ES2932873B2 - TONER CARTRIDGE RECYCLING PROCEDURE AND INSTALLATION - Google Patents

Description

TONER CARTRIDGE RECYCLING PROCEDURE AND INSTALLATION

TECHNIQUE SECTOR

The present invention relates to a method and an installation for the recycling of toner cartridges, of the type used in printers, photocopiers or other similar equipment for preparing documents. These types of cartridges contain dusty toner, the management of which involves relevant technical challenges, mainly the creation of explosive atmospheres.

STATE OF THE ART

In the state of the art, a whole series of procedures are known for recycling electronic equipment that make it possible to separate the metallic, plastic and other compound components, such as printer ink.

In the case of toner, as it is a powdery material, it is possible for it to become suspended in the air, creating an explosive atmosphere that introduces a great risk to people and equipment. Consequently, recycling of these products tends to be avoided. However, they comprise a whole series of valuable compounds whose recovery is highly interesting for ecological and economic reasons.

In addition, a large percentage of toner cartridges contain carbon bars mixed with magnetized iron particles, essential for proper printing operation. These particles can cause plugs in the absorption and transport process if they are not removed correctly, Its own magnetism can cause it to stick to processing or transport items, facilitating the creation of plugs, reducing the passage of air and causing even more sedimentation, and more risk of excessive heat and spark.

A first solution to these problems is found in ES2679569A1, which produces the grinding and separation by mechanical means of the different compounds. To reduce the risk, use equipment certified for explosive atmospheres (ATEX), but this solution is only partial. It is preferable to minimize the risk of explosion, since Ar uring carts that con tain mecha parts can pro ucr c spas and generate a deflagration.

A first solution is to carry out the recycling in an inert atmosphere, such as nitrogen or carbon dioxide, to eliminate the oxidizer. However, that solution is expensive and requires high energy consumption for maintenance.

The Applicant is not aware of a solution to these problems as effective as the one claimed.

BRIEF EXPLANATION OF THE INVENTION

The invention is a toner cartridge recycling method and installation according to the independent claims. They solve, in their different embodiments, the problems of the state of the art.

The invention allows the fragmentation and separation of materials to be carried out, obtaining a minimum of 80% recovery. Separating all fractions (ferrous, non-ferrous metal, plastic, dust) with a very low risk of explosion and very low energy consumption. The inert dust can be of natural origin, so there is no appreciable contamination.

Aspects as disparate as geometry, material density, adequate fragmentation will depend on the type of cartridges, and will be considered based on trial and error, preferably monitoring the amount of toner in the cartridges.

For this, the toner cartridge recycling procedure (including excess toner deposits), of the type that comprises a phase of grinding the cartridges in a first mill, a screening stage and a series of stages for separating the plastics and metals, includes in particular the stages of:

• Grinding of the toner cartridges in a first mill with an inert powder dispenser (calcium carbonate, gypsum...).

• Carry out a first separation with magnetic separators.

• Carry out a screening, preferably with a system of shaking the cartridges with rubber balls that move at high speed, hitting the cartridge fragments, and derive

o The fraction greater than a second mill with an inert powder dispenser, for its return to screening.

o a racc n n erme a a cc n e e mnac n e povo prior to the definitive separation by materials.

o The minor fraction to be discarded or recovered from toner powder, with optional magnetic separators.

In addition, it includes dust aspiration stages throughout the entire procedure, derived to one or more filters. Each machine or conveyor will include one or more suction mouths.

If the cartridges or toner tanks are heavily loaded, a previous stage of emptying the toner from the cartridges can be added.

It is desirable to add a stage of removal of rods prior to screening, using a vibrating machine to remove rods.

In the most preferred embodiment, a direct inlet to the second mill is provided for the plastic cartridges (with little or no metal).

To this end, the toner cartridge recycling facility that carries out the process comprises an inlet for cartridges and toner tanks to a first mill with an inert powder dispenser. At the exit of the first mill, one or more magnetic separators are arranged prior to a sieve that separates into three fractions. The largest fraction goes to a second mill, which also has an inert powder dispenser. Its output returns to the sieve. The minor fraction is stored, after an optional passage through magnetic separators. The intermediate fraction is sent to a dust removal cyclone, prior to the separators of the different materials (plastic, metals...)

This installation includes dust suction mouths throughout the installation connected to filters, which communicate with a suction system. This suction system generally has flow rate sensors to ensure proper suction and no accumulations in the suction system. The temperature, the filling of the final dust deposits and the presence of sparks or flames in the suction system are also monitored.

Preferably, in order not to saturate the filters too quickly, cyclones can be placed before the filters.

ras varan es are enunciated in as revn cacones nepen en es and will be written in later.

DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention, the following figures are included:

Fig. 1: Schematic view of an example of the procedure.

MODES OF CARRYING OUT THE INVENTION

Various embodiments of the invention are briefly described below, as an illustrative and non-limiting example thereof.

The procedure will be commented with the help of figure 1, where the diagram of an embodiment of the invention is represented. The procedure starts from the input (1) of a series of toner cartridges to a first mill (2). A first dust suction stage (3), prior to and during grinding, ensures that sufficient accumulation does not occur to generate an explosive atmosphere. The grinding is carried out in parallel with the action of a dispenser (4) that provides an inert powder, such as calcium carbonate, plaster or similar to the whole, reducing the possible transmission of the flame.

A first separation is carried out with vibrating machines (5) remove sticks, which eliminate the inner rods (generally aluminum, steel or iron) present in various models of cartridges. The first separation comprises magnetic separators (6) (on the conveyor belt, during dumping...). Next, a screening (7) is carried out, whose largest fraction (eg, greater than 30 mm) is passed to a second mill (8), which obtains smaller fragments, for its return to screening ( 7). This second mill (8) also includes a dispenser (4) for inert powder. A direct input (9) to the second mill (8) can be defined for the plastic cartridges, which do not require to be milled twice (because they contain little or no metal, for example).

The entrance to the second mill (8) from the screening (7) can be at a different point than the direct entrance (9), since this requires more grinding. The second mill (8) can be special for plastic, which is generally more difficult to grind due to its consistency, sometimes rubbery or very light.

Cr a o is carried out in a c r a o a e a system e oas e rubber that re oates at high speed, allowing a greater cleaning of the fractions. These balls force toner dust free from the ground parts, ensuring that they do not carry dust with them. The rubber balls are arranged between the sieve meshes (7) and their diameter prevents them from being dragged with any fraction. The material will be elastic to ensure that they bounce back strongly. For example, they can be put below the finest mesh, without being able to come out with the finest fraction. Thus they hit the mesh from below, shaking the cartridge pieces of the intermediate fraction.

The intermediate fraction of the screening (7) is classified, after passing through a dust removal cyclone (10) where the largest fragments fall and the dust continues with the air current. The classification is carried out by eliminating possible ferromagnetic metallic remains with a magnetic separator (6), non-ferrous with a Foucault tape (11) and separating the plastic by gravity (12). These fractions are already prepared for recovery.

The smaller part or fraction of the screening (7), for example less than 3 mm, is considered a mixture of toner powder and some inert, although it may have metallic, ferrous filaments that need to be captured by magnetic separators (6). If there is a vibrating machine (5) to remove sticks, the number of filaments is very small since it also recovers them.

The dispensers (4) will be at the entrance of the corresponding mills (2.8), so that the powder mix can be produced immediately. It is possible to include mixing machines prior to grinding or crushing, to ensure good distribution of the inert powder.

All transport within the facility will be carried out by pneumatic systems or by rubber bands or conveyor belts or other similar, non-metallic material, to avoid sparks and overheating due to friction. Endless screws will be especially avoided. They include, for example, suction stages (3) to avoid the accumulation of dust in the atmosphere itself. They include suction outlets in the lower parts, where dust can be deposited, at the entrance and close to the exit. Likewise, the rest of the machines will work in depression with suction stages (3), being able to stop or increase the suction at specific points depending on the type of cartridge and the activation, or not, of the direct input (9).

as e apas e asprac n , with their corresponding escos e asprac n, ervan e air and dust sucked into a series of filters (5), preferably with antistatic sleeves to ensure that there is no spark, including previous cyclones. Some flow rate sensors make it possible to ensure that the aspiration is correct at all times, and produce the cleaning of the filters (5), for example with compressed air jets that make the cake of dust fall into one or more bags.

You can define a phase prior to the first grinder (2) to empty the cartridges or deposits of excess toner from printers, photocopiers or others. These waste toner containers are mainly made of plastic materials, have a large volume, and always contain a high amount of toner. Therefore, it is preferable to empty them in a previous, manual or automatic chopping stage (13). This chopping stage (13) has its own suction stage (3), which will require great power and consistency, and which can be independent of the suction system of the rest of the installation.

The installation includes an alarm center for the suction system that monitors the temperature, the filling of the final dust deposits, the presence of sparks or flames (for example, using infrared) and the reduction of the air flow. The corresponding sensors have self-cleaning systems by air jet. Silos where dust accumulates behind the filters (5) are especially monitored. The installation includes irrigation equipment to stop any deflagration or fire, and automatic shut-off gates.

Preferably, a selection can be made, manual or automatic (by artificial vision, simple dimensions...) of the cartridges to ensure that each batch has the same or similar conditions and the stages of the procedure can be adapted to those models or specific manufacturer. Even, once the homogeneity of cartridges at the entrance is ensured, the average weight can be evaluated to estimate how much toner powder has remained as residue and dose the inert powder accordingly.

All the equipment that is in areas where there may be dust will be suitably certified for explosive atmospheres, according to regulations, and managed by the corresponding own or installation electronic equipment.

Claims (1)

1 - Process for recycling toner cartridges, comprising a phase of grinding the cartridges in a first mill (2), a screening stage (7) and a series of separation stages (5,6,11) of the plastics and metals, characterized by comprising the stages of: grinding of the toner cartridges in a first mill (2) with a doser (4) of inert powder; carry out a first separation with magnetic separators (6); carry out a screening (7), and derive the larger fraction to a second mill (8) with a dispenser (4) of inert powder, for its return to the screening (7); the intermediate fraction to a dust removal cyclone prior to the final separation by materials; the minor fraction to discard; and because it comprises dust aspiration stages (3) throughout the entire procedure, derived to one or more filters (5). 2- Process for recycling toner cartridges, according to claim 1, characterized in that the inert powder is calcium carbonate. 3- Process for recycling toner cartridges, according to claim 1, characterized in that it comprises the magnetic separation of the minor fraction of the screening (7). 4- Process for recycling toner cartridges, according to claim 1, characterized in that it comprises a preliminary stage of emptying the toner from the cartridges. 5- Process for recycling toner cartridges, according to claim 1, characterized in that it comprises a step for eliminating rods prior to screening (7). 6- Process for recycling toner cartridges, according to claim 1, characterized in that it comprises a direct input (9) to the second mill (8) for the plastic cartridges. - roce meno e reccae e car uc os ener, according to revn cacn, characterized in that the screening (7) comprises a system for shaking the cartridges. 8- Toner cartridge recycling facility, with the procedure of any of the preceding claims, characterized in that it comprises: one input (1) of toner cartridges to a first mill (2) with an inert powder dispenser (4), at the output of which one or more magnetic separators (6) are arranged prior to a sieve that separates into three fractions: a second mill (8) for the larger fraction, with a dispenser (4) of inert powder, and whose output is returned to the sieve; a dust removal cyclone (10) prior to a series of separators for the different materials, in the intermediate fraction, and a minor fraction deposit, and because it includes dust suction mouths throughout the installation connected to filters (5). 9- Toner cartridge recycling facility, according to claim 8, characterized in that it comprises one or more vibrating machines (5) removing sticks prior to the magnetic separators (6) and the sieve. 10- Toner cartridge recycling facility, according to claim 8, characterized in that the sieve comprises a system of rubber balls. 11 - Toner cartridge recycling facility, according to claim 8, characterized in that the second mill (8) comprises a direct inlet (9). 12- Toner cartridge recycling facility, according to claim 8, characterized in that it comprises magnetic separators (6) of the minor fraction of the screening (7). 13- Installation for recycling toner cartridges, according to claim 8, characterized in that the cartridges are moved by pneumatic systems or bands or conveyor belts of non-metallic material. 14- Toner cartridge recycling facility, according to claim 8, characterized in that the suction system includes cyclones prior to the filters (5). 15- Toner cartridge recycling facility, according to claim 8, characterized in that the aspiration system includes flow rate sensors. 16- Toner cartridge recycling facility, according to claim 8, characterized in that it comprises an alarm center for the aspiration system that monitors the temperature, the filling of the final dust deposits and the presence of sparks or flames in the suction system.