WO2017059497A1 - Traitement de matériaux résiduels - Google Patents

Traitement de matériaux résiduels Download PDF

Info

Publication number
WO2017059497A1
WO2017059497A1 PCT/AU2016/050945 AU2016050945W WO2017059497A1 WO 2017059497 A1 WO2017059497 A1 WO 2017059497A1 AU 2016050945 W AU2016050945 W AU 2016050945W WO 2017059497 A1 WO2017059497 A1 WO 2017059497A1
Authority
WO
WIPO (PCT)
Prior art keywords
product
plastics material
waste
materials
method defined
Prior art date
Application number
PCT/AU2016/050945
Other languages
English (en)
Inventor
Matthew James ACTON
Daniel Philip WADDINGTON
Original Assignee
Biocoal Group Pty Ltd
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
Priority claimed from AU2015904095A external-priority patent/AU2015904095A0/en
Application filed by Biocoal Group Pty Ltd filed Critical Biocoal Group Pty Ltd
Publication of WO2017059497A1 publication Critical patent/WO2017059497A1/fr

Links

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
    • 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
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L5/00—Solid fuels
    • C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
    • C10L5/34—Other details of the shaped fuels, e.g. briquettes
    • C10L5/36—Shape
    • C10L5/363—Pellets or granulates
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L5/00—Solid fuels
    • C10L5/40—Solid fuels essentially based on materials of non-mineral origin
    • C10L5/406—Solid fuels essentially based on materials of non-mineral origin on plastic
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L5/00—Solid fuels
    • C10L5/40—Solid fuels essentially based on materials of non-mineral origin
    • C10L5/48—Solid fuels essentially based on materials of non-mineral origin on industrial residues and waste materials
    • 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
    • B29B2017/0268—Separation of metals
    • B29B2017/0272—Magnetic separation
    • 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
    • B29B2017/0279—Optical identification, e.g. cameras or spectroscopy
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
    • C10L2290/24—Mixing, stirring of fuel components
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
    • C10L2290/28—Cutting, disintegrating, shredding or grinding
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
    • C10L2290/30—Pressing, compressing or compacting
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
    • C10L2290/40—Applying a magnetic field or inclusion of magnets in the apparatus
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
    • C10L2290/54—Specific separation steps for separating fractions, components or impurities during preparation or upgrading of a fuel
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L5/00—Solid fuels
    • C10L5/40—Solid fuels essentially based on materials of non-mineral origin
    • C10L5/403—Solid fuels essentially based on materials of non-mineral origin on paper and paper waste
    • 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
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel
    • 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

  • the present invention relates to processing waste materials and producing valuable end-use products .
  • the present invention relates particularly, although by no means exclusively, to a method of manufacturing a valuable end-use product in the form of a plastics material product from a co-mingled waste feed material, as described herein.
  • the present invention also relates particularly, although by no means exclusively, to a plant for
  • the present invention also relates particularly, although by no means exclusively, to a composite product that includes the above-described plastics material product and another carbon-bearing material that is suitable for use in high temperature processes .
  • a high temperature process is a metallurgical process , such as a steel making process in a steel making furnace .
  • Other examples of high temperature processes are processes that are carried out in power stations and kilns, such as cement making kilns, which require heat to be generated by fossil or engineered fuels.
  • the present invention also relates particularly, although by no means exclusively, to a method of
  • the present invention also relates particularly, although by no means exclusively, to a plant for
  • discarded packaging includes, by way of example only, cardboard cartons, disposable bags made from films of plastics materials, and bottles and containers made from plastics material.
  • waste materials are recycled and re-used in the production of new products .
  • a further proportion of the waste materials are processed to become a refuse-derived fuel (“RDF”) or a higher calorific solid recovered fuel (“SRF”) .
  • RDF refuse-derived fuel
  • SRF calorific solid recovered fuel
  • RDF reuse-derived fuel
  • solid recovered fuel is understood herein to mean a higher calorific category of the broader term refuse-derived fuel .
  • the present invention makes it possible to obtain higher economic value for waste materials than is possible at the moment.
  • the present invention provides an opportunity to process waste materials and produce a product that is substantially a plastics material .
  • the present invention provides an opportunity to use the substantially plastics material product as a component of a composite of the plastics material and another carbon-bearing material which is suitable for use as a source of energy and as a reductant in pyrometallurgical processes carried out in metallurgical furnaces .
  • the focus of the present invention is on producing a substantially plastics material product from a co-mingled waste feed material.
  • the present invention provides a method of
  • the shredding step is important in terms of "conditioning" the waste feed material for downstream size separation.
  • shredding has a different impact on plastics materials (such as in the form of plastic material bags and plastics bottles and other containers) and paper-based materials and other feed materials. More particularly, the applicant has found that there is a greater tendency for waste plastics materials to shred into larger pieces than the non-plastics material component of the waste material .
  • this impact of shredding on the waste material is particularly the case when waste material is subjected to a coarse shredding step.
  • the threshold size is not an absolute value and varies depending on the characteristics of the waste feed materials.
  • the threshold size is 60mm.
  • the threshold size is a size in a range of 50-70mm, tyically in a size in a range of 55-65mm.
  • the size separation step makes it possible to create a first process stream that is predominantly plastics material, i.e. a comparatively pure stream with respect to plastics materials.
  • the first process stream is then further processed to remove what are "contaminants" from the perspective of the end product, i.e. the substantially plastics material product. More particularly, the term "contaminants" is a relative term.
  • contaminant in terms of a particular product, such as the substantially plastics material product, may be an otherwise valuable material. Aluminium and other metals are examples .
  • the further processing steps for the first process stream may include an optical sorting to remove fibrous material and selected plastics materials, such as PVC, that are not required for the substantially plastics material product .
  • the further processing steps for the first process stream may include eddy current sorting to remove non- ferrous metals .
  • the further processing steps for the first process stream may include magnetic sorting to remove magnetic material .
  • the further processing steps for the first process stream may be carried out in any suitable sequence and the invention is not confined to the above sequence of steps.
  • the method may include further processing the second process stream, which is a mixture of waste plastics material and other waste feed materials such as paper, and producing an end-use product in the form of refuse-derived waste material that can be used as an energy source in cement kilns and other applications .
  • the further processing steps for the second process stream may include optical sorting to remove fibrous material and selected plastics materials that are not required for the substantially plastics material product.
  • the further processing steps for the second process stream may include eddy current sorting to remove non- ferrous metals, such as aluminium.
  • the further processing steps for the second process stream may be carried out in any suitable sequence and the invention is not confined to the above sequence of steps .
  • the method may include a magnetic separation step for separating magnetic material from the waste feed material before shredding step (a) .
  • the method may include a primary sorting step to remove gross contamination, such as large metal pieces, and items that are not desired in output products of the method or that may damage equipment used for downstream method steps prior to the magnetic separation step.
  • the primary sorting step may be a single step .
  • the primary sorting step may be a plurality of steps.
  • waste material that includes waste plastics materials and at least one other type of waste material from the group comprising waste paper, waste metals (ferrous and non-ferrous) , waste wood and other waste organic material, and waste inorganic material.
  • the co-mingled waste feed material may be obtained from any suitable source.
  • the co-mingled waste feed material may be obtained from a commercial materials recovery facility ("MRF") that receives and processes waste materials (for example by separating the materials into different categories) , and prepares recyclable materials for end-use manufacturers .
  • MRF materials recovery facility
  • Alternative terms for a materials recovery facility are materials reclamation facility and materials recycling facility.
  • the materials recovery facility may process municipal waste including domestically-sourced recyclable waste materials.
  • the materials recovery facility may process industrially-sourced recyclable waste materials.
  • the co-mingled waste feed material may include waste plastics material in the form of films or bottles or other containers made from plastics materials .
  • the co-mingled waste feed material may be obtained from a paper mill .
  • the paper mill waste may include paper mill rejects, such as hydro-puled paper and plastics materials
  • the method may produce other end-use products in addition to the substantially plastics material.
  • the other products may include metal .
  • the other products may include refuse-derived fuel
  • the substantially plastics material product may comprise at least 80 wt.% plastics material.
  • the substantially plastics material product may comprise at least 85 wt.% plastics material.
  • the substantially plastics material product may comprise at least 90 wt.% plastics material.
  • the substantially plastics material product may comprise at least 95 wt.% plastics material.
  • the plastics material may be any one or more than one of PVC, low density polyethylene, high density polyethylene and polypropylene.
  • the present invention also provides the substantially plastics material product manufactured by the above- described method.
  • the product may be in any suitable form.
  • the product may be compressed into block-shaped bags.
  • the present invention also provides a plant for manufacturing a product that substantially comprises plastics material from a co-mingled waste feed material , with the plant comprising:
  • a separator for separating the shredded waste plastics material and the other shredded waste feed materials based on size into a first process stream that is predominantly plastics material and at least a second process stream that is a mixture of plastics material and other feed materials such as paper;
  • the plant may include other types of sorters for the first process stream as required given the make-up of the waste material in the first process stream.
  • the plant may include any one or more than one of an optical sorter, an eddy current sorter and a magnetic sorter to remove "contaminants" from the second process stream to produce the substantially plastics material product .
  • contaminants is a relative term.
  • contaminant in terms of a particular product, such as the substantially plastics material product, may be an otherwise valuable material. Aluminium and other metals are examples .
  • the plant may include other types of sorters for the second process stream as required given the make-up of the waste material in the second process stream.
  • the end-use application for the substantially plastics material product may be as a component in a composite product for use in a metallurgical furnace, such as an electric arc furnace, and is described as a "polymer charge carbon", that comprises the plastics material product and another carbon-bearing material .
  • the other carbon-bearing material may comprise any one or more of rubber, coal, coke, char, and graphite.
  • the carbon-bearing material may comprise any one or more than one of rubber, coke fines, char fines, and coal fines .
  • the plastics material product may act as a binder for the other carbon-bearing material in the composite product.
  • the carbon in the composite product may act as a source of energy and/or as a reductant.
  • the carbon may act as a slag foaming agent.
  • the International application discloses a method of manufacturing a composite product for use in methods carr out in m allu g cal furnaces t. high temperatures of at least 400 C .
  • the composite product substantially comprises (a) a recycled polymeric material that acts as a binder selected from a plastics material such as recycled low density polyethylene, recycled high density polyethylene, and recycled
  • the method of manufacturing the composite product comprises mixing and heating the components of the composite product at the same time or sequentially and thereafter forming the heated mixture into a final product shape such as in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks.
  • the heating step melts at least a part of the plastics material to facilitate forming the product.
  • the product is a non-porous product that is at least substantially waterproof and comprises a continuous network of the plastics material and a uniform dispersion of the carbon-bearing material.
  • the product is formed to have sufficient strength and toughness to be able to be handled within high temperature processing plants and to be charged into metallurgical furnaces in the plants without significant breakdown of the product into smaller sized products.
  • the product is formed to be sufficiently large and have required
  • the present invention also provides a method of producing a composite product for use in a metallurgical furnace that comprises mixing and heating the above- described substantially plastics material and another carbon-bearing material at the same time or sequentially and thereafter forming the heated mixture into a final product shape of the composite product, with the heating step melting at least a part of the plastics material to facilitate forming the product.
  • the forming step may be an extrusion step .
  • the final product shape may be pellets, granules, blocks, pigs, patties, plugs, or pucks.
  • the present invention also provides the composite product manufactured by the above-described method.
  • the present invention also provides a plant for manufacturing the composite product.
  • Figure 1 is a diagram that illustrates one embodiment of a plant and a method of manufacturing a product that substantially comprises a plastics material from a co- mingled waste feed material;
  • Figure 2 is a diagram that illustrates one embodiment of a plant and a method of manufacturing a composite product that comprises the plastics material product manufactured in the method shown in Figure 1 and another carbon-bearing material.
  • One unit produces a substantially plastics material product, which is the main focus of this unit, and other refuse-derived products including refuse-derived fuels, from a co-mingled waste feed material.
  • the other unit produces a composite product of the plastics material product and another carbon-bearing material .
  • the plant may be operated as an integrated plant with the substantially plastics material product of the first unit being supplied directly into the second unit to produce the composite product.
  • the units may be operated
  • the plant produces at least two products , one of which is the substantially plastics material product and the other of which is the composite product.
  • the products also include refuse- derived products .
  • the invention is not confined to the use of the substantially plastics material product in the manufacture of the composite product.
  • Paper plant rejects feed material to the first unit
  • This material is hydro-pulped paper and plastics materials (associated with the paper) that cannot be used for new paper production and in this embodiment has the following components .
  • MRF Materials recovery facility
  • the rejects waste material from the materials recycling facility has the following components in this embodiment .
  • the outputs from the first unit include the following materials :
  • Fuels fines, PVC and fibres.
  • the first unit operates to process 4.9 tph of materials recovery facility rejects products and 3 tph of paper mill rejects products.
  • the waste feed materials are 94% recycled material. 20% of the products from the first unit are recycled (e.g. the aluminium) and the remaining products from the first unit are a plastics material product.
  • the total recycling that occurs in the first unit is over 95% and it is just 5% residuals that are being used as a fuel .
  • the in- feed waste material is transported from storage bins (not shown) on an in-feed system and then onto a separate conveyor system and is transported past a series of operation stations, as summarised below.
  • the in-feed system is a 2400 mm wide steel slat chain conveyor with flat loading section.
  • the flat area allows for 100m 3 of feed material to be loaded onto it. This approximates to 10 tonnes of paper mill rejects products and 7 tonnes of materials recovery facility (MRF) products based on the feed rates described above .
  • MRF materials recovery facility
  • This step 3 is to remove gross contamination, such as large metal pieces, and items that are not desired in the output products of the first unit or that may damage equipment in the plant.
  • This primary sort step is the only step that requires manual
  • the shredded waste material is fed under magnetic belt separators to remove magnetic material from the waste material .
  • Shredder - item 7 in Figure 1 The primary sorted waste material is transferred to the shredder 7.
  • the shredding operation is designed as a "coarse" shredding step to break up and liberate the in- feed material so that it can be effectively sorted by the downstream equipment.
  • the term "coarse” in the context of shredding is well understood by persons in the industry. In the described embodiment, shredding is maximised at around 10 tph.
  • One shredder option is a GENOX 2400 shredder capable of managing 10 tph waste materials .
  • the shredded waste feed material is then transferred to a primary screen 9 and separated into a fines fraction (i.e. —10 mm) , a 10-60 mm middlings fraction, and a +60 mm large fraction.
  • a fines fraction i.e. —10 mm
  • a 10-60 mm middlings fraction i.e. —10 mm
  • a +60 mm large fraction i.e. —10 mm
  • the selection of the threshold of 60 mm for the 10- 60mm fraction and the +60mm fraction is based on an assessment of the characteristics of the feed waste material and an objective of having the larger size fraction as a substantially "pure" stream with respect to plastics material .
  • the 10-60mm fraction and the +60mm fraction are processed as described in item 5 onwards .
  • the fines fraction is bagged and sold as a refuse derived fuel (RDF) 11 for example for use in cement kilns.
  • RDF refuse derived fuel
  • IFE Variomat Screen One option for the primary screen is an IFE Variomat Screen.
  • This screen has advantages compared to other screens such as ballistic separators, trommels and metal disc screens in the context of this embodiment of the invention. However, these other screens are options for other embodiments .
  • the advantages of the IFE Variomat Screen for this embodiment are as follows: • Screening area to footprint - unlike a trommel the whole screen is providing effective screening and therefore has great efficiencies for its foot print. The screen provides 24m 3 of screening area for a 24m 3 foot print a trommel would require up to 2.5 times more footprint to get the same screening result.
  • the screen is a downhill running vibratory type screen, with all parts external and easily accessible. This is a major advantage to the likes of a ballistic screen that in our experience need strip down even for simplistic cleaning. Reduction in blinding, the reverse rake louver type deck and the downhill flow of material means that the screening apertures are not prone to blinding (like all the other screens listed) . In addition the screen can be cleaned during operation, without loss of production. Screen sizes can be easily changed so that apertures can be adjusted to suit the waste stream.
  • the fines fraction (-10mm) is achieved using an IFE Trisomat screen.
  • the screen works by oscillating in a rotary manner at a high speed. This oscillation causes neoprene decks to flip up and down. Material is fed over the moving decks . The oscillations stop the small aperture holes from blinding up and allow wet materials to be effectively screened at a constant feed rate. Other screening mechanisms will very quickly blind if a batch of wet material is fed over the screen. The screen is also self-cleaning and will free itself of dirt by being left to run empty for a little while. Finally, the screen offers a great deal of versatility in that the neoprene decks can be changed very quickly and the size cut can be easily adjusted for seasonal and waste type variations .
  • the -10mm material that is cut from the material stream is a mainly inert product which includes items such as shredded paper and fine plastic film along with dried organic material .
  • This material has a high calorific value .
  • the 10-60mm fraction and the +60mm fraction are placed onto separate conveyor systems via vibratory feeders 13 and transported past a series of "contaminant" assessment and sorting stations and processed as described below to produce the substantially plastics material product (which is a form of a solid residual fuel (SRF) ) for the larger fraction and a refuse-derived fuel (RDF) for the smaller size fraction.
  • SRF solid residual fuel
  • RDF refuse-derived fuel
  • the first further processing station for each of the
  • 10-60mm fraction and the +60mm fraction is an optical sorter 15 which optically identifies and removes fibres and target plastics materials such as PVC . These materials are another refuse-derived product (RFD) and are bagged and sold as RDF.
  • RDF refuse-derived product
  • One option for an optical sorter for the detection and removal of plastics including PVC is a Red Wave Optical Sorter. Advantages of the system are the overall width of the unit. For this embodiment, both the larger (+60mm) and smaller (10-60mm) fractions will be fed in parallel optical sorting machines.
  • the 10-60 mm fraction and the +60 mm fraction are then each transported past an eddy current sorter 17 that identifies and removes non-ferrous metals, such as aluminium.
  • the aluminium is another valuable product.
  • the eddy currents are designed specifically for the size cut, with the smaller fraction passing over an 18 pole rotor and the larger fraction passing over a 10 pole rotor. Each rotor is designed to achieve maximum product removal from the waste.
  • the +60 mm fraction is then transported past a magnetic sorter 19 as a final safety measure to remove any magnetic material, such as steel, from the larger size fraction.
  • the main end-use product namely the substantially plastics material product
  • the main end-use product is fed directly into the second unit and processed in the second unit to produce a composite product.
  • the +60 mm fraction is then transported past a secondary screen 21 and separated into a smaller size fraction and a larger size fraction. Essentially, the screen 21
  • the product can be used in a wide range of end-use applications. One application is described below in relation to the second unit.
  • the second unit for producing a composite product as described in the above-mentioned International application PCT/AU2011/000960 (WO 2012/019216) in the name of the OneSteel NSW Pty Limited that is suitable for use as a polymer charge carbon for an electric arc steel making furnace has been designed to be independent of the first unit of the plant. This independence of the first and second units allows the plant to be able to produce two products at the same time. There will be situations in which the product of the first unit is transferred directly to the second unit and other situations where this is not the case. In some situations, the first and second units may be in different locations altogether . In this situation, the product of the first unit may be transported to the second unit.
  • the production of the composite product is achieved in the following steps illustrated in Figure 2, namely: 1. Granulation of the substantially plastic feed material from the first unit.
  • the substantially plastics material from the first unit is granulated to —2mm.
  • the granulator 23 is selected to be a high speed granulator .
  • granulated plastics material is discharged via a pneumatic conveyor to silo hoppers . It is noted that the invention is not confined to the —2mm granule size and the granules may be any suitable size. It is also noted that the granulation step may not be required for other end-use applications of the substantially plastics material from the first unit.
  • the granulated plastics material is discharged from the granulator 23 and transported via a pneumatic conveyor to silo hoppers 27. Due to the very light density of the product and the ability of the product to litter, the process system is sealed post granulation.
  • a coke feed which is suitable in terms of structural properties and calorific value and has a required particle size distribution is transferred via a drag link conveyor 33 to a storage hopper 27 and retained in the hopper.
  • the mixing of the plastics material and the coke is to a very precise recipe.
  • the plastics material and the coke are separately transferred from the respective hoppers 27 to respective weigh stations 29 and the predetermined weights of these feed materials in
  • the mixing plant 35 for this embodiment is designed to receive a maximum of lm 3 of feed materials and to mix them together to form a homogeneous mixture.
  • the mixing plant may be any suitable capacity.
  • each extruder 37 comprises an elongate cylindrical chamber that is heated along the length of the chamber and has an inlet end for receiving the composite product mixture and an outlet end that has a series of outlet openings that are shaped as required to form the extrusion profile.
  • Each extruder also includes a motor-driven auger in the chamber to move the composite product mixture along the length of the chamber from the inlet to the outlet.
  • the applicant has designed a control program and set out gear box ratios to balance throughput against heat absorbed into the product.
  • the optical sorters 15 are set up to record the composition of the plastics material in the waste plastic product in the first unit and to calculate the Standard Heat Capacity of the product. This information automatically sets auger speed and current settings - (torque output) of the motor.
  • the applicant has refined the relationship between auger speed, current draw, burden depth of the auger to ensure production of a high quality extruded rod.
  • Control of the cutter speed again is measured through a PLC and the inputs the PLC records (speed of motor, current draw and estimated SHC of product) .
  • the above-described first unit is an effective and efficient unit for forming a substantially plastics material product that has a number of possible end-use applications .
  • the above-described second unit is an effective and efficient unit for manufacturing a composite product that is suitable for use as a polymer charge carbon for an electric arc steel making furnace.
  • the embodiment of the present invention described in relation to the Figures is not confined to the specific equipment described above.
  • the present invention is also not limited to the particular arrangement of unit operations and additional unit operations may be used as required for a particular waste feed material.
  • the present invention is not confined to the use of the particular waste feed materials
  • the present invention is not confined to composite products that are suitable for use in high temperature processes .
  • the composite products of the present invention are suitable for use as building materials or as protective materials for building and wear resistant materials (e.g. for wear resistance or corrosion resistance) , such as alternatives to timber products and steel products .

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Geology (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un produit, composé essentiellement de matière plastique, à partir d'un matériau d'alimentation résiduel amalgamé, ce procédé comprenant les étapes suivantes consistant à: (a) déchiqueter le matériau d'alimentation résiduel; (b) séparer le matériau d'alimentation résiduel en plastique déchiqueté et l'autre matériau d'alimentation résiduel déchiqueté en fonction de leur taille et former une pluralité de flux de traitement, un flux étant composé majoritairement de matière plastique résiduelle; et (c) traiter également le flux de traitement pour éliminer des "contaminants" et produire le produit composé essentiellement de matière plastique.
PCT/AU2016/050945 2015-10-08 2016-10-07 Traitement de matériaux résiduels WO2017059497A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2015904095A AU2015904095A0 (en) 2015-10-08 Processing Waste Materials
AU2015904095 2015-10-08

Publications (1)

Publication Number Publication Date
WO2017059497A1 true WO2017059497A1 (fr) 2017-04-13

Family

ID=58487105

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2016/050945 WO2017059497A1 (fr) 2015-10-08 2016-10-07 Traitement de matériaux résiduels

Country Status (1)

Country Link
WO (1) WO2017059497A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19511141A1 (de) * 1995-03-27 1996-10-02 Kms Konstruktion Maschinen Und Mehrstufige Zerkleinerung von DSD-Material im Einwellenshredder
US20030178345A1 (en) * 2000-05-22 2003-09-25 Jouko Hautala Method for processing waste processing plant
WO2012019216A1 (fr) * 2010-08-09 2012-02-16 Onesteel Nsw Pty Limited Produits composites et procédé de fabrication
US20120048975A1 (en) * 2010-11-24 2012-03-01 Organic Energy Corporation Mechanized separation of mixed solid waste and recovery of recyclable products
US20130298455A1 (en) * 2012-05-11 2013-11-14 Re Community Energy, Llc Systems and methods for producing engineered fuel feedstocks with reduced chlorine content
DE102012106307A1 (de) * 2012-07-13 2014-05-15 Lober GmbH & Co. KG Verfahren zur Herstellung eines Ersatzbrennstoffes

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19511141A1 (de) * 1995-03-27 1996-10-02 Kms Konstruktion Maschinen Und Mehrstufige Zerkleinerung von DSD-Material im Einwellenshredder
US20030178345A1 (en) * 2000-05-22 2003-09-25 Jouko Hautala Method for processing waste processing plant
WO2012019216A1 (fr) * 2010-08-09 2012-02-16 Onesteel Nsw Pty Limited Produits composites et procédé de fabrication
US20120048975A1 (en) * 2010-11-24 2012-03-01 Organic Energy Corporation Mechanized separation of mixed solid waste and recovery of recyclable products
US20130298455A1 (en) * 2012-05-11 2013-11-14 Re Community Energy, Llc Systems and methods for producing engineered fuel feedstocks with reduced chlorine content
DE102012106307A1 (de) * 2012-07-13 2014-05-15 Lober GmbH & Co. KG Verfahren zur Herstellung eines Ersatzbrennstoffes

Similar Documents

Publication Publication Date Title
EP2318488B1 (fr) Procédé de traitement d'un mélange de particules de déchets de cellulose/plastique pour former un combustible
CA2209381C (fr) Procede et installation de traitement de plastiques mixtes
EA012098B1 (ru) Способ и система для измельчения и очистки пластиковых отходов и способ получения топлива из переработанных отходов
CA2318040A1 (fr) Procede de traitement de dechets divers et atelier de traitement
HU210451B (en) Method and apparatus recycling of wastes
CN102303381A (zh) 一种用于垃圾塑料的免水洗回收方法及专用设备
US20160271836A1 (en) Methods and apparatus for extruding recycled plastics
CN102303382A (zh) 一种垃圾塑料的收回再利用方法及专用设备
Makenji Mechanical methods for recycling waste composites
CN113891945A (zh) 生产聚合物产品的方法
JP3745619B2 (ja) 化学原料用廃棄プラスチック粒状化物の成形方法
WO2017059497A1 (fr) Traitement de matériaux résiduels
JP2923244B2 (ja) 廃棄物の固形燃料化リサイクルプラント
JP5165271B2 (ja) 廃プラスチック成型物を利用した治金用コークスの製造方法
CN115431431A (zh) 塑料填充复/组合再生质粗粒及制法
JP3420713B2 (ja) 廃プラスチック処理装置
JP2004188695A (ja) 廃ポリオレフィン類のリサイクル方法とそのシステム
JP4648887B2 (ja) 廃プラスチックの高密度成形方法
Wróbel et al. Conceptual Design of the RDF Granulation Line
Reis et al. MOBILE-PRO-U DESIGN: A NOVEL APPROACH FOR GLASS RECOVERY
KR20220135617A (ko) 생활폐기물 중 재활용품 선별과 고형연료 제조 및 혼합 폐합성수지 재활용 압축성형제품 제조 장치
KR101118162B1 (ko) 가연성 폐기물을 이용한 고체연료 및 그 제조방법
KR20200005699A (ko) 폐합성수지 및 폐고무류 분말화 방법
EP1479750A1 (fr) Système pour la production d'un combustible à partir de déchets
WO2006003409A1 (fr) Agregat artificiel comprenant un materiau plastique

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 16852907

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 16852907

Country of ref document: EP

Kind code of ref document: A1