Next Generation Recyclingmaschinen
PET-Recycling/Upcycling with the new LSP-Process (Liquid State Polycondensation)
12th Annual CARE Conference May 6 - 8, 2014 Seattle Renaissance, Seattle, WA Thomas Pichler
Next Generation Group in brief
PET properties and forces describing material
decomposition and reversible composition
PET Reactor – basic functions
Handling of various different input materials (bottle flakes, wovens, etc.)
Results from test Runs
Outlook on commercial availability
Contents
PET-Recycling/Upcycling with the new LSP-Process (Liquid State Polycondensation)
2/28 May 2014 - 12th Annual CARE Conference
Profile
Competence for the Plastic Industry
3/22
Employees 2013: 226
Total Sales 2013: € 51,5 Mio.
Next Generation Group
May 2014 - 12th Annual CARE Conference
Members
4/22
RECYCLING-SOLUTIONS for industrial plastic converters and end-of-life plastics > Headquarter Feldkirchen, AUSTRIA > Customer Care Center for NAFTA/USA > Customer Care Center for ASIA/CHINA www.ngr.at
FILTRATION-SYSTEMS for heavy contaminated end-of-life plastics > Hanau, GERMANY www.britas-recycling.de
PILOT PLANTS + LAB EQUIPMENT for optimizing plastic materials and converting technologies > Ebersberg, GERMANY www.drcollin.de
Next Generation Group
May 2014 - 12th Annual CARE Conference
5/11
Next Generation Group
May 2014 - 12th Annual CARE Conference
Global Spread
6/11
Next Generation Equipment in Operation
Sales & Customer Care Center AMERICA
Representative Office MALAYSIA
Sales & Customer Care Center CHINA
Representative Office TAIWAN
Headquarter Feldkirchen, AUSTRIA
BritAS GmbH Hanau, GERMANY
Dr. Collin GmbH Ebersberg, GERMANY
Next Generation Group
May 2014 - 12th Annual CARE Conference
LSP Technology
7/18 May 2014 - 12th Annual CARE Conference
L S P
=
Liquid State Polycondensation
long polymer chain = high viscosity = high molecular weight = high iV- value = high price
cleaved
PET properties and forces describing material decomposition and reversible composition
8/18
Terephthalic acid Ethylene glycol
Polyethylene terephthalate
May 2014 - 12th Annual CARE Conference
PET properties and forces describing material decomposition and reversible composition
Intrinsic Viscosity (IV; dl/g)
Fiber, Textile 0,40 – 0,70 (0,62)
Film Grade 0,60 – 0,70 (BOPET)
0,70 – 1,00 (Thermoforming Sheets)
Bottle Grade 0,78 – 0,85 (Carbonated)
0,70 – 0,78 (Water flat)
9/18 May 2014 - 12th Annual CARE Conference
PET properties and forces describing material decomposition and reversible composition
AA-Value (Acetaldehyde) + others
Less than 1,5 ppm
Color value (L,a,b)
Food Contact non objection letters (FDA, EFSA, etc.)
10/18 May 2014 - 12th Annual CARE Conference
Thermal decomposition
Thermal/ oxidative decomposition
Hydrolytic decomposition
Reason
Influence of too high temperature + too long exposure time
High Temperature+ Aerial oxygen
Moisture in the material
Comparison Decomposition-speed
1 10 10.000
PET properties and forces describing material decomposition and reversible composition
11/18 May 2014 - 12th Annual CARE Conference
SSP (Solid State Polycondensation)
LSP (Liquid State Polycondensation)
State of PET Solid / crystalline Liquid (melt)
Environment Vacuum or inert gas vacuum
Typical Temperature (200-240) °C (270-280) °C
IV – Lift – Speed (0,01 – 0,02) dl/g per hour
(0,01) dl/g per minute
PET properties and forces describing material decomposition and reversible composition
12/18 May 2014 - 12th Annual CARE Conference
PET-Reactor Basic Functions
May 2014 - 12th Annual CARE Conference 13/22
PET Upcycling unit for PET - fibers
Strand-Pelletizer
Shredder-Feeder-Extruder-
Combination
PET-Reactor
Handling of various different Input-Materials
May 2014 - 12th Annual CARE Conference 14/22
Input condition (clean in any case)
PET-fibre production waste textured and uncut
Material data Parameter Unity
Moisture Average 3368 ppm
iV-Average 0,62 dl/g
Spin finish ~ 0,5 %
Output 350 kg/h
Result iV-Average 0,665 dl/g
Results from test run
15/18 May 2014 - 12th Annual CARE Conference
LSP Test runs
iV-Measuring points
After Extruder
Before Reactor
Pellet
LSP Testresults
0.630
0.570 0.563
0.641
0.663 0.658
0.655 0.660
0.666 0.665
0.550
0.560
0.570
0.580
0.590
0.600
0.610
0.620
0.630
0.640
0.650
0.660
0.670
0.680
Fibre after Extruder beforeReaktor
Pellets 60min.after Start
Pellets 90min.after Start
Pellets120min after
Start
Pellets180min. after
Start
Pellets240min. after
Start
Pellets300min. after
Start
Pellets360min. after
Start
iV [d
l/g]
LSP –Testresults PET Fiber
LSP-Technology Laboratory facility / Prototype
New Laboratory facility Production capacity of 400 kg/h (tests @ 250 kg/h)
Results Test Run “Challenge Test” Fraunhofer
19/18
FDA non-objection Letter # 171 from Nov. 2013 under
http://www.fda.gov/food/ingredientspackaginglabeling/ packagingfcs/recycledplastics/ucm376377.htm
Outlook on commercial availability
Test program @ NGR Preforms Bottle flakes Fibres / woven / non-wovens Sheets
Technical implementation Up scaling Results long term tests
Test program in field Long term performance PET-properties
Colouring Energy consumption monitoring Operation parameters (controls)
11 2013
02 2014
01 2015
09 2014
Lab testing @ NGR
Beta + Market Testing (Field tests)
11 2014
Technical Implementation
Commercialization
20/18
Post Consumer Fiber Trials
21/18
Input Material:
Output Material:
Summary
22/18
LSP – Liquid State Polycondensation –
shifts IV-increase and decontamination into the molten phase
of PET (ideal for recycling-purposes)
Lab tests and pilote plant show encouraging results
Challenge tests have been very successful in terms
of decontamination (FDA non objection-letter received in Nov.2013)
Commercial availability to be expected early 2015
WE TAKE CARE OF YOUR PLASTIC WASTE
Next Generation Recycling Machines, Inc. Sales & Customer Care Center America 3000 Center Place, Suite 100 Norcross, GA 30093, USA Phone +1-678-720-9861, Fax -9863
Next Generation Recycling Machines Representative Office Malaysia D-12-08, Bl.D, PJ 8, No. 23, Jalan Barat, Seksyen 8 46050 Petaling Jaya, Selangor, Malaysia Phone +60 3 79588795, Fax: +60 3 79587795
Next Generation Recycling Machines Representative Office Taiwan 5F-7, No. 316, Wenchang Street Taipei 110, Taiwan Phone +886 2 8780 9346
[email protected], www.ngr.at
Next Generation Recyclingmaschinen GmbH HQ, Production and Customer Care Center Europe Gewerbepark 22 4101 Feldkirchen, Austria Phone +43 (0) 7233 70 1 07-0, Fax -2
Next Generation Recyclingmachines, Co., Ltd. Sales & Customer Care Center China No.6, Wuxi Road, Taicang Economic Development Zone, Taicang, Jiangsu 215400, China