1. INTRODUCTION
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are the biggest factors influencing the Nylon business; the competitive market against
polyester and vice-versa is a constant battle.
In this context the re-use of the polyamide is clearly a way to get an extra source
of raw material, and enable claims for carbon footprint reduction what aligns both
industry and market needs.
2000
1000
Nylon Staple
0
1990 2000
2005 2006
2007 2008
2009
2010
2011
2012
2015
Was observed by (3) that the majority of Nylon (Polyamide 6 and 66) is used on
carpet, the recycling of carpet was thought and patented first by DuPont in 1944, even
though the recycling of a dirty carpet represents a challenge still today.
The collection and sorting of materials are the biggest challenges for the supply
chain on recycling for that various methods on sorting are used, being the most common
the checking the melting point of the polymer and infrared or near infra-red technologies
(IR). The IR being a fast, accurate and non-destructive test are by far the most used.
There many ways to re-use the polymer and few studies are available in the
literature. The work from (1) at USC (University of South Carolina) did list four classes,
(2) and (3) agrees with it:
1. Chemical recycling or De-polymerization method to break down the long chain
of polymer into monomers than can be re-polymerized, which possibly converts
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the waste into products having a quality equivalent to that of the virgin
polymer. Polyamide 6 can be depolymerized to its monomer caprolactam, by
acidolysis, hydrolysis, aminolysis or catalyzed-de-polymerization in vaccum.
Whilst aminolysis is now the preferred route being used by DuPont, catalyzed
depolymerization in vacuum has recently been developing into promising process.
Companies recycling polyamide 6 and 6.6 by depolymerization includes: DuPont,
AlliedSignal, BASF and Novalis Fibers. This classic system for the closed-loop
recycling of carpets, which in theory can proceed forever.
a. Acidolysis Nylon 6 depolymerized using an acid catalyst, the cut nylon
6 waste is melted in a continuous reactor and treated with steam, the
monomer is formed by hydrolysis. After distillation and filtration the
caprolactam is recovered read for further usage.
b. Hydrolysis Depolymerization of PA6 in high-pressure steam reactor
(AlliedSignal), PA6 hidrolytically depolymerized in an aqueous system
under pressure give yields around 70% of caprolactam, see figure 2, the
expensive part on this process is the distillation to remove water.
c. Aminolysis DuPont identified ammonolysis as the best depolymerization
option for scrap carpet, yields on this process can reach 80% in theory. All
the preparation work is also required (backing separation, removal of dirt
and contaminants), followed by shredding, chipping, going through a
hammer mill, screening and then grounded to particles of 1.5mm. Water is
added to the material to form a slurry and then further separation by
density is performed, reaching ratios of 98.5% purity, this material is
transferred to the de-polymerization reactor. In the ammonolysis reactor,
the nylon is mixed with ammonia gas and phosphate catalyst, what is
separated later by distillation. This process is versatile and can even
process copolymers.
2. Extracting recycling or Recovery of polymer components method to recover
individual components of the polymeric mixture without reaching the monomer
level. Includes multiples extraction and separation steps.
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Recycled Polyamides.
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caprolactam feedstock, which is then filtered for high purity and shipped to AlliedSignal
polymerization plants to make their product branded INFINITYTM nylon 6 resin.
Some considerations about the cited classes is that de-polymerization is the
preferred route because it breaks the product into monomers which can then be repolymerized into new high quality nylon. It can be argued that this process does cut some
steps from the original monomer generation. When there is a blend and the nylon needs
to be separated by a solvent, for example, it can be difficult to re-use the solvent since it
will probably facilitate the dissolution of impurities that were on the outside of the
polymer and hence limit the polymer usage or require filtering. In case of melting blends,
where a different polymeric material is resultant, every time can restrict the future
number of applications in which the product can be used. Blends result in batches and
therefore quality levels can vary from time to time; still the possibility of avoiding
separation makes this method attractive for some applications.
In order to characterize what normally happens in the industrial processing of
nylon, one has to understand how virgin and recycled material, blended with different
ratios, behaves as raw material characterization, thermal and mechanical properties of the
fiber. The work of (2) was the one that most approximate to a fiber production reality.
The product variability is intrinsic to the amount of impurities present in the
polymer since recycled products have more impurities than virgin materials which
becomes an important point of control during the processing of such polymers. The work
of (4) demonstrates this point and discusses that the durability and reliability of products
using recyclate might be significantly reduced by the presence of impurities acting as
stress concentrators. The absence of impurities is the key for reliable mechanical
properties, therefore characterizing the size and concentration of impurities that the
product can allow could be critical to the success of the processing of the recyclates.
Degradation is another point that will occur in the process. The paper (5)
recommended color readings to access the degree of degradation noting substantial
differences after re-use of the polymer. In (6) the researcher observed the degradation
phenomenon not only results in brittleness and deterioration of the mechanical properties
of polymers, but also decreases stability and restricts the applications of the final
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products. In the textile apparel for example, this would limit the shades that the fiber can
be used in, normally light shades can be challenging.
Moisture Content
Increase confidence of the drying process is normally checked before and after
drying. The existence of moisture in melt spinning provokes hydrolytic scission
of chains with consequent reduction on molecular weight and therefore,
catastrophic reaction on fiber properties.
2.2.
Color Readings
Degradation can have big impact on color and a way to perceive such changes is
measuring the color of the chips or the as-spun fibers. The color readings of
waste streams or raw material, as well as cutting edge inline color measurements
(normally at the extruder, melted fiber), can enhance process control and allow
containment in case of off-quality events.
2.3.
Intrinsic Viscosity
Property checked in chips and as-spun samples using a capillary diameter
viscometer. This measurement will enable the calculation of molecular weight. In
order to determine material consistency, its recommended to combine rheology
measurements with filtration measurements over time.
2.4.
Density
Property measured on a density gradient column of carbon tethacloride with
toluene, suggested three readings after 6h equilibrium. With the density the
crystallinity fraction can be calculated. This measurement can indicate thermal
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2.5.
2.6.
Birefringence
Provide clear information of the amorphous and crystalline regions hence
orientation of the polymer. Normally defined by reflectance of light over the
lamellas which will have 0 if they are perfectly oriented; normally fibers will
vary around the 20 to 40.
2.7.
2.8.
Linear Density
Property measured in yarns, normally Denier (g/9000m) or Dtex (g/10000m).
2.9.
Mechanical Properties
For all the samples the tensile strength, modulus, and breaking elongation can be
measured using ASTM 3822. This measurement will be used for comparison of
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the many researchers reported in the literature. The well-known Instron machines
or Statimat from Textechno are widely used in the industry and research
laboratories today.
2.10.
In case of yarns the shrinkage is an important factor and in case of textured yarns
crimp is also good information. This paper will not discuss much of the thermal
properties such as shrinkage and crimp, but since thermal history is rich in
recycled materials, it is wise for the researcher to verify its effects mainly on
properties that will require further thermal treatment. This paper discusses
shrinkage and crimp of the yarn, but this should be carried out as far as the fabric
dyeing and its thermal setting finishing processes before garment preparation.
For this paper the results of many authors experimental work will be presented in
an indexed form. The initial property (the virgin material) value is set as an index one and
the following values are the percent variation in relation to its virgin value. This
eliminates the need to state the units and allows an overall qualitative comparison.
References are provided for further understanding of individual experiments performed.
The properties that will be discussed are first, tensile strength, which is a measure
of the steady force necessary to break a fiber and is given experimentally by the
maximum load developed in a tensile test performed using ASTM 3822. The second is
the elongation necessary to break a fiber, normally expressed as a percentage increase in
length, also termed as elongation at break, using the same ASTM standard.
The intention is to combine the available literature values into graphics that
explain or indicate the to be expected behavior of the re-processing of polymer. By the
end of the discussion an inclusion of waste will be presented, but the following graphs are
re-processing of same polymer, which should demonstrate the thermal history behavior
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Tensile Stress
(6)
(4)
(5)
9 10 11 12 13 14 15 16
Number of cycles
Figure 3. Results on Tensile Stress versus number of cycles
From (4), while testing strength, the diameter was verified for aged and un-aged
samples showing limited influence on it. Since the exploratory work was
considering influence of impurities diameter as well as cycles were verified that
samples containing impurities above 100 micrometer, their tensile strength
slightly decreases as the impurity diameter increases, which is expected as results
of localized stress on the chains. Its also concluded that impurity sizes have a
critical point for tensile properties and one should consider studying the impurity
impact by its type. This material characterization can be visualized by a plot of
Tensile strength versus (Diameter)(-1/2), suggested the author.
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From (6), the load at the yield point and draw point increases with increased
cycles of injection molding. The overall increment in the yield stress from the 1st
to the 16th cycle is approximately 25%, and a higher load at the cold drawing
region is observed for the 8th and the 16th processed PA6 samples.
1.00
0.90
(6)
0.80
(7)
0.70
(8)
0.60
(4)
0.50
(5)
0.40
1
9 10 11 12 13 14 15 16
Number of cycles
Figure 4. Results on Elongation at Break versus number of cycles
Figure 3 illustrates the elongation behavior from the work of (4), (5), (6), (7) and
(8).
From (4), the elongation is similar or lower compared with re-extruded reference
samples. Again, the existence of impurity explains the reduction on elongation
and was also noted in a relationship of the elongation with the diameter of
impurities, suggesting that there is a critical diameter after what cause
catastrophic failure.
From (5), the re-processing has an obvious reduction on elongation, making it the
most abrupt decrement.
From (6), the elongation at break is somewhat stable up to the 12th cycle and then
has an abrupt reduction in contrast with all the other works. The author also noted
the increase of the standard deviation after the 13th cycle on top of its value
decrement, which can be the characterization of a non-stable polymer chain.
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From (7), relates its tensile properties decrease to be directly related to molecular
weight reduction.
From (8), just note that this work was performed on nano-composites; the
elongation decrease follows the other tests trends.
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blend, was observed that by the increasing the fraction of recycle PA6 in the samples,
glass transition temperature decreases which suggested that amorphous regions were
extended with increase in waste material. The analyses was made in two phases, as-spun
and drawn fibers, the tensile properties of as-spun yarns such as tensile strength, breaking
elongation, and modulus were made and statistical studies on the samples indicate that
there is no significant difference between tensile properties of different samples at 95%
confidence level. Therefore, they were consider to have similar behavior as can be seen in
Figure 5.
Indexed Property
Tensile Stress
Elongation
20
40
60
80
100
% of Waste
Figure 5. Tensile Properties of As-spun Fiber versus blend
The second part of the study was performed on drawn yarns where statistical
analyses of tensile properties of drawn samples show that strength and modulus of 0%
(virgin material) samples is different from those of other samples at a 95% confidence
level, but elongation at break of drawn samples are the same. As seen in Figure 6, tensile
strength and elongation of virgin material are somewhat higher than yarns containing reused PA6-drawn yarns, of course drawing as-spun yarns results in the increase of tensile
strength and modulus with consequent decrease of breaking elongation, which can be
explained by the orientation and crystallinity increase of as-spun yarn subjected to the
drawing process.
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1.00
0.98
0.96
0.94
Tensile Stress
0.92
Elongation
0.90
0.88
0.86
0
20
40
60
80
100
% of Waste
Figure 6. Tensile Properties of Drawn Fiber versus Blend
Further work was performed on textured yarns by (2), but potential miss conceptions
about the texturing process could have misled the researcher. This paper will not discuss
the results, in order to be fair to the author a series of questions were forwarded to him
with no answers so far.
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5. CONCLUSION
The paper discussed briefly the current state on polyamide recycling and its
relevance in volume and technology. Emphasis was made on the various tests and
procedures employed by different researchers on this field, citing and comparing the
mechanical properties analyzed by them, overall was observed that there is no obstacle in
recycling fibers. This work did not discuss the thermal properties but do recommend to
not be forgotten by users of recycled fibers. Furthermore thoughts for further research are
shared on the last part of the paper.
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6. REFERENCES
(1) Mihut C, Captain DK, Gadala-Maria F, Amiridis MD. Review: Recycling of nylon
from carpet waste. Polym.Eng.Sci. 2001;41(9):1457-1470.
(2) Meyabadi TF, Mohaddes Mojtahedi MR, Mousavi Shoushtari SA. Melt spinning of
reused nylon 6: structure and physical properties of as-spun, drawn, and textured
filaments. Journal of the Textile Institute 2010;101(6):527-537.
(3) Scheirs J. Polymer recycling : science, technology, and applications. New York:
Wiley; 1998.
(4) Eriksson PA, Albertsson AC, Boydell P, Mnson JAE. Influence of impurities on
mechanical properties of recycled glass fiber reinforced polyamide 66. Polym.Eng.Sci.
1998;38(5):749-756.
(5) LozanoGonzlez M. Physicalmechanical properties and morphological study on
nylon6 recycling by injection molding. J Appl Polym Sci 2000;76(6):851-858.
(6) Su KH, Lin JH, Lin CC. Influence of reprocessing on the mechanical properties and
structure of polyamide 6. J.Mater.Process.Technol. 2007;192:532-538.
(7) La Mantia FP, Curto D, Scaffaro R. Recycling of dry and wet polyamide 6. J Appl
Polym Sci 2002;86(8):1899-1903.
(8) Goitisolo I, Eguiazbal JI, Nazbal J. Effects of reprocessing on the structure and
properties of polyamide 6 nanocomposites. Polym.Degrad.Stab. 2008;93(10):1747-1752.
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