Polyester with caustic material mixing methods and mixing reactors

1. A method for mixing a polyester with a caustic material, comprising:

providing a polyester;

drying the polyester;

mixing the dried polyester with the caustic material to form a mixture; and

heating the mixture in multiple temperature stages defined as a function of a reaction sequence of the reaction between the polyester and the caustic material,

wherein in a first of the temperature stages the polyester is heated to a temperature between 95° C. and 120° C., in a second of the temperature stages the polyester is heated to a temperature between 110° C. and 130° C., and in a third of the temperature stages the polyester is heated to a temperature between 120° C. and 140° C., and

wherein a reactor heats the mixture of the polyester and caustic material, the reactor including a twin shaft mixing screw for mixing of the mixture of polyester and caustic material, screw shafts that mesh with one another being used for the twin shaft mixing screw, at least one of the screw shafts having a sawtooth profile, and wherein the inner wall of the reactor is kept essentially free of adherences of the polyester.

2. The method of claim 1 ,

wherein prior to heating, the polyester is ground to a flake size ranging from about 0.005 m to about 0.01 m.

3. The method of claim 1 ,

wherein the reactor is preheated before the addition of the polyester to the reactor.

4. The method of claim 1 ,

wherein the time between the start and the end of the heating of the polyester ranges from 5 to 45 minutes.

5. The method of claim 1 ,

wherein the polyester stays in the heating step until the residual moisture is less than 3%.

6. The method of claim 1 ,

wherein the polyester stays in the heating step until more than 95% of the free caustic material.

7. The method of claim 1 ,

wherein the heating of the polyester is carried out in a reactor with a throughput of at least 2,000 kg/h.

8. The method of claim 1 ,

wherein in the respective stages a homogeneous temperature distribution of the temperature is set in the zones which are provided for the respective stages of the reactor which is used to carry out the method.

9. The method of claim 1 , wherein the screw shafts are provided with a screw pitch of about 100 mm and mesh with one another.

10. The method of claim 1 ,

wherein the polyester is heated for about ten minutes in the first stage, for about ten minutes in the second stage, and for about ten minutes in the third stage.

11. The method of claim 1 ,

wherein the polyester is heated to a temperature of about 110° C. in the first stage, to a temperature of about 120° C. in the second stage, and to a temperature of about 130° C. in the third stage.