krones bottle to bottle recycling: “technology for puritycleaning-effect krones has the competence...
TRANSCRIPT
Krones Bottle to Bottle Recycling:
“Technology for Purity
Dr. Thomas Friedlaender
Krones
47
7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Created by: Bernd Esmarch/Dr. Thomas FriedlaenderDate: August 2011
KRONES BOTTLE TO BOTTLE RECYCLING:
“TECHNOLOGY FOR PURITY”
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
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.
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7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
1) Basic requirements for PET - Recycling
g Lead postconsumer PET bottles back to reusable quality.
Conceptual formulation!
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
The washing process is the keysuccess factor!All kinds of decontaminationprocesses do need a washingprocess with clean flakes as outputmaterial.The quality of the wash process isdetermined by the capability to wash off the labels, glue, solvabledirt, sand etc.
Very important to achieve therequired input quality for therecycling line.Separation of non plasticmaterials, other plastics like PVC, multilayer and coloured bottles.Can be done automatically, semi-automatically and manually.
Different technologies to achievethe foodgrade quality.The parameters for thedecontamination are temperatureand time.
3. decontamination2. washing1. presorting
>80%
>95%
cleaning-effect
Krones has the competence in all areas of the Recycling Process
Krones has the competence in all areas of the Recycling Process
1) Basic requirements for PET - Recycling
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7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Only Krones has both HQ Washing Technolgy and Bottle-to-Bottle TechnologyThe washing step is the defining step for the quality of the recycled PET.In the subsequent steps it is impossible to compensate for bad washing quality.
Krones Washing High Quality solution Krones further processing
Colour
Glue removal
Foreign materials
YieldVirgin-PET vs. 100% Krones-RPET
1) Basic requirements for PET - Recycling
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
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.
50
7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
PVC, HDPE ; LDPE ; PLA and other plastics
Foreign materials like glas, metal, wood, stones
Coloured bottles (light blue transparent is accepted)
PET bottles for food and other contents than beverages.
Multilayer bottles
OIL
2) Importance of material sorting
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
g The output quality requirement has a strong relation to the quality of the input material.
g We make an analysis of the relevant post-consumer material.
g We design the required presorting -technology based on the input quality.
We offer engineering and technology for the presorting !
Krones focuses on every single process step! Krones focuses on every single process step!
2) Importance of material sorting
Metal Wood
Sheet
Labels Moisture
Otherplastics
Colouredbottles
Paper
otherplastics
Metal Wood
Sheet
Labels Moisture
Otherplastics
Colouredbottles
Paper
otherplastics
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7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
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.
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Wash off of all dirt contaminations fromthe surface of the ground material (flakes).
Consequent removal of glue, pulpe, caustic, label-colour and other substancesto achieve a successful “supercleaning“subsequently.
Removal of the washed off dirt out of thewashing process by filtration.
Smooth handling of the material inside thewashing process.
3) PET washing: The key to success !
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7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Bottle Flakes
ZZ airseparator
dry mixer
Silo
Prewasher
Caustic washer
Flotation tank
Post - washer
Mechanical dryer
Thermal dryer
ZZ air separatorParcival
to B2B
3) PET washing: The key to success !
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
g We know the optimal interaction between the washing parameters: “time, temperature, mechanical impact and chemistry”.
g Separation of the foreign substances at the right time is very important.
g The kind and washing steps of the different machines is the solution for clean flakes.
g Our intelligent filter systems lead to constant wash-quality and very low water- and chemistry consumption
More than 50 years of experience regarding bottle-washing!
The quality results of the Krones washingprocess are unmatched !
The quality results of the Krones washingprocess are unmatched !
3) PET washing: The key to success !
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7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Dry grinding and dry – prewashing!
g The main reason for the dry precleaning is to separate the dirt from the PET immediately.
g PET flakes and dirt particles together in a solution will lead to further contamination of the PET material. Especially label-colourand glue will affect the further treatment.
g The dry-washing and the following air separation remove labels, glue and dust before the material is entering the wet-washing-process.
The dry-prewashing is one key success factorto achieve a good washing result !
The dry-prewashing is one key success factorto achieve a good washing result !
3) PET washing: The key to success !
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Smooth caustic-washing-process with intensive filtration!
g The intensive washer with first in first out principle ensures uniform residence time .
g The 3 step filtration cares for a minimal degree of soiling in the intensive washer.
g A low speed agitator cares for smooth material handling.
g The upright design of the intensive washer leads to compaction of the material inside the machine and reinforces the friction.
g De-mixing of cap-material (PO) and PET is excluded by a technological trick.
Only PET and PO‘s will enter the intensive washer. Labels and other substances have
been separated before!
Only PET and PO‘s will enter the intensive washer. Labels and other substances have
been separated before!
Intensive washer
Storage Tank
Caustic
min 80°C – 85°CSieve
Big
Fine
Intensive washer
Storage Tank
Caustic
min 80°C – 85°CSieve
Big
Fine
Parcival
before Parcival
after Parcival
step 1
step 2step 3
roug
h
3) PET washing: The key to success !
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7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Water system with continual refreshing of all bathes!
g The freshwater is added into the last zone of the washing process and passes all bathes .
g With this water-flow-system the bathes are refreshed twice an hour and the cleaning quality stays on a constant level.
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.
Clean hot water flows against the dirt !Clean hot water flows against the dirt !
Enth
ärtu
ng
Nachwäscher / Postwasher
Enth
ärtu
ng
Nachwäscher / Postwasher
screen
drip pan
Flakes
pump
Flakes
screen
drip pan
Flakes
pump
Flakes
Swim-sink-separatorVorwäscher / prewasher
drain
Enth
ärtu
ng
Nachwäscher / Postwasher
Enth
ärtu
ng
Nachwäscher / Postwasher
screen
drip pan
Flakes
pump
Flakes
screen
drip pan
Flakes
pump
Flakes
Swim-sink-separatorVorwäscher / prewasher
drain
dirty flakesclean water
Intensive washer
Enth
ärtu
ng
Nachwäscher / Postwasher
Enth
ärtu
ng
Nachwäscher / Postwasher
screen
drip pan
Flakes
pump
Flakes
screen
drip pan
Flakes
pump
Flakes
Swim-sink-separatorVorwäscher / prewasher
drain
Enth
ärtu
ng
Nachwäscher / Postwasher
Enth
ärtu
ng
Nachwäscher / Postwasher
screen
drip pan
Flakes
pump
Flakes
screen
drip pan
Flakes
pump
Flakes
Swim-sink-separatorVorwäscher / prewasher
drain
dirty flakesclean water
Intensive washerIntensive washer
Clean waterDirty flakes
Enth
ärtu
ng
Nachwäscher / Postwasher
Enth
ärtu
ng
Nachwäscher / Postwasher
screen
drip pan
Flakes
pump
Flakes
screen
drip pan
Flakes
pump
Flakes
Swim-sink-separatorVorwäscher / prewasher
drain
Enth
ärtu
ng
Nachwäscher / Postwasher
Enth
ärtu
ng
Nachwäscher / Postwasher
screen
drip pan
Flakes
pump
Flakes
screen
drip pan
Flakes
pump
Flakes
Swim-sink-separatorVorwäscher / prewasher
drain
dirty flakesclean water
Intensive washer
Enth
ärtu
ng
Nachwäscher / Postwasher
Enth
ärtu
ng
Nachwäscher / Postwasher
screen
drip pan
Flakes
pump
Flakes
screen
drip pan
Flakes
pump
Flakes
Swim-sink-separatorVorwäscher / prewasher
drain
Enth
ärtu
ng
Nachwäscher / Postwasher
Enth
ärtu
ng
Nachwäscher / Postwasher
screen
drip pan
Flakes
pump
Flakes
screen
drip pan
Flakes
pump
Flakes
Swim-sink-separatorVorwäscher / prewasher
drain
dirty flakesclean water
Intensive washerIntensive washer
Clean waterDirty flakes
3) PET washing: The key to success !
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Dry grinding process. Most of the labels are separated before the 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 the washing liquid to achieve a constant cleaning result.
Hot post rinsing with soft- water to achieve a better cleaning result.
Water cascade refreshes all bathes continuously.
3) PET washing: The key to success !
Summary washing process
55
7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
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.
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Degassing of undesired substances .
No IV (Intrinsic Viscosity) degradation.
IV – elevation for CSD.
Process safety and quality control.
No yellowing of the material.
Prevent AA formation.
Low energy and water consumption.
4) How to create RPET for bottles
The requirement determines the process !The requirement determines the process !
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7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
g The Krones-Flake-Decontamination is fast and requires low decontamination temperature.
g The material is heated up smoothly outside of the vacuum-reactor, to achieve uniform temperature distribution inside the vacuum reactor.
g The residence- time in the vacuum reactor is very short and the temperature is low.
g The process builds up the IV without additional equipment.
g The Flake decontamination requires less energy than melting processes and is very gentle.
g When Pellets are required the decontaminated, hot flakes will be be transferred under vacuum direct into a Pellet-Extrusion.
The decontamination of the washed flakes is simple ,when the previous treatment steps have been done consistently !
We know about the quality requirements of theconverters and bottlers !
We know about the quality requirements of theconverters and bottlers !
4) How to create RPET for bottles
washing decontaminationdryingpc-bottles flakes flakes foodgrade flakes
Principlepellets
hot foodgrade flakesdirectly into the preform extrusion
melt-f ilt rat ionpellet isat ion
extrusiondegassing
cristallisat ionpellets
Krones - Process
washing decontaminationdryingpc-bottlespc-bottles flakesflakes flakesflakes foodgrade flakes
Principlepellets
hot foodgrade flakesdirectly into the preform extrusion
melt-f ilt rat ionpellet isat ion
extrusiondegassing
cristallisat ionpelletspellets
Krones - Process
Flake
Pellet
Preform
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
More Potential Savings : Preform Injection with rPET
rPET-Flakes are dry and warm when leaving KRONES reactor
Energy savings for drying / pre-heating
No intermediate storage and transport neccessary
Cost savings for equipment and storage area
Better utilization of smaller particles
Profit through higher yield
temp
t ime
hotwashedflakes extrusion
inject ionmolding
food-gradedeconta-minat ion
cool
dow
n &
stor
age
dryi
ngpr
e-he
atin
g
potential saving in process t ime, storage
and equipment / energy for drying
4) How to create RPET for bottles
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7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
KronesFlake decontamination module
Converters
Virgin PET
Inline recycling and preform manufacturing removes unneeded
steps!
Inline recycling and preform manufacturing removes unneeded
steps!
Preform injection with melt filtration
Preforms w/ RPET
Integrated path towards RPET content with flakes !
Washed PET flake
Kroneswashing module
4) How to create RPET for bottles
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
All out of one hand!
We take care of everything: From the bale to the bottle !We take care of everything: From the bale to the bottle !
Analysis of thepostconsumer
material
Analysis of thepostconsumer
materialCustomer oriented trials in
the pilot plantCustomer oriented trials in the pilot plant
Single and turnkeysolutions. Flake or PelletSingle and turnkey
solutions. Flake or Pellet
Pre-delivery inhousetestsPre-delivery inhouse
tests
Modular -systems frombale to bottleModular -systems from
bale to bottle
Complete installation of all process partsComplete installation of all
process parts
Monitoring and control of the entire processMonitoring and control of
the entire process
Start up and qualityassuranceStart up and quality
assurance
KRONES PET Recycling: Technology for Purity
58
7th China International Recycled Polyester Forum
krones Beispieltext7th China International Recycled Polyester Forum Shanghai We do more.
Thank you very much for your attention!