US20110253325A1 - Process for manufacturing insulating material - Google Patents

Process for manufacturing insulating material Download PDF

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Publication number
US20110253325A1
US20110253325A1 US13/131,743 US200913131743A US2011253325A1 US 20110253325 A1 US20110253325 A1 US 20110253325A1 US 200913131743 A US200913131743 A US 200913131743A US 2011253325 A1 US2011253325 A1 US 2011253325A1
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US
United States
Prior art keywords
paper
insulation material
paper sludge
cellulose
flakes
Prior art date
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Abandoned
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US13/131,743
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English (en)
Inventor
Andrea Cavaleri
Davide Contu
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Individual
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Individual
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Filing date
Publication date
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Assigned to CONTU, DAVIDE, CAVALERI, ANDREA reassignment CONTU, DAVIDE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CAVALERI, ANDREA, CONTU, DAVIDE
Publication of US20110253325A1 publication Critical patent/US20110253325A1/en
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/16—Special fibreboard
    • D21J1/20—Insulating board
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21B—FIBROUS RAW MATERIALS OR THEIR MECHANICAL TREATMENT
    • D21B1/00—Fibrous raw materials or their mechanical treatment
    • D21B1/04—Fibrous raw materials or their mechanical treatment by dividing raw materials into small particles, e.g. fibres
    • D21B1/06—Fibrous raw materials or their mechanical treatment by dividing raw materials into small particles, e.g. fibres by dry methods
    • D21B1/08—Fibrous raw materials or their mechanical treatment by dividing raw materials into small particles, e.g. fibres by dry methods the raw material being waste paper; the raw material being rags
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/64—Paper recycling

Definitions

  • the present invention regards production of thermal and acoustic insulation material.
  • the invention specifically regards a process for making cellulose-based thermal and/or acoustic insulation material, for example by using paper sludge.
  • Such process is for example known from EP-A-0 429 735, however provided wherein is the process of adding resins or other substances to the sludge in order to confer mechanical characteristics to the end product.
  • the German patent DE3307736 A1 describes a method for regenerating waste paper and cardboard in order to produce an aqueous mixture of fibres to be used as base material for producing thermal and acoustic insulations.
  • thermoacoustic insulation material in form of flakes start from scrap paper, cardboard and waste paper. Due to long periods of storage, often outdoors or in hygienically unhealthy places, the raw material (scrap paper, cardboard and waste paper etc) may reach high levels of organic contamination that consist in the development of colonies of bacteria, insects, fungi etc.
  • raw material must be sanitised and protected against possible new procreation of microorganisms before being used.
  • bioinhibitors such as for example boron compounds (e.g. boric acid, borax, etc.) which are added dry.
  • thermoacoustic insulation material obtained from such processes has high contents of substances such as calcium carbonate, ink, glaze, etc., initially present on the scrap paper, cardboard and waste paper, thus reducing the performance of the insulating material.
  • the present invention has the object of providing improved thermal and/or acoustic insulation material.
  • An embodiment of the present invention provides for the use of paper sludge, preferably derived from industrial processes that use long fibre cellulose, to produce thermal and/or acoustic insulations in form of flakes.
  • the present invention provides for the use waste paper as secondary raw material, instead of first extraction cellulose or cellulose recycled in the known production cycles for manufacturing thermal and/or acoustic insulations, without requiring integrating the same sludge with additives, substances or resins that confer mechanical characteristics to the end material.
  • the invention allows reducing production of wastes in paper industries. Paper industry wastes are not contaminated biologically and thus do not require sanitising operations. Also the aspect of conserving durability is facilitated in that it is possible to intervene using a wider range of products such as for example fungicides, flame retardants, colouring agents, etc due to the possibility—provided for by the invention—of using additives both in solid phase and in liquid phase, allowing addition of additives at several points of the process. Furthermore, the paper industry wastes do not contain substances such as calcium carbonate, glazing, ink which limit the thermal and acoustic insulation capacity of the end product.
  • FIG. 1 represents a first embodiment of a process for producing thermal and/or acoustic insulations in form of flakes
  • FIG. 2 represents a second alternative embodiment of a process for producing thermal and/or acoustic insulations in form of flakes.
  • the present description regards a process for producing cellulose-based thermal and/or acoustic insulations using paper sludge and, in particular, paper sludge mainly derived from processes that require long fibre cellulose as raw material.
  • the technical solution described herein provides for the use of paper sludge for producing insulation material as direct surrogates for first extraction cellulose or recycled cellulose or a combination of both.
  • the technical practicability of the invention lies in the characteristics of the sludge subject of the inventing suitable for such purpose.
  • the technical solution described herein may be summarised in the use of wastes from known paper production industrial processes, for producing thermal and/or acoustic insulations in form of flakes.
  • Paper sludge may also be classified as “polluting special waste” or “non-polluting special waste” depending on the chemical additives used in the production process. In any case, costs incurred for disposing of these wastes are not negligible and they weigh, even considerably, on the financial budgets of the paper industries.
  • Cellulose is a molecule capable of organising itself into chains and thus fibres. The mechanical characteristics of the paper produced are linked to the length of the cellulose fibres. Cellulose may be classified according to the mean length of the fibres. In literature, cellulose with fibres in the order of 20 microns is referred to as “short fibre”, cellulose with fibres in the order of 200 microns long is referred to as “average fibre”, and cellulose having fibres in the order of 1000 microns long is referred to as “long fibre”.
  • Conventional paper production methods may employ a wide range of cellulose and in conventional industrial processes the residual material, i.e. sludge produced by the paper industry, is purged by the cellulose fibres capable of conferring mechanical characteristics to the paper.
  • conventional industrial processes produce paper sludge with none or extremely low mechanical characteristics.
  • the present invention reduces the amount of paper industry production wastes and has lower impact on the ecosystem. Furthermore, paper industries gain a financial advantage in that they have the possibility to convert waste material to be disposed of (i.e. a cost) into secondary raw material (i.e. a resource). In addition, availability of low cost raw material may help reducing the price of the insulation material hence leading to an advantage for the users too.
  • Paper sludge may be used as raw material in currently known conventional industrial processes for producing cellulose-based thermal and acoustic insulation material in form of flakes. Illustrated below for exemplification purpose, but solely regarding the description outlined hereinafter, is a possible production process.
  • the paper sludge considered hereinafter may have different levels of water content.
  • paper industry waste sludge with high amount of long, average and short fibre cellulose is used for producing loose insulation material in form of flakes.
  • a diagram of an industrial process for producing the abovementioned loose insulation material in form of flakes is illustrated in FIG. 1 .
  • the industrial process A provides for that the paper industries 1 produce particular papers 2 using average and long fibre cellulose.
  • the paper sludge 3 derived from the industrial process A, is reutilized in a known industrial process B and used for producing thermal and/or acoustic insulations in form of flakes.
  • the sludge 3 may be used as a surrogate or in combination with conventionally used raw material.
  • the known industrial processes for producing insulation material in form of flakes conventionally use first extraction cellulose 11 and/or recycled cellulose 12 (scrap paper).
  • the industrial process B provides for initially subjecting surrogate secondary raw material 3 (sludge) characterising the present invention optionally together with conventional raw material 11 and/or 12 to a reduction of the size of the pieces by feeding them into a cutting device 4 .
  • a series of mixers 5 is used for homogenising material from different sources.
  • the sludge 3 possibly in first extraction cellulose 11 and/or recycled cellulose 12 association is fed into a pulper 6 .
  • additives 7 for example boron salts
  • insulation material in form of flakes may be added. Sludge is thus introduced into a mill 8 possibly associated to a drying device 9 .
  • the mill 8 may contain metal percussion means (such as for example balls or rolls) or other devices useable for the hammering required to open the cellulose fibres, thus reducing density thereof and producing flakes.
  • the cellulose flake 10 obtained at the end of the process may be used for thermal and/or acoustic insulation.
  • fungicides are added to the sludge produced in the paper industries. Even more preferably, such addition is performed in the paper industries when sludge is still in flowable form, with a solid state material content between 8% and 10% in weight. Alternatively, fungicides may be added during the aforeindicated process in the pulper 6 .
  • the construction details and embodiments may widely vary with respect to the details described and illustrated, without however departing from the scope of protection of the present invention, as defined in the attached claims.
  • paper industry wastes with high amount of long, average and short fibre cellulose are used for producing loose insulation material in form of flakes.
  • FIG. 2 A diagram of an industrial process for producing the abovementioned loose insulation material in form of flakes is illustrated in FIG. 2 .
  • the industrial process A provides for the production of special papers 16 using virgin cellulose or recycled cellulose 12 .
  • the cellulose 13 reaches refining 14 where—on one hand—wastes of the subsequent steps of the process 15 are supplied, while—on the other hand—paper industry wastes which are stored and concentrated in the step 17 are eliminated.
  • Such wastes be intended to be used in a process for producing insulation material in form of flakes of the type described above, it should be preferably provided for that they be treated, while still in the paper industry factory, with additives 18 in liquid solution.
  • additives may be one or more from among flame retardants, fungicides, colouring agents, etc. It is also preferable that such additives be added when the wastes or paper sludge are still in flowable form, with solid state material content comprised between 8% and 10% in weight.
  • step 19 The wastes of the process A are thus subsequently dried in step 19 , for example mechanically by means of a screw feeder, and lastly, possibly treated with additives 15 such as flame retardants, fungicides, colouring agents etc once again.
  • additives 15 such as flame retardants, fungicides, colouring agents etc once again.
  • the additives may be both in liquid form (solution) and solid form (powder).
  • wastes thus produced may be transferred and used as raw material for the process B of producing thermal and acoustic insulation material in form of flakes.
  • Such wastes are substantially made up of sludge, having solid state material content comprised between 25% and 60% in weight.
  • the production process B illustrated in FIG. 2 represents an alternative embodiment with respect to that illustrated in FIG. 1 .
  • Such process provides for that the wastes of the process A be initially stored in a step 21 and possibly composed in a mixture that may also provide for first extraction cellulose 11 and/or recycled cellulose 12 .
  • the wastes may be treated using additives 18 in liquid solution (liquid phase) such as flame retardants, fungicides, colouring agents, etc.
  • additives 18 in liquid solution such as flame retardants, fungicides, colouring agents, etc.
  • step 22 The material is thus dried in a step 22 , both naturally and by means forced ventilation and/or heating systems, and subsequently moved to step 23 for hammering 16 .
  • step 23 for hammering 16 .
  • the dried material is expanded in volume until it forms insulation flakes.
  • the flakes may also be treated with additives 15 in powder form, both during the hammering step and during the subsequent pre-packaging storage 17 .

Landscapes

  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Paper (AREA)
  • Processing Of Solid Wastes (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Inorganic Insulating Materials (AREA)
  • Organic Insulating Materials (AREA)
US13/131,743 2008-12-12 2009-12-11 Process for manufacturing insulating material Abandoned US20110253325A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ITTO2008A000927A IT1392112B1 (it) 2008-12-12 2008-12-12 Procedimento per realizzare materiale isolante
ITTO2008A000927 2008-12-12
PCT/IB2009/055713 WO2010067338A2 (en) 2008-12-12 2009-12-11 Process for manufacturing insulating material

Publications (1)

Publication Number Publication Date
US20110253325A1 true US20110253325A1 (en) 2011-10-20

Family

ID=40791137

Family Applications (1)

Application Number Title Priority Date Filing Date
US13/131,743 Abandoned US20110253325A1 (en) 2008-12-12 2009-12-11 Process for manufacturing insulating material

Country Status (6)

Country Link
US (1) US20110253325A1 (it)
EP (1) EP2389479B1 (it)
CA (1) CA2744887A1 (it)
IT (1) IT1392112B1 (it)
SI (1) SI2389479T1 (it)
WO (1) WO2010067338A2 (it)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1400884B1 (it) 2010-07-07 2013-07-02 Nesocell S R L Procedimento per realizzare materiale isolante.
CN103088697B (zh) * 2012-04-13 2017-06-13 广东省造纸研究所 一种彩色阻燃型绝缘钢纸板及其制造工艺
EP2752521A1 (en) * 2013-01-04 2014-07-09 UPM-Kymmene Corporation A method for manufacturing a fiber based product, a fiber based product and a starting material and its use
US10753044B2 (en) 2016-04-22 2020-08-25 Enerpaper S.r.l. Process for producing a flaked thermal-insulating and/or acoustic-insulating material
WO2024100087A1 (en) 2022-11-09 2024-05-16 Circusol Holding B.V. Method and system for manufacturing cellulose-based insulation

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4356060A (en) * 1979-09-12 1982-10-26 Neckermann Edwin F Insulating and filler material comprising cellulose fibers and clay, and method of making same from paper-making waste
US5635123A (en) * 1992-08-11 1997-06-03 Phenix Biocomposites, Inc. Biocomposite material and method of making

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4848572A (it) * 1971-10-05 1973-07-10
DE3307736A1 (de) * 1983-03-04 1984-09-06 Friedrich 2807 Achim Priehs Verfahren zum herstellen von material mit hohen schall- und waermedaemmeigenschaften aus altpapier und/oder pappe
FR2638469B1 (fr) 1988-11-03 1995-07-13 Tharrault Francois Procede et installation de fabrication de panneaux isolants et autres elements rigides utilisant des sous-produits de l'industrie papetiere
US5423993A (en) * 1993-08-06 1995-06-13 John A. Boney Fiber recovery system and process
DE4417503C2 (de) * 1994-05-19 1998-05-28 Julius Schulte Soehne Gmbh & C Fasermaterial aus der Papieraufbereitung

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4356060A (en) * 1979-09-12 1982-10-26 Neckermann Edwin F Insulating and filler material comprising cellulose fibers and clay, and method of making same from paper-making waste
US5635123A (en) * 1992-08-11 1997-06-03 Phenix Biocomposites, Inc. Biocomposite material and method of making

Also Published As

Publication number Publication date
SI2389479T1 (sl) 2014-01-31
EP2389479B1 (en) 2013-08-14
ITTO20080927A1 (it) 2010-06-13
WO2010067338A2 (en) 2010-06-17
IT1392112B1 (it) 2012-02-09
WO2010067338A3 (en) 2010-08-05
CA2744887A1 (en) 2010-06-17
EP2389479A2 (en) 2011-11-30

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AS Assignment

Owner name: CAVALERI, ANDREA, ITALY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CAVALERI, ANDREA;CONTU, DAVIDE;REEL/FRAME:026567/0133

Effective date: 20110525

Owner name: CONTU, DAVIDE, ITALY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CAVALERI, ANDREA;CONTU, DAVIDE;REEL/FRAME:026567/0133

Effective date: 20110525

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION