Krones Bottle to Bottle Recycling: Technology for Purity

Size: px

Start display at page:

Download "Krones Bottle to Bottle Recycling: Technology for Purity"

Primrose Marsh
6 years ago
Views:

1 Bottle to Bottle Recycling: Technology for Purity Dr. Thomas Friedlaender

KRONES BOTTLE TO BOTTLE RECYCLING: TECHNOLOGY FOR PURITY Created by: Bernd Esmarch/Dr. Thomas Friedlaender Date: August 2011 1.

2 KRONES BOTTLE TO BOTTLE RECYCLING: TECHNOLOGY FOR PURITY Created by: Bernd Esmarch/Dr. Thomas Friedlaender Date: August Basic requirements for PET- Recycling 2. Importance of material sorting 3. PET-washing:The key to success. 4. How to create RPET for bottles. 47

3 1) Basic requirements for PET - Recycling Conceptual formulation! g Lead postconsumer PET bottles back to reusable quality. 1) Basic requirements for PET - Recycling Very important to achieve required input quality for recycling line. Separation of non plastic materials, or plastics like PVC, multilayer and coloured bottles. Can be done automatically, semiautomatically and manually. cleaning-effect 1. presorting 2. washing The washing process is key success factor! All kinds of decontamination processes do need a washing process with clean flakes as output material. The quality of wash process is determined by capability to wash off labels, glue, solvable dirt, sand etc. 3. decontamination Different technologies to achieve foodgrade quality. The parameters for decontamination are temperature and time. >95% >80% has has competence competence in in all all areas areas of of Recycling Recycling Process Process 48

4 1) Basic requirements for PET - Recycling Only has both HQ Washing Technolgy and Bottle-to-Bottle Technology The washing step is defining step for quality of recycled PET. In subsequent steps it is impossible to compensate for bad washing quality. Washing High Quality solution Colour Glue removal Foreign materials Yield furr processing Virgin-PET vs. 100% -RPET 1. Basic requirements for PET- Recycling 2. Importance of material sorting 3. PET-washing:The key to success. 4. How to create RPET for bottles. 49

5 2) Importance of material sorting PVC, HDPE ; LDPE ; PLA and or plastics OIL Foreign materials like glas, metal, wood, stones Coloured bottles (light blue transparent is accepted) PET bottles for food and or contents than beverages. Multilayer bottles 2) Importance of material sorting We offer engineering and technology for presorting! g The output quality requirement has a strong relation to quality of input material. g We make an analysis of relevant post-consumer material. g We design required presorting - technology based on input quality. Metal Sheet Wood Labels Coloured bottles Moisture Or plastics or plastics Paper focuses on every single process step! focuses on every single process step! 50

6 1. Basic requirements for PET- Recycling 2. Importance of material sorting 3. PET-washing:The key to success. 4. How to create RPET for bottles. Wash off of all dirt contaminations from surface of ground material (flakes). Consequent removal of glue, pulpe, caustic, label-colour and or substances to achieve a successful supercleaning subsequently. Removal of washed off dirt out of washing process by filtration. Smooth handling of material inside washing process. 51

7 Bottle Flakes Silo Flotation tank dry mixer Post - washer ZZ air separator Mechanical dryer Prewasher Thermal dryer Caustic washer Parcival ZZ air separator to B2B More than 50 years of experience regarding bottle-washing! g We know optimal interaction between washing parameters: time, temperature, mechanical impact and chemistry. g Separation of foreign substances at right time is very important. g The kind and washing steps of different machines is solution for clean flakes. g Our intelligent filter systems lead to constant wash-quality and very low water- and chemistry consumption The The quality quality results results of of washing washing process process are are unmatched unmatched!! 52

8 Dry grinding and dry prewashing! g The main reason for dry precleaning is to separate dirt from PET immediately. g PET flakes and dirt particles toger in a solution will lead to furr contamination of PET material. Especially label-colour and glue will affect furr treatment. g The dry-washing and following air separation remove labels, glue and dust before material is entering wetwashing-process. The The dry-prewashing dry-prewashing is is one one key key success success factor factor to to achieve achieve a a good good washing washing result result!! Smooth caustic-washing-process with intensive filtration! g The intensive washer with first in first out principle ensures uniform residence time. Storage Tank g The 3 step filtration cares for a minimal degree of soiling in intensive washer. g A low speed agitator cares for smooth material handling. g The upright design of intensive washer leads to compaction of material inside machine and reinforces friction. Intensive washer step 1 Sieve after Parcival Caustic before Parcival min 80 C 85 C step 3 step 2 Fine rough Big g De-mixing of cap-material (PO) and PET is excluded by a technological trick. Only Only PET PET and and PO s PO s will will enter enter intensive intensive washer. washer. Labels Labels and and or or substances substances have have been been separated separated before! before! Parcival 53

9 Flakes drip pan Flakes screen pump 7th China International Recycled Polyester Forum Water system with continual refreshing of all bas! g The freshwater is added into last zone of washing process and passes all bas. clean water Cl ean w at er Dirty flakes dirty flakes g With this water-flow-system bas are refreshed twice an hour and cleaning quality stays on a constant level. En t h är t u n g Nachwäscher / Postwasher Swim-sink-separator Vorwäscher / prewasher g Hot freshwater is used to wash off remaining hot-melt- glue. g The waste water is carrying a constant low amount of substances and can pass every purification plant. Intensive washer drain Clean hot water flows against dirt! Clean hot water flows against dirt! Summary washing process Dry grinding process. Most of labels are separated before washing process. All aggregates with slow speed of rotation. Less fines and higher yield. Caustic washer prevents demixing of cap material and PET. Intensive micro filtration for washing liquid to achieve a constant cleaning result. Hot post rinsing with soft- water to achieve a better cleaning result. Water cascade refreshes all bas continuously. 54

10 1. Basic requirements for PET- Recycling 2. Importance of material sorting 3. PET-washing:The key to success. 4. How to create RPET for bottles. 4) How to create RPET for bottles Degassing of undesired substances. No IV (Intrinsic Viscosity) degradation. IV elevation for CSD. Process safety and quality control. No yellowing of material. Prevent AA formation. Low energy and water consumption. The requirement determines process! The requirement determines process! 55

11 g g g g g g 4) How to create RPET for bottles The decontamination of washed flakes is simple,when previous treatment steps have been done consistently! The -Flake-Decontamination is fast and requires low decontamination temperature. The material is heated up smoothly outside of vacuum-reactor, to achieve uniform temperature distribution inside vacuum reactor. The residence- time in vacuum reactor is very short and temperature is low. The process builds up IV without additional equipment. The Flake decontamination requires less energy than melting processes and is very gentle. Principle pc-bottles flakes flakes washing drying Flake decontamination - Process When Pellets are required decontaminated, hot flakes will be be transferred under vacuum direct into a Pellet-Extrusion. We We know know about about quality quality requirements requirements of of converters converters and and bottlers bottlers!! extrusion melt-filtration cristallisation pellets degassing pelletisation pellets foodgrade flakes hot foodgrade flakes directlyinto preform extrusion Pellet Preform 4) How to create RPET for bottles More Potential Savings : Preform Injection with rpet temp potential saving in process t ime, st orage and equipment / energy for drying rpet-flakes are dry and warm when leaving KRONES reactor Energy savings for drying / preheating hot washed flakes food-grade decontamination cool down & st orage drying pre-heating extrusion injection molding time No intermediate storage and transport neccessary Cost savings for equipment and storage area Better utilization of smaller particles Profit through higher yield 56

12 4) How to create RPET for bottles Integrated path towards RPET content with flakes! Preforms w/ RPET Virgin PET Preform injection with melt filtration Converters Flake decontamination module washing module Inline Inlinerecycling recyclingand and preform preform manufacturing manufacturingremoves removesunneeded steps! steps! Washed PET flake KRONES PET Recycling: Technology for Purity All out of one hand! Start up and quality Start up and quality assurance assurance Analysis of Analysis of postconsumer postconsumer material material Customer oriented trials in Customer oriented trials in pilot plant pilot plant Monitoring and control of Monitoring and control of entireprocess entireprocess Single and turnkey Single and turnkey solutions. Flake or Pellet solutions. Flake or Pellet Complete installation of all Complete installation of all process parts process parts Pre-delivery inhouse Pre-delivery inhouse tests tests Modular -systems from Modular -systems from bale to bottle bale to bottle We take care of everything: From bale to bottle! We take care of everything: From bale to bottle! 57

13 Thank you very much for your attention! 58

Recycling Line recostar PET for production and post-consumer scrap, preforms, bottle and sheet flakes, integrated pre-drying, dust-free processing,

Recycling Line recostar PET for production and post-consumer scrap, preforms, bottle and sheet flakes, integrated pre-drying, dust-free processing, optional inline solid stating, energy efficient, high