WO2002038276A1 - Procede de recyclage direct de dechets plastiques - Google Patents

Procede de recyclage direct de dechets plastiques Download PDF

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Publication number
WO2002038276A1
WO2002038276A1 PCT/IN2001/000096 IN0100096W WO0238276A1 WO 2002038276 A1 WO2002038276 A1 WO 2002038276A1 IN 0100096 W IN0100096 W IN 0100096W WO 0238276 A1 WO0238276 A1 WO 0238276A1
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WO
WIPO (PCT)
Prior art keywords
plastic wastes
plastic
tubular body
wastes
direct recycling
Prior art date
Application number
PCT/IN2001/000096
Other languages
English (en)
Inventor
Yash Vasant Joshi
Original Assignee
Yash Vasant Joshi
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Yash Vasant Joshi filed Critical Yash Vasant Joshi
Priority to AU2001267817A priority Critical patent/AU2001267817A1/en
Publication of WO2002038276A1 publication Critical patent/WO2002038276A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
    • B03B1/00—Conditioning for facilitating separation by altering physical properties of the matter to be treated
    • B03B1/02—Preparatory heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
    • B03B9/00—General arrangement of separating plant, e.g. flow sheets
    • B03B9/06—General arrangement of separating plant, e.g. flow sheets specially adapted for refuse
    • B03B9/061—General arrangement of separating plant, e.g. flow sheets specially adapted for refuse the refuse being industrial
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
    • B07B13/00—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices
    • B07B13/003—Separation of articles by differences in their geometrical form or by difference in their physical properties, e.g. elasticity, compressibility, hardness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B2017/0094—Mobile recycling devices, e.g. devices installed in truck trailers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0203—Separating plastics from plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0217—Mechanical separating techniques; devices therefor
    • B29B2017/0224—Screens, sieves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0255—Specific separating techniques using different melting or softening temperatures of the materials to be separated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/065—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts containing impurities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
    • B29K2709/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
    • B29K2711/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/008—Wide strips, e.g. films, webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7158—Bottles
    • 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
    • Y02W30/52—Mechanical processing of waste for the recovery of materials, e.g. crushing, shredding, separation or disassembly
    • 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
    • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

  • This invention relates to a process and apparatus for local reprocessing mixed post-consumer thermoplastic wastes.
  • Shopping bags, polystyrene foam, bubble film, PET bottles, other packaging materials and plastic articles presently constitute typically about 10 percent of solid wastes generated by urban and rural communities, in both developed and developing countries.
  • the activity of plastic reprocessing presently involves multiple agencies; namely, collectors, segregators, balers, pelletizers, secondary manufacturers. This method is economically unaffordable for processing very cheap plastic wastes, due to which recycled plastics can often cost more than virgin materials. As a result, most plastic wastes are presently being incinerated or land-filled.
  • the invention gives a process and apparatus suitable for direct conversion of mixed thermoplastic wastes to its saleable constituents in forms of plastic pellets, moulded articles or fibres.
  • the machines can be affordably installed at or near all places of origination of plastic wastes.
  • Household or curbside appliances based on the invention can work as "active litter-bins" to locally recycle lightly contaminated post-consumer plastic wastes.
  • Plastic raw materials are traditionally traded in form of pellets. Plastic wastes are also recycled into pellets or lumps, before converting into useful articles. Pelletization of plastic wastes involves processes of cleaning, sorting, shredding, pulverizing, density separation, and extrusion into pellets of uniform shapes. Conventional reprocessing industry uses large and expensive machinery for each of these purposes.
  • Segregation of plastic components is essential to produce commercial grade of recycled plastic. Presently, one or more of the following methods perform segregation:
  • the medium for separation can be either air or water/liquid. Examples are cited in US Patent Nos. 05169005, 4409098
  • the primary object of the present invention is to discover a simple and direct method for reprocessing mixed / unmixed post-consumer plastic wastes into usable pellets, moulded articles or fibres with use of simple technology and inexpensive machinery. This will enable reprocessing activity to be dispersed, rather than centralized.
  • An immediate advantage of the technology would be to enable reprocessing of different types of plastic wastes by dedicated machines, located near the source of wastes or on curbsides. Many plastic wastes generated at homes or offices, such as carry-bags, Styrofoam, PET bottles, polystyrene beverage cups, etc. are quite pure at source, and would generate good recycled plastic if they are reprocessed without allowing their contamination.
  • the next important object of the invention therefore is to produce a method for automatic segregation of plastic wastes from each other, and non-plastic contaminants like paper, glass, metal.
  • Plastics have to re-process in closed chambers for preventing their oxidation and volatilization, and also to avoid atmospheric pollution. It is necessary to add beneficiating ingredients, such as plasticisers, resins, pigments, and fillers, to the plastic batch to improve the properties of the intermediate or final output. Fillers such as sand can increase density of pellets allowing safe disposition of the heavy pellets in water bodies or landfills, without risk of their floatation. Other additives add value to the plastic by improving workability, colour, working life, or other attributes. Thus the process and apparatus of the invention should anaerobically process plastics, and allow for mixing of additives.
  • Figure 1 shows the section view of the preferred embodiment of the invention, which shows a low-cost vertical column cold-top extruder, designed for melting of typical household plastic wastes such as ITDPE (milk) bags or PET (carbonated beverage) bottles.
  • ITDPE milk
  • PET carbonated beverage
  • Figure 2 to 4 show the post extrusion device options.
  • the first option shown in figure 2 depicts a motorized scissors mechanism for cutting extruded plastic section into pellets that are immediately water-cooled and collected in a bin.
  • Figure 3 shows the second option in which molten plastic flows in an open compression mould placed below the machine.
  • Simple solid articles like medallions, stoppers and nameplates can be moulded.
  • Figure 4 shows the third option of drawing the molten plastic in fibre form.
  • Polymers like HDPE, PET are easy to draw as continuous fibres.
  • Good regulation of die temperature and extrusion pressure can produce reasonably good fibres that can be bunched, woven or knitted to produce useful plastic articles like ropes, woven belts, scrubbers, door mats, etc.
  • Figure 5 shows a scaled up embodiment of the invention designed for simultaneous segregated output of different plastic components from a mixed batch of plastic wastes. Non-melting contaminants are also continuously separated. This machine can work effectively as a curbside "active litter-bin”.
  • Figure 1 shows the base stand 6 supporting tubular body 1 which holds the plastic wastes.
  • Body 1 has hinge pin 25 rotatably carry lid 26.
  • Latch spring 24 latches lid 26 concentric to body 1 with latch 23.
  • Lid 26 carries pressing motor 4 having internally threaded hollow rotor shaft 5. The motor turns shaft 5 to move lead screw 3 up or down along with pressure plate 2.
  • An internal key way in lead screw 3 engages with an inward projecting stub of anti-rotation plate 27 to prevent rotation of screw 3 with shaft 5. In its lowest position, pressure plate 2 is approximately midway in body 1.
  • Electrical heater 8 banded around cylinder body 1 heats and melts plastic wastes 1 1 occupying the lowest level inside body 1.
  • Pressure plate 2 never descends to this level, thus ensuring its freedom to slide within body 1 without getting jammed by resolidified molten plastic between its sides and body 1. flowing up its sides.
  • the pressure plate connects to unmolten plastic wastes 9 in the top zone.
  • Under this layer lies the middle zone of semi-molten plastics 10 at a temperature between deflection temperature and melting temperature of the major plastic components of the batch.
  • the temperature of the lowest zone 3 is maintained equal to or slightly higher than the melting temperature of plastic that is to be extruded. This temperature can be progressively increased to extrude different plastic components progressively according to their melting / softening temperatures.
  • the solid, semi-solid and liquefied plastic mass behaves as a non-Newtonian fluid, transferring pressure from the pressure plate downwards, with a continuous drop in pressure due to friction of side-walls.
  • the molten plastic extrudes from the nozzle at bottom center of the body with this pressure and its own weight.
  • a metal sieve 7 resting on top of bottom plate 13 filters non- molten plastic or non-plastic components from the plastic melt before reaching nozzle 38.
  • a screw jack assembly installed on base stand 6 of body 1 lifts the bottom plate though insulation boards 14. Jack bolts 15 in a push plate press against base stand 6 to lift the insulation boards 14. This seals the periphery of bottom plate 13 against the machined face in the recess of pipe of body 1 , preventing leakages.
  • Extrusion die 12 is fitted to nozzle 38.
  • Lower part of body 1, heater 8, and top portion of base stand 6 are all collectively insulated with ceramic wool insulation 16.
  • FIG. 2 shows the motorized scissor mechanism in details.
  • Pellet cutter motor 19 fixed on base stand 6 drives a double-faced cam 20. Each face of cam operates one of the scissor blades 21 that together cut the extruded strand into pellets 22.
  • Bin 29 placed in water tub 41 under die 12 accumulates pellets and further cools them in water. Perforations in the bin allow flow of water to and from water tub 41, while automatically draining the water when removing the bin. Water-cooling of pellets 22 prevent them from adhering to each other and other metallic parts.
  • the cutter motor 19 base suspends a water pump 28 inside the water tub. The water pump lifts water from the tub and pours it on the extruded plastic strand to form a solid crust and facilitate cutting.
  • the RTD measures the temperature in centre of the die and the electronic temperature controller maintains it to the required set point.
  • Polymer components like polyolefins have lowest melting points and are extruded at low temperatures.
  • the differences in melting temperatures, or more correctly the melt-flow characteristics, help in separation of plastics by using the principle of fractional melting. With gradual increase in temperature of the melting zone, different plastic ingredients such as Polystyrene, Polypropylene, polyester, PET, etc get drained sequentially from the same die.
  • Figure 3 shows a different option of a split mould capable of directly hand-moulding recycled plastic in forms of small useful articles such as buttons, badges, name plates, etc.
  • PET plastic waste can be moulded to make pre-forms suitable for stretch blow-moulding of the same articles as before.
  • plastic is extruded at higher temperature than for forming pellets.
  • Motorized gate plate 47 plugs the die till the mould is ready to receive the melt.
  • the mould gets filled with molten plastic that fills up the mould cavity to the desired level.
  • the gate plate then plugs the die and the filled mould is closed, and allowed to cool.
  • the moulded article is removed by opening the mould and the cycle is repeated.
  • Figure 4 shows another option to directly convert recycled plastic to fibres.
  • the extruded plastic strand is guided through and cooled by a ring-cooling die 44.
  • the strand is solidified before it reaches the bin where it turns around a fixed idler roller 46 to reach another idler mounted on dancing roller 42.
  • the diameter of the strand and pulling speed is decided by many factors including the plastic composition, temperature of extrusion die, the pull on the fibre exerted by weight of the dancing roller, and the pattern of cooling. Steady conditions of temperature and cooling result in a fairly uniform size and output of fibre.
  • the fibre is wound around a motorized bobbin 45.
  • the motor driving the bobbin wraps the fibre as it accumulates under the dancing roller, with the motor starting when the dancing roller reaches the bottom, and stopping when it reaches the top. This allows production of long lengths of plastic fibres that can be used for making various stranded, knitted and woven articles such as cleaning mops, doormats, wire ropes, belts, multifilament ropes, etc.
  • FIG. 5 shows another embodiment of the invention suitable for curbside operations.
  • This machine is designed to handle heavily mixed plastic wastes. It is designed to continuously separate the components of the waste by using a process of fractional melting, in principle akin to the more commonly known process of fractional distillation.
  • the main body of this machine is placed horizontally and citizens deposit plastic wastes in an overhead hopper at one end.
  • a reciprocating electrically / pneumatically / hydraulically operated actuator 30 is movable at one end of body.
  • the pressure plate joined to the actuator normally presses plastic wastes into the cylinder body while pressing forward. intermittently, the pressing plate is retracted to admit plastic wastes from the hopper 36 into the cylinder body 1.
  • the cylinder body has a series of nozzles at various points along the centerline, placed between heaters, optional air-blowers and RTD sensors, for maintaining the desired temperature profile across the length of the different zones.
  • Plastic wastes are progressively heated as they pass each zone marked I to IV, and different components of plastic melt and extrude out of different dies fitted in the nozzles according to their order of melting.
  • a second pneumatic / hydraulic / electromechanical actuator exerts controlled amount of backpressure on the counter-pressure plate 48 pressing against the open end of body 1.
  • Non-melting residual wastes, including paper, plastic, stones, etc are discharged into the last collection chamber 40 D by lifting the plate 48. This discharge is suitable only for landfilling.
  • the other collection chambers collect different plastics that extrude at different temperatures. Scissors mechanisms or other post-processing options as above are located under each die .
  • the body can be placed at an inclination to the horizontal layout described in figure 5; to derive benefits of gravity assisted forward flow of plastic.
  • a dedicated machine can be used in conjunction with a coffee vending machine for recycling used coffee cups made from polystyrene.
  • Special features can be provided to clean plastic wastes from l ⁇ iown contaminants prior to recycling.
  • the likely impurities are beverage residues. Specific provision of rinsing and air drying of the plastic wastes before reprocessing would help to improve the quality of output of dedicated machines.
  • the last described embodiment of the invention is very useful for kerbsides, drop-boxes, offices, eating places, etc. where mixing of plastic wastes would be the rule. In such places, the machine has to continuously segregate the different plastic components to get reasonable throughput in fully automatic operations.
  • the simplest embodiments of the invention can do without automation, and have the heater as the sole active electrical component. Pressure is applied by a ballast on top of the column of plastic wastes. The ballast is lifted by hand or foot to load fresh plastic into the machine. The extruded plastic is collected in form of lumps.
  • the embodiment described in figure 1 has an intermediate level of automation. It has a pressing motor, programmable temperature controller, pellet cutting device, water pump, exhaust fan and electrical interlocks. It also has a provision for removing non-melting contaminants from the melting chamber. Heater 8 of the embodiment is switched ON and OFF through the temperature controller operating .
  • Low temperature plastics like LDPE melt at lowest temperatures, and extrude at temperatures as low as 120 deg. C measured near the die.
  • High temperature plastics like PET / nylon melt at much higher temperatures and extrude from the same die only after the temperature is raised.
  • Anaerobic melting and internal scrubbing of gases is the special feature of the invention.
  • the cold solid mass of plastic column in top zone of body 1 and lukewarm mass of deformed, compressed and semi-molten .plastic in the middle zone of body 1 act as sealant. These plastics recondense the volatile gases emitted from the molten plastic, and they also prevent atmospheric Oxygen from oxidizing the molten resins.
  • a suction fan creates a negative pressure in the region of extrusion die, water tub and top of the body 1 to further ensure that the very small quantity of gas emissions are evacuated from a single point, allowing appropriate gas treatment appliances like scrubbers can be installed to clean the eventual exhausts from any source of air pollution. Cooling of plastic extrusion within the long die, and immediate crust formation due to direct contact with water prevents oxidation and gas emissions from the extrusion.
  • non-melting impurities remain in the body as they do not melt at even the highest temperatures that the device can achieve. These are periodically removed by opening the bottom plate at the bottom of the body 1 with help of jack bolts 15. Without the bottom plate in place, body 1 is a through pipe and easy to clean with the heaters melting the plastic residues sticking to the inner sides of the cylinder body.
  • An embodiment of the invention has a screw feeder automatically dispenses specific additives to the plastic batch at one or more stages of passage through the machine from hopper to the extrusion die.
  • the scope of the invention is not limited by the described embodiments, but includes all plastic melters / extruders in which plastic wastes are intermittently admitted at one end of a closed cavity and pressed towards other end by a pressure plate which always connects to unmolten plastic at the feeding end while molten plastic extrudes from the other end.
  • a temperature gradient in the cavity causes plastic to heat and melt as it progressively travels in the cavity.
  • Liquefied constituents of plastic drain through one or more extrusion dies, located in different temperature zones. Additional heaters are used to condition the plastic leaving the die for ease of its post-processing such as cutting into pellets or drawing into fibres.
  • the invention allows fractional melting of plastics with or without the facility of melt - separation of its different constituents.
  • One embodiment of the invention employs devices and instrumentation to measure and control the rate of plastic melt flowing out of the die.
  • Another embodiment uses a combination of heating and cooling with air or water to control the zone temperatures to higher accuracy.
  • extrusion dies can be heated and / or cooled in controlled manner to regulate or stop extrusion from any die.
  • the overall scope of the invention is therefore limited only by the following claims.

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  • Engineering & Computer Science (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)

Abstract

L'invention concerne un procédé et des dispositifs destinés à un recyclage direct de déchets plastiques de consommation, tels que des verres en polystyrène, des bouteilles en PET, des sacs en polyéthylène et des films agricoles, d'où l'obtention de produits intermédiaires ou utilisables. Ces dispositifs sont adaptés à une installation au voisinage d'une source de déchets. Dans un mode de réalisation, les déchets plastiques sont acheminés vers la partie supérieure d'un cylindre puis entraînés vers la partie inférieure chauffée. La chaleur fait fondre les composants plastiques, lesquels sont extrudés par l'intermédiaire d'une filière au niveau de l'extrémité inférieure dudit cylindre. Ce dispositif permet de séparer les composants plastiques par augmentation régulée des températures d'extrusion jusqu'à des valeurs supérieures aux points de fusion de chacun de ces composants plastiques. Un autre dispositif utilisant cette invention maintient un profil de température constant sur toute la longueur d'un cylindre. Des filières multiples placées dans différentes zones de température permettent d'extruder différents composants plastiques, les déchets plastiques étant entraînés à travers des zones à température croissante. Le plastique extrudé peut être moulé, coupé en granulés ou récupéré sous forme de fibres, par exemple.
PCT/IN2001/000096 2000-11-01 2001-05-03 Procede de recyclage direct de dechets plastiques WO2002038276A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2001267817A AU2001267817A1 (en) 2000-11-01 2001-05-03 Method for direct recycling of plastic wastes

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN973/MUM/2000 2000-11-01
IN973MU2000 2000-11-01

Publications (1)

Publication Number Publication Date
WO2002038276A1 true WO2002038276A1 (fr) 2002-05-16

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AU (1) AU2001267817A1 (fr)
WO (1) WO2002038276A1 (fr)

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WO2003076154A1 (fr) * 2002-03-08 2003-09-18 Gonzalez Salazar Jose Luis Machine et procede de recyclage d'ordures inorganiques et d'obtention d'une pate moulable a differents usages
WO2006041277A1 (fr) * 2004-10-15 2006-04-20 Wim Albertus Cornelis Hardeman Appareil et procede pour former des produits finis a partir de plastique
DE102007041297A1 (de) * 2007-08-31 2009-03-05 Isr Interseroh Rohstoffe Gmbh Verfahren zur Herstellung von Spinn- und Stapelfasern aus Verbundfolienstücken
EP2933289A1 (fr) 2014-04-17 2015-10-21 Rexest Grupp OÜ Composition polymère à partir de déchets de plastique mélangés
WO2016081568A1 (fr) * 2014-11-18 2016-05-26 Mohawk Industries, Inc. Systèmes et procédés de fabrication de filament continu gonflant
EP3031782A1 (fr) 2014-12-09 2016-06-15 Producta S.A.S. di Ladikos Elefterios & C. Installation et procédé pour la réduction de polluants dans des gaz brûlés et l'eau de traitement provenant d'une unité de recyclage de résidus de gomme
WO2016095304A1 (fr) * 2014-12-18 2016-06-23 江苏微赛新材料科技有限公司 Procédé et dispositif de recyclage de matériaux moussants
US9550338B2 (en) 2012-05-31 2017-01-24 Mohawk Industries, Inc. Systems and methods for manufacturing bulked continuous filament
US9550713B1 (en) 2015-07-09 2017-01-24 Loop Industries, Inc. Polyethylene terephthalate depolymerization
US9630354B2 (en) 2012-05-31 2017-04-25 Mohawk Industries, Inc. Method of manufacturing bulked continuous filament
US9630353B2 (en) 2012-05-31 2017-04-25 Mohawk Industries, Inc. Method of manufacturing bulked continuous filament
US9636860B2 (en) 2012-05-31 2017-05-02 Mohawk Industries, Inc. Method of manufacturing bulked continuous filament
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DE10330044B4 (de) * 2002-07-04 2017-05-11 Denso Corporation Trennverfahren von Harz und Metall einer Leiterplatte und dessen Vorrichtung
US10252976B1 (en) 2017-09-15 2019-04-09 9449710 Canada Inc. Terephthalic acid esters formation
US20190118413A1 (en) 2012-05-31 2019-04-25 Mohawk Industries, Inc. Systems and methods for manufacturing bulked continuous filament from colored recycled pet
US10487422B2 (en) 2012-05-31 2019-11-26 Aladdin Manufacturing Corporation Methods for manufacturing bulked continuous filament from colored recycled pet
WO2019234511A1 (fr) * 2018-06-05 2019-12-12 Braskem S.A. Procédés de recyclage pour stratifiés et multicouches
US10538016B2 (en) 2012-05-31 2020-01-21 Aladdin Manufacturing Corporation Methods for manufacturing bulked continuous carpet filament
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US10695953B2 (en) 2012-05-31 2020-06-30 Aladdin Manufacturing Corporation Methods for manufacturing bulked continuous carpet filament
US10751915B2 (en) 2016-11-10 2020-08-25 Aladdin Manufacturing Corporation Polyethylene terephthalate coloring systems and methods
US10808096B2 (en) 2018-06-25 2020-10-20 9449710 Canada Inc. Terephthalic acid esters formation
CN111890596A (zh) * 2020-07-11 2020-11-06 周国星 一种废弃玻璃胶管处理设备
US11045979B2 (en) 2012-05-31 2021-06-29 Aladdin Manufacturing Corporation Methods for manufacturing bulked continuous filament from recycled PET
CN113290739A (zh) * 2021-05-24 2021-08-24 李志新 一种可降解塑料及其制备方法
US11242622B2 (en) 2018-07-20 2022-02-08 Aladdin Manufacturing Corporation Bulked continuous carpet filament manufacturing from polytrimethylene terephthalate
US11248103B2 (en) 2019-03-20 2022-02-15 9449710 Canada Inc. Process for the depolymerization of polyethylene terephthalate (PET)
US11279071B2 (en) 2017-03-03 2022-03-22 Aladdin Manufacturing Corporation Method of manufacturing bulked continuous carpet filament
US11351747B2 (en) 2017-01-30 2022-06-07 Aladdin Manufacturing Corporation Systems and methods for manufacturing bulked continuous filament from colored recycled PET
WO2022150299A1 (fr) * 2021-01-05 2022-07-14 Sofia Richard Systèmes et procédé de fabrication de pastilles à partir de matières plastiques mélangées
US11473216B2 (en) 2017-09-15 2022-10-18 Aladdin Manufacturing Corporation Polyethylene terephthalate coloring systems and methods
US12071519B2 (en) 2017-09-15 2024-08-27 9449710 Canada Inc. Terephthalic acid esters formation

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WO2003076154A1 (fr) * 2002-03-08 2003-09-18 Gonzalez Salazar Jose Luis Machine et procede de recyclage d'ordures inorganiques et d'obtention d'une pate moulable a differents usages
DE10330044B4 (de) * 2002-07-04 2017-05-11 Denso Corporation Trennverfahren von Harz und Metall einer Leiterplatte und dessen Vorrichtung
WO2006041277A1 (fr) * 2004-10-15 2006-04-20 Wim Albertus Cornelis Hardeman Appareil et procede pour former des produits finis a partir de plastique
GB2435007A (en) * 2004-10-15 2007-08-15 Wim Albertus Cornelis Hardeman Apparatus and method for forming end products from plastic
DE102007041297A1 (de) * 2007-08-31 2009-03-05 Isr Interseroh Rohstoffe Gmbh Verfahren zur Herstellung von Spinn- und Stapelfasern aus Verbundfolienstücken
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US9636860B2 (en) 2012-05-31 2017-05-02 Mohawk Industries, Inc. Method of manufacturing bulked continuous filament
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US11724418B2 (en) 2012-05-31 2023-08-15 Aladdin Manufacturing Corporation Methods for manufacturing bulked continuous carpet filament
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EP2933289A1 (fr) 2014-04-17 2015-10-21 Rexest Grupp OÜ Composition polymère à partir de déchets de plastique mélangés
WO2016081568A1 (fr) * 2014-11-18 2016-05-26 Mohawk Industries, Inc. Systèmes et procédés de fabrication de filament continu gonflant
EP3031782A1 (fr) 2014-12-09 2016-06-15 Producta S.A.S. di Ladikos Elefterios & C. Installation et procédé pour la réduction de polluants dans des gaz brûlés et l'eau de traitement provenant d'une unité de recyclage de résidus de gomme
WO2016095304A1 (fr) * 2014-12-18 2016-06-23 江苏微赛新材料科技有限公司 Procédé et dispositif de recyclage de matériaux moussants
US9550713B1 (en) 2015-07-09 2017-01-24 Loop Industries, Inc. Polyethylene terephthalate depolymerization
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