ES2584537A1 - Composite material substitute for wood resulting from the aggregation of products destined for landfills, procurement procedure and industrial plant needed for this purpose (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

Composite material substitute for wood resulting from the aggregation of products destined for landfill, procurement procedure and industrial plant necessary for that purpose. Composite material obtained from landfill material that includes: raw materials for recovery and pure raw materials, where the raw materials for recovery are: plastic composite materials, wood-derived materials, paper-derived materials and tissue fibers, materials obtained of debris from renovations and demolitions of buildings, and pure raw materials are sawdust and natural stone dust. The process comprises the steps of supply, treatment (crushing and grinding), separation of magnetic materials, washing, mixing, drying, storage for production, extrusion, cooling and cutting. The installation comprises several treatment lines for each material, washing units, storage silos, mixer, dryer, storage silos for production and extrusion, cooling and cutting media. Thanks to the means and characteristics, a material is obtained that takes advantage of all the materials coming from landfills, and depending on the proportions, materials with different functional and constructive properties are obtained. (Machine-translation by Google Translate, not legally binding)

Description

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DESCRIPTION

WOOD SUBSTITUTE COMPOSITE MATERIAL RESULT OF THE AGGREGATION OF PRODUCTS INTENDED FOR LANDSCAPES, PROCEDURE OF OBTAINING AND INDUSTRIAL PLANT NEEDED FOR SUCH PURPOSE.

OBJECT OF THE INVENTION

It is the object of the present invention, as the title of the invention establishes, a wood substitute composite material resulting from the aggregation of products destined for landfills. Also, the object of the invention is the manufacturing process of said composite material, as well as the industrial plant necessary for the application of said process and for obtaining said composite material.

The present invention characterizes the nature and origin of the materials used in the manufacture and the treatment to which they are subjected, achieving a product resulting from the use of products destined for previously transformed landfills.

Therefore, the present invention is limited within the scope of composite materials, also, within the scope of recycling of materials destined for landfills.

BACKGROUND OF THE INVENTION

They are called composite materials, those materials that are formed by the union of two materials to achieve the combination of properties that cannot be obtained in the original materials. These compounds can be selected to achieve unusual combinations of stiffness, strength, weight, high temperature performance, corrosion resistance, hardness or conductivity.

On the other hand there are numerous products that cannot be recycled and that should be deposited in a landfill where the necessary time will remain until they are transformed. For example:

• Composite containers for the transport of chemical products;

• Composite parts resulting from the dismantling of vehicles at the end of life;

• Carpets and interior car coverings;

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• Plastic and non-plastic compounds resulting from the separation in the CVO (Organic Valorization Centers);

• Old furniture such as sofas and mattresses;

• Plastic compounds resulting from agriculture;

• Wooden containers at end of life;

• Carpets resulting from remodeling of buildings;

• Separation partitions in wood derivatives;

• Separation walls of laminated plaster or plasterboard ®;

• Remains of waste from the textile industry

The time that the products take to be transformed cannot be quantified, because until now and in the history of recycling, not enough time has been spent to finish that process. However, we know it will take more than 300 years.

This type of products deposited in landfills will hardly be profitable through energy production, as they are products of difficult transformation and, therefore, do not release gases that can make a landfill profitable. Currently, with the support of the classification centers and with specific centers of use, some of these products can already be recovered and repositioned in their cycle, as for example do the dismantling units of vehicles at the end of their life.

Examples of products destined for landfills we have:

- Chemical products containers

- Old furniture and mattresses

- Vehicle wreckage

- Plastic composite products

- Waste of reforms and demolition of constructions.

All these products, in general, are not reused, being simply parked or buried in order to avoid their visualization, requiring large volumes of space for burial.

Published patent documents that make partial and non-complete use of all possible waste product materials are:

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- CN102167911: only use a certain type of plastic; 50% of its composition is wood;

- CN102205623: describes a method for the preparation of a plastic tank from multi-layer recycled materials of coextruded blown films;

- TW201111444: discloses a procedure for obtaining a vegetable fiber composite material produced by a method comprising the steps of mixing a vegetable fiber raw material containing a base content and between 60% and 80% percentages, starch in a content between 10% and 30%, and a biological polymer additive containing between 10% and 20%; replace the plastic;

- US6153293A: Disseminates a product for obtaining an artificial structural compound that is manufactured from wood fiber and extruded polyethylene, including recycled polyethylene, by reducing the wood fiber and polyethylene each to a finely divided particles, mechanical mixing of the wood and polyethylene fiber particles together with a measured amount of an endothermic foaming agent powder,

- W02012009005A1: describes a compound formulation consisting of industrial / residential agglomerate sewage sludge and recycled high density polyethylene (HDPE) and / or polypropylene (PP) materials. Does not mix plastics;

- WO2009099920A2: includes preliminary treatment of carpets and / or carpets; Do not mix plastics;

None of the above documents disclose the possibility of using all the materials that we find in landfills (plastic compounds, furniture and the like, construction debris, cardboard, pure raw materials such as sawdust and stone dust).

Therefore, it is the object of the present invention to develop a composite material that allows the use by aggregation of the materials found in a landfill, a fact that so far has not been achieved, developing a product, procedure and facilities such as those It is described below and is reflected in its essentiality in the independent claims.

DESCRIPTION OF THE INVENTION

It is the object of the present invention in the first place to obtain a composite material obtained by aggregating material from previously landfill objects.

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treated and in a certain proportion.

It is also the object of the present invention, the treatment procedure for the different materials from landfills in order to obtain a material such as that which is the object of the invention.

Additionally, and within the same inventive principle, it is also the object of the invention, the industrial plant or the facilities and means necessary to be able to implement the procedure and thus be able to obtain a composite product resulting from the aggregation of material from products from landfills .

The composite wood substitute material and obtained from landfill material comprises: recovery raw materials and pure raw materials.

Raw materials from recovery include:

- plastic composite materials

- wood derived materials

- paper-derived materials and tissue fibers

- materials obtained from construction debris and demolition debris

Pure raw materials comprise natural materials, which in turn comprises one or both of the following materials:

- stone dust (resulting from the micronization of limestone)

- sawdust resulting from cutting and polishing the wood.

The proportion of these materials is variable depending on the final qualities that you want to give the product, having more or less quantity of the different materials according to the final qualities of the product. Thus, we find that a greater amount of plastics, provides greater structural rigidity in addition to plasticity, while a greater amount of wood or fabric provides greater lightness, and a greater amount of micronized products, provides greater hardness.

The process consists of the aggregation of various products destined for landfills originating, in the end, a transformed product that replaces the wood in varied

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Applications. This process avoids the increase of sanitary landfills where the products, especially contaminated polymers, take more than 300 years until they are transformed, and consequently reduce the consumption of wood, given the substitutability of wood for the composite product object of the invention

The process includes the following phases:

1. Collection of raw materials destined for the landfill;

2. Preparation of raw materials for the landfill resulting from:

to. Plastic composite products;

b. Furniture and containers;

C. Waste remodeling in construction.

3. Preparation of pure raw materials and their storage;

4. Separation of metals;

5. Washing of raw materials

6. Storage for production

7. Mixing of all raw materials

8. Drying the mixed product

9. Dosage or composition and formula;

10. Extrusion / production of the product;

11. Cooling, cutting and packaging.

1.- Collection of raw materials

The collection of raw materials is very conditioned by the type of matter in question. Thus, it is necessary that the collection site has several download sockets, such as:

• Discharge socket for plastic compounds of the type:

- Waste resulting from plastic recycling units;

- Containers of chemical products;

- Polystyrene wastes;

- Polypropylene wastes;

- Expanded polyurethane wastes;

- Plastic composite elements resulting from the removal of vehicles;

- Vehicle upholstery;

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- Plastic composite elements resulting from appliances;

- Insulation of electrical conductors;

- Remains of insulated electrical conductors;

- Remains resulting from plastic composite elements used in agriculture.

• Discharge socket for products resulting from furniture and packaging

- Used furniture with and without metal

- Furniture upholstery

- Old mattresses

- Pallets in fine life

• Discharge outlet for products resulting from waste from construction renovations and demolitions

- Remains of plasterboard with wood and paper

- Remains of wood resulting from floors, doors and ceilings.

• Discharge socket for necessary products to the formulation

- Stone dust collection system

- Serrin collection system.

2.- Preparation of the raw material Plastic composite products

The preparation of the raw material resulting from plastic composite products involves some procedures depending on the origins of the products and the various types of composite products. That creates some limitations that require consideration of the system for unloading compounds that must be prepared for the collection to occur through a truck that unloads all the cargo through its tilt system. The unloaded product is inside a tank located underground.

The dimensions of the tank are projected so that the product is collected in loads or in bulk. In the lower part of the tank there is a conveyor or a crane bridge that removes the

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product deposited and takes it to the next phase.

In this phase, the unloaded products are carried through conveyor belts, in an inclined plane from 25 ° to 45 °, through a crusher. This crusher has the capacity to reduce waste up to 2 cm3 and download the result on a later mat. This tape has an inclination between 20 ° and 45 °. The fall of the product occurs in a mill that releases the grids with dimensions between 2.5 mm3 and 4 mm3. The result of this transformation is transported through a conduit to the interior of the silos.

Furniture and packaging

The unloaded product will be inside an underground tank. Above the tank, the same crane bridge used for plastic compounds removes the products and takes them to a crusher. This crusher will be responsible for the transformation, for example of furniture, a pallet, a mattress or any other, into small parts with a volume of less than 20cm3. When they are destroyed, they will be transported to the next phase.

The dimensions of the tank are projected so that the product is collected in loads or in bulk. That facilitates the collection process.

Waste from construction reforms and demolitions

The debris unloading system from construction reforms allows the collection through a truck, as with the system for unloading compounds and the system of products resulting from furniture and packaging.

Thus, all cargo will be discharged through the vehicle's tilting system. The unloaded product will be inside a vat in the form of a "v" underground.

Above the tank, the same crane bridge used for plastic and furniture compounds removes the products and takes them to a crusher. This crusher will be responsible for the transformation of the waste into parts with volume less than 2cm3. When they are destroyed, they will be transported to the next phase.

Taking into account the products it collects, this crusher has an anti-ballistic system for the protection of people and objects. On the side walls of the collection tank

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puts a system of activated metal covers through hydraulic cylinders that cover the tank. It is not possible to start a new discharge as long as the crushing is not completed, since the lids block the tank.

After the exit of the crushing tank, the product is carried by a conveyor mounted in front of the crusher. This conveyor has an inclination between 20 ° and 40 °. The mill will crush the product up to 5 and 7mm3 that will fall on a conveyor belt that will take the product to the respective silo, after passing through the washing system.

3. - Preparation of pure raw materials The raw materials considered pure are:

- Stone dust (resulting from limestone micronization);

- Serrin resulting from cutting and polishing wood.

Stone dust silos are fed by a truck with pressurized tank. The feeding of the sawdust occurs through a dump truck, which unloads it inside a vat in the form of a "v" underground. At the base of the tank there is a conveyor that feeds a conduit responsible for carrying the sawdust to the silo.

The storage of products called pure raw materials occurs in silos that can be squares formed by 3m x 3m plates (that is, 6m high until the start of the discharge cone) or cylindrical similar to those of raw material storage. The discharge cone is in the form of a reverse pyramid with an inclination of 45 °. Its output includes a rotary valve system.

4. - Separation of metals

The separation of metals includes two systems:

- Magnetization system for ferrous metals;

- System by vibration or eddy currents for non-ferrous metals.

All previously prepared products go through these two phases. First, by the Foucault vibration system or currents where they are separated from the others

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products. Here, the metals will remain in the lower part of the vibrator and the raw material is deposited in a conveyor in the upper part. Thus, the metals that were in the lower part will be carried by a conveyor belt to the magnetization system. At a certain point, at the top of the tape, there is a magnetization system, responsible for attracting ferrous metals, separating them from other metal materials.

5. - Washing of raw materials.

All products are subjected to this process whatever their origin, when they had not previously been subjected to a washing or micronization during their preparation. Pure products do not need washing.

The washing consists of putting all the products, except the cigars and those that were already subjected to the micronization and atomization, in a tank that drags inside, through a traction system, all the products until a sieve with a net 0.01mm

Thus, as soon as the water passes and the product is taken to a new conduit that elevates it to the silos of the raw material.

6. - Storage for production

Storage for production occurs in cylindrical silos with the shape of a self-weighing conical trunk, supported by load cells. These silos are 4m in diameter and 5m in height from the entrance of the cone to the top. In the union with the cone there is a diameter of 4m. The base of the silos is offset by 120 ° so that it has only 3 supports.

The load cells are compressed, mounted on oscillating accessories and interconnected through an aggregator box that sends signals to the weight controller. Thus, data on the weight of the raw material are always available.

There is at least one silo for the raw material resulting from plastic compounds, a silo for wood derivatives resulting from furniture, doors, floors and wood waste for recycling, a silo for paper derivatives and tissue fibers, a silo for products from of debris, a silo for dry sawdust, and a silo for natural stone.

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The silo of the stone dust is the same for the collection of raw material, since this product does not need extra treatment. Thus, all the raw material is ready to go to the dosing and production process.

7. Mixing of all raw materials

All raw materials, both from recycled materials and natural raw materials, are subjected to a mixer mixing process, preferably for 1 hour. An example of mixer specifications is one that has 3 arms with 4 blades, 2 to 2, with 45 ° inclination and 150 RPM rotation.

8. - Drying the mixture

At the exit of the mixer, the mixed raw material is subjected to a drying process comprising, a dryer itself, and an antechamber with a burner operated on fuel, biomass or natural gas. The heat accumulator in the antechamber is expelled through the ventilation system for the drying unit. That unit operates like a cylinder that rolls in the horizontal.

In this way all the raw material transports a very small amount of water.

9. Dosage or composition and formula

All previously mixed and dried raw material is stored in silos, and can be stored in different silos, according to the composition that has been prepared.

10. Extrusion / production of the product;

Storage silos for production supply the material to be extruded by means of extruders.

11. Cooling, cutting and packaging.

Once the material is extruded it undergoes a consecutive process of cooling, cutting and packaging.

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Thanks to the nature of the raw materials used, their preparation (trituration) the combination of raw materials, and their treatment is achieved a composite material that takes advantage of all the products that are dumped in the landfills, achieving a material assimilable to wood, with better resistance and durability properties and that can also be complemented in other properties, such as weight, hardness, plasticity, depending on the majority proportion of one raw material or another.

Unless otherwise indicated, all technical and scientific elements used herein have the meaning normally understood by the ordinary expert in the art to which this invention pertains. In the practice of the present invention procedures and materials similar or equivalent to those described herein can be used.

Throughout the description and the claims the word "comprises" and its variants are not intended to exclude other technical characteristics, additives, components or steps. For those skilled in the art, other objects, advantages and characteristics of the invention will be derived partly from the description and partly from the practice of the invention.

EXPLANATION OF THE FIGURES

To complement the description that is being made and in order to help a better understanding of the features of the invention, according to a preferred example of practical realization thereof, a set of drawings is accompanied as an integral part of said description. where, with an illustrative and non-limiting nature, the following has been represented.

In Figure 1, we can see a partial representation of the installation in which the first steps of the procedure are carried out.

In Figure 2, we can see a partial representation of the final part of the installation in which the final steps of the procedure are carried out.

PREFERRED EMBODIMENT OF THE INVENTION.

In view of the figures, a preferred embodiment of the proposed invention is described below.

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The composite wood substitute material and obtained from landfill material comprises: recovery raw materials and pure raw materials.

Raw materials from recovery include:

- plastic composite materials

- wood derived materials

- paper-derived materials and tissue fibers

- materials obtained from construction debris and demolition debris

Pure raw materials comprise natural materials, which in turn comprises one or both of the following materials:

- stone dust (resulting from the micronization of limestone)

- sawdust resulting from cutting and polishing the wood.

The proportion of these materials is variable depending on the final qualities that you want to give the product, having more or less quantity of the different materials according to the final qualities of the product. Thus, we find that a greater amount of plastics, provides greater structural rigidity in addition to plasticity, while a greater amount of wood or fabric provides greater lightness, and a greater amount of micronized products, provides greater hardness.

In any embodiment, the composite material comprises at least 50% of plastics, with the other proportions varying depending on the requirements sought and the nature of the materials used.

In a possible embodiment, but in no limiting case, a possible distribution of the proportions of the different materials could be:

- plastic compounds 65% -85%

- Wood derivatives% 5% -15%

- Paper derivatives and tissue fibers 5-15% - Stone dust between 2% to 10%

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Another possible form of realization could be the following proportion

- 2000kg plastic compounds

- 200 Kg wood derivatives

- 200 Kg paper and fiber derivatives

- Serrin derived from cuts and polishes of wood 200 Kg

- Products from dumps 50 Kg

- Stone powder 50 Kg

In figures 1 and 2 we can see the characteristics that the manufacturing plant presents that includes:

- several supply lines and preparation of raw materials except for pure materials, in this case two supply lines have been represented, there must be as many supply lines as different nature of the materials used in manufacturing,

- metal separating units (7) arranged at the exit of the supply lines and comprising vibration means to separate non-ferrous metals and means by magnetization to separate ferrous metals, which are arranged at the exit of the supply and preparation lines of raw materials.

- Washing units (8) of all raw materials except pure materials. ready to continuation of the metal separating units.

- Storage in first silos (9) of the raw materials prepared and connected with the washing silos

- A few second storage silos (10) and (11) for the stone dust and for the natural stone, arranged at the exit of the silos of the raw materials from recovery

- A mixer (12) connected with the previous silos

- A dryer (14) connected to the mixer outlet and comprising an antechamber with a burner operated on fuel, biomass or natural gas.

- Several storage silos for production (16), each of which may contain different proportions of raw materials from recovery or natural raw materials.

- Several extrusion units (17) connected at their exit consecutively with cooling units (18), cutting (19) and hardening (20).

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Preferably there should be:

- a supply line for plastic composites

- a supply line for wood-derived materials

- a supply line for paper-derived materials and tissue fibers.

- A supply line for materials derived from debris from reforms and

demolitions

Each of the supply lines includes:

- a collection tank (1) of materials

- a material removal conveyor (2) located under the collection tank (1)

- exit tapes (3) arranged in an inclined plane

- a shredder (4) in charge of reducing waste. In the case of plastic composites, they are crushed up to 2 cm3, in the case of furniture and containers they are crushed with a volume of less than 20 cm3 and in the case of waste from debris up to a volume of 2 cm3.

- Under the shredders there is a second exit belt (5) that is responsible for transporting the waste

- A mill (6), which in the case of plastic composite materials reduces waste between 2.5 mm2 and 4 mm3; in the case of furniture and packaging, the waste is crushed to a volume between 5 and 7 mm3.

Describing sufficiently the nature of the present invention, as well as the way of putting it into practice, it is stated that, within its essentiality, it may be put into practice in other embodiments that differ in detail from that indicated by way of example. , and which will also achieve the protection sought, provided that it does not alter, change or modify its fundamental principle.

Claims (12)

5 10 fifteen twenty 25 30 35 1.-Wood substitute composite material resulting from the aggregation of products destined for landfills comprising raw materials for recovery and pure raw materials, characterized in that: Raw materials from recovery include: - plastic composite materials - wood derived materials - paper-derived materials and tissue fibers - materials obtained from construction debris and demolition debris Pure raw materials comprise natural materials, which in turn comprises one or both of the following materials: - stone dust (resulting from the micronization of limestone) - sawdust resulting from cutting and polishing the wood. Where the proportion of plastics is at least 50% by weight with respect to the rest of the materials. 2. - Wood substitute composite material, according to claim 1, characterized in that the proportions of the different materials are: - plastic compounds 65% -85% - Wood derivatives 5% -15% - Paper derivatives and tissue fibers 5-15% - Stone dust between 2% to 10% 3. - Wood substitute composite material, according to claim 1, characterized in that the proportions of the different materials are: - 2000kg plastic compounds - 200 Kg wood derivatives - 200 Kg paper and fiber derivatives 5 10 fifteen twenty 25 30 35 - Serrin derived from cuts and polishes of wood 200 Kg - Products from dumps 50 Kg - Stone powder 50 Kg 4. - Procedure for obtaining a wood substitute composite material resulting from the aggregation of products destined for landfills, according to any of the preceding claims, characterized in that it comprises the steps of: - Collection of raw materials destined for the landfill in vats; - Preparation of raw materials destined for the landfill resulting from: - Plastic composite products; - Furniture and packaging; - Waste remodeling in construction. - Preparation of pure raw materials and their storage; - Separation of metals; - Washing of raw materials - Storage for production - Mixing of all raw materials - Drying the mixed product - Dosage or composition and formula; - Extrusion / product production; - Cooling, cutting and packaging. 5. - Procedure for obtaining a composite material, according to claim 4, characterized in that the preparation of the raw material of plastic products comprises the crushing steps until reducing the raw material to a size of up to 2 cm2 and subsequent transport to a mill in which the particles are chopped at a size between 2.5 mm3 and 4 mm3. 6. - Procedure for obtaining a composite material, according to claim 4, characterized in that the preparation of the furniture and packaging raw material comprises the crushing phase in parts with volumetry less than 20 cm3, and subsequent crushing until a product is obtained with a volume between 5 and 7 mm3. 7. - Procedure for obtaining a composite material, according to claim 4, characterized in that the preparation of the raw material wastes from 5 10 fifteen twenty 25 30 35 Construction remodeling includes the crushing stages up to a volume of less than 2 cm3. 8. - Industrial plant for obtaining a composite material according to any of claims 1-3 and application of the above method according to any of claims 4 to 7 characterized in that it comprises: - several supply lines and preparation of raw materials except for pure materials, there must be as many supply lines as a different nature of the materials used in manufacturing, - metal separating units (7) arranged at the exit of the supply lines - Washing units (8) of all raw materials except pure materials, arranged next to the metal separating units - First storage silos (9) of prepared raw materials connected to the washing silos. - A few second storage silos (10) and (11) for the stone dust and for the natural stone, arranged at the exit of the silos of the raw materials from recovery - A mixer (12) connected with the previous silos - A dryer (14) connected to the mixer outlet - Several storage silos for production (16), each of which may contain different proportions of the raw materials from the recovery or natural raw materials. - Several extrusion units (17) connected at their exit consecutively with cooling units (18), cutting (19) and hardening (20). 9. - Industrial plant for obtaining a composite material according to revindication 8, characterized in that it comprises: - a supply line for plastic composites - a supply line for wood-derived materials - a supply line for paper-derived materials and tissue fibers. - A supply line for materials derived from debris from reforms and demolitions 10. - Industrial plant for obtaining a composite material according to claim 8 or 9, characterized in that each of the supply lines comprises: - a collection tank (1) of materials 5 - a material removal conveyor (2) located under the collection tank (1) - exit tapes (3) arranged in an inclined plane - a shredder (4) in charge of reducing waste. - Under the shredders there is a second exit belt (5) that is responsible for transporting the waste 10 - A mill (6). 11. - Industrial plant for obtaining a composite material according to claim 8, characterized in that the metal separating units comprise vibration means or eddy currents for non-ferrous metals and magnetization means 15 for ferrous metals. 12. - Industrial plant for obtaining a composite material according to claim 8, characterized in that the dryer (14) comprises an antechamber with a burner operated on fuel, biomass or natural gas. twenty