WO2023140866A1 - Procédé d'adoucissement de granules de coque dure de noix de coco - Google Patents

Procédé d'adoucissement de granules de coque dure de noix de coco Download PDF

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Publication number
WO2023140866A1
WO2023140866A1 PCT/US2022/013460 US2022013460W WO2023140866A1 WO 2023140866 A1 WO2023140866 A1 WO 2023140866A1 US 2022013460 W US2022013460 W US 2022013460W WO 2023140866 A1 WO2023140866 A1 WO 2023140866A1
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WO
WIPO (PCT)
Prior art keywords
crumb material
crumb
water
soaked
solution
Prior art date
Application number
PCT/US2022/013460
Other languages
English (en)
Inventor
David Shoup
Original Assignee
Genus Industries, Llc Dba Icoir Products Group
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 Genus Industries, Llc Dba Icoir Products Group filed Critical Genus Industries, Llc Dba Icoir Products Group
Priority to PCT/US2022/013460 priority Critical patent/WO2023140866A1/fr
Publication of WO2023140866A1 publication Critical patent/WO2023140866A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01G—HORTICULTURE; CULTIVATION OF VEGETABLES, FLOWERS, RICE, FRUIT, VINES, HOPS OR SEAWEED; FORESTRY; WATERING
    • A01G20/00—Cultivation of turf, lawn or the like; Apparatus or methods therefor
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
    • E01C13/08—Surfaces simulating grass ; Grass-grown sports grounds

Definitions

  • Synthetic sports fields typically have synthetic turf fibers on top of an infill material.
  • the infill material allows the field to have a slight grade to it from the center of the field to the sides to allow for better drainage, and helps protect the players by providing shock absorption, traction, and foot stability.
  • most infill material consists of rubber crumbs, which mostly come from recycled tires.
  • Figure 1 shows the parts of a coconut and the hard shell used for crumb infill.
  • Figure 2 shows a diagram of an embodiment of synthetic turf with coconut crumb infill material.
  • Figure 3 shows an embodiment of a method of producing coconut crumb infill.
  • Figures 4-6 show examples of a hammer mill.
  • Figure 7-8 show examples of a shredding machine.
  • Figures 9 shows a view of the coconut crumb infill.
  • coconut hard shell material can meet the above standards without the health concerns, being an all-natural substance.
  • coconut shell has high lignin and cellulose content, and the casing contains materials that resistant to bacteria and fungi.
  • Other uses of coconut shell exists, including in the manufacture of mosquito coils, incense sticks, in plywood manufacturing as a phenolic extruder, and as filler in the manufacture of resin glue.
  • coconut crumb means one or more particles of the hard inner shell of a coconut cut down to particles typically having a size in the range from 4-7 millimeters, inclusive, but may include any crumbs of smaller than 10 mm.
  • coconut chips means one or more particles of the hard outer shell of a coconut cut down to particles having a size in the range from 20 to 40 mm, inclusive, by may include any crumbs larger than 20 mm. These ranges are estimates but are intended to differentiate between particles that are 20 mm or larger, which are called chips, and particles that are 7 mm or smaller, call crumb.
  • coconut crumb infill and “coconut crumb” are intended to be interchangeable.
  • Figure 1 shows a coconut 10 split open, with its husk 12 next to it.
  • the hard inner shell is what is of interest here, but it helps to clarify by looking at the other portions of the coconut.
  • the white innermost material 14 is typically referred to as its ‘meat’ ‘copra’ and contains coconut water.
  • the layer of spongy material 16 between the meat and the outer shell is referred to as ‘pith’ with ‘coir’ and ‘fiber’.
  • Pith is highly absorbent and has uses with shell infill materials that may be appropriate here, as an infill amendment to the coconut shell infill.
  • the hard outer shell 18 is what is also of interest here.
  • FIG. 2 shows a view of a synthetic turf field using coconut crumb infill instead of tire crumb infill.
  • the infill 20 is the second layer from the top and has a grade such that the finished field has a slope from the center of the field to the sidelines to allow for drainage.
  • the synthetic turf lies 22 on top of the coconut crumb infill. Underneath the coconut infill, there may be many layers. In this example, there are layers of a thick, resilient shock and drainage pan 24, a geotextile fabric 26, a compacted aggregate leveling course 28, a compacted aggregate base course 30, a layer of subbase material 32, and the compacted subgrade material 34. The selection and configuration of these materials is left up to the system designer, but in general the coconut crumb and replace the tire crumb as infill with no modifications of the underlying layers of the field.
  • FIG 3 shows an embodiment of a process for converting the hard inner shell of coconuts to coconut crumb. This process begins with the outer shell “skin” of the coconut 40. Typically, a coconut shell crusher opens the shells. The process then removes and discards the meat and the water. The shells then typically undergo cleaning and sanitization and dried to under 10% water content, not shown here.
  • the process starts with the coconut shells being run through some sort of shredding or break down machine at 42, such as a hammer mill and/or a shredder to produce coconut chips and waste material, referred to as ‘fines’ 44.
  • This process typically reduces the coconut shells to chip sizes in the 20 - 40 millimeter range.
  • the resulting material is then screened at 46 in which the material that is not of the right size, fines, 48, is either designated as waste material, but may be used in other processes. Some of it may be returned to the beginning of the process at 40 for reprocessing.
  • a conveyor 50 then moves the coconut chips 52 to a second break down process at 54.
  • a break down machine any machine that can break down the hard coconut shell into the desired sizes, referred to here as a ‘break down’ machine, would work in this process.
  • the resulting material 56 from the second breakdown process will typically comprise a mix of coconut crumb and fines. This material then undergoes screening at 58, with the waste materials or fines being recycled or used for other processes.
  • the resulting coconut crumb can then become turf field infill.
  • FIG 4 shows a diagram of a hammer mill 70.
  • the mill typically has a chute or other opening 72 to allow delivery of the coconut shells to the inner workings of the mill.
  • the hammers 78 rotate around a rotor with hanging metal knife blades that drives them to break up the coconut shells into the chips and round off the jagged edges.
  • a screen traps such as 78 the chips to undergo further processing and the waste material, also referred to as ‘fines’ are taken away. Note that this screening may comprises the screening process mentioned above, or may be prior to the screening.
  • Figure 5 shows a photograph of a hammer mill 70
  • Figure 6 shows embodiments of the different screens 78.
  • Some embodiments of the process may rely only upon a single hammer mill as the breakdown machine, with the hammers changed between the breaking down of the shells into coconut chips and coconut crumb.
  • the user can also adjust the rotor speed to be coordinated with the screen type to ensure the output meets a size specification. For shredders, it may involve changing the size of the blades.
  • Some embodiments may use two of one type of a break down machine such as two hammer mills or two shredders.
  • Some of the embodiments may rely upon a combination of different types of break down machines, using one type to produce coconut chips and another type to turn the chips into crumb.
  • the material trapped by the screen is then removed from the hammer mill and conveyed to another hammer mill.
  • the second break down machine may comprise the same break down machine after the machine is recalibrated.
  • the screens and/or the hammers are changed to reduce the chips to a smaller size, plus round or blunt the sharp edges of the crumbs.
  • the chips meaning portions of the outer shell having sizes in the range of 20-40 millimeters, undergo further processing to reduce their sizes to ‘crumbs,’ meaning that they have a size I in the range of 4-7 mm.
  • the further processing also serves to smooth out the edges and remove sharp comers from the crumbs.
  • FIG 7 shows an example of a shredder machine 80 with its outer layer of blades or teeth such as 82. These can grind up the coconut husks to a first chip size. The user selects the blade size to achieve the desired chip size. Inner teeth or blades such as 84 shown in Figure 8 can then grind the chips into the crumb size.
  • the shredder 80 may incorporate a screen located at the bottom to perform the screening, or may just have an outlet that produces the coconut crumb to undergo a separate screening process.
  • FIG. 9 shows an embodiment of the resulting crumbs.
  • Figure 9 shows a hand to provide a sense of scale of the resulting crumbs. As mentioned above, the crumbs typically has a size in the 4-7 mm range, but any particle at 10 mm or below falls under the label of ‘crumb.’
  • coconut crumb infill an environmentally friendly, where otherwise waste product of coconut shells replaces the non-biodegradable tire crumbs currently in use on synthetic turf fields, referred to here as coconut crumb infill.
  • the hard shells of the coconuts do not absorb water in a significant amount when wet, has antifungal characteristics, and while they will over time degrade, it is much less expensive and cost effective to replace them.
  • the material is organic, sustainable, renewable, and safe for people and pets.
  • the hard shells do not absorb water in a significant amount, so softening the coconut crumb shell infill material can become an issue.
  • One method involves using solutions of water with various salts, acids and/or bases, as added ingredients to soften the crumb infill material.
  • natural water refers to untreated water, with not softening agents or purifiers added. Initially, the process cleans the coconut hard shells, referred to here as the shells, by submersion in water. In one embodiment, the water is natural water.
  • the shells are then boiled for at least one hour in a salt solution.
  • the salt concentration is at least 30 grams of salt or more per liter of water.
  • the salt concentration is between 30-50 grams of salt per liter of water, and the water may be natural water.
  • the shells are steamed for at least eight hours.
  • the shells undergo a first soaking in an alkali solution of water and an alkali material, such as sodium hydroxide (NaOH) or one of its hydrates such as sodium hydroxide monohydrate, all of which are referred to here as sodium hydroxide.
  • the water may comprise natural water.
  • the solution with the coconut material in it will typically have a pH in the range of 5.8 to 6.8, prior to the addition of the alkali material.
  • the shells then undergo a second soaking in a salt solution of 5% magnesium chloride
  • the shells are rinsed with a solution of natural water, and a mix of acids and bases to ensure stable alkalinity of the solution between 100 to 150 ppm.
  • the acids include distilled vinegar at a concentration of 25%, and muriatic acid (HC1), and the base or alkali materials may comprise soda ash also known as sodium carbonate (Na2COs).

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental Sciences (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

L'invention concerne un procédé qui consiste à immerger le matériau de coque de noix de coco dans de l'eau pour produire un matériau granulaire propre, à faire bouillir le matériau granulaire propre dans une solution saline pour produire un matériau granulaire cuit, à cuire à la vapeur le matériau granulaire cuit pour produire un matériau granulaire cuit à la vapeur, à réaliser une première trempe du matériau granulaire cuit dans une solution d'eau et une matière alcaline pour produire un matériau granulaire trempé, à réaliser une seconde trempe du matériau granulaire trempé dans une solution saline pour produire un second matériau granulaire trempé, à rincer le second matériau granulaire trempé avec une solution alcaline stable pour produire un matériau granulaire humide ramolli, et à stocker le matériau granulaire humide ramolli.
PCT/US2022/013460 2022-01-24 2022-01-24 Procédé d'adoucissement de granules de coque dure de noix de coco WO2023140866A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2022/013460 WO2023140866A1 (fr) 2022-01-24 2022-01-24 Procédé d'adoucissement de granules de coque dure de noix de coco

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2022/013460 WO2023140866A1 (fr) 2022-01-24 2022-01-24 Procédé d'adoucissement de granules de coque dure de noix de coco

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WO2023140866A1 true WO2023140866A1 (fr) 2023-07-27

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3846562A (en) * 1970-09-22 1974-11-05 Pillsbury Co Process for the treatment of coconut
CN101467627A (zh) * 2007-12-28 2009-07-01 天津市中英保健食品有限公司 清水椰子的加工方法
US20150376015A1 (en) * 2013-02-20 2015-12-31 Osaka Gas Chemicals Co., Ltd. Granular Activated Carbon, and Manufacturing Method for Same
WO2018132419A1 (fr) * 2017-01-11 2018-07-19 Empire Technology Development Llc Produits à base de résidus de déchets de noix de coco imprégnés de tréhalose

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3846562A (en) * 1970-09-22 1974-11-05 Pillsbury Co Process for the treatment of coconut
CN101467627A (zh) * 2007-12-28 2009-07-01 天津市中英保健食品有限公司 清水椰子的加工方法
US20150376015A1 (en) * 2013-02-20 2015-12-31 Osaka Gas Chemicals Co., Ltd. Granular Activated Carbon, and Manufacturing Method for Same
WO2018132419A1 (fr) * 2017-01-11 2018-07-19 Empire Technology Development Llc Produits à base de résidus de déchets de noix de coco imprégnés de tréhalose

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