CN103619553A - 回收塑料产品的方法及其应用 - Google Patents

回收塑料产品的方法及其应用 Download PDF

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CN103619553A
CN103619553A CN201280030727.3A CN201280030727A CN103619553A CN 103619553 A CN103619553 A CN 103619553A CN 201280030727 A CN201280030727 A CN 201280030727A CN 103619553 A CN103619553 A CN 103619553A
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plastic
discarded object
plastics
waste
refuse
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纳塔拉森·塞瑟
钱德拉谢卡尔·拉姆钱德拉·阿比安卡尔
姆里纳尔·坎蒂·班纳吉
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Essel Propack Ltd
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Essel Propack Ltd
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B29B17/0042—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
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Abstract

本发明涉及用于回收塑料废弃物的方法，包括：将从不同来源收集的塑料废弃物分离，随后清洗分离的塑料废弃物以获得分离的清洁废弃物；研磨分离的清洁废弃物以获得磨碎的废弃物；将磨碎的废弃物引入挤出生产线以获得熔化的塑料，所述挤出生产线具有通气式挤出机组件作为其一部分；以及通过将熔化的塑料真空通气将杂质移除以获得无杂质的回收塑料。本发明进一步涉及由回收的塑料废弃物制成的多种物品，诸如工业化后回收的（IPR）塑料管、吹塑瓶和托盘。

Description

回收塑料产品的方法及其应用
技术领域
本发明涉及用于回收塑料废弃物的方法，通过所述方法可将无用的塑料废弃物转化成有用的资源。本发明进一步涉及这类回收塑料的应用。
背景技术
由于使用塑料管包装的产品数量持续增加，管包装工业迅速地加快发展。塑料是从石油资源得到的并且通常是不可生物降解的。对塑料管的前所未有的使用使其成为来自工业以及消费者的固体的、非环境友好的废弃物的主要成分。大部分工业化后的或消费者使用后的塑料管废弃物送到垃圾填埋场，这增加了严重的环境问题，如土地、水和空气污染。此外，工业化后塑料废弃物的处置费用给管加工商/制造商造成额外负担。
用于挤出回收塑料材料的传统方法包含许多重要的和昂贵的预处理步骤，诸如分离和珠粒化（beading）。当挤出方法及其产品回收材料的质量不如新料时，这些方法的商业可行性受到挑战。由于在工业化后或消费者使用后的塑料管中存在污染物和杂质，诸如印刷残余物、清漆、颜料、不同材料组分、遗漏的内含物和水分等，目前回收方法面临在挤出生产线上的材料非均匀流动的问题。
美国专利号5,780,696公开了一种回收塑料废弃物，特别是富含聚氯乙烯（PVC）塑料的废弃物的方法，这使得能够回收利用最大量的可重复使用的产品。这种方法将大量塑料转化成具有低氯含量的固体产品。美国专利申请号US2007/0149625A1公开了用于回收在市政固体废弃物中找到的废弃塑料的方法和设备。它还公开了通过将共同的介电性能提供给塑料材料并使用微波能处理塑料材料来回收塑料材料的方法。
需要开发一种处理技术以去除挥发性和非挥发性污染物，这可以由回收的塑料提供高品质的塑料材料并可用作新料的替代物。改进的回收方法可以减少/再利用废弃物，可以是经济的、节能的，减少碳排放、有助于环境保护，并且可提供具有高技术特性的新的终端产品。
鉴于上述问题以及社会环保意识，加工商有机会和动机采用新的绿色技术来减少和再利用废弃物。针对该需要提出本发明主题。
发明内容
本发明涉及回收塑料废弃物的方法。
在本发明的一个方面，提供了用于回收塑料废弃物的过程的方法，包括：将从不同来源收集的塑料废弃物分离，随后清洗分离的塑料废弃物以获得分离的清洁废弃物；研磨分离的清洁废弃物以获得磨碎的废弃物；将磨碎的废弃物引入挤出生产线中以获得熔化的塑料，所述挤出生产线具有通气式挤出机组件作为其一部分；以及通过将熔化的塑料真空通气将杂质移除以获得无杂质的回收塑料。
本发明进一步涉及由回收的塑料废弃物制成物品，诸如工业化后回收的（Industrial Post Recycled）（IPR）塑料管、吹塑瓶和托盘（pallates）。
参照以下描述将更好地理解本发明主题的这些及其他特征、方面和优点。提供该说明以便以简化形式引入构思的选择。该说明并不旨在确定本发明主题的关键特征或必要特征，也并不旨在用于限制本发明主题的范围。
附图说明
参照以下描述、所附权利要求和附图将更好地理解本发明主题的以上及其他的特征、方面和优点，其中：
图1显示了根据本发明主题的一个实施方式，用于回收塑料废料以获得回收塑料材料的方法。
具体实施方式
本发明提供了用于从废物来源（诸如加工商、制造商或消费者）回收塑料废弃物的方法。
一方面，本发明的一个实施方式提供了用于回收塑料废弃物的方法，包括：将从不同来源收集的塑料废弃物分离，随后清洗分离的塑料废弃物以获得分离的清洁废弃物；研磨分离的清洁废弃物以获得磨碎的废弃物；将磨碎的废弃物引入挤出生产线中以获得熔化的塑料，所述挤出生产线具有通气式挤出机组件作为其一部分；以及通过将熔化的塑料真空通气将杂质移除以获得无杂质的回收塑料。
在一个实施方式中，本发明提供了用于回收塑料废弃物的方法，包括：将从不同来源收集的塑料废弃物分离，随后清洗分离的塑料废弃物以获得分离的清洁废弃物；研磨分离的清洁废弃物以获得磨碎的废弃物；将磨碎的废弃物引入挤出生产线中以获得熔化的塑料，所述挤出生产线具有通气式挤出机组件作为其一部分；通过将熔化的塑料真空通气将杂质移除以获得无杂质的回收塑料；获得无杂质的回收塑料作为具有均匀直径的熔化的塑料的长空心线束；以及将线束冷却并切成回收塑料材料的球粒形式。
在另一个实施方式中，用于本发明的回收方法的塑料废弃物是从选自运行塑料管道作业（running plastic tubing operation）、工业化使用后的塑料或消费者使用后的塑料的来源中收集的。
工业化后的塑料废弃物需要回收源自原始设备制造商、加工商和装配商（assemblers）的塑料废弃物。
塑料废弃物可变地包含树脂，诸如聚对苯二甲酸乙二酯（PET）、高密度聚乙烯（HDPE）、聚氯乙烯（PVC）；低密度聚乙烯（LDPE）、聚丙烯（PP）或聚苯乙烯（PS）。
回收方法包括对塑料废弃物进行识别并且将其分成相似性质或类型的组，包括但不限于线性低密度聚合物、低密度聚合物或高密度聚合物种类。废弃物可进一步细分为素色管、彩色管、印刷管、非印刷管、烫金管（foil stamped tube）；盖外壳，金属化聚丙烯废弃物；肩台；挤出管废弃物；团块；和吹洗的材料废弃物等。根据塑料的最终用途的类型、颜色、印刷的类型和使用油墨的类型、使用的聚合物类型等，这种分离还可有多个亚组。对特定类型聚合物适合的回收方法进行选择以得到更好的回收结果。将分离的废弃物分别装袋和标记。
进一步地，将分离的塑料废弃物分别清洗。通过洗涤方法的组合来进行废弃塑料的清洗。一种类型的清洗是通过将废弃物倾入具有塑料废弃物的水槽中并在一段时间之后提出，在槽中留下硬杂质诸如泥土而完成。另外本发明的一个实施方式，清洗分离的塑料废弃物是通过用水和含约2%氢氧化钠的水多次清洗来完成。这有助于将来自收集的塑料废弃物的粘性材料松脱和去除。此外，将塑料废弃物保持在流水下这可以清除塑料废弃物中残留的杂质。然后将材料通过任何常规方法（诸如阴干）或其他非常规方法（诸如电吹风机）进行干燥。
在将塑料废弃物清洗之后，通过通常已知的方法将其尺寸减小/研磨。在一个实施方式中，研磨分离的洁净废弃物是使用废料粉碎机、凝聚器、撕裂机、制粒机完成的。废料粉碎机用来切碎和粉碎塑料废弃物中的坚硬材料诸如肩台、盖和封闭物废弃物作为早期分离，而凝聚器用来切碎塑料废弃物的套筒部分。凝聚法是非加热布置，因此使热降解损害降至最低，其中，塑料废弃物只被摩擦热加热而没有额外的热量提供给系统。用旋转西格玛刀片切割塑料材料并收集在托盘中。如果在输出中存在团块则将它们再次送去凝聚。获得塑料废弃物的细小珠粒作为这种方法的输出。
随后使材料进入挤出生产线，其中球粒形式的塑料废弃物通过进料漏斗进入并与旋转螺杆接触。挤出生产线添加有通气式挤出机组件，通过其将含有杂质的熔化的塑料真空通气。这种方法除去杂质并产生品质改进的塑料聚合物，其可进一步按需求处理。桶内的旋转螺杆迫使塑料废弃物珠粒进一步进入桶中，其被加热至塑料的期望的熔化温度。塑料珠粒逐渐地熔化。通过桶内的压力和摩擦还产生了一些额外的热量。通气式挤出机是一种具有沿着桶的开口部分通道（用于从塑料材料中去除空气和易挥发物质）的二级螺杆挤出机。在挤出机桶中通气式挤出机装配有一个或多个开口（通气口），挥发物可通过其逸出。因此，通气式挤出机能够以连续方式从聚合物中提取挥发物。
简单的塑料挤出螺杆具有不同的区域如：将树脂进料到具有相同螺槽深度的挤出机中的进料区或输送机；其中大部分树脂被熔化且螺槽深度变得越来越小的熔化区或压缩机；使用相同螺槽深度将残余颗粒熔化并混合成均匀温度和组成的计量区。
在任何阶段塑料废弃物的熔化的塑料的任何不规则流动将在最终产物中在某些点产生具有不希望的应变的产物。这些应变可导致冷却时的扭曲。扭曲可使输出的塑料的形状、颜色或质量变形。因此，要求熔化的塑料应没有任何扭曲。本发明的一个实施方式，挤出生产线包括通气式挤出机组件，优选透明的通气式挤出机，通过它可将熔融的含杂质塑料真空通气，从而减轻压力并允许通过真空抽出任何捕获的气体（通常是湿气或空气）。这种方法除去所有挥发性杂质并产生品质改进的塑料聚合物，其可进一步按需求处理。来自通气螺杆的输出具有最小的水分水平，而且也没有污染物诸如油墨和清漆。否则非通气的输出包含气体部分并且阻塞引发输送机的问题。
本发明进一步涉及从流动通过挤出生产线的熔化的塑料中去除不希望的污染物/杂质的方法，其中在真空中排出这些污染物（包括挥发性物质）。
将熔化的塑料送到用于产生桶内背压的自动滤网转换包装组件；塑料废弃物的均匀熔化和正确混合都需要背压。自动滤网安装在挤出机的末端法兰和模具之间。自动滤网移动穿过熔化的塑料流并且单废滤网离开时使新的滤网进入以从挤出物中移除杂质。使获得的纯化的熔化塑料进入模具，其可以产生所需产物的所需形状。
在一个实施方式中，获得具有均匀直径的熔化塑料的长空心线束然后通常用水浴将其冷却。将线束切成所需尺寸的球粒并通过振动器将其分离。将尺寸受控的球粒收集起来并以颗粒形式装袋。
在又一实施方式中，测试球粒颗粒的拉伸强度、伸长特性、颜色深浅、油墨可接受性和其他特性。
本发明主题的另一实施方式进一步提供了由本发明主题的回收塑料聚合物球粒颗粒制造的物品。高质量的回收球粒颗粒用于制造具有比传统回收管质量改进的塑料管。制成的塑料管可应用于多种管包装应用，如鞋油、油应用、洗手用品、洗脸用品等。
用于回收塑料废弃物的方法有助于环境保护，是生态友好的并减少碳排放。
本发明进一步提供了基于选择的编码/识别系统，将工业化后和消费后的塑料管分组的简单且经济的方法。本发明可用来纯化可在挤出机操作环境中方便地工作的多种聚合物。如所述，所公开的方法特别适于从工业化使用后的废料中重新获得回收的纯化塑料。
在一个实施方式中，物品可由回收的塑料材料制成。在另一实施方式中，由回收塑料材料制成的物品是工业化后回收的（IPR）塑料管、吹塑瓶和托盘。
在一个实施方式中，图1是挤出准备用于本发明的回收塑料材料中的纯化的塑料颗粒的制造方法100的示例性描述。方法100包括从多种来源收集塑料废料102，包括但不限于运行塑料管道操作、消费后的废弃物、工业化后的废弃物。在模块104，方法100包括将废弃物与以下形式收集的塑料废料分离：聚合物套筒、平套肩管、胶版印刷管、丝网印刷管、热箔管、团块、吹洗物、转换物、启动材料等。此外，在模块106中完成对分离废弃物的清洗，其包括用常规方法洗涤和干燥。所有分离的洁净废弃物的研磨是在模块108中通过高速研磨机（诸如废料粉碎机、凝聚器、撕裂机、造粒机等）分别完成的。研磨法将分离的废弃物转化成均匀尺寸的细小珠粒或薄片。模块110是将珠粒或薄片引入挤出生产线，所述挤出生产线具有通气式挤出机作为其一部分。挤出生产线将珠粒熔化并将其转化成熔化的塑料材料。在此阶段熔化的塑料可能具有一些杂质。在模块112中发生熔化的塑料的真空通气，其中挤出生产线的通气式挤出机将通气并从熔化的塑料中去除杂质诸如气体、油墨、清漆、标记。在一个实施方式中，通气式挤出机可以是透明的通气式挤出机（see-through ventingextruder）。此外，在真空通气之后，在模块114中获得无杂质的熔化的塑料，这种熔化的塑料的挤出发生在挤出生产线中并且获得熔化的塑料的较长的薄线束作为模块114的输出。在模块116中，线束的冷却是在水床或任何其他通常已知方法的帮助下完成的。在冷却之后，将线束切成球粒形式。在模块118中发生的是通过振动将球粒分离，其中获得不同尺寸和质量的颗粒作为振动的输出。在模块120中，完成颗粒的包装以进一步用于制造回收的纯化颗粒的塑料材料。
在一个优选的实施方式中，以上方法包括使用方法100由塑料废料获得精制的、纯化的颗粒120。获得的颗粒可用于制造多种物品。这类物品的非限制性实施例是工业化后回收的（IPR）塑料管、吹塑瓶、托盘等。
本发明主题之前描述的版本和它的等效物具有很多优点，包括以下描述的那些：
1.本发明主题提供了具有良好拉伸强度和其他技术特性的高质量回收塑料。
2.本发明主题增强了该方法的生态友好性。
3.回收塑料可用于多种应用。
4.减少工业的碳排放。
5.节约了工业化使用后废弃物的排放费用。
6.通过重复使用工业化后的废弃物创造收入。
7.由于塑料废弃物垃圾填埋的减少，减少了土地、空气和水污染。
虽然已经参照其某些优选实施方式非常详细地描述了本发明主题，但是其他实施方案也是可能的。这样，本发明主题的精神和范围不应限于其中包括的优选实施方式的描述。

Claims (9)

1.一种用于回收塑料废弃物的方法，包括：
将从不同来源收集的塑料废弃物分离，随后清洗分离的塑料废弃物以获得分离的清洁废弃物；
研磨所述分离的清洁废弃物以获得磨碎的废弃物；
将所述磨碎的废弃物引入挤出生产线以获得熔化的塑料，所述挤出生产线具有通气式挤出机组件作为其一部分；以及
通过将所述熔化的塑料真空通气将杂质移除以获得无杂质的回收塑料。
2.根据权利要求1所述的方法，进一步包括：
获得所述无杂质的回收塑料作为具有均匀直径的熔化的塑料的长空心线束；以及
将所述线束冷却并切成回收塑料材料的球粒形式。
3.根据权利要求1或2所述的方法，其中所述塑料废弃物是从选自运行的塑料管道操作、工业化使用后的塑料或消费者使用后的塑料的来源中收集的。
4.根据权利要求1或2所述的方法，其中所述塑料废料包括选自聚对苯二甲酸乙二酯（PET）、高密度聚乙烯（HDPE）、聚氯乙烯（PVC）、低密度聚乙烯（LDPE）、聚丙烯（PP）或聚苯乙烯（PS）的树脂。
5.根据权利要求1所述方法，其中所述清洗分离的塑料废弃物是通过用水和含有约2%氢氧化钠的水多次清洗来完成的。
6.根据权利要求1所述的方法，其中所述研磨分离的洁净废弃物是通过使用废料粉碎机、凝聚器、撕裂机或造粒机来完成的。
7.根据权利要求1所述的方法，其中所述通气式挤出机组件是透明的。
8.由权利要求1至7中任一项所述的回收塑料材料制成的物品。
9.根据权利要求8所述的物品，其中所述物品是工业化后回收的（IPR）塑料管、吹塑瓶和托盘。
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