Post on 11-Mar-2020
Indian Polyester 2016 - 11. August 2016
Innovative polyester and recycling technologies
by
Wolf Karasiak
Managing Director
Innovation - Experiences - Quality
Indian Polyester 2016 - 11. August 2016
BCF
NTF
Bulk Continuous Filaments
Nylon Textile Filaments
3 business units (PA6)
Aquafil Group Facts 2015
ER Energy & Recycle
>2700 employees 16 production plants worldwide
1 engineering company
130.000 tons polymer/fibersPA6.6 / Dryarn / XLA
No. 1 in Europe for PA6 BCF
No. 2 in World for PA6 BCF
65 million € EBITDA 499,1 million € turnover
Indian Polyester 2016 - 11. August 2016
THAILANDRayong –
Bangkok
BCF
ITALYArco TN
HEAD QUARTER
Polymerization
BCF
NTFSLOVENIALjubljana
Polymerization
BCF
NTF
CROATIAOroslavje
NTF
CHINAJiaxing
BCF
BCF Synthetic Yarn for Textile Flooring | NTF Nylon Textile Filament
USACartersville (Georgia)
BCF
Aquafil Group Facts
GERMANYBerlin
Engineering
Leuna
BCF
Indian Polyester 2016 - 11. August 2016
Germany (Berlin)
Headquarter
China
Sales & Technical Support
India
Sales & Technical Support
Aquafil Engineering
Indian Polyester 2016 - 11. August 2016
Aquafil Engineering Program
PA Polyamide – PA 6, 6.6PET Polyester – PET, PBT, ...
PET-bio based/degradable
PET-R EverPET® Recycling
Services
Polymer Plants
Basic / Detailed Engineering
Revamping / Optimization
Feasibility study
PET textile, film, bottle, technical
Indian Polyester 2016 - 11. August 2016
Aquafil Engineering Program
Continuous /
Batch
Poly Plant
+Drying Extruder ProductDosing WastePolymer
Chips
AQUAFIL
Polymer
Plants
AQUAFIL
Drying
Plants
AQUAFIL
Dosing
Units
AQUAFIL
Recycling
Indian Polyester 2016 - 11. August 2016
AQUAFIL ENGINEERINGPROCESSES THAT MAKE YOU COMPETITIVE
Polyester
Virgin
Technology
Polyester
Indian Polyester 2016 - 11. August 2016
Polyester 2-Reactor Technology
2003 - 2012
0,35-0,40 dl/g
0,58-0,68 dl/gUPR®
Conventional 4-Reactor PET plant
(i.e. Chinese standard, higher conversion costs)
DRC® Chips
AQUAFIL 2-Reactor PET plant
0,28 dl/g
0,58-0,64 dl/gEster 1 Finisher ChipsEster 2 Prepoly
Indian Polyester 2016 - 11. August 2016
Polyester 2-Reactor Technology
for Film , Bottle and Textile PET
Indian Polyester 2016 - 11. August 2016
Polymer Plants –Redefined
Low Building Technology - LBT®
Indian Polyester 2016 - 11. August 2016
Polyester LBT® Technology
Year Company Country T/D Product Status
2014 xxx USA xxx PET Film Operation
2015 xxx India xxx PET Film Operation
2016 xxx India xxx PET Film Engineering
14 m
7 m
0 m
200 t/d capacity
Indian Polyester 2016 - 11. August 2016
Polyester LBT® Technology
-50% erection and
building costs
-20% electrical
consumption
LOW BUILDING TECHNOLOGY
=
LBT®
200 t/d plant capacity
Patented equipment and technology
Indian Polyester 2016 - 11. August 2016
Polyester LBT® Technology
ADVANTAGES of LBT® Technology
Costs /
Consumption
Area Reason
- 50 % erection and building only half building height
- 20 % electrical only half building height
- x % HTM media simple plant design
- x % operation reliable and robust design
- x % operation / maintenance - maintenance during operation
- no cleaning of plant required
- x % vacuum system - Aquafil design without steam or
glycol injectors for vacuum system
- no waste water
Indian Polyester 2016 - 11. August 2016
Polyester LBT® Technology
1th Line USA - Film PET
2nd Line India - Film PET
Indian Polyester 2016 - 11. August 2016
Year Company Country T/D Product Status
2014 xxx Thailand xx PET Specialities Operation
2015 xxx Germany xx PET Copo Special. Manufacturing
2016 xxx India xx PET Specialities Engineering
Polyester Batch Technology
Indian Polyester 2016 - 11. August 2016
Polymer Plants –Redefined
Direct Film Casting - DFC®
Indian Polyester 2016 - 11. August 2016
Polyester DFC® Technology
Conventional PET chips plant + Film production
AQUAFIL LBT® Polycondensation + Direct Film Casting (DFC®)
PolyLine Extruder Film Chips Drying
FilmLine
PolyLine
FilmLine Film
Indian Polyester 2016 - 11. August 2016
Polyester DFC® Technology
ADVANTAGES of DFC® Technology
Aquafil DFC® Chips route film casting
Raw material + lower consumption - higher consumption due to cutting,
chips transport, drying and extruder
re-melting
Product quality + Better, less film break,
higher winding speed
- Lower due to chips transport, drying
and re-melting
Waste + Less - More due to dust, chips losses and
more film break
Investment + Lower (min. 50%) - Higher due to chips conveying,
storage, drying, extrusion
Energy
consumption
+ Lower - Higher
(reasons as above)
Building and land + Less - More
(reasons as above)
Man power + Less - More
(reasons as above)
Indian Polyester 2016 - 11. August 2016
Polyester DFC® Technology
AQUAFIL LBT® Polycondensation
+ Melt Modifikation System (MMS)
+ Direct Film Casting (DFC®)
PolyLine
PolyLine
Core Layer
Cap Layer
Chips ExtruderBatch
FilmLine
DFC®
Indian Polyester 2016 - 11. August 2016
Polyester / Polyamide
AQUAFIL ENGINEERINGPROCESSES THAT MAKE YOU COMPETITIVE
Recycling
Technologies
Indian Polyester 2016 - 11. August 2016
Polyester / Polyamide Recycling
Indian Polyester 2016 - 11. August 2016
Polyester / Polyamide Recycling
AQUAFIL RECYLING TECHNOLOGIES and BRANDS
• Polyamide
LDR® Process Technology
Econyl® Regeneration Technology
• Polyester
EverPET® Recycling Technology
EverPET ® - internal
EverPET ® - IV lift
EverPET ® - industrial
EverPET ® - consumer
new -> applied for patent
Indian Polyester 2016 - 11. August 2016
Polyester
AQUAFIL ENGINEERINGPROCESSES THAT MAKE YOU COMPETITIVE
EverPET®
internal
technology
Indian Polyester 2016 - 11. August 2016
Polyester EverPET ® - internal
EverPET® - internal, especially developed for BOPET producers
Core Layer
Skin Layer
Virgin
Polymer
Skin Layer
Recycled
Polymer
Problems:
- Mechanical recycling
from extruder/film line supplier
- Color
- IV different
- Mixing
- Performance
- Capacity limitation
(recycle content 20-25%)
EverPET®
Technology
Advantages:
- Like Virgin PET
- Same Performance
- Capacity up to 100%
Indian Polyester 2016 - 11. August 2016
Polyester
AQUAFIL ENGINEERINGPROCESSES THAT MAKE YOU COMPETITIVE
EverPET® - IV lift
technology
Indian Polyester 2016 - 11. August 2016
Polyester Recycling
Common Conventional Concept of Recycling
=> Mechanical Recycling
Problems of Mechanical Recycling:
• Raw material availability
• Raw material with high IV required
• Raw material quality
• Raw material uniformity
• Impurities
• Color
• No uniform viscosity
• Performance of R-PET
• Mixing performance of R-PET
• Dyeability of R-PET
PET ChipsIV ?
Silo/Dryer
Extruder
F
Filter UWP
washedPET flakes
IV 0,85
IV 0,62
PET film (direct)
IV 0,62
IV 0,58 - 0,55
film / fiber
Indian Polyester 2016 - 11. August 2016
HV Reactor DFC®
PET-W
AQUAFIL PET Recycling by HVR
PET FilmIV 0,58 – 0,76F
Silo/Dryer
Extruder
Pump Filter Pump Visco
PET FiberIV 0,58 – 0,64
DFS
PET BottleIV 0,80 – 0,85
UWP
Polyester EverPET ® – IV lift
PET Melt
AQUAFIL PET Melt Phase –
IV input variation will be equalized
IV increase in melt phase
IV, DEG and other input variation
Indian Polyester 2016 - 11. August 2016
AQUAFIL PET HV-DRC® Reactor for IV Increase
High Viscosity-DRC ® Reactor
Polyester EverPET ® – IV lift
3D Model Planning
High Viscosity for Direct Route
Indian Polyester 2016 - 11. August 2016
Polyester
AQUAFIL ENGINEERINGPROCESSES THAT MAKE YOU COMPETITIVE
EverPET®
industrial / consumer
technology
Indian Polyester 2016 - 11. August 2016
Polyester AQUAFIL Closed Loop Principle
Lactic acid / FDCS
(Food)
PLA / PEF
Landfillor
Incinerator
PTA + EG
PET
Chemical
Recycling
BHET
PET
EverPET®
Caprolactam
Nylon 6
Econyl®
AQUAFIL Route
not sustainable and ecological !
Bio-based Route
Indian Polyester 2016 - 11. August 2016
Polyester AQUAFIL Closed Loop Principle
EverPET®THE CLOSED
LOOP FOR PET
AQUAFIL EverPET® RECYCLING
AQUAFIL LBT® POLYCONDENSATION
WASHING / SORTING
Indian Polyester 2016 - 11. August 2016
ADVANTAGES of EverPET® Technology
Waste EverPET®
industrial
EverPET®
consumer
- different viscosities
- lamination / metallization / color
- different polymers
- high decontamination rate
- high recycling rate to poly plant
Polyester EverPET ®
Indian Polyester 2016 - 11. August 2016
AQUAFIL 2-Reactor Polycondensation Plant + EverPET® Recycling
UPR® Reactor
EverPET flakes
DRC® ReactorRaw Material Feed
AQUAFIL 2-Reactor Polycondensation
EverPET melt
Standard PTA / EG
100 – 0 %
0 – 100 %
PET IV 0,58 – 0,68
UPR®
DRC®
Polyester EverPET ®
Indian Polyester 2016 - 11. August 2016
AQUAFIL S.p.A.
wins
German Sustainability Award 2014
in the category
“Resource Efficiency”.
We are very proud to announce that at the prestigious awards ceremony the jury honored especially the
commitment of Aquafil throughout the value chain with the development of ECONYL® regeneration system and the
special services in the fight against one of the greatest environmental problems of our time: marine pollution.
On Friday 28. Nov. 2014 evening, Prof. Dr. Michael Braungart handed the German Sustainability Award in the
category "Resource Efficiency" to Giulio Bonazzi, CEO of Aquafil Group. In their statement, the jury says: "The
company has introduced new processes and technologies across the value chain and build new partnerships with
partners to close fiber circuits and to improve resource efficiency.
The National German Sustainability Award.
The award is endorsed by the German Federal Government, local and business associations as well as numerous
NGOs, among them UNESCO and UNICEF. The awards are presented to cities, companies and individuals
promoting the idea of a sustainable society by Federal Chancellor Angela Merkel or other members of her cabinet.
The German Sustainability Award was established in 2008 to encourage the acceptance of social and ecological
responsibility and to identify role models in this area.
Polyamide Econyl®
Indian Polyester 2016 - 11. August 2016
Econyl 2016
information and videos about Econyl
are available at
www.econyl.com
Polyamide Econyl®
Indian Polyester 2016 - 11. August 2016
Thank you for your attention.
We create future.
Drying Plants
Polyamide
Polyester
Masterbatch
Equipment
Dosing Unit
Viscometer
Polymer Filter
Gas Cleaning
Recycling Plants
Polyamide
Polyester
Environment
Polymer Plants
Polyamide
Polyester
Masterbatch