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Title:
A SYSTEM AND PROCESS FOR THE SEPARATION AND RECYCLING OF BLENDED POLYESTER AND COTTON TEXTILES FOR RE-USE
Document Type and Number:
WIPO Patent Application WO/2020/252523
Kind Code:
A1
Abstract:
The present invention relates to a system and process for separation and recycling of blended polyester and cotton textiles (or other regenerated cellulosic fibre textile fabric) on a commercial scale, thereby allowing the separated components to be re-used across a variety of alternative industries. The textiles are shredded and mixed with an aqueous solution of sulfuric acid and water, before being heated and pressurised in a sealed reactor, resulting in a liquid comprising cellulose particles and polyester fibre. The output is dewatered, with free liquid filtered to recover any cellulose particles present therein. The dewatered fibre mix is washed with a liquid wash before being dewatered and again free liquid being filtered to recover any cellulose particles. The recovered cellulose particles and the polyester fibres present in the washed dewatered fibre mix are output for re-use.

Inventors:
SPEIGHT ROBERT (AU)
O'HARA IAN (AU)
ZHANYING ZHANG JAN (AU)
MOLLER DAVID (AU)
JONES ADRIAN (AU)
ROSS GRAHAM (AU)
Application Number:
PCT/AU2020/050608
Publication Date:
December 24, 2020
Filing Date:
June 17, 2020
Export Citation:
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Assignee:
BLOCKTEXX LABS PTY LTD (AU)
International Classes:
C08J11/04; D01G11/00
Domestic Patent References:
WO2019047174A12019-03-14
Foreign References:
US3937675A1976-02-10
US20080306255A12008-12-11
US2287332A1942-06-23
Other References:
OUCHI, A. ET AL.: "A new methodology to recycle polyester from fabric blends with cellulose", CELLULOSE, vol. 17, 2010, pages 215 - 222, XP019767576
RUUTH, E.: "Chemical recycling of cotton-based waste textiles by sulfuric acid hydrolysis", DEPARTMENT OF CHEMICAL ENGINEERING - LUND UNIVERSITY, MASTER THESIS, 15 June 2020 (2020-06-15), XP055773160, Retrieved from the Internet [retrieved on 20200812]
Attorney, Agent or Firm:
ADAMS PLUCK (AU)
Download PDF:
Claims:
Claims:

1. A process for the separation and subsequent recycling of textile fabrics formed of blended polyester and cellulosic material, comprising:

in a first stage, shredding a material feed comprising the textile fabrics; in a second stage, mixing the shredded feed material with an aqueous solution of sulfuric acid and water;

in a third stage, heating and pressuring the mixed shredded feed material and aqueous solution in a sealed reactor to a temperature and pressure sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre;

in a fourth stage, dewatering the output from the third stage to obtain a pre washed dewatered fibre mix comprising polyester fibre and cellulose particles;

in a fifth stage, filtering the free liquid resulting from the preceding stage to recover any cellulose particles present therein and using at least some of the filtered free liquid to supplement the aqueous solution provided to the second stage;

in a sixth stage, washing the dewatered fibre mix resulting from the fourth stage with a liquid wash and agitating the mixture for a period of time;

in a seventh stage, dewatering the output from the sixth stage to obtain a washed dewatered fibre mix and thereafter filtering the resultant free liquid to recover any cellulose particles contained therein; and

in a final stage, outputting both the recovered cellulose particles and the polyester fibres present in the washed dewatered fibre mix for re-use.

2. A process in accordance with claim 1 , further comprising repeating the sixth and seventh stage one or more times such that the filtered free liquid output from the seventh stage is used, in at least one of the repeats, for the liquid wash input to the sixth stage.

3. A process for the separation and subsequent recycling of textile fabrics formed of blended polyester and cellulosic material, comprising:

in a first stage, shredding a material feed comprising the textile fabrics; in a second stage, mixing the shredded feed material with an aqueous solution of sulfuric acid and water;

in a third stage, heating and pressuring the mixed shredded feed material and aqueous solution in a sealed reactor to a temperature and pressure sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre;

in a fourth stage, the liquid comprising the cellulose particles and polyester fibre is subjected to a first washing process whereby it is washed with a liquid spray in a rotating drum washer and wherein free liquid extracted from the washer is filtered for recovering any cellulose particles therein before being returned for use in the second stage;

in a fifth stage, a washed fibre mix comprising polyester fibre and cellulose particles output from the rotating drum washer is subject to a second washing process whereby it is washed with a liquid spray in a rotating drum washer and wherein free liquid extracted from the washer is filtered for recovering any cellulose particles therein before being returned for use in the second stage; and

in a final stage, outputting both the recovered cellulose particles and the polyester fibres present in the washed fibre mix for re-use.

4. A process in accordance with claim 3, wherein the liquid spray comprises water.

5. A process in accordance with any one of the preceding claims, wherein the recovered cellulose particles are washed in multiple stages using a counter current washing process and wherein water is used as the wash liquid for the final wash stage.

6. A process in accordance with any one of the preceding claims, further comprising re dosing the filtered free liquid resulting from the wash stage(s) with acid before returning it to the second stage.

7. A process in accordance with any one of the preceding claims, further comprising drying the washed and recovered cellulose particles using a dryer, thereby resulting in a micro/nano cellulose powder output.

8. A process in accordance with any one of the preceding claims, further comprising drying the washed dewatered fibre mix output from the final stage, thereby resulting in a high grade and quality recycled polyethylene terephthalate (PET) output.

9. A process in accordance with claim 8, further comprising melting, extruding and pelletising the PET output.

10. A process in accordance with claim 9, further comprising adding a combination of chain extenders and/or stabilisers to the melt prior to extrusion.

11. A process in accordance with any one of the preceding claims, wherein, in the third stage, steam is injected into the sealed reactor to increase the temperature and pressure to a level sufficient for catalysation.

12. A process in accordance with any one of the preceding claims, wherein, in the third stage, the mixed shredded textile fibre and aqueous solution is stirred while in the sealed reactor.

13. A process in accordance with any one of the preceding claims, wherein in the third stage, the shredded textile fibre mix is heated to approximately 120-150 degrees Celsius.

14. A process in accordance with any one of the preceding claims, wherein in the third stage, the shredded textile fibre mix is pressured to approximately 5 bar (abs).

15. A process in accordance with any one of the preceding claims, wherein the aqueous solution comprises approximately 2 to 4% sulfuric acid by solution.

16. A process in accordance with claim 15, wherein the aqueous solution comprises approximately 2.5% sulfuric acid by solution.

17. A process in accordance with claim 1 , wherein, in both the fourth and seventh stages, the dewatering is implemented using a rotary screen and wherein the dewatered fibre mix is fed to an underlying conical bottom tank comprising an agitator which is used for implementing the sixth stage.

18. A process in accordance with any one of the preceding claims, wherein the free liquid is collected in a dirty wash tank that collects free liquid containing cellulose particles and wherein the liquid in the dirty wash tank is passed through a decanter centrifuge for recovering the cellulose particles.

19. A process in accordance with claim 18 when dependent on claim 1 , wherein the filtered liquid output from the decanter centrifuge is used as the wash liquid for at least one of the intermediate counter current washing stages.

20. A process in accordance with claim 19, further mixing the cellulose particles output from the decanter centrifuge with free liquid contained in a dirty wash tank collected from a preceding stage and subsequently passing the mixed liquid through a further decanter centrifuge prior to outputting the cellulose particles in the final stage.

21. A system for the separation and subsequent recycling of textile fabrics formed of blended polyester and cellulosic or regenerated cellulosic material, comprising:

a shredded configured to shred a material feed comprising the textile fabrics; a mixer configured to mix the shredded feed material with an aqueous solution of sulfuric acid and water;

a reactor configured to heat and pressurise the mixed shredded feed material and aqueous solution to a temperature and pressure sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre;

a dewatering device configured to dewater the output from the third stage to obtain a pre-washed dewatered fibre mix comprising polyester fibre and cellulose particles;

a filter configured to filter the free liquid output from the dewatering device to recover any cellulose particles present therein and wherein at least some of the filtered free liquid is recovered to supplement the aqueous solution provided to the reactor for a subsequent batch of feed material;

an agitating device configured to wash and agitate the dewatered fibre mix with a liquid wash and agitating the mixture for a period of time;

a dewatering device configured to dewater an output from the agitating device to obtain a washed dewatered fibre mix; and

a filter configured to filter the free liquid extracted from the washed dewatered fibre mix to recover any cellulose particles contained therein.

22. A system in accordance with claim 21 , wherein the dewatered fibre mix is washed and subsequently dewatered one or more time such that the filtered free liquid output from one of the repeats is used for the liquid wash input to a subsequent washing stage.

23. A system in accordance with claim 20 or claim 21 , wherein the recovered cellulose particles and polyester fibres are washed in multiple stages using a counter current washing process and wherein water is used as the wash liquid for the final wash stage.

24. A system in accordance with any one of the claims 21 to 23, further comprising a dryer configured to dry the washed and recovered cellulose particles, thereby resulting in a micro/nano cellulose powder output.

25. A system in accordance with any one of the preceding claims 21 to 24, further comprising a dryer configured to dry the washed dewatered fibre mix, thereby resulting in a high grade and quality recycled polyethylene terephthalate (PET) output.

26. A system in accordance with claim 25, further comprising a melt extruder configured to melt and extrude the PET output for subsequent pelletisation.

27. A system in accordance with any one of the preceding claims 21 to 26, further comprising a steam supply for injecting steam into the reactor to increase the temperature and pressure to a level sufficient for catalysation.

28. A system in accordance with any one of the preceding claims 21 to 27, wherein the shredded textile fibre mix is heated in the reactor to approximately 120-150 degrees Celsius.

29. A system in accordance with any one of the preceding claims 21 to 28, wherein in the shredded textile fibre mix is pressured in the reactor to approximately 5 bar (abs).

30. A system in accordance with any one of the preceding claims 21 to 29, wherein the aqueous solution comprises approximately 2 to 4% sulfuric acid by solution.

31. A system in accordance with claim 30, wherein the aqueous solution comprises approximately 2.5% sulfuric acid by solution.

32. A system in accordance with any one of the preceding claims 21 to 31 , wherein the dewatering device comprises a rotary screen and wherein the dewatered fibre mix is fed to an underlying conical bottom tank comprising an agitator for subsequent washing.

33. A system in accordance with claim 32, wherein the free liquid is collected in a dirty wash tank that collects free liquid containing cellulose particles and wherein the liquid in the dirty wash tank is passed through a decanter centrifuge for recovering the cellulose particles.

34. A system for the separation and subsequent recycling of textile fabrics formed of blended polyester and cellulosic or regenerated cellulosic material, comprising:

a shredded configured to shred a material feed comprising the textile fabrics; a mixer configured to mix the shredded feed material with an aqueous solution of sulfuric acid and water;

a reactor configured to heat and pressurise the mixed shredded feed material and aqueous solution to a temperature and pressure sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre;

a multi-stage rotating drum washing apparatus configured to: in a first wash stage, wash the liquid comprising the cellulose particles and polyester fibre with a liquid spray for outputting a washed fibre mix comprising polyester fibre and cellulose particles;

in a second wash stage, further wash the fibre mix output from the first stage with a liquid spray;

a filter configured to filter free liquid extracted from the washed dewatered fibre mix to recover any cellulose particles present therein and wherein at least some of the filtered free liquid is recovered to supplement the aqueous solution provided to the reactor for a subsequent batch of feed material.

Description:
A SYSTEM AND PROCESS FOR THE SEPARATION AND RECYCLING OF BLENDED POLYESTER AND COTTON TEXTILES FOR RE-USE

Field of invention

The present invention relates to a system and process for separation and recycling of blended polyester and cotton textiles (or other regenerated cellulosic fibre textile fabric) on a commercial scale, thereby allowing the separated components to be re-used across a variety of alternative industries.

Background of invention

The number of garments bought each year by consumers is soaring, with a 60% rise significantly due to the boom of fast fashion, a concept where clothing is created quickly with low quality material based on current fashion trends, only to be worn for a short period of time before being discarded.

Clothing made as part of fast fashion is inexpensive to purchase to entice consumers into continuously buying garments made to typically last a maximum of six wears before being discarded.

Globally, the clothing industry produces over 1.2 billion garments per year and less than 1% of these are recycled. Currently, Australia has the second highest per capita textile waste in the world, at 23 kg per year. The sheer number of textiles being bought and

disposed of has overwhelmed the traditional disposal route of charity store donation and increasingly these products are ending up in landfill, either in Australia or overseas. The burden of the growing fast fashion trend is falling on charities, who spend $13 million per year sending 60,000 tons to landfill, including approximately 4,000 tons of clothes.

The excessive amount of clothing being sent to landfill is creating major

environmental concerns, including deforestation, polluting groundwater, depleting non renewable resources and emitting huge quantities of greenhouses gases. Synthetic fibres often favoured by fast fashion brands, such as polyester, can take up to a thousand years to biodegrade in landfill. Articles of clothing that are incinerated instead of being sent to landfill are further harming the environment by increasing air pollution.

Two popular types of material used to make clothing are polyester and cotton. Polyester is derived from fossil fuels, contributing to global warming, while cotton requires large quantities of water and pesticides to grow. l Sustainability is a global concern for consumers and industry. In order to reduce the impact on the environment due to the creation and elimination of clothing made for fast fashion, clothing must be recycled, rather than discarded.

Clothing can be recycled by being shredded and used, for example, as stuffing in punching bags or converted into non-woven materials such as insulation and floor matting. Whilst this keeps textiles out of landfill, this traditional approach does not have sufficient demand to keep up with the ever-growing supply of unwanted clothing.

Clothing can also be recycled by a mechanical recycling process. This process works for single fibre product recycling such clothing made from either 100% cotton or 100% polyester but cannot separate blended fibres such as polyester/cotton which make up over 75% of the world’s clothing. Another downside of the mechanical recycling process is that fibre length is shortened due to cutting. This means that there is limited reuse of fibres with this method unless blended with new virgin fibres.

Chemical recycling has been proposed for solving the ever-increasing problem of textile waste. However, there are limited processes for chemical recycling, and none that operate on a large, commercial scale. Currently chemical recycling processes for textiles operate to recycle either cotton or polyester, resulting in only a portion of clothing being recycled from polyester/cotton blend clothing. Furthermore, current chemical recycling processes are focussed on making recycled material back into textile fibre and fabrics, which limits the utilisation of the recycled material.

It would be advantageous if there were provide a system and process that was able to recycle both cotton and polyester from polyester/cotton blend clothing at scale in an energy and cost-efficient manner. It would also be advantageous if the recycled material could be used for more than textiles.

Summary of invention

In accordance with a first aspect there is provided a process for the separation and subsequent recycling of textile fabrics formed of blended polyester and cellulosic material, comprising: in a first stage, shredding a material feed comprising the textile fabrics; in a second stage, mixing the shredded feed material with an aqueous solution of sulfuric acid and water; in a third stage, heating and pressuring the mixed shredded feed material and aqueous solution in a sealed reactor to a temperature and pressure sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre; in a fourth stage, dewatering the output from the third stage to obtain a pre-washed dewatered fibre mix comprising polyester fibre and cellulose particles; in a fifth stage, filtering the free liquid resulting from the preceding stage to recover any cellulose particles present therein and using at least some of the filtered free liquid to supplement the aqueous solution provided to the second stage; in a sixth stage, washing the dewatered fibre mix resulting from the fourth stage with a liquid wash and agitating the mixture for a period of time; in a seventh stage, dewatering the output from the sixth stage to obtain a washed dewatered fibre mix and thereafter filtering the resultant free liquid to recover any cellulose particles contained therein; and in a final stage, outputting both the recovered cellulose particles and the polyester fibres present in the washed dewatered fibre mix for re-use.

In an embodiment the method further comprises repeating the sixth and seventh stage one or more times such that the filtered free liquid output from the seventh stage is used, in at least one of the repeats, for the liquid wash input to the sixth stage.

In accordance with a further aspect there is provided a process for the separation and subsequent recycling of textile fabrics formed of blended polyester and cellulosic material, comprising: in a first stage, shredding a material feed comprising the textile fabrics; in a second stage, mixing the shredded feed material with an aqueous solution of sulfuric acid and water; in a third stage, heating and pressuring the mixed shredded feed material and aqueous solution in a sealed reactor to a temperature and pressure sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre; in a fourth stage, the liquid comprising the cellulose particles and polyester fibre is subjected to a first washing process whereby it is washed with a liquid spray in a rotating drum washer and wherein free liquid extracted from the washer is filtered for recovering any cellulose particles therein before being returned for use in the second stage; in a fifth stage, a washed fibre mix comprising polyester fibre and cellulose particles output from the rotating drum washer is subject to a second washing process whereby it is washed with a liquid spray in a rotating drum washer and wherein free liquid extracted from the washer is filtered for recovering any cellulose particles therein before being returned for use in the second stage; and in a final stage, outputting both the recovered cellulose particles and the polyester fibres present in the washed fibre mix for re-use.

Preferably the liquid spray comprises water.

In an embodiment the recovered cellulose particles are washed in multiple stages using a counter current washing process and wherein water is utilised as the wash liquid for the final wash stage. Preferably the filtered free liquid resulting from the wash stage(s) is re-dosed with acid before returning it to the second stage.

In an embodiment the method further comprises drying the washed and recovered cellulose particles using a dryer, thereby resulting in a micro/nano cellulose powder output.

In an embodiment the method further comprises drying the washed dewatered fibre mix output from the final stage, thereby resulting in a high grade and quality recycled polyethylene terephthalate (PET) output. The PET output may be melted, extruded and pelletised. Preferably a combination of chain extenders and/or stabilisers is added to the melt prior to extrusion.

In an embodiment, in the third stage, steam is injected into the sealed reactor to increase the temperature and pressure to a level sufficient for catalysation.

In an embodiment, in the third stage, the mixed shredded textile fibre and aqueous solution is stirred while in the sealed reactor.

In an embodiment the shredded textile fibre mix is heated to approximately 120-150 degrees Celsius.

In an embodiment the shredded textile fibre mix is pressured to approximately 5 bar

(abs).

Preferably the aqueous solution comprises approximately 2 to 4% sulfuric acid by solution. More preferably the aqueous solution comprises approximately 2.5% sulfuric acid by solution.

In an embodiment, in both the fourth and seventh stages, the dewatering is implemented using a rotary screen and wherein the dewatered fibre mix is fed to an underlying conical bottom tank comprising an agitator which is used for implementing the sixth stage.

In an embodiment the free liquid is collected in a dirty wash tank that collects free liquid containing cellulose particles and wherein the liquid in the dirty wash tank is passed through a decanter centrifuge for recovering the cellulose particles.

Preferably the filtered liquid output from the decanter centrifuge is utilised as the wash liquid for at least one of the intermediate counter current washing stages.

In an embodiment the method further comprises mixing the cellulose particles output from the decanter centrifuge with free liquid contained in a dirty wash tank collected from a preceding stage and subsequently passing the mixed liquid through a further decanter centrifuge prior to outputting the cellulose particles in the final stage.

In accordance with yet another aspect there is provided a system for the separation and subsequent recycling of textile fabrics formed of blended polyester and cellulosic or regenerated cellulosic material, comprising: a shredded configured to shred a material feed comprising the textile fabrics; a mixer configured to mix the shredded feed material with an aqueous solution of sulfuric acid and water; a reactor configured to heat and pressurise the mixed shredded feed material and aqueous solution to a temperature and pressure sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre; a dewatering device configured to dewater the output from the third stage to obtain a pre-washed dewatered fibre mix comprising polyester fibre and cellulose particles; a filter configured to filter the free liquid output from the dewatering device to recover any cellulose particles present therein and wherein at least some of the filtered free liquid is recovered to supplement the aqueous solution provided to the reactor for a subsequent batch of feed material; an agitating device configured to wash and agitate the dewatered fibre mix with a liquid wash and agitating the mixture for a period of time; a dewatering device configured to dewater an output from the agitating device to obtain a washed dewatered fibre mix; and a filter configured to filter the free liquid extracted from the washed dewatered fibre mix to recover any cellulose particles contained therein.

In an embodiment the dewatered fibre mix is washed and subsequently dewatered one or more time such that the filtered free liquid output from one of the repeats is used for the liquid wash input to a subsequent washing stage.

In an embodiment the recovered cellulose particles and polyester fibres are washed in multiple stages using a counter current washing process and wherein water is used as the wash liquid for the final wash stage.

The system may further comprise a dryer configured to dry the washed and recovered cellulose particles, thereby resulting in a micro/nano cellulose powder output.

The system may further comprise a dryer configured to dry the washed dewatered fibre mix, thereby resulting in a high grade and quality recycled polyethylene terephthalate (PET) output.

In an embodiment the system comprises a melt extruder configured to melt and extrude the PET output for subsequent pelletisation.

Preferably the system comprises a steam supply for injecting steam into the reactor to increase the temperature and pressure to a level sufficient for catalysation. In an embodiment the shredded textile fibre mix is heated in the reactor to approximately 120-150 degrees Celsius.

In an embodiment the shredded textile fibre mix is pressured in the reactor to approximately 5 bar (abs).

Preferably the aqueous solution comprises approximately 2 to 4% sulfuric acid by solution. More preferably the aqueous solution comprises approximately 2.5% sulfuric acid by solution.

In one embodiment the dewatering device comprises a rotary screen and wherein the dewatered fibre mix is fed to an underlying conical bottom tank comprising an agitator for subsequent washing.

In an embodiment the free liquid is collected in a dirty wash tank that collects free liquid containing cellulose particles and wherein the liquid in the dirty wash tank is passed through a decanter centrifuge for recovering the cellulose particles.

In yet another aspect there is provided a system for the separation and subsequent recycling of textile fabrics formed of blended polyester and cellulosic or regenerated cellulosic material, comprising: a shredded configured to shred a material feed comprising the textile fabrics; a mixer configured to mix the shredded feed material with an aqueous solution of sulfuric acid and water; a reactor configured to heat and pressurise the mixed shredded feed material and aqueous solution to a temperature and pressure sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre; a multi-stage rotating drum washing apparatus configured to: in a first wash stage, wash the liquid comprising the cellulose particles and polyester fibre with a liquid spray for outputting a washed fibre mix comprising polyester fibre and cellulose particles; in a second wash stage, further wash the fibre mix output from the first stage with a liquid spray; a filter configured to filter free liquid extracted from the washed dewatered fibre mix to recover any cellulose particles present therein and wherein at least some of the filtered free liquid is recovered to supplement the aqueous solution provided to the reactor for a subsequent batch of feed material. Brief description of drawings

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a process flow separating blended cotton and polyester textiles, in accordance with an embodiment of the invention;

Figure 2 is a schematic illustration of the process of Figure 1 ;

Figure 3 is a schematic of a system for implementing the process of Figure 1 ; and

Figure 4 is a process flow for counter current washing implemented by the system of Figure 3.

Detailed description

Embodiments of the invention described herein relate to systems and processes that divert textile waste from landfill by the chemical separation of polyester and cotton (or any other cellulosic material). More particularly, embodiments chemically separate blended polyester and cotton textiles back into their base component parts (high grade polyethylene terephthalate and cellulose particles) for re-use. In a particular form, the base component parts are turned into (PET) pellets and cellulose powder that can be used across a variety of alternative industries.

Embodiments described herein can advantageously recover approximately 98% of total fibre volume, with the cellulose powder recovered at approximately 95% of total fibre volume. The remaining liquids from the process are recycled back for later use, with zero waste output. Embodiments can successfully be implemented at scale, delivering long terms benefits environmentally and economically.

Hereafter the description will describe a process for chemically separating and recycling garments formed of blended polyester and cotton. It will be understood, however, that the system and process could equally be applied for separating polyester from any form of cellulosic material, including, for example, flax (linen), hemp, jute, kapok, ramie and sisal, or indeed regenerated cellulosic material, such as Tencel or Viscose.

In general terms, and with reference to Figure 1 , the process according to a first embodiment comprises eight stages. In a first stage (S1), a feed comprising blended polyester and cotton (or as stated above any other desired cellulosic or re-generated cellulosic fibre) material is shredded. In a second stage (S2), the shredded feed material is mixed with an aqueous solution of sulfuric acid and water. In a third stage (S3), the mixed shredded feed material and aqueous solution is heated and pressured in a sealed reactor to a level sufficient for acidic catalysation, thereby resulting in a liquid comprising cellulose particles and polyester fibre. In a fourth stage (S4), the output from S3 is dewatered to obtain a pre-washed dewatered fibre mix comprising polyester fibres and cellulose particles. In a fifth stage (S5), the free liquid resulting from the preceding stage is filtered to recover any cellulose particles present therein. At least some of the filtered free liquid is used to supplement the aqueous solution provided to S2. In a sixth stage (S6), the dewatered fibre mix is washed using a washing liquid, resulting from the fourth stage with a liquid wash and agitating the mixture for a period of time. In a seventh stage (S7), the output from the sixth stage is dewatered to obtain a washed dewatered fibre mix and the resultant free liquid is subsequently filtered to recover any cellulose particles contained therein. In a final stage (S8), both the recovered cellulose particles and the polyester fibres present in the washed dewatered fibre mix are output ready for re-use.

Turning to Figure 2, it can be seen that there are five inputs to the process namely a feed material (10) comprising textile garments, acid (12) which is used as the catalyst for the chemical separation, steam (14) for achieving a desired temperature and pressure for catalysation, water (16) for use in washing and as a mixing agent for the acid catalyst, and a neutralising agent (18) for neutralising any free liquid purged from the process (which, as will become evident from subsequent paragraphs, is negligible).

Each of the afore-described stages will now be described in detail with reference to both Figures 2 and 3.

Material Shredding (S1)

In S1 , the feed material (10) is shredded to increase the surface area of the material, in turn increasing the reactive area for the subsequent chemical reaction. As shown in Figures 2 and 3, the shredding is carried out by a textile shredder (20) located upstream of one or more reactors (22). It will be understood that prior to shredding, the garments will be decommissioned and have the non-polyester/cotton hardware, such as zips and buttons, mechanically removed.

The shredded textile (hereafter feed material 10) may be transported to the reactors (22) via a belt conveyor. According to embodiments described herein, one reactor (22) may process up to 2,000 tons of feed material per year. The conveyor may, for example, feed a reactor hopper (24) disposed above each reactor (22) that can contain enough feed material (10) for each processing batch. The shredder (20) may operate continuously, feeding each reactor hopper (24) in sequence as required. Chemical Processing (S2 and S3)

The chemical treatment process involves reacting the feed material (10) in a heated stirred reactor (22) in the presence of an acid catalyst. According to the illustrated

embodiment, the maximum reactor operating conditions are approximately 5 bar (abs) and between 120 to 150 Degrees Celsius. In an alternative embodiment, the feed material (10) may be agitated in the reactor (22) using steam vents, thus obviating the need for a stirring mechanism, and thereby minimising the number of moving parts within the reactor (22). The feed material (10) is passed from the reactor hopper (24) to the reactor (22) via a slide valve at the base of the hopper (24).

At S2, an acid mixture comprising sulfuric acid (12) and water (16) is subsequently added to the reactor (22) to the operating level, before the stirrer is activated to ensure good mixing of the textile with the acid. According to the illustrated embodiment, the acid mixture comprises water (16) with between 2.0 to 4.0% sulfuric acid (12) by solution. The

The reactor is then sealed, following which steam (14) is injected into the reactor until the desired pressure and temperature are reached (stage S3). The reactor pressure and temperature are maintained for a period of 15 minutes (although it will be understood that this time may be shorter or longer, depending on the amount of material present in the reactor). At the end of the period, the pressure inside the reactor (22) is vented.

Liquid and Cellulose Particle Separation

At S4, the mixture output from each reactor (22) is pumped to a dewatering device for separating free liquid from the treated material. According to the illustrated embodiment, a rotary screen (28) is located above one or more wash tanks and is used for dewatering.

As will be described in more detail below, the first free liquid stream (hereafter the“pre-wash liquid stream”) is sent to the acid recovery process. In an alternative embodiment a series of conical trommel washers contained within a high pressure sleeve may be used in place of, or in addition to the rotary screen (28), for dewatering.

The dewatered fibre exiting the rotary screen (28) drops into a conical bottom tank (30) equipped with a high-speed agitator. Wash liquid is added to the tank (30) and the mixture is stirred using the high-speed agitator to enhance the physical separation of the cellulose particles from the polyester fibre (S6).

In stage S7, the contents of the tank (30) are pumped back through the rotary screen (28) to separate the free wash liquid which at this stage contains a high proportion of cellulose particles that have been separated from the residual polyester fibres. Still at stage S7, the free wash liquid is collected in a dirty wash tank (32a...32n) before being processed through a solid bowl decanter centrifuge (34), or other suitable solid liquid separator, to recover the solid particles from the wash liquid. The clear water is then stored in a clean tank ready (36a...36n) for the next wash cycle, while the dewatered polyester fibre is returned to the stirred tank (30) for further washing.

According to illustrated embodiment, this two-stage process (S6 and S7) is repeated three times using a counter-current washing process to remove as many of the cellulose particles from the polyester fibre.

To maximise the recovery of the acid and separation of the cellulose from the polyester a counter current washing process may be used with three wash cycles. This process can be seen diagrammatically in Figure 4. As shown, the output from reactor (22) goes through seven processes:

1. Pre-wash separation

2. 1st wash

3. 1st wash separation

4. 2nd wash

5. 2nd wash separation

6. 3rd wash

7. 3rd wash separation

Water is used as the wash medium for the 3rd wash. The water may be re-dosed with acid to facilitate the separation. The 3rd wash water is collected in a dirty

tank (32a...32n) and processed through the decanting centrifuge (34). The wash water is then stored in the 3rd wash water tank (36a...36n) for the next washing cycle. The 3rd wash water is used as the wash liquid for the 2nd wash. The cleaned 2nd wash water will be used as the washing liquid for the 1st wash.

As mentioned previously, the pre-wash liquid stream recovered from S4 is recycled to the process acid tank to be used in the reactor (22) with the next batch of textile. The free liquid recovered from the 1st wash is used to make up for any lost acid into the process acid tank and the excess used as a purge from the system. The purge stream is neutralised using a neutralising agent prior to discharge.

The 3rd wash separation is undertaken using a dewatering centrifuge that is capable of reducing the moisture content of the polyester prior to drying. According to the illustrated embodiment, this is carried out using a hydro extractor (26) Cellulose recovery

As stated above, each of the free liquid streams (i.e. resulting from S5 and S7) is processed through a decanting centrifuge. This centrifuge is configured to collect all the solid cellulose material and provide a Clear water stream that can be re-used for washing. Each of the clear liquid streams is separated (as outlined above) to ensure efficiency in the acid recovery process.

Multiple tanks will be required for each of the dirty and clean liquid streams. The dirty liquid from the washing process is directed into the dirty tanks (32a...32n). The liquid stored in the tanks is mixed by using an appropriate stirrer. After processing through a decanting centrifuge, the clean liquid is then stored in a clean tank (36a... 36n) ready for the next wash cycle.

The cellulose particle output from each of the centrifuges can be re-processed through the dirty wash tanks (32a... 32n) to ensure the cellulose is fully washed in a similar way to the counter-current washing described above with reference to Figure 4. The cellulose material extracted from the pre-wash spin is sent to the 1st wash tank. The cellulose material from the 1st wash is sent to the dirty 2nd wash tank. The cellulose material from the 2nd wash is sent to the 3rd wash tank. The cellulose material from the 3rd wash is then conveyed to a drum dryer (40), or other suitable drying device, where it is dried for packaging as a powder (S8).

Polyester Drying and Pelletisation

An industrial tunnel dryer (42), or other suitable drying device, is used to dry the washed and dewatered polyester fibres output at S8 to the required moisture content prior to pelletisation. In an embodiment LPG is used as a heat source for the industrial dryers.

Alternatively, or in addition to drying (i.e. as a preceding step), the washed and dewatered polyester fibres are spun using a suitable spinning mechanism for reducing moisture content. For example, the drying and/or spinning process may carried out to achieve a total moisture content of between 2 - 4%. The dry polyester is subsequently processed through a holt melt extrusion pelletiser (44) to reform raw polyester pellets. The polyester may be agglomerated prior to extrusion to further reduce moisture to less than 1%. Due to the low bulk density of the fibre, a feeder may be used to compact the polyester into the

heater/extruder. The heater/extruder (44) may comprise one or more vents for volatile components including water and dies from the coloured polyester. Before pelletisation the molten polyester may be passed through a filter to remove any final particulate matter.

Preferably a combination of chain extenders and stabilisers are added to the molten polyester for improving the quality of the final polyester filament. By way of example, the extenders and stabilisers may include epoxidized soybean oil (ESBO), Irgafos 168, Irgafos 126 and/or Irganox 1010. Due to the high flows the extender may discharge underwater before the filament is cut into pellets that are discharged into a small hopper feeding a bulky bag prior to transport.

In alternative embodiment to that described above, a freeze dryer, centrifuge or tray dryer could be used in place of, or in addition to, the industrial tunnel dryer referred to above. It will be understood that the actual drying system may vary depending on the desired implementation. It will also be understood that the cellulose output may vary depending on the needs of the customer. For example, it may be dried, provided as a slurry, etc.

In yet another alternative embodiment to that described above, the number of washing and filtering stages may be reduced by implementing a multi-stage washing process in what was previously characterised as“S4”. For example, rather than directing the mixture output from each reactor (22) to a dewatering device, it could instead be passed into a multi-stage drum washer where it subjected to a multi-stage washing process. More particularly, in one embodiment, a two-stage trommel washer could be used for the washing process. In a first washing stage, the mixture output from each reactor (i.e. comprising the cellulose particles and polyester fibre) is passed to a first trommel washer whereby it is sprayed with water using an internal spray. Free liquid extracted from the first washer stage is filtered for recovering any cellulose particles therein before being returned for use in the second stage (i.e. in the same manner as described for the Figure 2/3 embodiment). In a second washing stage, a washed fibre mix output from the first washing stage is delivered downstream to a second trommel washer where it is subjected to a second washing process using a water spray. Again, free liquid extracted from the washer is filtered for recovering any cellulose particles therein before being returned for use in the second stage. The output of the second washing stage (i.e. a washed mix of cellulose particles and polyester fibre) is then ready for drying and pelletisation (or other desired output) in the same manner as for the Figure 2/3 embodiment.

It will be understood that a combination of the wash and filter stages (and related equipment) both described above and with reference to Figure 2/3 may be implemented, depending on the desired application.

It will be understood that one or more of the following advantages arise from one or more embodiments as outlined in preceding paragraphs:

- waste blended polycotton garments can be chemically separated and then recycled back into their base component parts to allow these components to be re-used (across a variety of industries), thereby prevent waste garments from ending up in landfill; - all liquids used in the process are recovered and recycled within the facility;

- the process requires only low amounts of energy to be used;

- embodiments are provide a highly efficient, zero waste recycling eco-system that can recover more than 95% of the raw materials from a polyester and cellulose product;

- embodiments may result in significant C02e reduction with every 1 kg of textiles recycled leading to 30kg of C02e reduction;

- embodiments address both the supply and demand needs of customers - the recycling of waste textiles as a form of supply and processing this into a raw material to satisfy the demand for rPET and cellulose for manufacturing.

In this specification, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of. A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

The preceding description is provided in relation to several embodiments which may share common characteristics and features. It is to be understood that one or more features of any one embodiment may be combinable with one or more features of the other embodiments. In addition, any single feature or combination of features in any of the embodiments may constitute additional embodiments.

In addition, the foregoing describes only some embodiments of the inventions, and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

Furthermore, the inventions have described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the inventions. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments.

Further, each independent feature or component of any given assembly may constitute an additional embodiment.