CN111872035A - 废纸箱造纸固体尾废无害化利用加工技术及其产品 - Google Patents
废纸箱造纸固体尾废无害化利用加工技术及其产品 Download PDFInfo
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Abstract
本发明公开了一种废纸箱造纸固体尾废无害化利用加工技术及其产品,加工技术包括尾废的梳解、磁选、碎切、烘干、混炼和挤出成型。该技术对废纸箱造纸产生的终极尾废进行无害化处理,全部将其转化为管材或者盆体等有应用价值的产品,处理的工艺和设备简单,处理成本低,无二次污染。尾废经处理所制作的产品具有成本低、坚固耐用的特点。真正实现了尾废的资源化无害化,解决了多年来困扰造纸业发展的普遍性难题。
Description
技术领域
本发明属于造纸固体废渣无害化利用技术及其产品领域,尤其是涉及一种对以废纸箱为原料造纸所产生的终极固定废物,进行无害化处理的技术以及利用该尾废直接制取的产品。
背景技术
随着社会的发展和进步,纸质包装箱的应用越来越广泛。据统计,2017年我国纸箱用纸量超过了5000万吨,2018年全国瓦楞纸箱和箱纸板的产量分别为2,733.46万吨、1,147.60万吨,其中快递行业使用包装箱达到500多亿个。这些数量庞大纸箱,使用后绝大部分又回流到了造纸厂,被用来制作再生纸。利用废纸箱作为原料进行造纸,虽然可节约大量的木材资源,但生产过程会产生大量的废水和废渣。据有关部门测定,每生产一吨再生纸,就产生含水量约65%左右的污泥700公斤。除此之外,由于废纸箱原料中还夹杂着相当比例的胶带、塑膜、线绳和装订金属钉等杂物,利用废纸箱造纸还会产生大量难以处理的固体废物。譬如,据有关统计2016年我国仅快递业就使用胶带达170亿米,这些胶带绝大部分被缠绕在了纸箱上。针对废纸箱夹杂的非纸质材料,在现有废纸箱造纸生产中,一般是通过破碎、浮选、磁选等处理工艺,将废纸箱上的胶带、塑膜和金属进行回收利用,但有很大部分因相互缠绕交联,难以分离,无法将各种杂质全部分离利用,最终形成了废纸箱造纸生产中特有的比重较轻的固体尾废。该固体尾废主要为塑胶条(带)、橡胶、化学纤维、布条、金属丝(钉)等,总体上具有“三高一低”的特点,一是数量庞大,据不完全统计,目前全国再生纸生产产生的废渣达1500~1600万吨/年;二是处理成本高,尾废中各杂质组分相互交织、粘联缠绕,以混杂结团成堆的形式存在,无法利用工业法进行完全的分离,按照环保要求进行分离、利用和无害化的成本高,企业无法承担;三是造成环境污染的危害高,尽管现有企业都会采取反复分离的方法,来减少尾废的数量,但处理过程中又会产生大量的废水,造成环境污染,而对于最终无利用价值的尾废进行焚烧和填埋终极处理,不仅会产生废气污染,而且填埋后降解周期长,对周边产生污染;四是利用价值低,尾废中的塑胶条(带)、橡胶、化学纤维、布条、金属丝(钉)等杂质,不仅混杂分离难度大,而且其每一组分本身可利用的价值低,企业无法从其利用中获取经济效益。废纸箱造纸的尾废已成为影响废纸箱再生利用,以及造纸业绿色可持续发展的重要因素。
为解决废纸箱造纸尾废污染的问题,有的企业采取精细分拣,单独收集加工的方式对固体废渣进行处理。首先将造纸固废进行分离,先分拣为绞绳及轻渣两类,然后分别对绞绳及轻渣进一步再分拣,最后对分拣出的杂质分别加工利用。该技术对废纸箱尾废处理具有一定指导意义,但在技术和实际应用上还存在不足。该技术所说的造纸废绞绳主要包括金属材料、塑料和纤维,轻渣为软塑料、橡胶及硬塑料、纸纤维、铝渣、废铁丝、布条、泡沫、泥沙、木块等混合物。对分拣得到的绞绳,通过一次破碎、二次破碎、磁选、三次破碎、磁选和风选处理,得到铁丝和小塑料片;对轻渣经过反复的打散、分选、漂洗、高速磨浆、脱水、打包等处理,获得废铁、废塑料、低渣、重渣和浆液;固体尾废经过反复的处理,除了得到塑料、废铁和浆液为可利用物外,还有低渣和重渣废弃物需要处理。众所周知,废纸箱造纸企业产生的大量尾废是各种橡塑条带、纤维绳条、布带和金属条片的交织体,其处理的瓶颈在于工业分离技术、处理成本和最终的无害化。采用上述技术对废纸箱造纸固废进行精细分拣,单独收集加工处理,一是分拣的难度大,工艺复杂,存在二次污染;二是处理成本高,有效利用低,企业难以承担高昂的处理费用,实际应用的价值低;三是经过复杂处理工艺,虽然得到了尾废中的塑料和废铁,但最终的低渣和重渣无法处理,势必还要进行后续处理,投入产出比小,尾废治理不彻底。面对废纸箱造纸的尾废处理,现有处理方式普遍存在设备和工艺复杂,运转成本高的问题,不仅企业难以承受,也无法满足废渣资源化和无害化的生态环保要求。
发明内容
本发明要解决的技术问题是提供一种对现有废纸箱造纸产生的终极尾废进行一次性无害化资源化处理的技术,以及利用尾废直接制造的产品。
为解决上述技术问题,本发明解包括如下步骤:
A、梳解:将固体尾废置于梳解机中进行梳理,利用机械力对尾废进行破团梳解分离,解除相互间的交联和缠绕,使其成为能散落的松散体;
B、磁选:利用磁选设备对梳解后的尾废进行磁选,分离祛除尾废中体积较大的磁性金属材料;
C、碎切:将上述磁选后的尾废经输送带送入碎切机中进行混合破碎切割,使尾废中金属、木质、塑料等硬质材料破碎为颗粒状,塑胶条带和线绳布带等软体材料破断为短绒状;
D、烘干:将破碎后的尾废进行烘干,使其水分含量达到5%以下;
F、混炼和挤出成型:将烘干后的尾废直接送入螺杆挤出机中,利用挤出机中对其进行加热混炼和挤出,并制作成品。
所述破碎工艺中,金属、木质、塑料等硬质材料破碎成不大于5厘米的颗粒;烘干温度在70-100℃,尾废水分含量不大于3%。
所述混炼和挤出成型至少包括两级混炼,烘干后的尾废首先进入一级混炼挤出机进行初次混炼,一级混炼挤出物再进入二级混炼挤出机中,由二级混炼挤出机通过模口挤出成型产品,或者通过模具制作成品。
所述成品为管材或一体式托盘。
所述管材包括直管和曲状树桩管。
所述直管外表设有覆塑层,管体外表面呈光滑状。
本发明的有益效果在于:本发明包括废纸箱造纸固体尾废无害化利用加工技术以及用尾废直接获得的尾废产品。加工技术包括原料的处理和混炼挤出成型,所述原料为现有废纸箱造纸生产中形成的终极尾废,也就是造纸废渣经分拣回收处理后剩余的,目前普遍认为没有工业利用价值,最终需要进行焚烧或者填埋的那部分轻质固体废物。在处理时,首先对这些终极尾废进行机械梳解,使其被充分打散,然后进行磁选,分离出磁性金属体,祛除金属的尾废经机械碎切,尾废各组分充分混合,且大小和长度更加适合后续的混炼和挤出,挤出前尾废经烘干或自然晒干祛除大部分水分后,用螺杆挤出机对其加热混炼,通过不同的模头可直接挤出制作不同的管材,也可通过模具制作园艺盆体或工业托盘。在利用废纸箱造纸产生的轻质尾废中,各主要成分的重量份一般为:金属占5-10%、塑料占35-45%、纤维织物占40-50%。尾废在混炼机中经加热和螺旋挤压混炼,其中的塑料和部分织物受热熔融,金属和部分不能熔化的纤维织物经过混炼发生变性,被熔融塑料包覆后相互交联,经挤出机挤出直接制作的管材,在冷却后,管体中含有金属固体颗粒和纤维织物起到骨架作用,管壁内部交联度高,耐压强度大,可用作地下污水管道。同时,受金属固体颗粒和纤维织物的影响,管体挤出后,其外表呈粗糙状,并具有树皮天然纹理状的挤出纹,无需外观处理,就可直接作为园艺树桩使用,也可将其注入模具中制作园艺盆体或者托体。本技术在不添加其它辅料的情况下,可一次性将该尾废转化为具有一定利用价值的产品,工艺和设备简单,处理成本低,无二次污染,废渣全部被有效利用,能够彻底将废物处理干净,而不产生污染物,尾废经处理后直接变为了有价值的产品,所制作的产品具有成本低、坚固耐用的特点,真正实现了尾废的资源化无害化,解决了多年来困扰造纸业发展的普遍性难题。
附图说明
下面结合附图和实施例对本发明作进一步描述:
图1是本发明工艺流程示意图;
图2是本发明一种产品部分剖视图;
图3是本发明另一种产品示意图;
图4是本发明一体式托盘示意图。
具体实施例
参照图1所示,为本发明所述废纸箱造纸固体尾废无害化利用加工技术工艺流程包括梳解、磁选、碎切、烘干、混炼和挤出成型。固体尾废为使用废纸箱作为原料制作再生纸生产中产生的终极废物,该终极废物一般是企业利用现有技术对造纸固废进行分拣回收处理后,最终剩余的、无法再进行回收利用的轻质固体废物,通常叫固体尾废。该固体尾废干燥后各主要成分重量份占比一般为:金属占5-10%、塑料占35-45%、纤维织物占40-50%。
实施例1
取废纸箱造纸尾废一吨,经检测尾废中金属类材料(铁、铝等)占7%,塑料类(聚乙烯、聚丙烯、聚氯乙烯等)材料占43%,纤维织物(聚酯纤维、植物纤维等)占45、其它杂质5%。
利用该尾废制作管材,具体包括如下步骤:
A、梳解:将上述固体尾废置于辊筒梳解机中进行梳理,利用辊筒的机械力对尾废进行破团分离,梳解开松,解除纤维相互间的交联和缠绕,使其成为能散落的松散体。
B、磁选:利用带式磁选除铁机对梳解打散后的尾废进行磁选,分离祛除尾废中体积较大的铁丝、铁钉和铁块等金属材料。
C、碎切:将上述磁选后的尾废经输送带送入碎切机中进行混合破碎切割,碎切机为轮片式,它通过高速运转的轮片将尾废中残存的金属、木质、塑料等硬质材料打碎,碎片颗粒不大于5厘米,将塑胶条带和线绳布带等软体材料切割破断为短绒,其长度不大于20厘米。
D、烘干:将破碎后的尾废送入热风烘干机中进行烘干,烘干温度为60-100℃,烘干后其水分含量在5%(重量)以下。
F、混炼和挤出成型:将烘干后的尾废直接送入螺杆挤出机中,挤出机采用申请人申请并获得专利权的专利号为201921014865.8,名称为造纸废渣综合再生利用混炼挤出装置,也可以是其他公知的挤出机。本实施例采用长螺杆一级挤出,挤出机上设有管材模头,尾废经挤出机中对其进行加热混炼和挤出,并经风冷和水冷快速冷却成形获得直管,也可使用水冷减缓冷却速度获得如图3所示自然弯曲的树桩形管体1;管体外径15厘米,管壁厚1厘米,直管可用作地下排水管道,弯曲树桩管可作为园艺美化。一吨废纸箱造纸尾废可制作0.9吨左右成品管材。
实施例2
取废纸箱造纸尾废1吨,经检测尾废中金属类材料(铁、铝等)占5%,塑料类(聚乙烯、聚丙烯、聚氯乙烯等)材料占45%,纤维织物(聚酯纤维、植物纤维等)占47%、其它杂质3%。
利用该尾废制作管材,具体包括如下步骤:
A、梳解:将上述固体尾废置于辊筒梳解机中进行梳理,利用辊筒的机械力对尾废进行破团分离,梳解开松,解除纤维相互间的交联和缠绕,使其成为能散落的松散体。
B、磁选:利用带式磁选除铁机对梳解打散后的尾废进行磁选,分离祛除尾废中体积较大的铁丝、铁钉和铁块等金属材料。
C、碎切:将上述磁选后的尾废经输送带送入碎切机中进行混合破碎切割,碎切机为轮片式,它通过高速运转的轮片将尾废中残存的金属、木质、塑料等硬质材料打碎,碎片颗粒不大于3厘米,将塑胶条带和线绳布带等软体材料切割破断为短绒,其长度不大于15厘米。
D、烘干:将破碎后的尾废送入热风烘干机中进行烘干,烘干温度为60-100℃,烘干后其水分含量在5%(重量)以下。
F、混炼和挤出成型:将烘干后的尾废直接送入螺杆挤出机中,挤出机为带有加热装置的混炼挤出装置,挤出机上设有管材模头,尾废在挤出机中经加热混炼从模头挤出后获得管体,管体在输送平台上经冷却定形得到直管形管体1,管体外径10厘米,管壁厚1厘米。管体1成形后,为提高其外表的光滑度,可在外表进行覆塑处理,使其成为带有覆塑层2的尾废直管,覆塑后的直管可用作造纸厂原纸辊的内芯管。
实施例3
取废纸箱造纸尾废1吨,经检测尾废中金属类材料(铁、铝等)占10%,塑料类(聚乙烯、聚丙烯、聚氯乙烯等)材料占40%,纤维织物(聚酯纤维、植物纤维等)占45%、其它杂质5%。
利用该尾废制作一体式托盘,具体包括如下步骤:
A、梳解:将上述固体尾废置于辊筒梳解机中进行梳理,利用辊筒的机械力对尾废进行破团分离,梳解开松,解除纤维相互间的交联和缠绕,使其成为能散落的松散体。
B、磁选:利用带式磁选除铁机对梳解打散后的尾废进行磁选,分离祛除尾废中体积较大的铁丝、铁钉和铁块等金属材料。
C、碎切:将上述磁选后的尾废经输送带送入碎切机中进行混合破碎切割,碎切机为轮片式,它通过高速运转的轮片将尾废中残存的金属、木质、塑料等硬质材料打碎,碎片颗粒不大于5厘米,将塑胶条带和线绳布带等软体材料切割破断为短绒,其长度不大于20厘米。
D、烘干:将破碎后的尾废送入热风烘干机中进行烘干,烘干温度为60-100℃,烘干后其水分含量在5%(重量)以下。
F、混炼和挤出成型:将烘干后的尾废通过塑料混炼挤出机进行混炼和挤出。混炼和挤出成型至少包括两级混炼,烘干后的尾废首先进入一级混炼挤出机进行预混炼,一级混炼的挤出物进入二级混炼挤出机中,由二级混炼挤出机将挤出物注入工业托盘模具中,冷却后获得可用于货物码垛使用的一体式托盘3。一级混炼的温度为130-150℃,二级混炼的温度为140-160℃,尾废经两级加热混炼,其中的塑性成分塑化性能好,各组分混合均匀。托盘中含有金属块和纤维织物,不仅耐磨性强,而且具有较强韧性,使用寿命长。
本发明对废纸箱造纸所形成的终极废渣,经机械化预处理后,用混炼挤出机对其进行加热、混炼并挤出制作成形物品。尾废在挤出机中经高温加热和压力挤出,其中的生物得以灭活,毒性成分也被破坏,整个处理过程不仅不会产生污染,而且尾废得以无害化。制成品中固性成分被塑胶包覆,结构紧密,整体耐压性能强,无毒无害;可广泛应用作地下污水管道、园艺树桩和盆体;实现了造纸尾废的资源化利用。本发明所述造纸尾废处理工艺,主要针对废纸箱造纸产生的尾废进行无害化资源化处理,但也可推广应用于以其它原料制造再生纸废渣的处理,只要该废渣中含有一定数量的塑性材料即可。
Claims (6)
1.一种废纸箱造纸固体尾废无害化利用加工技术,其特征是包括如下步骤:
A、梳解:将固体尾废置于梳解机中进行梳理,利用机械力对尾废进行破团梳解分离,解除相互间的交联和缠绕,使其成为能散落的松散体;
B、磁选:利用磁选设备对梳解后的尾废进行磁选,分离祛除尾废中体积较大的磁性金属材料;
C、碎切:将上述磁选后的尾废经输送带送入碎切机中进行混合破碎切割,使尾废中金属、木质、塑料等硬质材料破碎为颗粒状,塑胶条带和线绳布带等软体材料破断为短绒状;
D、烘干:将破碎后的尾废进行烘干,使其水分含量达到5%以下;
F、混炼和挤出成型:将烘干后的尾废直接送入螺杆挤出机中,利用挤出机中对其进行加热混炼和挤出,并制作成品。
2.按照权利要求1所述的废纸箱造纸固体尾废无害化利用加工技术,其特征是所述破碎工艺中,金属、木质、塑料等硬质材料破碎成不大于5厘米的颗粒;烘干温度在70-100℃,尾废水分含量不大于3%。
3.按照权利要求2所述的废纸箱造纸固体尾废无害化利用加工技术,其特征是所述混炼和挤出成型至少包括两级混炼,烘干后的尾废首先进入一级混炼挤出机进行初次混炼,一级混炼挤出物再进入二级混炼挤出机中,由二级混炼挤出机通过模口挤出成型产品,或者通过模具制作成品。
4.一种利用权利要求1至3任一项所述的废纸箱造纸固体尾废无害化利用加工技术制作的造纸尾废型材,其特征是所述成品为管材或一体式托盘。
5.按照权利要求4所述的废纸箱造纸固体尾废无害化利用加工技术制作的造纸尾废型材,其特征是所述管材包括直管和曲状树桩管。
6.按照权利要求5所述的废纸箱造纸固体尾废无害化利用加工技术制作的造纸尾废型材,其特征是所述直管外表设有覆塑层(2),管体(1)外表面呈光滑状。
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