Equipment for recycling waste carpets and recycling process thereof

Abstract

The equipment comprises a waste carpet regeneration workshop, and the waste carpet regeneration workshop is sequentially provided with a metal detector, a velvet cutting machine, a vacuum suction device, a material storage tank, a short velvet conveying and stirring cage, a cleaning and drying line, a vacuum suction device, a material storage tank, a short velvet conveying and stirring cage and a pelletizer. The device comprises a mechanical arm, a bottom back conveying belt, a pre-opening shredder, a shredded material conveying belt, a crusher, a conveying stirring cage, a coarse powder machine, a spiral separator, a fine powder machine, a spiral separator and a multi-layer-mesh vibrating screen. According to the invention, waste carpets are subjected to fluff cutting by the fluff cutting machine, short fluff is sucked into the storage tank for storage by the vacuum suction device, the short fluff is conveyed to the cleaning and drying line by the stranding cage at the bottom of the tank, the cleaned short fluff is squeezed by the high-pressure water through the compression roller and enters the drying oven for drying, and the dried short fluff is sucked into the outdoor storage tank by the vacuum suction device. And a stranding cage at the bottom of the storage tank conveys the short fibers to a granulator for granulation. The mechanical arm continuously places the bottom and back subjected to fluff cutting on the conveying belt to the shredding machine to be shredded, coarse powder separation is conducted, fine powder separation is conducted, and colloidal calcium powder separated out through the vibrating screen replaces a new raw material to manufacture carpets.

Description

Technical Field

[0001] This invention relates to the field of waste carpet processing, recycling and reuse technology, specifically to a device for recycling waste carpets and its recycling process. Background Technology

[0002] Carpets are floor coverings made from fibers such as synthetic fibers, cotton, linen, wool, silk, and grass yarn, woven by hand or machine. In recent years, synthetic fibers have become particularly prevalent. Carpets are used in residences, office buildings, hotels, conference rooms, entertainment venues, stadiums, exhibition halls, vehicles, ships, airports, and other locations. They effectively reduce noise, provide insulation and decorative effects, improve foot comfort, and prevent slipping. Carpets are a traditional craft and interior soft furnishing product with a long history. Since the early 1980s, modular carpets have entered China from Europe and America. Especially in the last two decades, the development of modular carpets has been booming, increasing at a rate of 10% annually. my country alone produces and sells over 100 million square meters of modular carpets annually, meaning that hundreds of millions of discarded carpets are converted into solid waste each year. Solid waste carpets also put enormous pressure on environmental pollution. This project aims to fundamentally reduce the generation of solid waste by recycling and classifying discarded carpets in the market and processing them further, thus protecting the ecological environment and achieving resource recycling.

[0003] Because discarded carpets are often heavily soiled and prone to trapping foreign objects within their pile—mostly sand, dust, particles, staples, pins, and paper clips—and because carpets vary in age, installation environment, and level of contamination, recycled carpets require separate processing, making full recycling a significant challenge. Therefore, there is an urgent need to design equipment and processes for recycling discarded carpets to address these issues. Summary of the Invention

[0004] The purpose of this invention is to provide a device and process for recycling waste carpets, so as to overcome the shortcomings of the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A device and process for recycling waste carpets includes a waste carpet recycling workshop. The waste carpet recycling equipment and process are sequentially installed with: a metal detector, a pile-shaving machine, a vacuum suction device, a storage tank, a stirring cage, a washing and drying line, a vacuum suction device, a winch, and a granulator. The above equipment is organically connected into one unit, referred to as "pile-granulation unit".

[0006] The waste carpet backing recycling equipment and its process are installed sequentially as follows: robotic arm, conveyor belt, pre-opening shredder, conveyor belt, crusher, type I auger, storage tank, type II auger, coarse powder mill, type I spiral separator, fine powder mill, type II spiral separator and multi-layer vibrating screen, and adhesive calcium powder is packaged and used to replace raw materials in proportion to make new carpets. The above equipment is organically integrated into one unit, referred to as "shredding and grinding screen".

[0007] By adopting the above-described invention, the pre-opening shredder shreds the shavings from the backing material, reducing noise, decreasing load, and increasing efficiency in subsequent crushing, coarse powder, and fine powder processing equipment. Each unit is activated by a single button on the central control cabinet. Based on the unit output of the fine powder mill, the synchronous controller sends signals to the frequency converters of the spiral separator, coarse powder mill, and conveyor to adjust and control the material conveying rate. Through a vacuum suction device, conveyor belt, conveyor, and spiral separator, each unit is integrated into a single unit, enabling automatic material conveying and creating a clean, unmanned, and lights-out production environment.

[0008] Preferably, a negative pressure fan is connected to one side of both the coarse powder mill and the fine powder mill, and one end of each of the two sets of negative pressure fans is fixedly connected to the type I spiral separator and the type II spiral separator, respectively.

[0009] By adopting the above-mentioned invention, a negative pressure fan is used to extract colloidal calcium powder and short fibers from coarse powder mills and fine powder mills. The colloidal calcium powder separated by the Type I and Type II spiral separators is sorted by a multi-layer vibrating screen and used to replace raw materials to make new carpets, while the short fibers are used for granulation and direct sale.

[0010] Preferably, the robotic arm, conveyor belt, pre-opening shredder, type I auger, crusher, type II auger, coarse powder mill, type I spiral separator, fine powder mill, type II spiral separator and multi-mesh vibrating screen are all provided in two sets, and are located on the left and right sides of the storage tank respectively.

[0011] By adopting the above-mentioned invention, two sets of equipment with the same structure and configuration and their processes can effectively save space and labor in the production workshop, and greatly improve the recycling efficiency of waste carpets.

[0012] Preferably, the coarse powder mill, fine powder mill, and multi-mesh vibrating screen can all collect colloidal calcium powder.

[0013] By adopting the above-mentioned invention, the coarse powder mill and the fine powder mill can effectively separate the colloidal calcium powder and short fibers from the backing of the carpet. The colloidal calcium powder is further sorted, collected and reused under the separation of multi-layer mesh vibrating screen.

[0014] Preferably, the short fibers separated by the coarse powder mill, fine powder mill, and multi-layer vibrating screen are collected and used for subsequent granulation and sale, so that the recycled waste carpet can generate more revenue.

[0015] A device for recycling waste carpets and a recycling process thereof, comprising the waste carpet recycling device as described in any one of the claims, characterized in that it includes the following steps: 1. Beat and shake the recycled waste carpet to shake out foreign objects such as sand, dust, particles, staples, pins and paper clips mixed in with the carpet surface. 2. Waste carpets are detected by a metal detector, and tiny metal pieces hidden deep in the pile are rejected before the pile is shredded. The shredded short fibers fall into a container and are periodically sucked into a storage tank by a vacuum suction device. The auger at the bottom of the storage tank automatically transports the short fibers to a washing and drying machine. The short fibers are washed by high-pressure water and passed through several sets of pressure rollers to squeeze out most of the water from the surface of the short fibers. The short fibers are then carried by a conveyor belt into an oven for drying. The dried short fibers fall into a container and are then sucked out to an outdoor storage tank by a vacuum suction device for granulation.

[0016] Third, the waste carpet backing is continuously placed onto the conveyor belt by a robotic arm and transported to the pre-opening shredder for shredding, reducing the noise and load on subsequent equipment when processing the waste carpet backing; 4. The shredded carpet backing enters the crusher via a conveyor belt. The crushed material is then transported to the storage tank by a type I auger. In subsequent use, the material in the storage tank is transported to the coarse powder mill by a type II auger. The crushed material is then separated from the colloidal calcium powder and short fibers by a spiral separator. 5. The colloidal calcium powder separated from the coarse powder is conveyed by a spiral separator to a fine powder mill for further pulverization, so that the colloidal calcium powder and short fibers are further separated. The colloidal calcium powder is then conveyed by the spiral separator to a multi-mesh vibrating screen to obtain high-purity colloidal calcium powder, which is then packaged and used to replace raw materials in the production of new carpets. The short fibers are then used for granulation and sale.

[0017] In the above technical solution, the device and recycling process for recycling waste carpets provided by the present invention have the following beneficial effects: The equipment and process for recycling waste carpets involves beating and vibrating the carpet, then using a metal detector to prevent tiny metal particles hidden deep within the pile from being removed before shredding. A pre-opening shredder shreds the entire backing, and a crusher processes the backing into particles of approximately 2mm. These particles are then conveyed to a storage tank via a Type I auger. A Type II auger at the bottom of the storage tank then conveys the backing particles to a coarse pulverizer. The coarse pulverizer further crushes the backing particles, separating most of the short fibers and calcium carbonate powder carried within. A Type I spiral separator transports the crushed short fibers outdoors for collection and granulation, while the calcium carbonate powder is transported to a fine pulverizer for further crushing. Again, a Type II spiral separator transports the crushed short fibers outdoors for collection and granulation, and the calcium carbonate powder is transported to a multi-mesh vibrating screen for sorting and packaging, replacing raw materials in a specific ratio to produce new carpets. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0019] Figure 1 This is a three-dimensional structural diagram of an embodiment of a device and recycling process for recycling waste carpets according to the present invention.

[0020] Figure 2 This diagram illustrates a three-dimensional structure conveyor belt, pre-opening and shredding, auger conveying, crushing, auger conveying, coarse powder, spiral separator, fine powder, spiral separator, and screening process, as provided in an embodiment of the equipment and recycling process for recycling waste carpets according to the present invention.

[0021] Figure 3 This invention provides a schematic diagram of the process flow for an embodiment of a device and process for recycling waste carpets.

[0022] Figure 4 This is a schematic diagram of the process flow for beating and vibrating waste carpets, metal detection, shaving, and automatic cleaning and drying, provided as an embodiment of the equipment and process for recycling waste carpets according to the present invention.

[0023] Explanation of reference numerals in the attached figures: 1. Waste carpet recycling workshop; 2. Robotic arm; 3. Conveyor belt; 4. Back-end pre-opening shredder; 5. Shredded material conveyor; 6. Crusher; 7. Type I auger; 8. Storage tank; 9. Type II auger; 10. Coarse powder mill; 11. Type I spiral separator; 12. Fine powder mill; 13. Type II spiral separator; 14. Multi-layer mesh vibrating screen; 15. Negative pressure fan. Detailed Implementation

[0024] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0025] like Figure 1-4 As shown in the figure, the present invention provides a waste carpet recycling equipment and recycling process, including a waste carpet recycling workshop 1. The waste carpet recycling workshop 1 is equipped with, in sequence: a metal detector, a lint remover, a vacuum suction device, a storage silo, a winch, a washing and drying line, an outdoor storage tank, a stirring cage, and a granulator. Other components include: a robotic arm 2, a conveyor belt 3, a pre-opening shredder 4, a shredded material conveyor belt 5, a crusher 6, a type I stirring cage 7, a storage tank 8, a type I winch 9, a coarse powder mill 10, a type I spiral separator 11, a fine powder mill 12, a type II spiral separator 13, a multi-layer mesh vibrating screen 14, and a negative pressure powder mill 15.

[0026] Specifically, in this embodiment, a negative pressure fan 15 is fixedly connected to one side of both the coarse powder mill 10 and the fine powder mill 12. One end of each negative pressure fan 15 is fixedly connected to the type I spiral separator 11 and the type II spiral separator 13, respectively. The robot arm 2, conveyor belt 3, pre-opening shredder 4, conveyor belt 5, crusher 6, type I auger 7, type II auger 9, coarse powder mill 10, type I spiral separator 11, fine powder mill 12, type II spiral separator 13, multi-mesh vibrating screen 14, and negative pressure fan 15 are all set in two groups and are located on the left and right sides of the storage tank 8, respectively. The coarse powder mill 10, fine powder mill 12, and multi-mesh vibrating screen 14 can all collect colloidal calcium powder. The short fibers crushed and separated by the coarse powder mill 10 and fine powder mill 12 and the short fibers screened by the multi-mesh vibrating screen 14 are collected and used for subsequent granulation and direct sale.

[0027] This invention provides a device and process for recycling used carpets. The used carpet is shaken and vibrated to dislodge foreign objects such as sand, dust, particles, staples, pins, and paper clips embedded in the carpet surface. Then, the used carpet is passed through a metal detector to prevent tiny metal particles hidden deep within the pile from being removed before the pile is shredded. After being shaving, the backing material is continuously placed onto the conveyor belt 3 by the robotic arm 2 and transported to the pre-opening shredder 4 for shredding. The shredded material is then transported to the backing crusher 6 via the conveyor belt 5 and crushed into particles of about 2mm. The crushed particles are then transported to the storage tank 8 by the type I auger 7 for storage. When further crushing is required, the particles in the storage tank 8 are transported to the coarse powder mill 10 by the type II auger 9 for crushing. After coarse crushing, most of the colloidal calcium powder and short fibers are separated. The short fibers are transported outdoors for collection and granulation by the type I spiral separator 11, while the colloidal calcium powder is transported to the fine powder mill 12 for further crushing and separation. The short fibers are then transported outdoors for collection and granulation by the type II spiral separator 13, while the colloidal calcium powder is transported to the multi-layer mesh vibrating screen 14 for sorting and packaging, and then used to replace the raw materials in proportion to make new carpets.

[0028] like Figure 1-4 As shown, a device and recycling process for recycling waste carpets includes the following steps: 1. Beat and shake the recycled waste carpet to shake out foreign objects such as sand, dust, particles, staples, pins and paper clips mixed in with the carpet surface. Second, metal detectors can prevent tiny metal particles hidden deep within the pile of old carpets from being removed before the pile is shredded. 3. The pile from the shavings of waste carpet falls into the basket and is then drawn into the storage tank by a vacuum suction device. The auger at the bottom of the tank transports the pile to the washing and drying line for washing and drying. The dried short pile falls into the basket and is drawn into the outdoor storage tank by the vacuum suction device for granulation. Fourth, the shredded backing is placed onto the conveyor belt 3 by the robot arm 2, and the backing enters the pre-opening shredder 4 to reduce noise and load during subsequent processing of the backing; 5. The shredded backing falls onto conveyor 5 and is further conveyed to backing crusher 6, where the shredded backing is crushed into particles of about 2mm. VI. The crushed bottom material is conveyed to the storage tank 8 by the type I auger 7, and the granular material in the storage tank is conveyed to the coarse powder mill 10 for crushing by the type II auger 9. 7. The coarse powder mill pulverizes the crushed material, separating the short fibers and colloidal calcium powder carried by the particles. The short fibers are then transported outdoors for collection and granulation through a type I spiral separator. 8. The colloidal calcium powder is conveyed by the spiral separator 11 to the fine powder mill 12 for further crushing and separation, and the short fiber is conveyed outdoors for collection and granulation; 9. The colloidal calcium powder separated by the fine powder mill 12 is conveyed by the type II spiral separator 13 to the multi-layer mesh vibrating screen 14 for sorting and packaging, and is used to replace raw materials in proportion to make new carpets.

[0029] Working Principle: This invention relates to a device and process for recycling waste carpets. After the waste carpet is patted and vibrated, a metal detector prevents tiny metal particles hidden deep within the pile from being removed before the carpet is shredded. The shredded backing is continuously placed onto a conveyor belt 3 by a robotic arm 2. The backing is then conveyed to a pre-opening shredder 4 for shredding. The shredded backing is then conveyed to a crusher 6 by a conveyor 5, where it is broken into particles of about 2mm. These particles are then conveyed to a storage tank 8 by a type I auger 7. The granular material in the storage tank 8 is conveyed to a coarse pulverizer 10 by a type II auger 9, where the short fibers and colloidal calcium powder encased in the particles are crushed and separated. The short fibers are then conveyed outdoors for collection and granulation by a type I spiral separator 11, while the colloidal calcium powder is conveyed by the spiral separator to a fine pulverizer 12 for further crushing and separation. The short fibers are then conveyed outdoors for collection and granulation by a type II spiral separator 13, while the colloidal calcium powder is conveyed by the spiral separator to a multi-mesh vibrating screen 14 for sorting and packaging, and then used to replace raw materials in proportion to make new carpets.

[0030] The foregoing description merely illustrates certain exemplary embodiments of the present invention. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the invention. Therefore, the above figures and descriptions are illustrative in nature and should not be construed as limiting the scope of the claims of the present invention.

Claims

1. A device and recycling process for recycling waste carpets, comprising a waste carpet recycling workshop (1), wherein the waste carpet recycling workshop (1) is sequentially equipped with: a metal detector, a shredder, a vacuum suction device, a storage tank, a winch, a washing and drying line, a vacuum suction device, a storage tank, a winch and a granulator; a robot (2), a conveyor belt (3), a pre-opening shredder (4), a shredded material conveyor belt (5), a crusher (6), a type I winch (7), a storage tank (8), a type II winch (9), a coarse powder mill (10), a type I spiral separator (11), a fine powder mill (12), a type II spiral separator (13), a multi-layer mesh vibrating screen (14) and a negative pressure fan (15).

2. The apparatus for recycling the waste carpet and the recycling process thereof according to claim 1, wherein, Negative pressure fans (15) are fixedly connected to one side of both the coarse powder mill (10) and the fine powder mill (12), and one end of each of the two negative pressure fans (15) is fixedly connected to the type I spiral separator (11) and the type II spiral separator (13), respectively.

3. The equipment and recycling process for recycling waste carpets according to claim 1, characterized in that, The robotic arm (2), conveyor belt (3), pre-opening shredder (4), shredded material conveyor belt (5), crusher (6), type I agitator (7), storage tank (8), type II agitator (9), coarse powder mill (10), type I spiral separator (11), fine powder mill (12), type II spiral separator (13), multi-layer mesh vibrating screen (14), and negative pressure fan (15) are all provided in two sets, and are located on the left and right sides of the storage tank (8), respectively.

4. The equipment and recycling process for recycling waste carpets according to claim 1, characterized in that, The coarse powder mill (10), fine powder mill (12), and multi-mesh vibrating screen (14) can all collect colloidal calcium powder.

5. The equipment and recycling process for recycling waste carpets according to claim 4, characterized in that, The short fibers pulverized and separated by the coarse powder mill (10) and fine powder mill (12) are separated, collected, granulated, and sold directly by a spiral separator. The colloidal calcium powder separated by the multi-mesh vibrating screen (14) is used to replace raw materials in proportion for making new carpets.

6. The equipment and recycling process for recycling waste carpets according to claim 1, comprising the equipment for recycling waste carpets according to any one of claims 1-5, characterized in that, Includes the following steps: (1) The recycled waste carpet is beaten and vibrated so that foreign objects such as sand, dust, particles, staples, pins and paper clips mixed in the carpet surface are beaten and vibrated out in advance. Then, the waste carpet is passed through a metal detector to prevent micro metal parts hidden deep in the pile from being removed before the pile is cut. (2) The carpet pile is removed by the depilator and the pile is drawn into the short pile storage tank by the vacuum suction device. The short pile in the tank is transported to the washing and drying machine by the auger for washing and drying. The vacuum suction device draws the dried pile into the outdoor short pile storage tank and transports the short pile to the granulator for granulation through the auger. (3) The backing of the waste carpet after the pile has been shredded is continuously placed on the conveyor belt (3) by the robotic arm (2). The backing is automatically transported to the pre-opening shredder (4) to pre-open and shred the backing, thereby reducing the load on the subsequent backing processing process. (4) The pre-opened and shredded bottom material is conveyed to the crusher (6) by the conveyor belt (5) to crush the shredded bottom material into particles of about 2mm; (5) The crushed material is conveyed to the storage tank (8) by the type I auger (7), and the material in the storage tank (8) is conveyed to the coarse powder mill (10) by the type II agitator (9) for crushing and separation; (6) The coarse powder is transported to the fine powder mill (12) by the type I spiral separator for further crushing and separation. The fine powder is transported to the multi-layer vibrating screen (14) by the type II spiral separator (13) for sorting and packaging, and is used to replace the raw materials to make new carpets. A small amount of short pile quilts are transported to the outdoor area by the negative pressure fan (15) for collection and granulation.

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