WO2024074580A2 - Procédé de fabrication d'un produit comportant des fibres recyclées - Google Patents

Procédé de fabrication d'un produit comportant des fibres recyclées Download PDF

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Publication number
WO2024074580A2
WO2024074580A2 PCT/EP2023/077500 EP2023077500W WO2024074580A2 WO 2024074580 A2 WO2024074580 A2 WO 2024074580A2 EP 2023077500 W EP2023077500 W EP 2023077500W WO 2024074580 A2 WO2024074580 A2 WO 2024074580A2
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WO
WIPO (PCT)
Prior art keywords
cellulose
viscose
fibers
product
cellulosic fibers
Prior art date
Application number
PCT/EP2023/077500
Other languages
English (en)
Other versions
WO2024074580A3 (fr
Inventor
Mikael Lindström
Stefan ANTONSSON
Gunnar Henriksson
Kristina ELG CHRISTOFFERSSON
Original Assignee
Re:Newcell Ab
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Publication date
Application filed by Re:Newcell Ab filed Critical Re:Newcell Ab
Publication of WO2024074580A2 publication Critical patent/WO2024074580A2/fr
Publication of WO2024074580A3 publication Critical patent/WO2024074580A3/fr

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Classifications

    • 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
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • D01F2/06—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from viscose
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08B—POLYSACCHARIDES; DERIVATIVES THEREOF
    • C08B16/00—Regeneration of cellulose
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D1/00—Treatment of filament-forming or like material
    • D01D1/02—Preparation of spinning solutions
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D1/00—Treatment of filament-forming or like material
    • D01D1/10—Filtering or de-aerating the spinning solution or melt
    • D01D1/106—Filtering
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F11/00—Chemical after-treatment of artificial filaments or the like during manufacture
    • D01F11/04—Chemical after-treatment of artificial filaments or the like during manufacture of synthetic polymers
    • D01F11/08—Chemical after-treatment of artificial filaments or the like during manufacture of synthetic polymers of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F13/00—Recovery of starting material, waste material or solvents during the manufacture of artificial filaments or the like
    • D01F13/02—Recovery of starting material, waste material or solvents during the manufacture of artificial filaments or the like of cellulose, cellulose derivatives or proteins
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • D01F2/06—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from viscose
    • D01F2/08—Composition of the spinning solution or the bath
    • 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
    • B29B2017/001—Pretreating the materials before recovery
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B29K2105/122—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles microfibres or nanofibers

Definitions

  • the invention relates to chemical recycling of textile comprising cellulosic fibers and non-cellulosic fibers and in particular the manufacture of a new material.
  • the textile industry is growing fast.
  • the textile industry is a contributor to pollution, including CO2 emissions. It is desirable to reduce the environmental impact of the textile industry by increasing the recycling of textiles.
  • Textiles can for instance be reused, chemically recycled or mechanically recycled.
  • Chemical recycling of textiles can be made in various ways, producing multiple products depending on the textile source. Chemical recycling involves some kind of chemical reaction of the material, which is the case in the viscose process.
  • the viscose process is a well-known multistep process to produce a regenerated textile fiber.
  • the exact partition and labeling of the process step varies, however, the chemistry remains the same.
  • the overall objective of the process is to first increase the reactivity and accessibility of the cellulose fiber followed by solubilization of the cellulose by xanthation.
  • the solubilized cellulose (cellulose xanthate) is later regenerated in acid, and viscose fibers are spun.
  • Dissolving pulp also called dissolving cellulose
  • Dissolving pulp is often used to produce viscose.
  • Dissolving pulp is for instance made through the sulfite process or made through the sulfate process (also known as kraft pulping or kraft process) with a prehydrolysis step to remove hemicelluloses.
  • the sulfite process produces pulp with a a-cellulose content up to 92 percent. It can use ammonium, calcium, magnesium or sodium as a base.
  • the sulfate process with a prehydrolysis step produces pulp with a a-cellulose content up to 96 percent.
  • Special alkaline purification treatments can yield even higher a-cellulose levels.
  • the pulp can be produced form several different cellulose sources, the most common one is wood and another cellulose source is cotton linters. The purity is of importance as other polysaccharides such as hemicelluloses and extractives can interfere with the viscose process.
  • the cellulose is converted to alkali cellulose by immersing the pulp into a mixture comprising sodium hydroxide in the steeping step.
  • This soda treatment can, in addition to deprotonate cellulose, remove any potential remaining unwanted material, such as hemicelluloses, that is left in the pulp.
  • the fibers will swell during the treatment, enabling the soda and other compounds to penetrate the fiber wall further.
  • concentration and temperature of the soda treatment determines the extent of both conversion and swelling, an optimization is required to reach the most preferable outcome.
  • the alkali cellulose mixture is pressed to remove excess of soda.
  • the excess of soda can be filtered to remove fines and other particles and then reused in the prior steeping step.
  • the alkali cellulose mixture is then shredded to further enhance the reaction in both the mercerization and xanthation steps, respectively.
  • This is a mechanical pretreatment that increases the active surface, enable accessibility for upcoming treatment with sodium hydroxide and carbon disulphide.
  • the shredded alkali cellulose is stored for instance in silos during the mercerization, pre-ageing, step where an oxidative depolymerization reaction takes place.
  • the degree of polymerization, DP is reduced to achieve a sufficiently low viscosity of the viscose dope. However, to maintain a good tensile strength of the viscose fiber, it is of importance not to lower the DP excessively.
  • a DP of 250 - 300 is suitable for alkali cellulose prior to xanthation.
  • the degree of polymerization (DP) is expressed as the limiting viscosity number and measured according to ISO 5351 : 2010.
  • the alkali cellulose xanthate solution (viscose dope) is often diluted with a sodium hydroxide solution.
  • the alkali cellulose xanthate at least partily dissolved in the viscose dope.
  • the concentration of the sodium hydroxide solution is set to result in predetermined concentrations of both the alkali and the cellulose in the viscose dope.
  • the viscose dope is placed in a ripening vessel for e.g. 16-17 hours. In the ripening vessel the number of xanthate groups on each glucose unit reduces and distributes evenly throughout the chain to enable an acceptable coagulation in the later spin bath .
  • the viscose dope is normally filtered, for instance in order to avoid clogging and other problems.
  • the reject from the filtration typically comprises undissolved fibers, cellulose xanthate gel, dirt particles and so on. Often a cut off size of 15-20 pm is used for the filtration.
  • the reject is normally processed and recycled to the viscose process.
  • the amount of reject in the filtration of the viscose dope increases since the reclaimed textiles comprise a mixture of different fibers such as for instance cellulose fibers and polyester fibers as well as other synthetic fibers.
  • the filtrate (liquid which has passed through the filter) may be de-aerated and then filtered again.
  • the viscose dope is pushed out in jet rays directly into an acid bath containing e.g. sulphuric acid, sodium sulfate and zinc sulfate.
  • the alkali cellulose xanthate will, in contact with the acid, quickly regenerate into cellulose, forming filaments and later staple fibers .
  • Chemical pretreatments to improve the accessibility and reactivity of cellulose can be performed. Some pretreatments swell the cellulose fiber and thus breaking some of the hydrogen bonds that are linking the cellulose chains together. Mechanical treatment can also be used, whereby the active surface of the cellulose fibers is increased by beating and thereby results in an improvement of the cellulose accessibility.
  • the starting materials for recycling of textiles including but not limited to post consumer textiles, often comprise both cellulosic and non-cellulosic fibers etc. These may not be dissolved in the viscose process and are normally removed to an extent, which is necessary in the mentioned filtering step.
  • EP 3868929 describes producing a molded body comprising cellulose, in particular by means of a lyocell process or a viscose process, based on a starting material in such a way that the regenerated cellulosic molded body has at least part of the synthetic plastic of the starting material incorporated in the cellulose. Some synthetic plastic is contained in the molded body, some synthetic plastic may also be removed.
  • EP 3511451 describes a process where cellulose- containing material is recycled and used to manufacture a cellulose-containing body, where a part of the non-cellulosic material in the starting material is present in the final product.
  • the depleted material can be mixed with starting material to contain some of the non-cellulosic material and achieve desired properties.
  • the non- cellulosic impurities can be selectively depleted from the cellulose such that at least one predefined synthetic plastic remains at least partially in the depleted starting material.
  • a method for manufacturing a material comprising the sequential steps of: i) providing a viscose dope comprising cellulose xanthate and undissolved non-cellulosic fibres, and filtering the viscose dope to obtain a material comprising at least a part of the undissolved non-cellulosic fibres, ii) pressing the material obtained in step i) , so that the amount of undissolved non-cellulosic fibers in the material after the pressing is at least 40 wt%, iii) contacting the material with an acid solution so that the cellulose xanthate is at least partially converted to cellulose, and iv) washing the material in an aquaeous solution.
  • a product manufactured according to the method comprising a) at least 40 wt% of non-cellulosic fibers, and b) regenerated cellulose wherein at least some of the regenerated cellulose is incorporated between the non-cellulosic fibers.
  • An advantage of the invention is the recycling of as much of the starting material as possible by making both the usually desired filtered viscose dope of a viscose process, while at the same time making use of the removed material (filter reject) .
  • This has the advantage of improving the recycling process of textiles since the non-cellulosic fibers in reclaimed textiles can be utilized in an economic way.
  • the new material has unique and desired properties. It is for example more elastic than films made out of pure regenerated cellulose.
  • Figure 1 shows a schematic overview of a typical viscose process.
  • non-cellulosic fibers denotes fibers which are not cellulose, and may be other natural fibers or synthetic fibers.
  • regenerable cellulose fibers denotes cellulose fibers, where the cellulose fibers have undergone a process where the cellulose fibers are processed into a pulp and subsequently extruded to a fiber. Examples include but are not limited to viscose. Such fibers are produced by regeneration of dissolved forms of cellulose.
  • synthetic fibers denotes fibers made by humans through chemical synthesis, as opposed to natural fibers that are directly derived from living organisms, such as plants (like cotton) or fur from animals.
  • synthetic fibers are nylon, and polyester .
  • textile and “textile material” as used throughout the description and the claims denote a flexible material made by creating an interlocking bundles of yarns or threads, which are produced by spinning fibers into long and twisted lengths. Textiles are then formed by weaving, knitting, crocheting, knotting, tatting, felting, bonding or braiding these yarns together.
  • viscose dope denotes a mixture comprising cellulose xanthate formed during a viscose process by reacting carbon disulphide with alkali cellulose. Depending on the origin of the cellulose the mixture may comprise additional fibers, for instance if the cellulose comes from recycled textiles, the viscose dope may comprise additional fibers which are not cellulose fibers. Altough the viscose dope comprises dissolved cellulose xanthate it is typically a mixture since it comprises additional undissolved fibers.
  • undissolved denotes that some matter for instance a fiber is not dissolved in the surrounding liquid medium and hence a solution is not formed by the fiber. In case of a fiber in a liquid medium the undissolved fiber is in soled state.
  • a method for manufacturing a material comprising the sequential steps of: i) providing a viscose dope comprising cellulose xanthate and undissolved non-cellulosic fibres, and filtering the viscose dope to obtain a material comprising at least a part of the undissolved non-cellulosic fibres, ii) pressing the material obtained in step i) , so that the amount of undissolved non-cellulosic fibers in the material after the pressing is at least 40 wt%, iii) contacting the material with an acid solution so that the cellulose xanthate is at least partially converted to cellulose, and iv) washing the material in an aquaeous solution
  • the material manufactured in the first aspect is the same as the product which is described in the second aspect. I.e. the product of the second aspect is manufactured by the method of the first aspect .
  • the amount of undissolved non- cellulosic fibers in the material after the pressing is at least 40 wt%. In one embodiment, the amount of undissolved non-cellulosic fibers in the material after the pressing is at least 50 wt%. In one embodiment, the amount of undissolved non-cellulosic fibers in the material after the pressing is at least 60 wt%. In one embodiment, the amount of undissolved non-cellulosic fibers in the material after the pressing is at least 70 wt%. In one embodiment, the amount of undissolved non- cellulosic fibers in the material after the pressing is at least 80 wt%.
  • the viscose dope in a viscose process is filtered at least once.
  • undissolved non-cellulosic fibres, xanthate gel and other unwanted particles of a certain size are removed.
  • the cut-off depends on the filter and is determined by selecting a suitable filter with an appropriate cut-off .
  • Such a filtering step is performed at least once at a point in the viscose process after the xanthation, but before the cellulose xanthate is converted back to cellulose.
  • a filtering step is present in step i) .
  • the filter reject (material which has not passed through the filter, i.e. non-liquid material which is too large to pass the filter) may be obtained through e.g. scraping or backwashing of the filters and is usually thrown out or worked up and returned into the process to an earlier step.
  • the filter reject is collected and treated further according to the method of the invention. The filter reject is thus the material which is treated further in the next step.
  • the viscose dope is made from at least one textile material.
  • the problem with non-cellulosic fibers and cellulose fibers which are mixed together typically occurs when textiles are used and are processed to be used as a starting material in the viscose process.
  • the processing of textiles such as pre and post consumer textiles is described as a whole or in part for instance in WO 2018/073177, WO 2018/104330, WO 2020/127453, and WO 2021/185704. Textiles can be recycled by processing them and then the processed material can be used for viscose process. In such cases a complete separation of cellulose fibers and non-cellulosic fibers may not always be necessary. Instead the non-cellulosic fibers can be filtered away during the viscose process and the non- cellulosic fibers together with cellulose can be turned into a useful new material.
  • the undissolved non-cellulosic fibers comprise synthetic fibers.
  • Synthetic fibers are made from synthesized polymers of small molecules.
  • the synthetic fibers comprise at least one selected from polyester, acryl, polyamide, polyurethane, polyether, nylon, and elastane.
  • the filtering in step i) is performed using at least one filter selected from the group consisting a filter with a sintered metal sheet, a frame filter press, a polymer filter, and a centrifugal discharge pressure leaf filter.
  • the filtering in step i) is followed by backwashing to obtain the material.
  • the material is recovered by mechanically removing the material from the filter for instance by scraping .
  • particles larger that 15 pm are retained in the filtering mentioned in step i) , wherein the particle size is measured according to ISO 13320:2020. Particles with a size larger than 15 pm are retained in the filter, whereas particles with a size smaller than 15 pm are not retained in the filter.
  • particles larger that 20 pm are retained in the filtering mentioned in step i) , wherein the particle size is measured according to ISO 13320:2020.
  • particles larger that 5 pm are retained in the filtering mentioned in step i) , wherein the particle size is measured according to ISO 13320:2020.
  • particles larger that 40 pm are retained in the filtering mentioned in step i) , wherein the particle size is measured according to ISO 13320:2020.
  • the material is stored in a first storage compartment after step i ) and before step ii ) . In one embodiment the material is stored in a second storage compartment after step ii ) and before step iii ) . This has the advantage of providing the possibility to accumulate material when the viscose process is run and then make a production run of the new material .
  • the pressing in step ii ) is performed using at least one press selected from the group consisting of a screw press and a tube press .
  • filtered viscose dope from step i ) ( i . e . the material which passes through the filter ) is returned to the viscose process .
  • the pressing in step ii ) provides further viscose dope , which is returne to the viscose process . This gives an improved process economy so that material is not wasted .
  • the material obtained after step ii ) is shaped into a desired shape before step iii ) .
  • the remaning cellulose xanthate turns into cellulose .
  • the material also comprises a number of non-cellulosic fibers .
  • the material is shaped to a certain shape before contacting with the acid, that shape will be retained after the treatment with acid .
  • the formed cellulose and the non-cellulosic fibers in the material will form a material where the non-cellulosic fibers are embedded in the cellulose .
  • the material is shaped into a desired shape during heat treatment .
  • the material is shaped into a desired shape during heat treatment at or above the glass-transition temperature ( Tg) of the synthetic fibers .
  • the material obtained after step ii ) is rolled before step iii ) . This creates a sheet of material which is easy to contact with acid and easy to handle .
  • the material is rolled to a thickness in the range 0 . 05- 1 mm before step iii ) . This thickness gives a suitable treatment time in acid and makes the final material possible to handle in an easy way . It is however possible to make the material thicker or thinner .
  • the acid solution in step iii ) comprises at least one acid selected from the group consisting of sulphuric acid, sodium sul fate and zinc sul fate .
  • the acid solution is comparable with the acid solution used in the viscose process to react the cellulose xanthate to cellulose .
  • the same acid solution is used for step iii ) as for the viscose process . This setup can simpli fy the process when performed in or near a viscose factory .
  • CS 2 is released during step iii ) and in one embodiment this is returned into the viscose process . This recycling makes the process more economical .
  • a product manufactured according to the above described method comprising a ) at least 40 wt% of non-cellulosic fibers , and b ) regenerated celloluse , wherein the non-cellulosic fibers are embedded in the regenerated cellulose .
  • the manufacturing method gives a product where the non- cellulosic fibers are embedded in cellulose .
  • the non- cellulosic fibers constitute a fairly high fraction of the material ( at least 40 wt% ) .
  • the non- cellulosic fibers can be viewed as reinforcement in the regenerated cellulose .
  • the non-cellulosic fibers contributes strongly to the mechanical properties of the material . Due to the in-situ regeneration of the cellulose xanthate the adhesion between the non- cellulosic fibers and the regenerated cellulose becomes high, which further contribute to the mechanical properties of the finished material .
  • the product comprises at least 40 wt% of non-cellulosic fibers . In one embodiment , the product comprises at least 50 wt% , at least 60 wt% , at least 70 wt% or at least 80 wt% of non-cellulosic fibers .
  • the non-cellulosic fibers are at least one selected from polyester, acryl , polyamide , polyurethane , polyether, nylon, and elastane .
  • the non- cellulosic fibers as well as the cellulosic fibers typically come from post consumer or pre-consumber textiles to be recycled . Textiles often comprise cellulosic fibers such as for instance cotton mixed with one or more of the above mentioned non-cellulosic fibers .
  • the product has a thickness in the inverval 0 . 05- 1 mm . It is an advantage that the process can be scaled up and in a large scale it is an advantage to be able to roll the material .
  • the material can be rolled to a certain thickness and it has turned out that a thickness in the interval 0 . 1- 1 mm gives suitable properties with respect to handling of the material and other properties .
  • the width of the material is in the interval 100- 1500 mm . This is a suitable width with respect to handling of the material in a factory .
  • the invention is not limited to rolled material and other shapes can easily be manufactured .
  • the material is typically shaped right before and/or in the very beginning of the treatment with the acid solution . Due to the properties of the material the shape will last when the cellulose xanthate has been converted to cellulose .
  • the product as at least one selected from padding and lining .
  • the finished material is a useful product and can be used in many di f ferent applications . Such applications include but are not limited to padding and lining .
  • the solid matter over a certain si ze is retained and recovered .
  • the filters used are filters which are normally used in the viscose process to filter the viscose dope .
  • the recovered solid non-cellulosic fibers are typically together with cellulose xanthate in liquid form and cellulose xanthate in gel form, particles and other impurities .
  • the recovered solid non-cellulosic fibers together with some remaining cellulose as well as remaining liquid viscose dope is the filter reject and is often discarded, but the present invention makes it possible to use it.
  • the filter is backwashed to recover the filter reject, which is then the material comprising undissolved fibres obtained by filtering of viscose dope in a viscose process provided in step i) .
  • the undissolved fibers comprise non-cellulosic fibers as well as some undissolved cellulosic fibers and solid particles such as impurities and gel of cellulose xanthate.
  • the filter is scraped to obtain the filter re j ect .
  • the reject may be stored in a container before step ii) and/or before step iii) .
  • the storage allows a better planning of the process in large scale. It is also possible to transport the reject to another geographical location to prepare it further there.
  • the acid solution comprises at least one selected from sulphuric acid, sodium sulfate and zinc sulfate.
  • the acid solution is typically an acid solution which is commonly used for viscose manufacturing.
  • the acid solution comprises 100-150 g/1, for example about 130 g/1, of sulphuric acid (H2SO4) .
  • the acid solution comprises 200-400 g/1, for example about 310 g/1, of sodium sulfate (Na2SC>4) .
  • the acid solution comprises 5-20 g/1, for example about 9.5 g/1, of zinc sulfate (ZnSCg) .
  • the concentration of the acid solution is set to result in the regeneration of cellulose.
  • the step iv) of washing removes acid from the material and ceases chemical reactions .
  • the material may be rolled up on a cylinder or a spool i f the material is made as a sheet or in another shape which can be rolled .
  • the resulting final product is a synthetic fiber- reinforced cellulose-containing material . It can be used for various purposes including but not limited to padding or lining .
  • An advantage of the method is thereby making use of the filter rej ect of a viscose process and providing an additional final product with a high content of fibers of the type that were not dissolved in the viscose process .
  • This includes non-cellulosic fibres such as synthetic fibres such as at least one selected from polyester, acryl , polyamide , polyurethane , polyether, nylon, and elastane .
  • the final product will also have a content of regenerated cellulose fibers . As these fibers are regenerated in the presence of the exsisting undissolved fibers , they are to some extent intertwined with the undissolved fibers , providing a material with desirable properties .
  • the material may for example have a good elasticity .
  • the properties will be slightly di f ferent dependent on the type of synthetic fiber present .
  • the relatively pure viscose dope obtained after step i ) and the filtering can for example be further processed as usual in the viscose process .
  • the pure viscose dope desired for use in the spinning process and the resulting viscose end product of the viscose process is thereby not compromised
  • CS2 gas is released and obtained during step iii) .
  • the obtained CS2 gas can be used for multiple purposes.
  • the obtained CS2 gas is returned into the viscose process and used in the xanthation step.
  • the non-cellulosic fibers are at least one selected from polyester, polyacrylonitrile, polyamide, polyurethane, and polyether. In one embodiment of the product, the non- cellulosic fibers are at least one selected from nylon and elastane.
  • the product is a cloth being 0.05-1 mm thick and 100-1500 mm broad.
  • the celluloses recycled from textiles through the viscose process usually have different properties than natural cellulosic fibers. They may for example have a relatively short chain length.
  • non-cellulosic fibers such as synthetic fibers are present in an unusually high proportion and the cellulosic fraction are at least to some extent incorporated into the undissolved non-cellulosic ( e . g . synthetic ) fibers as they are regenerated in the presence of the existing undissolved fibers .
  • This provides a material with desirable properties .
  • the material can have a relatively high elasticity .
  • the present method is intended to be carried out together with additional steps and stages in the regeneration of reclaimed cellulose , such as an initial collection of textiles to be recycled, and also subsequent steps such as a subsequent viscose process or other use of the material . Additional stages are known in the art and can easily be combined with the steps according to the invention by a skilled person . A number of additional steps are suitably performed in the regeneration of reclaimed cellulose as described in the prior art .
  • the starting material originate from pre-consumer textile waste .
  • Pre-consumer textile waste includes but is not limited to combing waste and cuttings .
  • the starting material originate from post-consumer textiles .
  • Post-consumer cellulose containing waste includes but is not limited to laundry waste and used clothes

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Biochemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Artificial Filaments (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un matériau, le procédé comprenant les étapes séquentielles consistant à : i) fournir un dopant de viscose comprenant du xanthate de cellulose et des fibres non cellulosiques non dissoutes, et filtrer le dopant de viscose pour obtenir un matériau comprenant au moins une partie des fibres non cellulosiques non dissoutes, ii) presser le matériau obtenu à l'étape i), de telle sorte que la quantité de fibres non cellulosiques non dissoutes dans le matériau après le pressage est d'au moins 40 % en poids, iii) mettre en contact le matériau avec une solution acide de telle sorte que le xanthate de cellulose est au moins partiellement converti en cellulose, et iv) laver le matériau dans une solution aqueuse. Le matériau fabriqué est un produit qui peut être utilisé à diverses fins. Les avantages de l'invention consistent en ce qu'il est possible d'utiliser des fibres non cellulosiques restantes au lieu de les jeter lors de la fabrication de viscose à partir de déchets textiles.
PCT/EP2023/077500 2022-10-06 2023-10-04 Procédé de fabrication d'un produit comportant des fibres recyclées WO2024074580A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE2251160A SE2251160A1 (en) 2022-10-06 2022-10-06 Method for manufacturing a product comrpising recycled fibers by filtration and acid treatment of a viscose dope
SE2251160-4 2022-10-06

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WO2024074580A2 true WO2024074580A2 (fr) 2024-04-11
WO2024074580A3 WO2024074580A3 (fr) 2024-05-23

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Citations (6)

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Publication number Priority date Publication date Assignee Title
WO2018073177A1 (fr) 2016-10-19 2018-04-26 Re:Newcell Ab Recyclage de textiles cellulosiques
WO2018104330A1 (fr) 2016-12-06 2018-06-14 Re:Newcell Ab Fibres de cellulose
EP3511451A1 (fr) 2018-01-15 2019-07-17 Lenzing Aktiengesellschaft Procédé de recyclage d'un produit textile mélangé comportant de la cellulose et de la matière plastique synthétique
WO2020127453A1 (fr) 2018-12-19 2020-06-25 Re:Newcell Ab Séparation de fibres
EP3868929A1 (fr) 2018-01-15 2021-08-25 Lenzing Aktiengesellschaft Corps moulé, comportant de l'élastane incorporé dans la cellulose et procédé de fabrication
WO2021185704A1 (fr) 2020-03-16 2021-09-23 Re:Newcell Ab Procédé en une étape pour le retrait de métaux et le blanchiment avec de l'acide

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CA746729A (en) * 1966-11-22 Muller Hans Process for the filtration of artificial silk and synthetic foil spinning materials by means of filter surfaces to which an alluvial medium is applied
AT517020B1 (de) * 2015-02-06 2020-02-15 Chemiefaser Lenzing Ag Recycling von cellulosischen Kunstfasern
CN106065085A (zh) * 2016-06-30 2016-11-02 余燕平 一种可溶解纺织品的回收、再生、循环使用技术
EP3511448A1 (fr) * 2018-01-15 2019-07-17 Lenzing Aktiengesellschaft Procédé de recyclage du matériau textile comprenant de la cellulose
EP3511140A1 (fr) * 2018-01-15 2019-07-17 Lenzing Aktiengesellschaft Procédé de séparation d'un composant cible fibreux à partir de déchets textiles
EP3747614A1 (fr) * 2019-06-04 2020-12-09 Lenzing Aktiengesellschaft Procédé de fourniture d'une matière de départ traitée contenant de la cellulose ayant une répartition de longueur de fibre prédéfinie
EP3983583A4 (fr) * 2019-06-13 2023-07-12 TreeToTextile AB Fibres produites à partir de déchets cellulosiques recyclés

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018073177A1 (fr) 2016-10-19 2018-04-26 Re:Newcell Ab Recyclage de textiles cellulosiques
WO2018104330A1 (fr) 2016-12-06 2018-06-14 Re:Newcell Ab Fibres de cellulose
EP3511451A1 (fr) 2018-01-15 2019-07-17 Lenzing Aktiengesellschaft Procédé de recyclage d'un produit textile mélangé comportant de la cellulose et de la matière plastique synthétique
EP3868929A1 (fr) 2018-01-15 2021-08-25 Lenzing Aktiengesellschaft Corps moulé, comportant de l'élastane incorporé dans la cellulose et procédé de fabrication
WO2020127453A1 (fr) 2018-12-19 2020-06-25 Re:Newcell Ab Séparation de fibres
WO2021185704A1 (fr) 2020-03-16 2021-09-23 Re:Newcell Ab Procédé en une étape pour le retrait de métaux et le blanchiment avec de l'acide

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SE2251160A1 (en) 2023-11-28
WO2024074580A3 (fr) 2024-05-23

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