PET RECYCLING LINE TO MAKE NONWOVEN SPUNBOND FABRIC
KIFF SYSTEMS PET RECYCLING PLANT with 800 kg/h INPUT CAPACITY (500 ÷ 600 kg/h OUTPUT CAPACITY)
(Note that the line is flexible therefore both PET and HDPE bottles can be processed)
- TECHNICAL DATA AND CONSUMPTIONS
1.1 PLANT FOR PET BOTTLES RECYCLING
The plant is designed for recycling post-consumer PET bottles coming from municipal collection, curb-side collection or “deposit system”.
Kiff systems recycling technology allows recycling of highly contaminated bottles without affecting the output flakes quality.
The plant is designed according to the most recent technology to guarantee:
- The highest quality and final product consistency
- The highest operating factor, minimizing the stop time for cleaning, scheduled and extraordinary maintenance
- The most efficient water, additives, and services consumption
- The most efficient manpower utilization
The supply aim is complete within the following battery limits:
- From bales opener
- To flakes big bags filling station.
1.2 CAPACITY
- Input capacity: 800 kg/h
- Estimated production per hour output : 500÷600 kg/h
The plant is designed for a continuous operation 24/24 h, 7 days a week less the scheduled maintenance stop. Generally, is considered 1 shift per week plus two weeks per year as a minimum stop time.
Losses: fine residues and eliminated material. The line will lose PET/HDPE during the process (about 3% of the input material), because of the aerodynamic separator, of the centrifuge and of the washing process.
1.3 INPUT CHARACTERISTICS
This system has been designed to recycle post-consumer PET bottles, coming from selection centres. The characteristics of the input material are as follows:
Bale characteristics
Minimal size 1000x800x1200 mm
Density 200 Kg/m3
Bales will be unwired by removing metal wire before feeding the plant.
Note: For bales with higher density, corresponding to bales of 1000 kg approx., it is necessary to install a special bales breaker.
Bottle Characteristics
Average weight 40 gr.
Volume 500-5000 cc
Base In polyolefins, if present
Labels Paper or polyolefins.
The presence of PS or PVC etiquettes requires the installation of specific modules in the plant.
Caps PP or HDPE only.
If aluminium caps are present, the installation of an additional separator is suggested.
Garnitures
EVA, PP. If PVC garnitures for soft drinks in carbonate are present, the installation of an additional separator is suggested. In any case, Kiffsystems must be informed.
Colour
The colour selection is made before the Kiffsystems recycling line.
Solid impurities
Non-PET bottles and containers non-PET bottles and containers are supposed to be manually or automatically selected before the recycling line.
of which:
PVC bottles/containers/caps Manually or automatically selected before the Kiffsystems recycling line.
of which:
PE, PP bottles/containers PE, PP content after automatic and manual selection ≤ 1%.
of which:
Dark coloured bottles/containers Coloured bottles must be manually or automatically selected before the Kiffsystems recycling line
Inert (excluding metals) max 0,5 %
Metals (magnetic) Traces (to be defined by the customer)
Paper/Cardboard min 1 % – max 3 %
Contamination:
The contaminants present in the material will be organic substances, detergents, paper, glues, labels, metals (in limited quantity). Contaminations of toxic noxious products are not foreseen. We mention the average value that can be expected. Data will be rectified according to customer bottle specification.
1.4 FINAL PRODUCT QUALITY
The final product of the washing process are PET flakes. The process has no influence on the intrinsic viscosity (I.V) of the material (indicatively between 0,71 and 0,78 dl/g) Flake’s diameter will be, in the average, between 5 and 12mm. Flake’s fraction with diameter lower than 1 mm is ≤ 1%, while the fraction with diameter ≥ 12 mm is ≤ 5%.
A detailed description of the final product characteristics is resumed here below:
Flake’s size
In the average, between 3 and 10mm. Flakes fraction with diameter > 10mm is 5%. Flakes fraction with < 1mm is 1%
Surface moisture 0.7%
Glue Content Max. 20 ppm
pH value Neutral (pH +/- 0,5)
HDPE/ PP content Max. 20 ppm
PET dust )particle size < 1mm) Max. 1%
Paper/ wood Max. 20 ppm
Bulk density Min. 200-300 g/l
PARAMETERS DEPENDING ON OPTICAL AND MANUAL SORTING
The characteristic of flakes listed below are not covered by was line guarantee as they they will depend on:
- Effectiveness and number of operator and manual sorting
- Quality of input material
PVC (rigid and labels) 50 ppm.
Coloured PET flakes (green, amber) 100 ppm (excluding light blue)
Metals 20 pm (magnetic and non-magnetic)
PA from barrier bottles
Yellow flakes degraded, blocker, oil bottles.
NOTES
- The final PVC contamination depends on input material value. We consider that PVC is almost not present. In alternative, material flakes sorter can be added to the wash line. Price and conditions to be defined.
- Coloured and Opaque PET flakes contamination depend on input material value and on the design of optical sorting sections. Also, these parameters will be defined with a test.
- Metals: We assume that flakes sorter will separate metals and that there is a minor quantity in input material. If this is not the case, then it will be necessary to consider an additional metal separator.
- PA from laminated bottles will be partly removed by the washing process if bottles delaminate. It is necessary to separate multilayer bottles in the input material sorting area to achieve the required PA level.
- The degraded bottles, blocker, oil bottles need to be sorted by manual sorting
- Other contamination, silicone, rubber will be selected by manual sorter.
1.5 SUB PRODUCT
The process produces polyolefins as sub-product that come from caps and etiquettes. They are, in particular, HDPE/PP flakes, separated from PET by flotation, after the intensive washing and rinsing, with a humidity up to 4%. PET flakes might be present.
1.6 LAYOUT AND BUILDING
We are enclosing at this present preliminary quote a preliminary layout (ref.
P088843_revB_2019_11_14) to give you an idea of the different spaces needed. Of course, other studies are possible on the basis of your specific needs.
1.7 SYSTEM REQUIREMENTS
The main data concerning the utilities are listed here below:
Electric power
Electric power: 400 V, 3ph +/-3%.
No micro interruptions, free from the influence of induced electromagnetic fields
Frequency: 50 Hz
Circuits for the cabinet internal lighting and service sockets:
Power: 230 V, 1ph, 50 Hz , differential protection
Max tooling power: 16 A
Auxiliary circuits
Power contactors, control instruments and 24 V, 1ph, 50Hz , generated by a electro pneumatic valves, PLC control transformer, insulated, inside the cabinet button
Compressed air
Pressure: Min 6, max 10 bar
Condensation temperature: – 20 °C
Quality: Filtered. Oils and dusts absent
Process Water
Pressure: 3 bar
Temperature: Max 25 °C
Total hardness: Max 8 dH (Fr. degrees)
pH: Around 7
Carbonates: None
Chlorides: Max 10 ppm
Solids: Max 10 mg/l, no weed, max Ø 20 μm
Sulphates: Max 7 ppm
Alkalinity: 180 m HOS/CM
Saturated steam
Pressure: min 4 bar (133 °C)
1.8 AIR EMISSIONS CONTROL
Air is used to convey PET flakes pneumatically from the various modules of the system. Moreover, vapor emissions from the modules where hot water is used have to be removed from the working environment. The installation of a system to aspire and filter the air is suggested.
1.9 UTILITIES CONSUMPTION
Consumption of the utilities used during the process are listed here below:
Electric power: 0,22-0,27 kW/kg PET flakes
Water: 1,5 – 3,5 litres/ kg PET flakes
This value is valid if the treated material is in accordance with the standard specification
Compressed air:
3 Nm3/h for the plant with pressure 6 bar for the system (instruments, valves,) + 0,8 – 1 m3 / minute at 8 bars for each automatic detector
Steam:
200 kcal/kg (PET flakes) for hot pre-washing plant + 250 kcal/kg for washing unit – Total: 450 kcal/kg
Chemical additives:
The quantity of chemical additives is in connection with the quantity of contamination to be eliminated and with the finished quality requested by the product. There are several products on the market, and they are used in similar percentages, but they have different costs.
Note: operator number required for sorting table changes according to bottle quality (contaminations) and number of detectors installed-
Kiff Systems will not be responsible for any emission generated in the air, in the water, or in solid conditions by the plant, the material to be processed or the contaminants present in it.
- PROCESS DESCRIPTION
2.1 GENERAL SYSTEM PHILOSOPHIES
All of our systems are built on the same basic tenets. We have developed these tenets through years of experience and hundreds of systems. To understand our process, you must first understand these tenets.
- Ruggedness:
Recycling involves processing materials over which you have little control in a harsh environment. Machines must be able to accommodate all reasonable contaminants and conditions without catastrophic failure or unreasonable wear.
- Maintainability:
Because of the abrasive nature of the materials passing through the machines, all machines must be designed to control wear and be quickly and easily maintained. In many cases, the machine downtime due to maintenance determines the success of the entire operation.
- Reliability:
The highest quality, most economical, consistent end product is only gained through high efficiency and reliability of the plant
- Early contaminate removal:
Since contamination causes machine wear, reduces throughput, and affects product quality, it is essential to remove as much contamination as economically possible early in the process.
- Utility consumption:
This is the largest single cost of any recycling system and must be controlled.
- Modular design:
Advances in technology and ever-changing material requirements necessitate the ability to upgrade a system to stay competitive.
– OPTIONAL SERVICES TO BE QUOTED ON CUSTOMER REQUEST
– Soundproofing:
The machines and plants do not include soundproofing. Under certain use and installation conditions, the sound level may exceed 85 dB(A). Should soundproofing not be purchased, the client must, at his own expense, provide devices compliant with the applicable legislation.
– Dust control:
The machines and plants do not include systems for dust control, recovery or seal. When processing certain materials, dust may be produced. Should these systems not be purchased, the client must, at his own expense, provide devices compliant with the applicable legislation.
– Erection: Erection of machinery and plant at the installation site.
– Utilities:
All the networks for the supply of electrical energy, industrial water, compressed air and steam, including the relative safety and regulation devices up to the battery limit of the single machines, utilities, control panel indicated on our drawings.
– Lifting equipment and devices: All devices and equipment for unloading, lifting and positioning of the machinery such as cranes, forklifts, plates, cables, belts and hooks.
EXCLUSIONS FROM DELIVERY
The following works and services are not included in the supply. The purchaser must carry them out or have them carried out at his own expenses.
– Civil works:
The design and execution of the civil works necessary for anchoring and installation of the machinery, the piping, the pneumatic conveyance, and the electrical cables and cable trays.
– Pits for wastewater:
The channels and collection pits for the wastewater used in the process and in cooling the machinery.
– Chimneys for atmospheric emissions:
The tubes and chimneys to convey dust-laden air, fumes and vapour eventually discharged during plant operation at the points indicated on our drawings. The purchaser must verify with the competent authorities if specific authorisations are required and deal with applications, therefore.
– Fixing devices: such as:
brackets, expansion bolts, tie rods to anchor the machines and plant components; brackets for attachment to pneumatic transport pipe supports, electrical cable trays support, utility piping supports.
– Machinery earthing:
The pre-setting of the machines and connection to the earthing plant.
– First filling fluids:
The machines are delivered without first fill fluids, which must be procured and inserted at the expense of the client to our indications. In particular, the reducers, the oleo-dynamic units, and the refrigeration groups, etc., must be filled.
– Safety in the work environment:
All the devices required to adapt the working area to applicable norms and legislation are excluded:
- fire prevention and protection systems
- atmospheric discharge protection
- heating plant
- ventilation and fume and dust extraction plant
- devices for the overall reduction of the sound level
- personal safety devices
- illumination plant
KIFFSYSTEMS PET BOTTLES TO SPUNBOND NONWOVENS
RPET spunbond line in order to produce nonwoven applications.
The calculations are based on bottle outlet capacity of 1000 kg/h and spunbond line S 3200 with a net width of 3200mm.
For a comparison also we have considered a washing line with a bottle’s outlet capacity of 800 kg/h plus spunbond line S 2400 with a net width of 2400mm, if you consider a typical grammage for bags (80 g/m2), the total production with Spunbond line S2400 (530 kg/h) is 53.000.000 g/m2 per year.
If you prefer the S3200 (700 kg/h), the total production is 70.000.000 g/m2 per year.
1.DESIGN BASIS FOR WASHING LINE
CLIMATIC DATA
Location: to be confirmed
Air temperature: to be specified
Air humidity: to be specified
Site altitude: less than 1000 m above sea level
Recommended working ambient conditions (at Buyer’s care)
Temperature (°C): 20 – 30, max 40 at the upper platform
Relative Humidity (%): ≥ 60 with 20°C; ≤ 50 with 30°C
PRODUCT DIRECTION: To be defined
PAINTING: To be defined
RAW MATERIAL: Post consumed PET bales
PRODUCTION CAPACITY: up to 1000 kg/h of flakes (depending on inlet material quality)
PERSONNEL REQUIREMENT: (direct manpower)
On shift: 5 operators, total 20 units (4 teams)
On daily basis: 2 (Plant manager, Raw materials/Finished product handling laboratory
– Maintenance: 1 mechanic and 1 electrician (on demand)
SPACE REQUIREMENTS
– Process equipment area: approx. 2000 m2 (100×20)
– Service equipment area approx. 1000 m2
– Raw materials warehouse: approx. 4000 m2 (outdoor)
– Finished product warehouse: ≥ 1000 m2
– Recommended building ≥ 4000 m2 (typical 100×40)
2.DESIGN BASIS FOR SPUNBOND LINE
CLIMATIC DATA
Location: to be confirmed
Air temperature: to be specified
Air humidity: to be specified
Site altitude: less than 1000 m above sea level
Recommended working ambient conditions (at Buyer’s care)
Temperature (°C): 20 – 30, max 40 at the upper platform of Spunbond section
Relative Humidity (%): ≥ 60 with 20°C; ≤ 50 with 30°C
PRODUCT DIRECTION: To be defined
PAINTING: To be defined
PRODUCT Spunbond nonwoven S layout
RAW MATERIAL: PET flakes out of bottles recycling prewashed, pregounded and premixed. Specifications:
– Bulk apparent density: ≥ 0.35 g/cm3
– Intrinsic viscosity: from 0.72 to 0.84 dl/g
– Residual humidity: ≤ 0.9%
– Max contaminants content: 400 ppm (PVC ≤ 50 Polyolefin <-20)
– Dust (<1 mm): ≤ 0.6%
– Yellowness after thermal treatment (1 hours/200°C): absent
ADDITIVES: Colour, UV protection If any, in form of master-batch
granules. Specifications in due time
NET WIDTH: After edge trimming and winding into a roll: 3200 mm
PRODUCTION CAPACITY: up to 220 kg/h/m per beam
WEIGHT RANGE: from 10 to 120 gsm
PRODUCTION SPEED: Up to 400 m/min
PERSONNEL REQUIREMENT (direct manpower): – S line
On shift: 4 operators, total 16 units (4 teams)
On daily basis: 1 (Plant manager, Raw materials/Finished product handling laboratory
– Maintenance: 1 mechanic and 1 electrician (on demand)
SPACE REQUIREMENTS
– Process equipment area: approx. 1000 m2 (40×25)
– Service equipment area approx. 400 m2
– Raw materials warehouse: approx. 300 m2
– Finished product warehouse: ≥ 1000 m2
– Recommended building ≥ 2000 (typical 80×25)
- SCOPE OF SUPPLY AND PRICES
3.1 WASHING LINE – PET bottles to flakes
Main components
3.1.1 1 Bales feeding and opening systems
3.1.2 1 Pre-washing and Screening systems
3.1.3 1 Sorting system
3.1.4 1 Grinding unit
3.1.5 1 Washing system
3.1.6 1 Rinsing and Floating systems
3.1.7 1 De-dusting, final Colour Sorting and Bags Filling systems
3.2 STAPLE FIBER LINE – PET Flakes to spunbond nonwovens
Main components:
3.2.1 1 Raw material feeding system
3.2.2 1 Extrusion section
3.2.3 1 Spinning system
3.2.4 1 Web forming system
3.2.5 1 Calendering system
3.2.6 1 Winding system
- SUPPLY LIMITS
Besides the equipment specifically indicated as Buyer’s supply, the Buyer shall provide for the following:
- a) Civil works
– Building, foundations, ventilation, air conditioning, lighting etc.
– Sound proofing cabins where required
– Auxiliary structures non specified as Seller’s supply
- b) Utilities
Supply and distribution to the plant user’s points of:
– Electric power
– Cables and cabling materials
– Services compressed air
– Chilled water
– Steam
– Industrial water
– Washing water treatment (biological treatment recommended) suitable to treat the washing process water to a level suitable for its discharge in accordance to local regulations
Quantity to be treatet: 3 m3 of water/ton of flakes
- c) Piping and piping materials for:
– Chilled water
– Diathermic oil
– Exhausting ducts, chimneys
– Steam
– Industrial water
- d) Raw materials and auxiliary materials
– Polymer
– Additives
– Consumable materials, lubricants, diathermic oil, antifrozen agents etc.
- e) Miscellaneous
– General tools, lifting and transport means
– Protection and safety devices according to local rules or special requirements
– Transportation and insurance expenses from delivery site to the assembling site, unloading of the equipment from containers/trucks, arrangement of the equipment ready for erection, erection tools materials, manpower etc.
– Equipment erection under Seller’s supervision
– Laboratory equipment
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