Possibility Routes for Textile Recycling Technology

The Current State-of-the-Art of the Processes Involved in the Chemical Recycling of Textile Waste

The textile industry's rapid growth and reliance on synthetic fibres have generated significant environmental pollution, highlighting the urgent need for sustainable waste management practices. Chemical recycling offers a promising pathway to reduce textile waste by converting used fibres into valuable raw materials, yet technical challenges remain due to the complex compositions of textile waste, such as dyes, additives, and blended fabrics.

Sustainable Production of Microcrystalline and Nanocrystalline Cellulose from Textile Waste Using HCl and NaOH/Urea Treatment

Bio-nanomaterials are gaining increasing attention due to their renewable and eco-friendly characteristics. Among these, nanocrystalline cellulose (NCC) stands out as one of the most advanced materials for applications in food, healthcare, composite production, and beyond. In this study, NCC was successfully extracted from cotton-based textile waste using a combination of chemical and mechanical methods. The cellulose fibers were first hydrolyzed using a dilute HCl solution, neutralized, and then dried, resulting in microcrystalline cellulose (MCC) with diameters ranging from 7 to 15 µm and lengths up to 300 µm (as observed via optical microscopy and scanning electron microscopy, SEM). To achieve nanoscale dimensions, NaOH/urea solution with mechanical treatment was applied, resulting in the successful extraction of NCC in the supernatant, particularly under room-temperature conditions. Dynamic light scattering (DLS) analysis confirmed the presence of nanostructures (average sizes ranging from 120 nm to 750 nm), and atomic force microscopy (AFM) analysis verified the nanoscale range (diameters between 2 and 4 nm and lengths from 200 nm to 1 µm). Fourier transform infrared (FTIR) spectroscopy revealed the conversion of cellulose I to cellulose II, confirming the successful transformation into NCC. For the first time, NCC was obtained from undyed cotton textile wastes using NaOH/urea treatment after HCl hydrolysis, eliminating the need for pre-treatment and intermediate steps.

Textile Recycling: Efficient Polyester Recovery from Polycotton Blends Using the Heated High-Ethanol Alkaline Aqueous Process

Textile production has doubled in the last 20 years, but only 1% is recycled into new fibers. It is the third largest contributor to water pollution and land use, accounting for 10% of global carbon emissions and 20% of clean water pollution. A key challenge in textile recycling is blended yarns, such as polycotton blends, which consist of polyester and cotton. Chemical recycling offers a solution, in particular, alkali treatment, which hydrolyzes polyester (PET) into its components while preserving cotton fibers. However, conventional methods require high temperatures, long durations, or catalysts. Our study presents, for the first time, the heated high-ethanol alkaline aqueous (HHeAA) process that efficiently hydrolyzes PET from polycotton at lower temperatures and without a catalyst. A near-complete PET hydrolysis was achieved in 20 min at 90 °C, while similar results were obtained at 70 °C and 80 °C with longer reaction times. The process was successfully scaled at 90 °C for 20 min, and complete PET hydrolysis was achieved, with a significantly reduced liquid-to-solid ratio, from 40 to 7 (L per kg), signifying its potential to be implemented in an industrial context. Additionally, the cotton maintained most of its properties after the treatment. This method provides a more sustainable and efficient approach to polycotton recycling.

Assessment of the effects of the use of preconsumer cotton waste on the quality of rotor yarns

Due to the shortage of raw fiber materials and stricter legislative conditions, it has become necessary to process even the more contaminated fiber wastes that contain only a small amount of useable fibers. Hence, this paper investigates the impact of different cleaning channels on the Rieter R37 rotor spinning machine in controlling spinning strategy and yarn quality using recovered blowroom cotton waste fibers. The study involves spinning 98-tex yarns with different cleaning channels during the spinning process, using recovered blowroom cotton waste in blends with virgin cotton processed into slivers by two methods. Qualitative indicators in the fiber-sliver-yarn line were evaluated and graphically compared. The statistical significance of the influencing factors was determined using the Generalized Anova. Additionally, the quality of the experimental samples was compared to authentic data from global production using the USTER® STATISTIC. The results underline the significant influence of fiber quality, sliver preparation method and implemented cleaning channels on the arrangement of fibers in yarn structures as evidenced by structural and mechanical parameters. In particular, the comparison with USTER® STATISTICS confirms that all yarns meet the required quality standards for selected applications, including those spun exclusively from 100 % cotton waste. Furthermore, the results demonstrate that this innovative technology enables yarn manufacturers to meet customer demands, ensure optimal yarn quality and achieve cost savings by optimizing waste removal without compromising fiber yield.

Transforming textile waste into nanocellulose for a circular future

The expansion of the textile industry and improvements in living standards have led to increased cotton textile production, resulting in a rise in textile waste, with cotton accounting for 24% of total textile waste. Effective waste management through recycling and reuse is crucial to reducing global waste production. Nanocellulose has diverse applications in environmental, geotechnical, food packaging, and biomedical engineering areas. As interest in nanocellulose's unique properties grows, cotton-based textile waste emerges as a promising source for nanocellulose development. However, there is a notable lack of comprehensive reviews on the extraction of nanocellulose from textile waste as a sustainable biomaterial. This paper aims to address this gap by exploring current extraction processes, properties, and recent applications of nanocellulose derived from textile waste. We discussed (1) the potential of nanocellulose resources from different textile wastes, (2) a comparison of the various extraction methods, (3) the functionalization technology and the potential application of such nanocellulose in the textile industry, and (4) the life cycle assessment (LCA) and potential gap of the current technology. It also emphasizes the potential reintegration of extracted nanocellulose into the textile industry to manufacture high-value products, thus completing the loop and strengthening the circular economy.

Qualitative classification of waste garments for textile recycling based on machine vision and attention mechanisms

The increasing volume of garment waste underscores the need for advanced sorting and recycling strategies. As a critical procedure in the secondary usage of waste clothes, qualitative classification of garments categorizes post-consumer clothes based on types and styles. However, this process currently relies on manual labor, which is inefficient, labor-intensive, and poses risks to workers. Despite efforts to implement automatic clothes classification systems, challenges persist due to visual complexities such as similar colors, deformations, and occlusions. In response to these challenges, this study introduces an enhanced intelligent machine vision system with attention mechanisms designed to automate the laborious and skill-demanding task of garment classification. Initially, a waste garment dataset comprising approximately 27,000 garments was curated using a self-developed automatic classification platform. Subsequently, the proposed attention method parameters were selected, and a series of benchmarks were conducted against state-of-the-art methods. Finally, the proposed system underwent a two-week online deployment to evaluate its running stability and sensitivity to similar colors, deformation, and occlusion in industrial production settings. The benchmarks indicate that the proposed method significantly improves classification accuracy across various models. The visualization interpretation of Grad-CAM reveals that the proposed method effectively handles complex environments by directing its focus toward garment-related pixels. Notably, the proposed system elevates classification accuracy from 68.28 % to human-level performance (>90 %) while ensuring greater running stability. This advancement holds promise for automating the classification process and potentially alleviating workers from labor-intensive and hazardous tasks associated with clothes recycling.

Advances in regenerated cellulosic aerogel from waste cotton textile for emerging multidimensional applications

Rapid development of society and the improvement of people's living standards have stimulated people's keen interest in fashion clothing. This trend has led to the acceleration of new product innovation and the shortening of the lifespan for cotton fabrics, which has resulting in the accumulation of waste cotton textiles. Although cotton fibers can be degraded naturally, direct disposal not only causes a serious resource waste, but also brings serious environmental problems. Hence, it is significant to explore a cleaner and greener waste textile treatment method in the context of green and sustainable development. To realize the high-value utilization of cellulose II aerogel derived from waste cotton products, great efforts have been made and considerable progress has been achieved in the past few decades. However, few reviews systematically summarize the research progress and future challenges of preparing high-value-added regenerated cellulose aerogels via dissolving cotton and other cellulose wastes. Therefore, this article reviews the regenerated cellulose aerogels obtained through solvent methods, summarizes their structure, preparation strategies and application, aimed to promote the development of the waste textile industry and contributed to the realization of carbon neutrality.

Internal water circulation mediated synergistic co-hydrolysis of PET/cotton textile blends in gamma-valerolactone

Recycling strategies for mixed plastics and textile blends currently aim for recycling only one of the components. Here, we demonstrate a water coupling strategy to co-hydrolyze polyester/cotton textile blends into polymer monomers and platform chemicals in gamma-valerolactone. The blends display a proclivity for achieving an augmented 5-hydroxymethylfurfural yield relative to the degradation of cotton alone. Controlled experiments and preliminary mechanistic studies underscore that the primary driver behind this heightened conversion rate lies in the internal water circulation. The swelling and dissolving effect of gamma-valerolactone on polyester enables a fast hydrolysis of polyester at much lower concentration of acid than the one in the traditional hydrolysis methods, effectively mitigating the excessive degradation of cotton-derived product and undesirable product formation. In addition, the system is also applicable to different kinds of blends and PET mixed plastics. This strategy develops an attractive path for managing end-of-life textiles in a sustainable and efficient way.

Recycled PET/PA6 Fibers from Waste Textile with Improved Hydrophilicity by In-Situ Reaction-Induced Capacity Enhancement

Due to the increasing amounts of textile waste, textile to textile recycling is of prime concern. Polyethylene terephthalate (PET) represents the most extensively used type of chemical fiber. Its spinnability suffers from impurities and degradation in the processing, which limits its recycling to new fibers. Here, recycled polyester is blended with a small amount of recycled nylon, and the regenerated fibers, which demonstrated good mechanical properties, were obtained via a melt spinning machine. The mechanical properties, thermal properties, rheological properties, and chemical structure of the modified recycled fibers were investigated. It was found that when compared with rPET-T fibers, the elongation at break of rPET-Ax fibers increased to 17.48%, and the strength at break decreased to 3.79 cN/dtex. The compatibility of PET and PA6 copolymer were enhanced by copolymers produced by in-situ reaction in the processing. Meanwhile, the existence of PA6 increases the crystallization temperature and improves the hydrophilicity of the fibers. This study realized the high-value recycling of waste PET fabric to new fibers, which opens a door for the large utilization of waste textiles.

High-Quality Cellulosic Fibers Engineered from Cotton-Elastane Textile Waste

Even small amounts of elastane in cotton-elastane blended textiles can prevent fiber-to-fiber recycling strategies in textile recycling. Herein, the selective separation of elastane from cotton blends was addressed by the aminolytic degradation of the synthetic component. Polar aprotic solvents were tested as elastane solvents, but side reactions impeded aminolysis with some of them. Aminolysis of elastane succeeded under mild conditions using dimethyl sulfoxide in combination with diethylenetriamine and 1,5-diazabicyclo[4.3.0]non-5-ene as a cleaving agent and catalyst, respectively. The analysis of the nitrogen content in the recovered cellulose fraction demonstrated that 2 h of reaction at 80 °C reduced the elastane content to values lower than 0.08%. The characterization of the recovered cellulose showed that the applied conditions did not affect the macromolecular properties of cellulose and maintained a cellulose I crystal structure. Degraded elastane products were recovered through precipitation with water. Finally, the cellulosic component was turned into new fibers by dry-jet wet spinning with excellent tensile properties.

Environmental sustainability assessment of a polyester T-shirt - Comparison of circularity strategies

The considerable environmental burden of textiles is currently globally recognized. This burden can be mitigated by applying circular economy (CE) strategies to the commonly linear, short garment life cycles that end with incineration or landfill disposal. Even though all CE strategies strive to promote environmental sustainability, they might not be equally beneficial. Environmental data on different textile products is insufficiently available, which leads to complications when assessing and deciding on different CE strategies to be implemented. This paper studies the environmental impacts of a polyester T-shirt's linear life cycle through life cycle assessment (LCA) and evaluates the benefits attainable by adopting different CE strategies, and their order of priority, while noting uncertainty arising from poor data quality or unavailability. The LCA is complemented by assessing health and environmental risks related to the different options. Most of the linear life cycle's LCA-based impacts arise from use-phase washing. Hence, it is possible to reduce the environmental impact notably (37 %) by reducing the washing frequency. Adopting a CE strategy in which the shirt is reused by a second consumer, to double the number of uses, enables an 18 % impact reduction. Repurposing recycled materials to produce the T-shirt and recycling the T-shirt material itself emerged as the least impactful CE strategies. From the risk perspective, reusing the garment is the most efficient way to reduce environmental and health risks while washing frequency has a very limited effect. Combining different CE strategies offers the greatest potential for reducing both environmental impacts as well as risks. Data gaps and assumptions related to the use phase cause the highest uncertainty in the LCA results. To gain the maximum environmental benefits of utilizing CE strategies on polyester garments, consumer actions, design solutions, and transparent data sharing are needed.

Chemical recycling of waste clothes: a smarter approach to sustainable development

Amount of fabric waste has increased many folds in the past few years due to increasing population and rapidly changing fashiosn trends. Its larger portion being dumped in the landfills is creating a lot of problem in its management. This is causing problems to environmental components of earth, viz., air, water, and land. Chemically, cotton-based fabrics are made up of mainly cellulose with small components of other chemicals and contribute to a big segment of overall textiles. Along with donating the cloths for various purposes, scientific solutions are also feasible for valorizing waste fabrics to value-added products. This review article focuses on important strategies for addressing fabric waste for their possible conversion to significant products of varied applications. It emphasizes on chemical routes suitable for this purpose for producing cellulose, sugar, composites, etc. This will provide an insight to the readers for understanding the chemical significance of waste fabric and exploring the best possible ways for its efficient management, ensuring a step ahead towards sustainable development.

Post-consumer textile thermochemical recycling to fuels and biocarbon: A critical review

This study aims to look at waste-to-energy (tertiary recycling) of post-consumer textile waste, based on a literature review. Because textiles are mostly made of cotton and polyester, which are carbon and energy sources, they can potentially be converted thermochemically into fuels and biocarbon. The critical parameters determining thermal recycling are summarized and discussed with a focus on pyrolysis, gasification, and torrefaction. For cotton and polyester mixtures, torrefaction presents a low environmental impact and an energy-dense fuel that can be used in cogeneration systems, reducing the energy requirements of these processes by 50-85%. Catalytic pyrolysis of cotton textile waste yields to a high conversion (90 wt%), a liquid fuel of high yields (35-65 wt%), and biocarbon (10-18 wt%), providing carbon and energy closure loops. However, pyrolysis is energy-intensive (T > 500 °C) and produces hazardous chemicals from the conversion of PET, nylon, and polyacrylonitrile. Gasification can handle many types of textile waste, but it needs continuous monitoring of the emissions. More research is needed to overcome existing limitations, LCA and sustainability assessment are required for the thermal recycling processes in order to estimate their future-proofing and sustainability. For the transition to a circular economy, consumers' awareness of resources limits and sustainable use is pivotal to change purchasing behavior and achieve a recycling thinking.

Current Prospects for Plastic Waste Treatment

The excessive amount of global plastic produced over the past century, together with poor waste management, has raised concerns about environmental sustainability. Plastic recycling has become a practical approach for diminishing plastic waste and maintaining sustainability among plastic waste management methods. Chemical and mechanical recycling are the typical approaches to recycling plastic waste, with a simple process, low cost, environmentally friendly process, and potential profitability. Several plastic materials, such as polypropylene, polystyrene, polyvinyl chloride, high-density polyethylene, low-density polyethylene, and polyurethanes, can be recycled with chemical and mechanical recycling approaches. Nevertheless, due to plastic waste’s varying physical and chemical properties, plastic waste separation becomes a challenge. Hence, a reliable and effective plastic waste separation technology is critical for increasing plastic waste’s value and recycling rate. Integrating recycling and plastic waste separation technologies would be an efficient method for reducing the accumulation of environmental contaminants produced by plastic waste, especially in industrial uses. This review addresses recent advances in plastic waste recycling technology, mainly with chemical recycling. The article also discusses the current recycling technology for various plastic materials.

Recycled Poly(Ethylene Terephthalate) from Waste Textiles with Improved Thermal and Rheological Properties by Chain Extension

Annual production of textile fibers is continuing to rise and the substantial discharge of undegradable waste polyester fibers can cause serious environmental and even health problems. Thus, the recycling and reuse of recycled poly(ethylene terephthalate) from waste textiles (rPET-F) is highly desirable but still challenging. Here, five chain extenders with a different number of epoxy groups per molecules were used to blend with discarded PET fibers and improve its viscosity and quality loss in the recycling process. The molecule weight, thermal properties, rheological properties and macromolecular architecture of modified r-PET were investigated. It was found that all modified rPET-F samples show higher viscosities and better thermal properties. rPET-F modified by difunctional EXOP molecules show linear structure and improved rheological properties. rPET-F modified by polyfunctional commercial ADR and synthesized copolymers exhibit a long chain branched structure and better crystallization. This study reveals a deeper understanding of the chain extension and opens an avenue for the recycling of PET textiles.

Reuse of Textile Waste to Production of the Fibrous Antibacterial Membrane with Filtration Potential

Wasted synthetic fabrics are a type of textile waste source; the reuse of them brings environmental protection and turns waste into a valuable material. In this work, the used nylon (polyamide) stockings were transmuted into a fine fibrous membrane via an electrospinning process. In addition, the safety antibacterial agent, monoacylglycerol (MAG), was incorporated into a recycled fibrous membrane. The results revealed that the neat, recycled polyamide (rPA) fibers with a hydrophobic surface could be converted into hydrophilic fibers by blending various amounts of MAG with rPA solution prior to electrospinning. The filtration efficiency and air/water vapor permeability of the two types of produced membranes, neat rPA, and rPA/MAG, were tested. Their filtration efficiency (E100) was more than 92% and 96%, respectively. The membranes were classified according to Standard EN1822, and therefore, the membranes rPA and rPA/MAG were assigned to the classes E10 and E11, respectively. The air permeability was not affected by the addition of MAG, and water vapor permeability was slightly enhanced. Based on the obtained data, prepared rPA/MAG fibrous membranes can be evaluated as antifouling against both tested bacterial strains and antimicrobial against S. aureus.