Innovation - Experiences - Quality · Innovation - Experiences - Quality. Indian Polyester 2016 -...

Indian Polyester 2016 - 11. August 2016

Innovative polyester and recycling technologies

by

Wolf Karasiak

Managing Director

Innovation - Experiences - Quality


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


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


Germany (Berlin)

Headquarter

China

Sales & Technical Support

India

Sales & Technical Support

Aquafil Engineering


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


Aquafil Engineering Program

Continuous /

Batch

Poly Plant

+Drying Extruder ProductDosing WastePolymer

Chips

AQUAFIL

Polymer

Plants

AQUAFIL

Drying

Plants

AQUAFIL

Dosing

Units

AQUAFIL

Recycling


AQUAFIL ENGINEERINGPROCESSES THAT MAKE YOU COMPETITIVE

Polyester

Virgin

Technology

Polyester


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


Polyester 2-Reactor Technology

for Film , Bottle and Textile PET


Polymer Plants –Redefined

Low Building Technology - LBT®


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



-50% erection and

building costs

-20% electrical

consumption

LOW BUILDING TECHNOLOGY

=

LBT®

200 t/d plant capacity

Patented equipment and 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



1th Line USA - Film PET

2nd Line India - Film PET


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


Polymer Plants –Redefined

Direct Film Casting - DFC®


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



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)



AQUAFIL LBT® Polycondensation

+ Melt Modifikation System (MMS)

+ Direct Film Casting (DFC®)

PolyLine

PolyLine

Core Layer

Cap Layer

Chips ExtruderBatch

FilmLine

DFC®


Polyester / Polyamide


Recycling

Technologies


Polyester / Polyamide Recycling


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


Polyester


EverPET®

internal

technology


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%


Polyester


EverPET® - IV lift

technology


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


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


AQUAFIL PET HV-DRC® Reactor for IV Increase

High Viscosity-DRC ® Reactor

Polyester EverPET ® – IV lift

3D Model Planning

High Viscosity for Direct Route


Polyester


EverPET®

industrial / consumer

technology


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


Polyester AQUAFIL Closed Loop Principle

EverPET®THE CLOSED

LOOP FOR PET

AQUAFIL EverPET® RECYCLING

AQUAFIL LBT® POLYCONDENSATION

WASHING / SORTING


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 ®


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 ®


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®


Econyl 2016

information and videos about Econyl

are available at

www.econyl.com

Polyamide Econyl®


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

Innovation - Experiences - Quality · Innovation - Experiences - Quality. Indian Polyester 2016 -...

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