WO2014169140A1 - Procédé et appareil de régénération et de recyclage de gazon synthétique - Google Patents

Procédé et appareil de régénération et de recyclage de gazon synthétique Download PDF

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Publication number
WO2014169140A1
WO2014169140A1 PCT/US2014/033679 US2014033679W WO2014169140A1 WO 2014169140 A1 WO2014169140 A1 WO 2014169140A1 US 2014033679 W US2014033679 W US 2014033679W WO 2014169140 A1 WO2014169140 A1 WO 2014169140A1
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WO
WIPO (PCT)
Prior art keywords
turf
infill
synthetic turf
used synthetic
section
Prior art date
Application number
PCT/US2014/033679
Other languages
English (en)
Inventor
Timothy Jay GENTRY, Sr.
Larry E. Mashburn
David Anthony BROWN, Jr.
Original Assignee
Textile Management Associates, Inc.
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 Textile Management Associates, Inc. filed Critical Textile Management Associates, Inc.
Publication of WO2014169140A1 publication Critical patent/WO2014169140A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • 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
    • 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
    • B29L2031/732—Floor coverings
    • 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 application is related to the field of synthetic turf, and more particularly to methods and apparatuses for purifying and recycling synthetic turf.
  • Synthetic turf has been used for years in athletic playing surfaces such as football, baseball, and soccer fields, and has more recently been used in other applications where an alternative to natural grass is desired. These applications include, for example, playgrounds, residential and commercial lawns, landscaping, jogging paths, paintball fields, tennis courts, putting greens, and dog runs.
  • synthetic turf includes a pile fabric having a backing and a plurality of upstanding ribbons, also called face fibers or filiform formations, resembling natural grass.
  • Many synthetic turf products also include an infill material dispersed among the upstanding ribbons, which may include sand, tire rubber crumb, and/or other particulates, either singularly or in combination with each other. The infill material simulates soil in natural turf, acts as a ballast, and/or contributes to the physical properties of the turf, such as resiliency, that make the turf suitable for a particular use.
  • Synthetic turf has a limited useful life, the length of which depends on the construction of the turf, the application for which it is used, and how the turf is maintained.
  • a typical synthetic turf for use as an athletic field may have a useful life of from about 8 to 15 years.
  • a large amount of synthetic turf is currently being used in hundreds of athletic fields and in other applications.
  • To avoid sending that turf to landfills at the end of its useful life there is a need for a method of recycling and reusing all or portions of the synthetic turf.
  • a synthetic turf that is recyclable is also a need for a synthetic turf that is recyclable.
  • Recycling of a product typically refers to converting that product into a material or product for another use or extracting at least one of the individual components or materials of the product for use of that component or material in another product.
  • the recycled product may be used in a similar product, such as when paper products are recycled to make other paper products, or may be used in a completely different product, such as when tires are recycled to make asphalt.
  • Many synthetic turf products include components that are not found in carpet and that are incompatible with, or at least undesirable in, conventional carpet recycling methods. For example, conventional carpet does not include infill. Typical infill materials for synthetic turf installations include sand, tire rubber crumb, and/or other particulates, either singularly or in combination with each other. Thus, recycling synthetic turf presents a unique problem not encountered in the recycling of carpet.
  • U.S. Patent Application Publication Number 2012/0315816 entitled “Methods of Recycling Synthetic Turf, Methods of Using Reclaimed Synthetic Turf, and Products Comprising Same" to Fowler et al. describes a process to recycle synthetic turf either by using an agglomeration step or feeding turf fragments directly into an extruder to form extrudates in various forms.
  • the Fowler application makes brief mention that turf infill can be removed by hand or by machine in paragraph [0040], but no other specific information is given regarding the importance of and degree of removal that is desirable for such process.
  • Fig. 1 shows a flow chart of a process for purifying and recycling synthetic turf
  • FIG. 2 shows three different somewhat schematic views of a turf purification apparatus
  • FIG. 3 shows three different somewhat schematic views of a modified turf purification apparatus
  • FIG. 4 shows a conveyance apparatus moving removed infill material from a turf purification apparatus
  • FIG. 5 shows a conveyance apparatus moving removed infill material to a portable storage container
  • Fig. 6 shows a sorter with multiple tiers of mesh size, sorting removed infill material
  • Fig. 7 shows products made from extrudate pellets that were created by the recycling method described herein;
  • FIG. 8 shows a turf purification apparatus in action
  • Fig. 9 shows the turf purification apparatus of Fig. 8 in action.
  • Fig. 10 shows the turf purification apparatus of FIGS. 8 and 9 at rest.
  • Embodiments of this disclosure provide a method and apparatus for recycling and reusing an existing synthetic turf.
  • the synthetic turf to be recycled using the present method and apparatus includes a pile fabric having a backing and a plurality of upstanding ribbons, also called face fibers or filiform formations, resembling grass.
  • the upstanding ribbons are made of polyethylene, polypropylene or a blend thereof.
  • the ribbons may also be made of nylon or any other material known in the art alone or in combination with polypropylene and/or polyethylene.
  • face fibers are tufted or sewn into a primary backing material which can be made of a number of different materials including, but not limited to, polypropylene and polyester.
  • a primary coating material, or precoat is applied to the fiber and primary backing to hold the face fibers in place.
  • the primary coating of most synthetic turfs includes polyurethane and also typically includes a filler such as calcium carbonate or coal fly ash.
  • Primary coatings may also include latex, hot melt adhesives, and/or thermoplastics in addition to or instead of polyurethane.
  • Synthetic turfs may also have a secondary coating which may be similar to the primary coating described herein.
  • Synthetic turfs may also have a secondary backing which can be made of a number of different materials including, but not limited to, polypropylene and polyester.
  • the face fibers typically make up from about 19 wt% to about 80 wt% of a synthetic turf.
  • the primary backing typically makes up from about 1 wt% to about 25 wt% of a synthetic turf.
  • the primary coating typically makes up from about 15 wt% to about 80 wt% of a synthetic turf.
  • Synthetic turf may also include an infill material dispersed among the upstanding ribbons, which acts as a ballast and/or contributes to the physical properties of the turf, such as resiliency, that make the turf suitable for a particular use.
  • Synthetic turf infill may be made of any material suitable for providing desired physical properties for the synthetic turf, but most often includes materials such as sand, gravel, cork, polymer beads, and rubbers, including but not limited to crumb rubber, ethylene propylene diene monomer (EPDM) rubber, and neoprene rubber.
  • materials such as sand, gravel, cork, polymer beads, and rubbers, including but not limited to crumb rubber, ethylene propylene diene monomer (EPDM) rubber, and neoprene rubber.
  • EPDM ethylene propylene diene monomer
  • neoprene rubber neoprene rubber.
  • the most common infill type used over the past quarter century is bar far silica sand in various forms and combinations with or without other infill materials.
  • the face fibers may include polyethylene, polypropylene, nylon, or other materials singly or in combination.
  • the face fibers may include from about 0 wt% to about 100 wt% polyethylene, from about 0 wt% to about 100 wt% polypropylene, and from about 0 wt% to about 100 wt% nylon.
  • the face fibers include blends of polypropylene (PP) and polyethylene (PE) in any of the following ratios of PP:PE-5:95; 10:90; 50:50; 90: 10; 95:5 or any ratio that is within these ranges of ratios.
  • the face fibers include blends of PP and nylon in any of the following ratios of PP:nylon-5:95; 10:90; 50:50; 90: 10; 95:5 or any ratio that is within these ranges of ratios.
  • the face fibers include blends of PE and nylon in any of the following ratios of PE:nylon-5:95; 10:90; 50:50; 90: 10; 95:5 or any ratio that is within these ranges of ratios.
  • the face fibers include blends of PP, PE, and nylon in any of the following ratios of PP:PE:nylon- 10: 10:80; 10:80:10; 80: 10: 10; 33:33:33 or any ratio that is within these ranges of ratios.
  • the primary backing may include polyester, polypropylene, and other materials singly or in combination.
  • the primary backing may include from about 0 wt% to about 100 wt% polyester or from about 0 wt% to about 100 wt% polypropylene.
  • the primary backing includes blends of PP and polyester in any of the following ratios of PP:polyester-5:95; 10:90; 50:50; 90: 10; 95:5 or any ratio that is within these ranges of ratios.
  • the primary coating may include polyurethane, latex, hot melt adhesive, and/or thermoplastics alone or in combination.
  • Suitable hot melt adhesives include, but are not limited to, Reynolds 54-041, Reynolds 54-854, DHM 4124 (The Reynolds Company P.O. Greenville, SC, DHM Adhesives, Inc. Calhoun, GA).
  • Suitable thermoplastics include, but are not limited to polypropylene, polyethylene and polyester.
  • the primary coating may also include a filler that may be coal fly ash, calcium carbonate, iron oxide, or barium sulfate, or any other filler known in the art.
  • the primary coating may include from about 0 wt% to about 100 wt% polyurethane, from about 0 wt% to about 100 wt% latex, from about 0 wt% to about 100 wt% hot melt adhesive, and/or from about 0 wt% to about 100 wt% thermoplastic.
  • the primary coating may include from about 0 wt% to about 80 wt% filler.
  • the primary coating includes polyurethane, latex, or thermoplastic and from about 20 wt% to about 80 wt% filler, or from about 40 wt% to about 60 wt% filler.
  • the primary coating includes hot melts and from about 0 wt% to about 50 wt% filler, or from about 1 wt% to about 25 wt% filler.
  • Table 1 Several embodiments of primary coating and secondary backing compositions are shown below in Table 1.
  • the methods described herein may be used to purify, recycle and reuse synthetic turf, including turf described above, or other synthetic surfaces having chemical make-up similar to synthetic turf.
  • a flowchart showing a version of the method is shown in FIG. 1.
  • Recycling synthetic turf begins with the removal of the material from the point of installation.
  • the synthetic turf is installed by unrolling a 15 foot wide by 150 foot long strip of turf.
  • a field typically requires multiple rolls, which are laid out on the field side by side and seamed together to form the field.
  • Infill is then installed.
  • the infill may be one or more of sand, rubber, and/or any other suitable material as described previously.
  • the onsite removal infill may be removed prior to the removal of the turf or at the same time. For example, a machine may collect the onsite removal infill and place it into a container or onto the field.
  • the turf and the onsite removal infill may be removed at the same time by a machine or by hand (as described, for example, in U.S. Patent Application Publication Number 2012/0309858 entitled "Method for Recycling Synthetic Turf and Product" to Taylor et al.).
  • the individual strips of turf may be re-rolled and shipped to a recycling facility. Alternatively, the strips of turf may be cut and optionally much of the infill is dumped out.
  • the turf then may be downsized into sections (e.g., 1 foot by 1 foot for ease and efficiency of shipping). The downsizing may be accomplished by hand or machine.
  • the machine may be large or small and may use rotary blades or knives or any of a variety of different methods known in the art.
  • the downsized pieces are typically placed on pallets and shipped to a recycling facility. Prior to recycling the pieces may be downsized even further to a size suitable for the recycling equipment being used.
  • the turf pieces may be downsized using any method known in the art (e.g., cutting, chopping, shredding, pulling, and the like).
  • a suitable size for the turf pieces for recycling depends on the extrusion equipment being used, and a person of skill in the art familiar with that equipment is familiar with the size of material that is appropriate.
  • Turf pieces that are ready for recycling are referred to herein as turf fragments.
  • the sizes of the turf fragments are highly variable. Likewise, the turf fragments may have any shape.
  • the turf fragments may include very small particles, or fines, that are almost dust-like, but also may include small irregularly shaped particles having a longest dimension of up to about 0.25 to 0.5 inch, and in many cases also may include ribbons of material having widths of less than 0.25 inch, but lengths up to about 2 inches. In some embodiments the very small particles, or fines, make up about 5% or less of the turf fragments.
  • the turf fragments typically are a loosely packed low density solid material.
  • the TRS data may have been roughly accurate based on the total mass of infill presumed to be entrained with the turf prior to initial onsite removal by TRS, but the newly discovered information at UTT regarding subsisting infill— articularly, silica-based elements— strongly suggested more steps and processes were needed in order to get reclaimed synthetic turf in better condition for recycling.
  • Claims of 95% (wt) or more of onsite infill removal where turf is being reclaimed from a field turn out to be a mere first step to provide a reliably "clean" turf roll for further recycle processing.
  • the infill removal requirements are simply turning out to be considerably more complex than previously thought. The reason for this previously unappreciated complexity is thought to be based primarily on the dynamic nature of bulk densities of silica-based materials entrained within artificial turf.
  • pockets of compacted infill invariably develop. Removed rolls that appear to have a relatively small volume of infill apparently have significantly more mass of compacted sand than previously thought. After the experience with the Cincinnati field and Hoboken field projects, these pockets of compacted sand with much higher than average bulk densities within reclaimed turf present a significant source of undesirable (and effectively unrecyclable) material subsisting within reclaimed but unprocessed artificial turf rolls. If and when this subsisting material is not properly removed, cutting equipment is susceptible to damage and/or destruction, along with any other equipment such as, for example, extruding equipment that may be used to form new products from recycled turf fibers and backing.
  • the turf purification apparatus 100 preferably includes at least two beater bars 102 A and 102B and optionally three or more beater bars 102C as shown for example on a modified turf purification apparatus 104 shown in FIG. 3.
  • the modified version of the turf purification apparatus 104 shown in FIG. 3 includes a side view of a turf roll 106 being fed through the turf purification apparatus 104.
  • the turf roll 106 is physically beaten by the beater bars 102 and brushed by one or more brushes 108 rotating on their length axes.
  • the various parts of the purification apparatus are preferably driven by electric motors as shown in FIGS. 2 and 3
  • the residual infill removed from the turf roll 106 drops out at an effluent location 110, preferably directed by the help of one or more vibrating members 112.
  • Residual infill material removed from the turf roll 106 preferably lands on a conveyance device 114 (e.g., one or more conveyor belts) and is conveyed to a portable container 116 as shown, for example, in FIGS. 4 - 5.
  • the turf roll 106 can be cycled through the purification apparatus 100 twice if desired for higher purity, but cycling the turf roll through any version of the purification apparatus more than twice was deemed inefficient based on the diminished improvement of purity.
  • Cycling the turf roll 106 through the purification apparatus 104 one time was determined to be an optimal solution considering efficiency and desired purity at that stage of the process.
  • Using a single cycle from about 70,000 to about 100,000 ft 2 of turf rolls containing typical residual infill can be purified to high levels (i.e., down to from about 4% (wt) to about 2% (wt) infill) for further processing in from about 10 to about 18 hours.
  • the disclosed method disclosed herein further includes downsizing steps and separation steps for further separating from about 1% (wt) to about 3% (wt) of non-recyclable components (infill) from the turf before extrusion.
  • the turf roll 106 is preferably cut using one or more cutting technologies for cutting synthetic turf or carpet. The cutting step loosens much of the ingrained infill material and allows for more infill to be removed during sorting. After cutting, the cut material is sorted using a sorter to separate sand, rubber, and chopped turf material.
  • the sorter is preferably a vibratory sorter with multiple sections having different mesh sizes such as, for example, the vibratory conveyor available from LMC, INC. of Donalsville, Georgia as shown in FIG. 6.
  • the chopped material is further downsized, preferably by grinding, to pieces having a longest length dimension of no more than approximately 0.25 inches.
  • the ground material is then sorted using a sorter to further separate sand, rubber, ground turf material, and any other trash or unprocessible material. At this point, less than 1% (wt) of the remaining material separated as ground turf material is properly classifiable as infill (sand and/or rubber).
  • the ground turf material is then preferably densified prior to extrusion.
  • the densification process includes melting any thermoplastic material portion of the synthetic turf after grinding using a controlled heat source while turf fragments are conveyed (e.g., a conveyor belt) to the extruder. During conveyance, the temperature preferably ranges from about 250°F to about 350°F for an exposure time period of from about 0.75 minutes to about 1.5 minutes.
  • the densification step preferably curls polypropylene and/or polyethylene materials thereby densifying them while simultaneously attaching or otherwise comingling such materials with polyurethane particles, fillers or other materials that are not influenced by the heat.
  • Agglomeration was a prior option that proved to be considerably expensive, not many agglomerator contractors were available, and agglomerators were not particularly helpful with greige or uncoated turf.
  • the densification step described herein allows increased extruder capacity by two or three times (by mass) than without conducting a densification step.
  • the agglomeration process is not very a good process for conduxing of materials which are uncoated. Materials such as polyethylenes and or polyolefms alone would melt and stop up an agglomerator, so it is desirable to be able to have the option of foregoing agglomeration and using the densification step described above.
  • the step of extruding the mixture of synthetic turf fragments and additive may be carried out with any equipment suitable for extrusion or known to one of skill in the art.
  • extruders may be used for this process depending upon the type of mixing or heating that is desired.
  • suitable extruders include single screw and twin screw extruders.
  • the twin screw extruder can have co-rotating or counter rotating screws and the single screw extruder has one rotating screw.
  • the screws can be designed for different purposes but have the capacity to heat and mix the material.
  • Extruders typically have variable screw speeds and variable heating as well as variable feed rates. The appropriate speed and heat rate is determined by the type of output desired.
  • Extrusion is carried out at elevated temperatures.
  • the temperature during extrusion is between about 200°F and about 500°F, or between about 250°F and about 450°F.
  • the temperature during extrusion is between about 350°F and about 400°F.
  • the rate of extrusion is from about 3 to about 2,000 lbs/hour, or from about 100 to about 500 lbs/hour, or from about 300 to about 500 lbs/hour.
  • Extrusion can be carried out using any size die that will provide a product of the desired size and shape, but in some embodiments is carried out using a die that has an aperture in the shape of a slot.
  • the size of the slot may vary depending on the size of the extruder, the size of the available cutting equipment, and/or the desired use of the extrudate.
  • One of skill in the art can easily determine the appropriate size of the slot based on the available equipment and desired end use of the product.
  • the extrudate is preferably pelletized and can be used as the primary component to create various structures via injection molding such as, for example, a dog bowl 200 and pallets 202 A, 202B, and 202C as shown in FIG. 7.
  • the pellets can be used as the only component via injection molding to create these types of products.
  • FIGS. 8-10 Actual images of the turf purification apparatus 100 are shown in FIGS. 8-10.

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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)
  • Road Paving Structures (AREA)

Abstract

L'invention concerne un procédé et un appareil de régénération et de recyclage de gazon synthétique. Le procédé consiste à retirer une section de gazon synthétique usé, amener la section vers un batteur rotatif pour battre et éliminer le sable de remplissage, et amener la section dans une brosse rotative, une surface filamenteuse du gazon étant directement mise en contact avec la brosse rotative de façon à faire tomber une matière de remplissage entraîné de la section de gazon synthétique usé.
PCT/US2014/033679 2013-04-10 2014-04-10 Procédé et appareil de régénération et de recyclage de gazon synthétique WO2014169140A1 (fr)

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US201361810538P 2013-04-10 2013-04-10
US61/810,538 2013-04-10

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WO2014169140A1 true WO2014169140A1 (fr) 2014-10-16

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201900014517A1 (it) * 2019-08-09 2021-02-09 Sabbie Di Parma S R L Macchina per impianti di smaltimento e riciclo di campi in erba sintetica

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0185646A2 (fr) * 1984-12-17 1986-06-25 Monsanto Company Procédé de traitement pour gazon artificiel
US20100319510A1 (en) * 2009-06-20 2010-12-23 Bearden John H Apparatus for collecting artificial turf for recycling
EP2387875A1 (fr) * 2010-05-17 2011-11-23 Loon- en Verhuurbedrijf Th. Schuurman en zoon V.O.F. Dispositif d'élimination d'intercalaire pour éliminer l'intercalaire d'une bande de gazon artificiel
US20130064996A1 (en) * 2008-12-15 2013-03-14 Larry Mashburn Method of recycling synthetic turf
WO2013042817A1 (fr) * 2011-09-23 2013-03-28 코오롱글로텍주식회사 Procédé de recyclage d'herbe artificielle contenant de la matière fibreuse

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0185646A2 (fr) * 1984-12-17 1986-06-25 Monsanto Company Procédé de traitement pour gazon artificiel
US20130064996A1 (en) * 2008-12-15 2013-03-14 Larry Mashburn Method of recycling synthetic turf
US20100319510A1 (en) * 2009-06-20 2010-12-23 Bearden John H Apparatus for collecting artificial turf for recycling
EP2387875A1 (fr) * 2010-05-17 2011-11-23 Loon- en Verhuurbedrijf Th. Schuurman en zoon V.O.F. Dispositif d'élimination d'intercalaire pour éliminer l'intercalaire d'une bande de gazon artificiel
WO2013042817A1 (fr) * 2011-09-23 2013-03-28 코오롱글로텍주식회사 Procédé de recyclage d'herbe artificielle contenant de la matière fibreuse

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201900014517A1 (it) * 2019-08-09 2021-02-09 Sabbie Di Parma S R L Macchina per impianti di smaltimento e riciclo di campi in erba sintetica

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