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Polymerization Technologies

GTC can offer polymerization technologies for producing commodities and differentiated specialties.  These technologies can also be utilized to upgrade or revamp existing lines including: covers textile grade, bottle grade, and industrial yarn grade applications. 

   Continuous Polymerization:

 
    GTC can provide state-of-the-art Continuous Polymerization (CP) technology.  This    
    technology has an innovative and enhanced 3-reactor process, surpassing all other
    technologies currently available.  Applications include:
  • Regular and various specialty products of textile grade, bottle grade, and industrial grade
  • Small to medium scale CP lines for simultaneous production
  • Low cost polymer production
    Technical Features:
  • State-of-the-art, compact design with 3 major patented proprietary reactors (DCER, MTPR, HFPR)
  • Low temperature operation and gentle process for superior quality
  • No agitators in Esterification Reactor and Pre-polymerizer
  • No transfer pumps needed from esterification reactor to pre-polymerizer and from pre-polymerizer to final polymerizer
  • Optional additive/catalyst injection point design for simultaneous production 
  • Low operation cost due to decreased energy consumption, maintenance, and man-power
    Process Capacity:
  • Textile Grade: 150 to 900 ton/day, for super-bright, semi-dull, and full-dull (common Esterification Reactor with multiple CP lines can be adopted for different product types).
  • Bottle Grade: 360 to 750 ton/day (single line) for homo-polymer, co-polymer
  • Industrial Yarn Grade: 100 to 300 ton/day
 

  Solid State Polymerization - For Industrial Yarn Grade:

 
   GTC can offer the most cost effective and efficiently designed Solid State Polymerization (SSP)
   technology specially designed for polyester industrial yarn grade.
 
   Capacity
  • One step process: 10,000 t/y to 25,000 t/y
  • Two step process: 30,000 t/y to 40,000 t/y
   Technical Features
  • Increases the IV up to 1.05
  • Broad operating capacity with high turn-down ratio
  • One or two-step process depending on product type and capacity
   Typical Feed Stock Properties
 

Items

Parameters
Viscosity (h)

0.64 ± 0.012
Melting Points (°C)

260 ± 2
End Carboxyl Group (mol/t)

< 30
Particles (numbers per mg)

< 0.4
Moisture Content (wt%)

< 0.4
Ash Content (wt%)

< 0.02
Chip Size (mm)

2.5 x 2.5 x 3.0
TiO2 Content (wt%)

0
 

   SSP Chip Properties
 

Items

Parameters
Viscosity (h)

1.00˜ 1.05 ± 0.012
Melting Points (°C)

260 ± 2
End Carboxyl Group (mol/t)

< 16
Moisture Content (ppm)

< 30

  Differentiated Polymers

  • TES process (low IV polymer conjugate spinning)
    • TES can be adopted as the side stream of the main CP line by reacting the pre-polymer and the polymer at the pre-fixed ratio
    • IV: range between 0.46 to 0.52
  • LMP process (low melting point polymer for conjugate spinning)
    • Melting point: range between 110°C to 125°C
  • Alkali soluble polymer process (super micro denier filament)
  • Coil-coating polyester resin process
  • Master batch injection system and TLI

Spinning / Downstream Processing Technologies

GTC can offer spinning/downstream processing technologies covering high value added textile grade and industrial yarn grade applications. 
 

  Super-Micro Denier Filament

 
   GTC can offer improved super-micro denier filament including chip drying, chip extrusion,    
   spinning, and winding.
 
   Applications include:
  • Light-weight luxury clothing including natural suede
  • Utilization in facial cleansers
  • Traditional micro denier filament

  Special Conjugate Fiber

 
   LMP Conjugate Fiber:
   GTC can offer sheath-core type conjugate fiber, co-spun with LMP (Low Melting-Point
   Polyester).  The technology includes sheath-core conjugate fiber production processes
   starting from chip drying, chip extrusion, co-spinning, drawing, crimping, cutting, and baling.
 
   SBS Conjugate Fiber:
   GTC can offer spiral crimped hollow conjugate fiber which is made by co-spinning the low IV
   polyester side-by-side with regular polyester, allowing for high bulkiness per unit volume.  This
   offering also includes the side-by-side conjugate fiber production process including: direct co-
   spinning, drawing, annealing, gear pulling, cutting, and bailing.  The main applications include
   weather protective clothing and fiber fill for stuffed toys.
 

  Industrial Yarn Spinning

 
   GTC can offer an optimized design on industrial yarn spinning technology resulting in higher
   efficiency and lower energy consumption.  The main applications include automotive,
   recreational, and construction.