Mild and efficient stripping of blended cotton-polyester fabrics based on an extended acetolysis system

Abstract The acetolysis technology for waste polyester fibers is characterized by simplicity, efficiency, and cost-effectiveness. However, challenges emerge when processing polyester-cotton blends, as the cotton component cannot endure more aggressive chemical conditions due to its distinct chemical properties. To overcome this, we now employ the concept of "acetylation" for a mild cotton-stripping pretreatment. During acetylation, the cotton component gradually dissolves in the acetic acid solution, forming a homogeneous solution, while the polyester fiber remains in solid form, thereby ensuring efficient separation (removal rate exceeding 90%). The entire process utilizes inexpensive bulk chemicals and is straightforward to operate. Given the similarity in the solvent system, this approach is termed the extended acetolysis system. Comprehensive techno-economic analysis and life cycle assessment indicate that, even when benchmarked against petroleum-based pricing, the extended acetolysis system can achieve economic viability alongside appreciable environmental benefits.