃ to 150℃ thereby forming a treated textile substrate comprising the at least one other textile polymer and a biosolvent extract solution comprising the biosolvent and at least a portion of the spandex in the blended textile substrate; and separating the biosolvent extract solution and the treated textile substrate.
In certain embodiments, the at least one other textile polymer is selected from the group consisting of cotton, viscose, lyocell, nylon, polyester and blends thereof.
In certain embodiments, the at least one other textile polymer comprises cotton.
In certain embodiments, the blended textile substrate is a woven textile substrate, non-woven textile substrate, a knitted textile substrate, or a mixture thereof.
In certain embodiments, the biosolvent is a ketone, an ester, a carboxylic acid, an alcohol, an aldehyde, or a mixture thereof.
In certain embodiments, the biosolvent comprises between 5-7 carbon atoms.
In certain embodiments, the biosolvent is dihydrolevoglucosenone, ethyl levulinate, gamma-valerolactone, ethyl lactate, furfural, furfuryl alcohol, levulinic acid, or a mixture thereof.
In certain embodiments, the biosolvent is dihydrolevoglucosenone, ethyl levulinate and gamma-valerolactone, or a mixture thereof.
In certain embodiments, the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 20 to about 1: 100, respectively.
In certain embodiments, the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 50, respectively.
In certain embodiments, the temperature is 120℃ to 140℃ and the step of contacting the blended textile substrate with the biosolvent occurs at atmospheric pressure.
In certain embodiments, the treated textile substrate contains less than 1%by weight of spandex.
In certain embodiments, the method further comprises the step of separating the spandex from the biosolvent extract solution thereby forming a recovered biosolvent and a recovered spandex.
In certain embodiments, the recovered biosolvent is reused in the method.
In certain embodiments, the average molecular weight of the at least one other textile polymer in the treated textile substrate is substantially unchanged from the average molecular weight of the at least one other textile polymer in the blended textile substrate.
In certain embodiments, the method comprises: contacting the blended textile substrate with a biosolvent selected from the group consisting of dihydrolevoglucosenone, ethyl levulinate, gamma-valerolactone and mixtures thereof, wherein the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 50, respectively; at a temperature between 120℃ to 140℃ thereby forming a treated textile substrate and a biosolvent extract solution comprising the biosolvent and at least a portion of the spandex in the blended textile substrate; and separating the biosolvent extract solution and the treated textile substrate.
In certain embodiments, the step of contacting the blended textile substrate with the biosolvent is conducted for 1-3 hours.
In certain embodiments, the at least one other textile polymer is PET, nylon, cotton, or blends thereof.
In certain embodiments, the method further comprises the step of separating the spandex from the biosolvent extract solution thereby forming a recovered biosolvent and a recovered spandex; and optionally reusing the recovered biosolvent in the method.
In certain embodiments, the molecular weight of at least one other textile polymer in the treated textile substrate is substantially unchanged from the molecular weight of the at least one other textile polymer in the blended textile substrate.
The above and other objects and features of the present disclosure will become apparent from the following description of the disclosure, when taken in conjunction with the accompanying drawings.
Figure 1 depicts a flow diagram for the spandex separating process according to certain embodiments of the methods described herein
Figure 2 depicts a Fourier-transform infrared spectroscopy (FTIR) spectrum of untreated and treated samples of (A) polyester, (B) nylon, and (C) cotton samples.
Throughout the present disclosure, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising" , will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. It is also noted that in this disclosure and particularly in the claims and/or paragraphs, terms such as “comprises” , “comprised” , “comprising” and the like can have the meaning attributed to it in U.S. Patent law; e.g., they can mean “includes” , “included” , “including” , and the like; and that terms such as “consisting essentially of” and “consists essentially of” have the meaning ascribed to them in U.S. Patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the present invention.
Furthermore, throughout the present disclosure and claims, unless the context requires otherwise, the word “include” or variations such as “includes” or “including” , will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.
The use of the singular herein includes the plural (and vice versa) unless specifically stated otherwise. In addition, where the use of the term "about" is before a quantitative value, the present teachings also include the specific quantitative value itself, unless specifically stated otherwise. As used herein, the term "about" refers to a ±10%, ±7%, ±5%, ±3%, ±1%, or ±0%variation from the nominal value unless otherwise indicated or inferred.
The present disclosure provides a method of separating spandex from a blended textile substrate comprising spandex and at least one other textile polymer, the method comprising: contacting the blended textile substrate with a biosolvent at a temperature between 80℃ to 150℃ thereby forming a treated textile substrate comprising the at least one other textile polymer and a biosolvent extract solution comprising the biosolvent and at least a portion of the spandex in the blended textile substrate; and separating the biosolvent extract solution and the treated textile substrate.
The blended textile substrate can comprise spandex and at least one textile polymer. The at least one textile polymer can be any textile polymer known in the art. Exemplary textile polymers include, but are not limited to, cotton, viscose, lyocell, modal, cellulose triacetate, cupro, linen, hemp, ramie, bamboo, sisal, polyester [such as polyethylene terephthalate (PET) ] , nylon, cashmere, merino wool, mohair, qiviut, angora, alpaca, llama, camel hair, vicuna, aralac, silk, acrylic, and elastolefin. In certain embodiments, the at least one textile polymer is selected from the group consisting of cotton, viscose, lyocell, nylon, polyester, and blends thereof. In certain embodiments, the blended textile substrate comprises nylon and at least one textile polymer selected from the group consisting of PET, cotton, and nylon.
The blended textile substrate may comprise spandex in the amount between about 0.1%and about 30%, about 0.1%and about 25%, about 0.1%and about 20%, about 1%and about 20%, about 1%and about 15%, about 1%and about 10%, or about 1%and about 5%by weight.
The blended textile substrate is a woven textile substrate, non-woven textile substrate, a knitted textile substrate, or a mixture thereof.
The size of the blended textile substrate may also be optionally reduced prior to being subjected to the method described herein. The size of the blended textile substrate can be mechanically reduced using any method known in the art, such as by cutting, tearing, breaking, shredding, and/or other mechanical size reduction techniques. Advantageously, the reduction of the size of the blended textile substrate can increase the surface area of the blended textile substrate and assist in the isolation of spandex. In certain embodiments, the size of the blended textile substrate is reduced by using a textile opening machine.
In certain embodiments, the blended textile substrate is cleaned prior to being subjected to the methods described herein. The blended textile substrate can be cleaned using any method known in the art, such as by washing in a solvent and/or directed air flow to remove, e.g., non-fibrous material.
Biosolvents are derived from biomass, typically from cellulosic biomass, such as corn stover, saw grass or wood dust by different chemical processes. This emerging class of solvents is often investigated as alternative and replacement to traditional petroleum-based solvents as they offer advantages, such as being renewable and biodegradable. Because of the excellent solvating power of biosolvents for a wide range of chemicals, more applications for biosolvents in chemical processes are emerging.
In certain embodiments, the biosolvent comprises an organic solvent having or more functional groups selected from a ketone, an ester, a carboxylic acid, an alcohol, an aldehyde, and a mixture of biosolvents thereof. In certain embodiments, the biosolvent comprises at least 3 carbon atoms, at least 4 carbon atoms, or at least 5 carbon atoms. The biosolvent can comprise between 3-30 carbon atoms, 3-20 carbon atoms, 3-10 carbon atoms, 5-10 carbon atoms, 5-7 carbon atoms, 5-6 carbon atoms, or 6-7 carbon atoms.
Exemplary biosolvents include, but are not limited to dihydrolevoglucosenone, a levulinate C
1-C
6 alkyl ester, such as methyl levulinate, ethyl levulinate, or propyl levulinate, gamma-valerolactone, a lactate C
1-C
6 alkyl ester, such as methyl lactate, ethyl lactate, and propyl lactate, furfural, furfuryl alcohol, levulinic acid, or a mixture thereof. In certain embodiments, the biosolvent is selected from the group consisting of dihydrolevoglucosenone, ethyl levulinate and gamma-valerolactone, and mixtures thereof.
The blended textile substrate and the biosolvent can be present in a ratio of about 1: 10 to about 1: 100; about 4: 50 to about 1: 100; about 3: 50 to about 1: 100; about 2: 50 to about 1: 100; about 3: 100 to about 1: 100; or about 1: 50, respectively.
The step of contacting the blended textile substrate with a biosolvent can occur at a temperature between about 80℃ to about 150℃, about 90℃ to about 150℃, about 100℃ to about 150℃, about 110℃ to about 150℃, about 120℃ to about 150℃, about 120℃ to about 140℃, about 120℃, or about 140℃.
In general, the amount of time that the blended textile substrate and the biosolvent are allowed to remain in contact for can depend on a number of parameters, such as the composition of the blended textile substrate, the surface area of the blended textile substrate, the choice of biosolvent, the temperature that the biosolvent extraction step is conducted at, and the mass ratio of the blended textile substrate to the biosolvent. The selection of the appropriate time that the blended textile substrate and the biosolvent are allowed to remain in contact is well within the skill of a person of ordinary skill in the art. In certain embodiments, the blended textile substrate and the biosolvent are allowed to remain in contact for about 30 minutes to about 5 hours, about 1 hour to about 5 hours, about 1 hour to about 4 hours, about 1 hour to about 3 hours, about 1.5 hour to about 3 hours, about 2.5 hour to about 3 hours, about 1.5 hours, about 2.5 hours, or about 2.9 hours.
The treated textile substrate can be separated from the biosolvent extraction solution by filtration. The treated textile substrate can then be optionally washed water and dried. In certain embodiments, the treated textile substrate can comprise less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, less than about 0.5%, less than about 0.1%by weight of spandex.
The spandex can be recovered from the biosolvent extraction solution by any number of methods, such as by distilling the biosolvent from the biosolvent extraction solution thereby yielding the recovered spandex.
Blended textile substrates, such as reclaimed garments and textiles typically incorporate a variety of dyes and/or chemical finishes and may be contaminated with other materials, such as dirt, grease, and the like. The blended textile substrate can optionally be processed in one or more pre-treatment stage (s) to remove dyes, finishes, contaminants (oils, grease, etc. ) and the like from blended textile substrate. Processing to remove non-textile components, such as buttons, zippers, fasteners, and the like may take place, if desired, prior to the methods described herein.
As demonstrated in the examples below, the method described herein advantageously produces recovered textile materials from the blended textile substrate with relatively unchanged molecular weights and the FTIR data of the recovered textile materials (Figure 2) show no substantial decomposition products.
The process flow diagram is presented in Figure 1. The dissolution temperature can be kept below the respective boiling point of the biosolvent. The treated solid material will be collected by filtration and drying. Used solvent can be recovered by vacuum evaporation for re-use. Spandex typically constitutes less than 25%by mass of textile blends, and in many cases lower than 5%by mass, it is therefore more logical to focus on the recovery of the higher volume (and hence higher value) among the constituent materials (e.g. PET, nylon and cotton) . With this concept in mind, the dissolution of spandex with some degree of degradation of spandex can be accepted. Residual spandex collected during the solvent recovery process can be potentially used as adhesive. Zero waste is generated by this treatment process. For petroleum-based solvent, spandex can be dissolved in polar aprotic solvents, such as dimethylformamide (DMF) and dimethylacetamide (DMAc) , which are both potential carcinogens. Some examples of polar aprotic biosolvents used in the methods described herein include Cyrene
TM (dihydrolevoglucosenone) , ethyl levulinate and gamma-valerolactone,
EXAMPLES
Example 1
Fabric was first opened by fabric opening machine. Solid to liquid ratio was kept at 1: 50. After treatment, rinsing of samples with the same solvent at room temperature during the filtration step is performed to remove surface residue. Recovered material is dried by vacuum drying at 100℃ for 1.5 hours. Composition of the original sample and recovered sample are determined according to AATCC 20A-2018. Molecular weight of the recovered material is by gel permeation chromatography (GPC) .
Example 2
To confirm if the chemical structure and molecular weight of polyester, nylon and cotton is affected by the treatment, textile samples of 100%purity (without spandex) were tested at the same conditions as the separation treatment. The chemical structure of the recovered samples was analyzed by FTIR as shown in Figure 2. Molecular weights of the material before and after treatment were checked. No change in both chemical peaks and decrease in molecular weight was observed.
Claims (20)
- A method of separating spandex from a blended textile substrate comprising spandex and at least one other textile polymer, the method comprising: contacting the blended textile substrate with a biosolvent at a temperature between 80℃ to 150℃ thereby forming a treated textile substrate comprising the at least one other textile polymer and a biosolvent extract solution comprising the biosolvent and at least a portion of the spandex in the blended textile substrate; and separating the biosolvent extract solution and the treated textile substrate.
- The method of claim 1, wherein the at least one other textile polymer is selected from the group consisting of cotton, viscose, lyocell, nylon, polyester and blends thereof.
- The method of claim 1, wherein the at least one other textile polymer comprises cotton.
- The method of claim 1, wherein the blended textile substrate is a woven textile substrate, non-woven textile substrate, a knitted textile substrate, or a mixture thereof.
- The method of claim 1, wherein the biosolvent is a ketone, an ester, a carboxylic acid, an alcohol, an aldehyde, or a mixture thereof.
- The method of claim 5, wherein the biosolvent comprises between 5-7 carbon atoms.
- The method of claim 1, wherein the biosolvent is dihydrolevoglucosenone, ethyl levulinate, gamma-valerolactone, ethyl lactate, furfural, furfuryl alcohol, levulinic acid, or a mixture thereof.
- The method of claim 1, wherein the biosolvent is dihydrolevoglucosenone, ethyl levulinate and gamma-valerolactone, or a mixture thereof.
- The method of claim 1, wherein the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 20 to about 1: 100, respectively.
- The method of claim 1, wherein the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 50, respectively.
- The method of claim 1, wherein the temperature is 120℃ to 140℃ and the step of contacting the blended textile substrate with the biosolvent occurs at atmospheric pressure.
- The method of claim 1, wherein the treated textile substrate contains less than 1%by weight of spandex.
- The method of claim 1 further comprising the step of separating the spandex from the biosolvent extract solution thereby forming a recovered biosolvent and a recovered spandex.
- The method of claim 13, wherein the recovered biosolvent is reused in the method.
- The method of claim 13, wherein the average molecular weight of the at least one other textile polymer in the treated textile substrate is substantially unchanged from the average molecular weight of the at least one other textile polymer in the blended textile substrate.
- The method of claim 1, wherein the method comprises: contacting the blended textile substrate with a biosolvent selected from the group consisting of dihydrolevoglucosenone, ethyl levulinate, gamma-valerolactone and mixtures thereof, wherein the blended textile substrate and the biosolvent are present in a mass ratio of about 1: 50, respectively; at a temperature between 120℃ to 140℃ thereby forming a treated textile substrate and a biosolvent extract solution comprising the biosolvent and at least a portion of the spandex in the blended textile substrate; and separating the biosolvent extract solution and the treated textile substrate.
- The method of claim 16, wherein the step of contacting the blended textile substrate with the biosolvent is conducted for 1-3 hours.
- The method of claim 16, wherein the at least one other textile polymer is PET, nylon, cotton, or blends thereof.
- The method of claim 16 further comprising the step of separating the spandex from the biosolvent extract solution thereby forming a recovered biosolvent and a recovered spandex; and optionally reusing the recovered biosolvent in the method.
- The method of claim 16, wherein the molecular weight of at least one other textile polymer in the treated textile substrate is substantially unchanged from the molecular weight of the at least one other textile polymer in the blended textile substrate.
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