Plastic pyrolysis – How to reduce the product defective rate of PET fiber? 05-12-2023
Innovation in biopolymers (bioplastics) and plastics recycling has hit an all-time high, according to the latest-available patent data published by intellectual property firm, Appleyard Lees.
The third annual edition of the company’s Inside Green Innovation: Progress Report reveals that priority patent filings in bioplastics increased by almost a quarter in the 12 months to 2021 (from 458 to 569), with the 2020-21 period revealing a level of innovation in the field not seen since 2002. Plastic pyrolysis
Year-on-year rises in patent filings among the different types of bioplastics – including PHAs, butylene-based polymers and PLA – is broadly similar, while the latter remains ahead of the pack by a total of 93 patent filings in 2021, only 10 filings short of its previous high in 2011. However, starch blends’ recent patent numbers have fallen for the first time in six years.
Meanwhile, recent innovation activity in chemical recycling of plastics is sharply reversing the decline seen in the previous decade, with applications for thermal recycling pyrolysis technology increasing for three consecutive years and up by 25% from 2020 to 2021.
Appleyard Lees patent attorney, David Jasiewicz, said: “We’re in the midst of a second peak in bioplastics innovation, with the 2018-2021 period showing a significant increase in patent filing activity which outstrips the previous pinnacle in the early 2000s.”
Two key bioplastics trends emerge Plastic pyrolysis
Technology innovation by the top patent filers indicates two trends in the bioplastics sector: improving bioplastics’ mechanical properties and appearance in line with conventional plastics and improving the materials’ biodegradability.
For example, South Korea’s LG Chemical has filed applications including copoloymers of lactones, lactic acid and other hydroxyacids, aiming to improve thermal and mechanical properties when compared to PLA. It has also shown innovation in resin compositions which blend bioplastics with the intention of replacing traditional plastics such as polyethylene films. Plastic pyrolysis
Meanwhile Mitsubishi Chemical Corporation of Japan has focused on improving bioplastics’ biodegradability, such as finding bioplastic alternatives to PLA in additive manufacturing and blending polyesters with PHAs to use in shopping bags or food packaging.
CarbonScreen startup to develop monitoring method that doubles carbon fiber production speed
CarbonScreen technology will make it possible to control complex carbon fiber production through sensor monitoring, potentially increasing speeds to 30 m/min, enhancing turnover and making carbon fiber more available to other markets.
Felix Pohlkemper and Tim Röding from RWTH Aachen University’s Institut für Textiltechnik (ITA, Germany) are developing a technology with their startup company CarboScreen GmbH (Aachen) that makes complex carbon fiber production controllable through sensor monitoring. Plastic pyrolysis
With the help of CarboScreen technology, it should be possible to double the production speed from the current 15 meters/minute to 30 meters/minute in the medium term. The doubling of production speed alone could result in an increase in turnover of up to €37.5 million per year. Pohlkemper and Röding were awarded third place in the AVK Innovation Award 2023 in the Processes and Procedures category for their development.
The production of carbon fibers is highly complex and in current state-of-the-art, the manufacturing process is only monitored manually by semi-skilled workers. However, even minimal fiber damage during production leads to a reduction in the quality of the carbon fiber. In extreme cases, it can also lead to plant fires. Plastic pyrolysis
To ensure production quality, the production speed is currently limited to a maximum of 15 meters/minute. Using CarbonScreen’s technology could not only increase production speed and thus production volume, but could also reduce specific production costs of carbon fiber, potentially resulting in lower prices. This, in turn, would make it possible to drive carbon fiber and other composite materials more widely in markets like aerospace, wind and automotive.
RadiciGroup’s 100% natural nylon awarded in the Fibers and Insulation category
The Biofeel Eleven, RadiciGroup’s 100% natural nylon yarn derived from sustainable sources, has earned the prestigious ISPO Textrends award in the Fibers and Insulation category for the Fall/Winter 2025/26 collections.
This recognition, bestowed by a panel of industry experts, celebrates innovative trends within the textile and apparel sectors. Presented at the ISPO fair in Munich, a prominent event for fabrics and sportswear scheduled from November 28 to 30, 2023, RadiciGroup proudly accepts the award in the Fibers and Insulation category.
Since its introduction to the market in March, Biofeel Eleven has rapidly ascended to the “Top Ten” of new yarn products, showcasing its remarkable technical and environmental performance. Plastic pyrolysis
Derived from a small, non-edible bean cultivated in India’s semi-arid soils, which do not compete with food production, this natural yarn originates from a unique oil extracted from the beans. RadiciGroup in Italy transforms this oil into biopolymers, crafting the distinctive Biofeel Eleven yarn.
Noteworthy characteristics of this yarn include low water absorption, heightened lightness, and enhanced strength properties.
These attributes enable the creation of durable yet comfortable fabrics—a crucial combination for sportswear and beyond. Plastic pyrolysis
How to reduce the product defective rate of PET fiber?
Fibers are elongated substances of a certain length and fineness, usually consisting of many molecules. Fibers can be divided into two categories: natural fibers and chemical fibers.
Natural Fibres: Natural fibers are fibers extracted from plants, animals, or minerals, and common natural fibers include cotton, silk, and wool. Natural fibers have good breathability, moisture absorption, and comfort, and are widely used in textiles, garments, home furnishings, and other fields. Plastic pyrolysis
Chemical fibers: Chemical fibers are fibers synthesized from raw materials through chemical methods, mainly including polyester fibers, nylon fibers, acrylic fibers, adenosine fibers, and so on. Chemical fibers have good strength, abrasion resistance, and durability, and are widely used in textiles, construction, automotive, medical, and other fields.
Chemical fibers have a wide range of applications, but there are still difficulties in their production and processing.
Raw material treatment: The manufacture of chemical fibers usually requires pre-treatment of raw materials, including polymerization, spinning, and other processes. The treatment of raw materials has an important impact on the quality and performance of the final fiber, so the composition, purity, and treatment conditions of the raw materials need to be controlled. Plastic pyrolysis
Spinning process: The spinning of chemical fibers is to melt the polymer and then stretch it into silk through the spinneret orifice. During the spinning process, parameters such as temperature, pressure, and speed need to be controlled to ensure the uniformity and strength of the fibers.
Stretching and shaping: Chemical fibers need to be stretched and shaped after spinning to improve their strength and dimensional stability. This process requires control of temperature, humidity, stretching speed, and other factors to obtain the desired fiber properties. Plastic pyrolysis
These are some of the difficulties that exist in the production and processing of chemical fibers. With the progress of science and technology and the improvement of processes, these difficulties have been gradually solved, and the production technology of chemical fiber has been continuously upgraded.
World’s First Nylon Plant, world record in Seaford, Delaware
Seaford, Delaware, United States–The city of Seaford, in western Sussex County, is known as the “Nylon Capital of the World,” because this is where one of the world’s most famous fibers was first produced on a large scale; DuPont’s siting of their nylon factory downstate in Seaford was regarded as a boon to Delaware; the Moderne plant came online with 850 workers in December 1939, setting the world record for being the World’s First Nylon Plant, according to the WORLD RECORD ACADEMY. Plastic pyrolysis
“This booklet commemorates the designation of the DuPont Nylon Plant in Seaford, Delaware, as a National Historic Chemical Landmark. The designation was conferred by the American Chemical Society ( A C S ) , a non-profit scientific and educational organization of 150,000 chemists and chemical engineers. A plaque marking the A C S designation was presented to the plant on October 26, 1995,” the American Chemical Society says.
“The inscription reads: ” At this site on December 15, 1939, DuPont began commercial production of nylon. Among the earliest successes of a fundamental research program novel in the American chemical industry, nylon was the first totally synthetic fiber to be fashioned into consumer products. Plastic pyrolysis
Prepared wholly with materials readily derived from coal, air, and water, nylon has properties superior to its natural counterparts, such as silk. Nylon revolutionized the textile industry and led the way for a variety of synthetic materials that have had enormous social and economic impact on the fabric of everyday life worldwide.”
“DuPont developed nylon in record time, five years between the creation of the molecule in the laboratory and plant start-up.The process was technically complex, involving new raw materials, new fiber-forming techniques and unfamiliar materials of construction. Plant construction took one year and cost $8 million.
The plant at Seaford initially employed 850 people and had a capacity of 4 million pounds a year; DuPont announced an expansion before the first pound was produced. T h e Seaford plant is still operating today, employs 1,600 people, and has a capacity of 400 million pounds—100 times greater than in 1939.” Plastic pyrolysis
Closed Loop Partners invests $15M in recycling this year
The investments have helped to finance new collection carts and recycling technologies, supporting municipalities in advancing local circular economies.
According to Closed Loop Partners, it has provided approximately $15 million in investments to local municipalities for projects to upgrade recycling infrastructure and services across the Midwest and Southeast U.S. in the last year. Deployed by funds within the New York-based firm’s private credit arm, the Closed Loop Infrastructure Group, these investments are helping advance the infrastructure needed to collect, process and return materials to supply chains at their end of life. Plastic pyrolysis
Closed Loop Infrastructure Group’s first fund was established in 2014 and funded by some of the world’s largest retailers, corporate foundations, technology and consumer goods companies, including 3M, Amazon, Coca-Cola, Colgate-Palmolive, Johnson & Johnson, BlueTriton, Keurig Dr Pepper, Procter & Gamble, PepsiCo, Danone North America, Danone Waters, Starbucks, Unilever and Walmart Foundation. It provides below-market rate loans to finance projects that build circular economy infrastructure in the United States. Since then, Closed Loop Infrastructure Group has added three additional funds—Closed Loop Circular Plastics Fund, Closed Loop Local Recycling Fund and Closed Loop Beverage Fund—that have invested in more than 45 different projects to date, including procuring recycling carts, making recycling facilities upgrades, supporting innovative recycling technologies and more, keeping more than 3 million materials in circulation and avoiding more than 6 million metric tons of greenhouse gas emissions, according to Closed Loop Partners. Across all their investments, the funds have catalyzed capital inflow from other sources equivalent to three times what has been deployed. Plastic pyrolysis