krones bottle to bottle recycling: “technology for puritycleaning-effect krones has the competence...

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”


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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1) Basic requirements for PET - Recycling

g Lead postconsumer PET bottles back to reusable quality.

Conceptual formulation!


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


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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







50



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


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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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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Bottle Flakes

ZZ airseparator

dry mixer

Silo

Prewasher

Caustic washer

Flotation tank

Post - washer

Mechanical dryer

Thermal dryer

ZZ air separatorParcival

to B2B



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 !


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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 !



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


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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


screen

drip pan

Flakes

pump

Flakes

screen

drip pan

Flakes

pump

Flakes

Swim-sink-separatorVorwäscher / prewasher

drain

Enth

ärtu

ng


Enth

ärtu

ng


screen

drip pan

Flakes

pump

Flakes

screen

drip pan

Flakes

pump

Flakes


drain

dirty flakesclean water

Intensive washer

Enth

ärtu

ng


Enth

ärtu

ng


screen

drip pan

Flakes

pump

Flakes

screen

drip pan

Flakes

pump

Flakes


drain

Enth

ärtu

ng


Enth

ärtu

ng


screen

drip pan

Flakes

pump

Flakes

screen

drip pan

Flakes

pump

Flakes


drain


Intensive washerIntensive washer

Clean waterDirty flakes

Enth

ärtu

ng


Enth

ärtu

ng


screen

drip pan

Flakes

pump

Flakes

screen

drip pan

Flakes

pump

Flakes


drain

Enth

ärtu

ng


Enth

ärtu

ng


screen

drip pan

Flakes

pump

Flakes

screen

drip pan

Flakes

pump

Flakes


drain


Intensive washer

Enth

ärtu

ng


Enth

ärtu

ng


screen

drip pan

Flakes

pump

Flakes

screen

drip pan

Flakes

pump

Flakes


drain

Enth

ärtu

ng


Enth

ärtu

ng


screen

drip pan

Flakes

pump

Flakes

screen

drip pan

Flakes

pump

Flakes


drain


Intensive washerIntensive washer

Clean waterDirty flakes



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.


Summary washing process

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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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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 !


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


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


57



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



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

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Thank you very much for your attention!

krones bottle to bottle recycling: “technology for puritycleaning-effect krones has the competence...

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