Recycling in Textiles

241 Pages·2006·1.54 MB·English

by  Youjiang Wang

240 x 159 /Pantone 132 C & Pantone Black C 18 mm
W W
OODHEAD PUBLISHING IN TEXTILES OODHEAD PUBLISHING IN TEXTILES
W W
OODHEAD PUBLISHING IN TEXTILES OODHEAD PUBLISHING IN TEXTILES
A n increasing amount of waste is generated each year from textiles and their production. R
For economic and environmental reasons it is necessary that as much of this waste as e
c
possible is recycled instead of being disposed of in landfill sites. In reality the rate of textile y
recycling is still relatively low. On average, approximately 10 million tonnes of textile waste c
l ‘Diamonds’
is currently dumped in Europe and America each year. Considering the diversity of fibrous i
n
waste and structures, many technologies must work in concert in an integrated industry in g
order to increase the rate of recycling. Recycling in textiles shows how this can be i
n
achieved.

t
e
The first part of the book introduces the subject by looking at the general issues involved x
t
and the technologies concerned. Part II explores the chemical aspects of textile recycling. i
l
Part III focuses on recycled textile products, including nonwovens and alternative fibres. e
Finally, the last part of the book discusses possible applications of recycled textiles, s
including using recycled products in the operating theatre, for soil stabilisation and in
concrete reinforcement.
Recycling in textiles presents several promising technologies and ideas for recycling
systems. This is the first book to bring together textile recycling issues, technology, Recycling in textiles
products, processes and applications. It will prove an invaluable guide to all those in the
industry who are now looking for ways to recycle their textile waste.
Dr Youjiang Wang is Professor of Polymer, Textile & Fiber Engineering at Georgia
Institute of Technology, USA. He is a Fellow of the American Society of Mechanical
Engineers (ASME) and of The Textile Institute.
W
a
n
g
Woodhead Publishing Ltd CRC Press LLC Edited by Youjiang Wang
Abington Hall 6000 Broken Sound Parkway, NW
Abington Suite 300
Cambridge CB1 6AH Boca Raton
England FL 33487
www.woodheadpublishing.com USA
ISBN-13: 978-1-85573-952-9 CRC order number WP9104
ISBN-10: 1-85573-952-6 ISBN-10: 0-8493-9104-0
Recycling in textiles
Edited by
Youjiang Wang
CRC Press
Boca Raton Boston New York Washington, DC
Cambridge England
Published by Woodhead Publishing Limited in association with The Textile Institute
Woodhead Publishing Ltd
Abington Hall, Abington
Cambridge CB1 6AH, England
www.woodheadpublishing.com
Published in North America by CRC Press LLC
6000 Broken Sound Parkway, NW
Suite 300, Boca Raton, FL 33487, USA
First published 2006, Woodhead Publishing Ltd and CRC Press LLC
© 2006, Woodhead Publishing Ltd
The authors have asserted their moral rights.
This book contains information obtained from authentic and highly regarded sources.
Reprinted material is quoted with permission, and sources are indicated. Reasonable
efforts have been made to publish reliable data and information, but the authors and the
publishers cannot assume responsibility for the validity of all materials. Neither the
authors nor the publishers, nor anyone else associated with this publication, shall be
liable for any loss, damage or liability directly or indirectly caused or alleged to be
caused by this book.
Neither this book nor any part may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying, microfilming and
recording, or by any information storage or retrieval system, without permission in
writing from Woodhead Publishing Limited.
The consent of Woodhead Publishing Limited does not extend to copying for general
distribution, for promotion, for creating new works, or for resale. Specific permission
must be obtained in writing from Woodhead Publishing Limited for such copying.
Trademark notice: Product or corporate names may be trademarks or registered trade-
marks, and are used only for identification and explanation, without intent to infringe.
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
Library of Congress Cataloging in Publication Data
A catalog record for this book is available from the Library of Congress.
Woodhead Publishing ISBN-13: 978-1-85573-952-9 (book)
Woodhead Publishing ISBN-10: 1-85573-952-6 (book)
Woodhead Publishing ISBN-13: 978-1-84569-142-4 (e-book)
Woodhead Publishing ISBN-10: 1-84569-142-3 (e-book)
CRC Press ISBN-10: 0-8493-9104-0
CRC Press order number: WP9104
The publishers’ policy is to use permanent paper from mills that operate a
sustainable forestry policy, and which has been manufactured from pulp
which is processed using acid-free and elementary chlorine-free practices.
Furthermore, the publishers ensure that the text paper and cover board used
have met acceptable environmental accreditation standards.
Typeset by Ann Buchan (Typesetters), Middlesex
Printed by TJ International Limited, Padstow, Cornwall, England
Contents
Contributor contact details ix
1 Introduction 1
Y. WANG, Georgia Institute of Technology, USA
Part I General textile recycling issues and technology
2 Textile recycling: a system perspective 7
J. M. HAWLEY, University of Missouri, USA
2.1 Introduction 7
2.2 Systems theory 8
2.3 Understanding the textile and apparel recycling process 8
2.4 Textile recycling companies 10
2.5 The sorting process 12
2.6 The pyramid model 13
2.7 Textile recycling constituents 18
2.8 Discussion and future trends 22
2.9 References 23
3 Designing textile products that are easy to recycle 25
B. GULICH, Saxon Textile Research Institute, Germany
3.1 History 25
3.2 Product responsibility 26
3.3 Current situation in Germany 26
3.4 Basic methods 27
3.5 Examples 29
3.6 Conclusions 36
3.7 References 36
iii
iv Contents
4 Carpet stewardship in the United States – 38
a commitment to sustainability
R. PEOPLES, The Carpet and Rug Institute and
Carpet America Recovery Effort, USA
4.1 Introduction 38
4.2 Carpet industry environmental stewardship 39
4.3 Carpet recycling – early efforts 40
4.4 The Carpet America Recovery Effort 41
4.5 Creating a new industry – material flows 42
4.6 The role of non-carpet products in carpet recycling 44
4.7 Conclusions 44
4.8 Future trends in the USA 45
5 Systems planning for carpet recycling 46
M. REALFF, Georgia Institute of Technology, USA
5.1 Introduction 46
5.2 The need for strategic systems planning 46
5.3 Previous system issues 47
5.4 The estimation of carpet recycling volumes 49
5.5 Initial collection schemes 50
5.6 The alternative structures for consolidating and 52
sorting of carpet
5.7 Case studies 55
5.8 Discussion 55
5.9 Conclusions and future trends 56
5.10 References 57
6 Carpet recycling technologies 58
Y. WANG, Georgia Institute of Technology, USA
6.1 Introduction 58
6.2 Fiber identification and sorting 60
6.3 Size reduction 61
6.4 Mechanical separation of carpet components 61
6.5 Solvent extraction of nylon from carpet 62
6.6 Depolymerization of nylon 63
6.7 Melt processing 64
6.8 Use of waste fibers as reinforcement in polymer composites 65
6.9 Waste to energy conversion 66
6.10 Conclusions 67
6.11 References 67
Contents v
Part II Chemical aspects in textile recycling
7 Recycling waste water from textile production 73
R. SCHNEIDER, Institute for Textile Chemistry and Chemical Fibres,
Germany
7.1 Introduction 73
7.2 System analysis 73
7.3 Optimization of processes for water recycling 77
7.4 Direct re-use of waste water 83
7.5 Waste water treatments and water recycling with 85
membrane technology
7.6 Re-use of reclaimed/recycled water 88
7.7 Future trends 90
7.8 Sources of further information 91
7.9 References 92
8 Recycling and re-use of textile chemicals 95
G. BUSCHLE-DILLER, Auburn University, USA
8.1 Introduction 95
8.2 Fabric preparation processes 97
8.3 Dyeing and printing processes 101
8.4 Recycling of finishing compounds 107
8.5 Waste minimization at source 108
8.6 Conclusions 110
8.7 References 110
Part III Recycled textile products
9 Development of products made of 117
reclaimed fibres
B. GULICH, Saxon Textile Research Institute, Germany
9.1 Reclaimed fibres as raw materials 117
9.2 Characteristics of reclaimed fibres 118
9.3 Products and markets 119
9.4 Examples developed by the STFI 125
9.5 Other examples 133
9.6 Future trends 135
9.7 References 136
vi Contents
10 Manufacturing nonwovens and other products 137
using recycled fibers containing spandex
K. D. LANGLEY and Y. K. KIM, University of Massachusetts
Dartmouth, USA
10.1 Introduction 137
10.2 Spandex 137
10.3 Review of recycling 141
10.4 Evaluation and characterization of the remnant material 142
10.5 Fiber separation trial at recycling plant 143
10.6 Laboratory-scale processing of the recycled material 143
10.7 Chemical treatment of the raw material 145
10.8 Mechanical processing of the chemically treated samples 146
10.9 Types of nonwovens 148
10.10 Markets for needle-punched fabrics 149
10.11 Experiments in production of nonwoven samples 152
10.12 Flocking study 154
10.13 Oil absorption with fibrous waste 160
10.14 Conclusions 161
10.15 Acknowledgments 162
10.16 References 162
11 Textile products produced from alternative fibers 165
B. R. GEORGE, A. BOCKARIE and H. MCBRIDE,
Philadelphia University, USA, A. EVAZYNAJAD, Gudebrod
Inc., USA, N. BIEAK, Auburn University, USA
11.1 Introduction 165
11.2 Experimental procedures 168
11.3 Results and discussion 172
11.4 Conclusions 178
11.5 References 178
Part IV Applications of recycled textiles
12 Recycling of textiles used in the operating theatre 183
M. J. ABREU and M. E. SILVA, University of Minho,
Portugal, L. SCHACHER and D. ADOLPHE, Ecole Nationale
Supérieure des Industries Textiles de Mulhouse, France
12.1 Introduction 183
12.2 Directives 184
12.3 Standards 184
Contents vii
12.4 Products 185
12.5 Materials 187
12.6 Properties required 189
12.7 Market 193
12.8 Environmental aspects 195
12.9 Waste management 197
12.10 Future trends 200
12.11 Conclusions 200
12.12 References 201
12.13 Further reading 202
13 Composite products from post-consumer carpet 203
J. MUZZY, Georgia Institute of Technology, USA
13.1 Introduction 203
13.2 Separating carpet 203
13.3 Composites from sorted carpet 204
13.4 Wood fiber reinforced composites 207
13.5 Products from reinforced post-consumer carpet 209
13.6 Conclusions 212
13.7 Acknowledgements 212
13.8 References 212
14 Utilization of recycled carpet waste fibers for 213
reinforcement of concrete and soil
Y. WANG, Georgia Institute of Technology, USA
14.1 Introduction 213
14.2 Fiber reinforced concrete 214
14.3 Recycled fiber reinforced concrete 214
14.4 Fiber reinforced soil 218
14.5 Recycled fiber reinforced soil 220
14.6 Conclusions 222
14.7 References 223
Index 225

Contributor contact details
Chapters 1, 6 and 14 Chapter 4
Dr Youjiang Wang Dr Robert Peoples
School of Polymer, Textile and Fiber Director of Sustainability, The Carpet
Engineering and Rug Institute
Georgia Institute of Technology Executive Director, Carpet America
Atlanta Recovery Effort (CARE)
GA 30332-0295, USA 310 Holiday Av.
Dalton
E-mail:[email protected]
GA 30720
Fax: [phone]
USA
Chapter 2 E-mail: [email protected]
Dr Jana M Hawley
Department of Textile and Apparel
Chapter 5
Management
University of Missouri Dr Matthew Realff
Columbia, MO 65211, USA School of Chemical and Biomolecular
Engineering
E-mail: [email protected]
Georgia Institute of Technology
Atlanta
Chapters 3 and 9
GA 30332-0100
USA
Dipl Ing Bernd Gulich
Saxon Textile Research Institute
Tel: [phone]
Annaberger Strasse 240
Fax: [phone]
09125 Chemnitz, Germany
E-mail: [email protected]
Tel: [phone]
E-mail: [email protected]
Chapter 6 – see Chapter 1
Website: www.stfi.de
ix