Integrated process for treating recycled streams of pet and ptt

Abstract

A process for producing a polyester polyol comprising reacting a recycle stream selected from recycled PET carpet, carpet fiber, containers, textiles, articles or mixtures thereof, with a glycol in a reactor, thereby forming a digested product stream comprising polyols, and an undigested stream; and then reacting the digested product stream with a hydrophobe selected from dimer fatty acids, trimer fatty acids, oleic acid, ricinoleic acid, tung oil, corn oil, canola oil, soybean oil, sunflower oil, bacterial oil, yeast oil, algae oil, castor oil, triglycerides or alkyl carboxylate esters having saturated or unsaturated C 6 -C 36 fatty acid units, saturated or unsaturated C 6 -C 36 fatty acids, alkoxylated castor oil, saturated or unsaturated C 9 -C 18 dicarboxylic acids or diols, cardanol-based products, recycled cooking oil, branched or linear C 6 -C 36 fatty alcohols, hydroxy-functional materials derived from epoxidized, ozonized, or hydroformylated fatty esters or acids, or mixtures thereof.

We claim: 
     
         1 - 14 . (canceled) 
     
     
         15 . A process comprising:
 (a) reacting a recycle stream selected from recycled PET carpet, PET carpet fiber, recycled PET textiles, bales of PET containers or mixtures thereof; with a glycol in a reactor, thereby forming a completely digested product stream comprising polyols, and at least one undigested stream comprising undigested materials selected from polyolefins, dyes, or inorganic fillers;   (b) separating the at least one undigested stream from the completely digested product, thereby forming a separated digested product stream; and   (c) reacting the separated digested product stream in the reactor with a hydrophobe selected from oleic acid, ricinoleic acid, tung oil, corn oil, canola oil, soybean oil, sunflower oil, bacterial oil, yeast oil, alge oil, castor oil, triglycerides or alkyl carboxylate esters having saturated or unsaturated C 6 -C 36  fatty acid units, saturated or unsaturated C 6 -C 36  fatty acids, alkoxylated castor oil, saturated or unsaturated C 9 -C 18  dicarobxylic acids or diols, cardanol-based products, recycled cooking oil, branched or linear C 6 -C 36  fatty alcohols, hydroxy-functional materials derived from epoxidized, ozonized or hydroformylated fatty esters or acids, or mixtures thereof, thereby forming a polyester polyol.   
     
     
         16 . The process of  claim 15  wherein the polyester polyol has a hydroxyl number of 25 to 800 mg KOH/g. 
     
     
         17 - 68 . (canceled) 
     
     
         69 . The process of  claim 15  wherein the recycle stream further comprises at least one of recycled PET carpet, PTT carpet and PET textiles. 
     
     
         70 - 84 . (canceled)