Behind The Scenes Heroes Of Textile Technology "Life Gate"

The annual National Conference on science and technology awards has attracted much attention. According to the regulations, the total number of prizes awarded by the three awards is not more than 300 each year.

We should be proud of the two textile projects, "the integration technology of efficient recycling of waste polyester and the industrialization of fiber preparation" and the "high performance special braiding technology and equipment and industrialization", and won the 2018 National Science and technology progress award two.

The former is closely related to the strategic demand of China's circular economy construction, focusing on the bottleneck of green development of textile industry. The latter is a "behind the scenes hero" for meeting the major national strategy and important livelihood needs of deep-sea data such as real-time pmission, deep-sea scaling, submersible, deep-sea exploration, military camouflage, aircraft carrier mooring, marine ranching, etc.

Recently, the reporter interviewed the first adults of the two projects, and visited them to break the international monopoly and create hardships and unremitting efforts behind the world's leading technology.

China plan for waste polyester regeneration technology

Project Name: industrial integration technology for efficient regeneration and fiber preparation of waste polyester

The main participants are Wang Huaping, Qian Jun, Chen Hao, Jin Jian, Dai Zexin, Wang Shaobo, Chen Ye, Tong Vinci, Xing Xi Quan, Fang Hui.

The main completion units: Ningbo Dafa Chemical Fiber Co., Ltd., Donghua University, Haiyan Haili environmental protection Fiber Co., Ltd., Polytron Technologies Inc, China Textile Science Research Institute Limited, Zhongyuan University of Technology

Award: 2018 National Science and technology progress award two and so on.

The project is mainly completed by people at the scene of the award.

"During the period of the project, about 1 million 177 thousand and 200 tons of recycled polyester fiber products were produced, equivalent to 10 million 800 thousand mu of cotton production; 1 tons per use of waste polyester textiles was equivalent to reducing CO2 emissions by 3.2 tons, which was reduced by about 3 million 760 thousand tons of CO2 emissions, equivalent to the 1 year CO2 absorption of 10 thousand hectares of Sen Lin."

I believe that from this set of figures, we have already felt the exemplary role of resource recycling and greening in the "integration technology of waste polyester high efficiency regeneration and fiber preparation".

It is understood that the project has created a scheme of Chinese characteristics for the regeneration of waste polyester, which has realized the efficient recovery and high value utilization of waste polyester textiles, greatly improved the technical level of polyester regenerated fiber, changed the traditional concept and the existing pattern of producing recycled raw materials only for low-grade products, and provided new ideas for the development of fiber recycling industry after China's total prohibition of solid waste imports, and promoted the development of recycled polyester fiber industry to high-end fiber industry.

Therefore, the project won two of the national science and Technology Progress Award in 2018.

As the first adult of the project, Professor Wang Huaping of Donghua University is already a famous scholar in the field of chemical fiber. This is also the third time he has won the national science and technology progress award. But he recalled the national science and technology awards, and he told reporters: "it is inevitable that there will be some tension, because any technology point condenses too much effort and effort of team members, but in the face of questions, it is necessary to express the whole process as far as possible in a few minutes, which is indeed very stressful."

01 ORIGIN

The annual output of polyester in China is 40 million tons, and fiber and beverage bottles account for more than 90%.

At present, the waste polyester mainly includes waste materials, such as waste silk, scrap, weaving, dyeing and finishing, and garment processing. The total amount of waste after the consumption of fiber and bottles is over 1 billion tons, the capacity of regenerated spinning is 10 million tons, and the regeneration rate is less than 10%. There are still a large number of polyester wastes being buried and burned as garbage, which not only wastes resources, but also has heavy environmental burden.

How to solve these waste polyester textiles and polyester bottles, develop recycling technology, make it recycled, is a feasible way to meet the requirements of China's circular economy and sustainable development.

However, waste polyester has many characteristics, such as many sources, large quality differences, and difficult to separate dyes and polymers. It is very difficult to recycle, and the quality of regenerated spinning is generally low.

In terms of recycling, there has been mature R & D system and sorting and cleaning technology research and development in the world, and export of resources has been formed. However, our old clothes trade has not yet been opened, and the recycling system and sorting and cleaning technology of waste PET bottles have not been formed yet.

In terms of regeneration technology, the United States and Japan have developed chemical methods as representatives of the world, which can achieve high quality regeneration through depolymerization, purification and repolymerization. However, a large amount of dyes and other materials can not be reused as waste treatment, and the process is complex and costly, and industrialization is blocked. Most of China uses a simple melt regenerated spinning process, with low product quality and limited application.

Process circuit diagram

　　針對以上瓶頸，2009年開始，寧波大發化纖有限公司(以下簡稱“大發”)、東華大學、海鹽海利環保纖維有限公司(以下簡稱“海鹽海利”)、優彩環保資源科技股份有限公司(以下簡稱“優彩”)、中國紡織科學研究院有限公司(以下簡稱“中紡院”)、中原工學院等單位，依托中國化纖再生循環技術創新聯盟，以廢舊聚酯資源綜合利用最優化、加工高效清潔化、產品高品質高值化為目標，另辟蹊徑，提出再生混雜物處理“能用必用”、“需除則凈”的新思路，自主創建“微醇解—脫揮—增粘”新再生路線，并基于該路線進行系統創新，率先攻克了廢舊聚酯纖維制品再生成本與品質難兼顧的產業難題，制備的廢紡再生纖維性能達原生級別，可媲美國際廢舊聚酯回收再生方案，走出了一條具有中國特色的廢舊聚酯再生道路。

Wang Huaping said, "perfect coordination between units is essential.

The three scientific research units of Donghua University, China Textile Institute and Zhongyuan University of Technology are mainly responsible for basic theoretical research and industrial technology development of project technology, providing theoretical basis and technical support for the development of high quality differentiated series of recycled polyester fibers. In the process of project implementation, they organize and coordinate scientific research personnel to tackle key problems together and provide scientific research platform guarantee, so that the project can be implemented smoothly. Dafa, Haiyan Haili and you Cai three companies are mainly responsible for the project's industrialization technology development and industrial extension, providing infrastructure, production equipment and strong financial support for the project, and establishing a good product sales channel.

02 innovation

According to Wang Huaping, the project is closely related to the strategic demand for recycling and recycling of waste polyester resources, based on independent innovation, with the support of national key research and development programs, and in-depth study of the mechanism of polyester and hybrid components. With homogenization and stabilization as the core, four major technological innovations have been formed around resource pretreatment, melt quality control, multi component in-situ utilization and high value differential.

Project representative product - high quality recycled polyester staple fiber

To overcome the problem of resource recovery from multiple sources of waste, the second is to create a new process of "micro alcoholysis, devolatilization and tackifying" to overcome the difficulties of reproducing spinning stability, quality control and regeneration efficiency from multiple sources of waste polyester. Thirdly, research and development of dye in situ collocation, hybrid polymer in-situ utilization, multi-point on-line addition and modification and color matching technology, so as to achieve regeneration, high-efficiency differential combination and flexible switching, not only break through the bottleneck of the utilization of mixed components of waste products, but also meet the customized requirements of regenerated fibers in application. Fourthly, the invention invented low melting point / regenerated polyester composite direct spinning technology, which solved the problem of regenerative composite spinning, and realized the unification of low cost, high efficiency regeneration and high added value. First, research and develop efficient pre-treatment technology and equipment for waste polyester textiles and bottles, so as to achieve efficient resource classification and standardization.

The main difficulty of melt spinning technology of low melting point / regenerated polyester core / core composite fiber is that the regenerated melt can guarantee the good spinnability of the regenerated melt although the quality of the regenerated melt is improved by adjusting the quality and viscosity. However, compared with the raw material, there are still the characteristics of fast rising of the components and high shear of the export. Therefore, the composite core and the core layer should be matched in the high shear zone. However, the commonly used phthalic low melting point copolyester formula is prone to break under high shear.

Based on the innovative design of macromolecule structure, the project has developed a new formula of multiple synergistic copolymerization, which can significantly improve the composite spinnability under high shear and meet the requirements of high pressure and high shear.

At the same time, with the technology developed at low temperature, large air volume, multi-path drafting, low temperature and long distance drafting, the composite spinning efficiency is increased by 50%, and the production rate is 99%, which is 2% higher than that of the original composite spinning. The product performance is consistent with that of the original material, and the cost of the fiber is reduced by 16%.

About the fourth innovation, Wang Huaping added.

Project product application display

Based on the above innovation, the project has conquered the difficulties of melt viscosity increasing, the fluctuation of melt quality, the color fastness of regenerated fiber, the control of ecological safety, and the differentiation of regenerated fibers. A flexible and highly efficient preparation technology system of recycled polyester fiber was established with strong adaptability and high competitiveness. A high value professional product development system based on the characteristics of regenerated polyester resources was established, and the application of recycled polyester fiber in clothing, home textiles, shoe materials, automobile interior decoration and geotechnical industry was promoted.

03 achievement

It is precisely because the new process system created by the project takes into account the cost of regeneration and high quality. It not only makes the regenerated fiber reach the original grade, but also has better color difference and color fastness than the original fiber, and the cost is lower than that of the original fiber and meets the requirements of cleaner production.

At the same time, the project is closely linked to the strategic demand of China's circular economy construction, focusing on the bottleneck of green development of textile industry, and has also been supported by the state and local governments, and the speed of industrialization promotion has also been significantly accelerated.

Project representative product - high quality regenerated polyester filament

It is understood that the project has built the world's largest "fiber to fiber" efficient recycling and "bottle to fiber" large-scale, intelligent and regenerated polyester fiber production base.

In terms of polyester waste spinning and reproducing spinning, Dafa and excellent color companies have built 19 production lines including eco dumpling dumplings, super soft rashmere, multicolor, geomembrane, automotive interior accessories and low melting point composite short fiber production lines in Cixi, Yuyao and Jiangyin, with a capacity of 300 thousand tons / year.

In the treatment of waste bottles and differential regeneration filament, Haiyan Haili has built 8 production lines of profiled section, colorful FDY, POY and ITY in sea salt, and the production capacity is 150 thousand tons / year.

The products are popular among famous brands such as Adidas, general motors, Samsonite, Hongxiang and exported to 15 countries, such as Europe, America and Southeast Asia.

In 2015-2017 years, the unit completed sales of 7 billion 990 million yuan, 343 million yuan in profits, 148 million yuan in taxes and 261 million dollars in export earnings.

Production site

In the whole project, the construction of the recycling system is a very complex project. Besides the influence of technical factors, it is also very restricted by the people's environmental awareness and national policies and regulations.

In the recycling of waste polyester textiles, the project takes the chemical fiber factory as the core and extends it to the resource processing company. In addition to its own supporting waste spinning plant, it also cooperates with other granular plants to establish a cooperation base in Hebei, Henan, Anhui and Fujian to ensure the supply of resources.

Wang Huaping told reporters: "the construction of related systems in our country is still in the initial stage. Japan, the European Union and the United States have been developing the recycling system for a long time, but they are also improving in various forms, operation stability and long-term aspects.

In the next stage, we are ready to cooperate with downstream brands to establish a joint system of resource oriented enterprises, fiber enterprises, brand enterprises and post processing enterprises. Starting from the source, we will design homogeneous and heterogeneous products, make clear the way of recycling and realize the cycle of point to point.

At the same time, we are also considering cooperation with home textiles to establish a point to point recycling system, such as curtain recovery system, so as to gradually improve the recycling efficiency of recycled polyester.

In addition, we hope that more units will participate in the regeneration cycle of other kinds of textiles, such as nylon and cellulose, and even the regeneration cycle of a large proportion of mixed textiles. "

In the construction of recycling system for waste PET bottles, reporters recently learned that Haiyan Haili has gradually made efforts to build domestic recycling system in the "high quality development forum of recycled fiber chemical industry".

For example, it built a PET bottle network covering three provinces and one city in the Yangtze River Delta region, including more than 20 self operated recycling stations and more than 300 cooperative recycling networks, and the annual recovery volume of polyester bottles can reach 150 thousand tons.