Process for producing a paraffinic recyclate from quartz composite

Description

[0001] The invention relates to a process for producing a particulate recyclate from quartz composite by comminuting quartz composite moldings made from a polymer matrix with inorganic filler particles embedded therein.

[0002] Quartz composite molded parts come in a variety of forms. For example, kitchen sinks, countertops, sanitary ware such as shower trays or shower trays, as well as floor and wall tiles, skirting boards, and similar items are made from quartz composite. These molded parts primarily consist of a polymer matrix, for example, based on an acrylate, with filler particles embedded in the cured polymer matrix. These filler particles can be inorganic or organic. Quartz sand, for example, is used as such a filler. Color pigments are also often embedded in the polymer matrix to impart a specific color to the molded part.

[0003] Over time, used molded parts inevitably accumulate, either because they are no longer needed after a long period of time and are replaced as part of renovation or conversion work, because they are defective, or for other reasons. Of course, the production of new molded parts also generates corresponding scrap parts that cannot be used for sale. As the use of such quartz composite molded parts increases, the amount of old parts that are no longer needed inevitably increases. These are usually disposed of by waste disposal companies.

[0004] The report "LIFE Project Number LIFE GREEN SINKS Project data", 31.

[0005] December 2015 (2015-12-31), pages 1-24, XP093021198, available online at

[0006] URL: http: / / webgate.ec.europa.eu / life / publicWebsite / index.cfm?fuseaction=search. dspPage&n_proj_id=4523 describes a study on the recycling of quartz composite molded parts, specifically kitchen sinks.

[0007] JP H10 249860 A describes the use of a recycled powder as an additive to a synthetic resin from which a molded article is produced.

[0008] The invention is therefore based on the problem of providing a method that enables the further recycling of such quartz composite molded parts.

[0009] To solve this problem, a method for producing a particulate recyclate from quartz composite according to claim 1 is provided.

[0010] In the method according to the invention, pre-shredded molded parts are shredded in a hammer mill, during which shredding a sufficient number of particles are produced that lie within a target grain size range that the particulate recyclate should have. In such a hammer mill, the material to be ground is shredded by kinetic impact and impact shredding. A plurality of movable hammers are attached to a rotor and rotate via the rotor in the mill housing. The hammers strike the material to be ground, i.e. the molded parts, thereby shredding them. In addition, the shredded pieces are also thrown against the housing wall, which further breaks them up. During the time the material to be ground remains in the housing, the material to be ground is continuously struck and further shredded due to the relatively high rotation speed of the rotor and thus of the hammers.This results in the formation of correspondingly small particles, a considerably high proportion of which have a grain size that is in the range of a desired target grain size or, as a fine fraction, is even smaller.

[0011] It has now surprisingly been found that the ground material, i.e. the molded parts, are sufficiently crushed in such a hammer mill at room temperature. On the one hand, a sufficiently large proportion of particles forming the recyclate with a desired grain size distribution is obtained in a single grinding pass. On the other hand, there is a particular advantage that there is no clumping or briquetting, i.e. the formation of large particles that cannot be used as recyclate, in particular as recyclate to be added to a casting compound for the production of new parts. In other mills, such as a roller mill, comminution takes place by shearing the ground material, i.e., high shear energy is introduced. This shear energy presumably leads to heating of the crushed particles, which in turn leads to softening of the polymer matrix, at least in the surface area.The individual particles therefore become slightly sticky, which is likely the cause of clumping or briquetting. Surprisingly, it has now been discovered that such processes do not occur in a hammer mill, as the material is not subjected to shear stress there, but is merely subjected to impact energy or impact energy when centrifuged against the housing wall. These energies or energy inputs do not lead to excessive heating of the particles, so that, surprisingly, surface stickiness and thus clumping or briquetting do not occur. Therefore, the material to be ground in such a hammer mill can advantageously be ground for longer periods, which in turn results in a sufficiently high proportion of the particle quantity that lies within the target grain size range within the grinding process.Thus, the process according to the invention allows for the first time the production of a sufficiently large quantity of particles forming the recyclate and, on the other hand, the production of these particles in an economically viable manner. Consequently, the process according to the invention allows for the efficient recycling of corresponding used quartz composite parts to form a particulate recyclate that can be reused as an aggregate, for example, as an aggregate in a casting compound for the production of new quartz composite parts.

[0012] In an alternative embodiment to the claimed invention, it can be provided that a particle fraction containing particles forming the recyclate and having a maximum target grain size is withdrawn via a sieve. According to this first embodiment of the invention, only the particle fraction containing particles that have the target grain size or a smaller grain size, including any very small fine fraction, is withdrawn from the hammer mill via a sieve. If, for example, the target grain size is 1.0 mm, the particle fraction withdrawn is the amount of particles that includes particles with a maximum grain size of 1.0 mm or less. Larger particles remain in the hammer mill and can be further processed until they too are correspondingly reduced in size and withdrawn. Here, therefore, only the target fraction is withdrawn directly, preferably continuously. The target grain size can be 1.0 mm, in particular 0.8 mm.Such a target grain size is useful when the particulate recyclate is to be used as an additive in a casting compound for the production of new quartz composite molded parts. This target grain size corresponds to the maximum filler grain size of the inorganic or organic fillers present in the casting compound and thus in the new product. The individual recyclate particles consist partly of the polymer matrix and contain inorganic or organic filler particles such as those present in the recycled old part. A specific filler proportion from "old fillers" can now be added to the casting compound via the recyclate particles. The selection of the target grain size of the recyclate particles ensures that the filler particles added in this way always have a maximum filler grain size that is to be contained in the new molded part.

[0013] An alternative method embodiment (according to the invention) to the variant not according to the invention described above, in which the target fraction is withdrawn directly from the hammer mill, provides that a first particle fraction with a maximum grain size that is larger than the target grain size of the particles forming the recyclate is withdrawn from the hammer mill via a sieve, after which a second particle fraction containing particles forming the recyclate with a grain size that is equal to or smaller than the target grain size is withdrawn from the first particle fraction in a downstream sieve device and particles that are larger than the target grain size are separated from a third particle fraction.In this process configuration, a first particle fraction, which is coarser than the actual target fraction, is screened from the hammer mill and then sieved in a screening device to separate the desired target fraction, the second particle fraction. Consequently, the recyclate particles from the coarse first particle fraction removed from the hammer mill are classified in the screening device. The hammer mill's screen, through which the first particle fraction is removed, not only defines the maximum grain size of the first particle fraction, but also varies the residence time of the material in the mill.The larger the sieve or the sieve openings, and thus the maximum grain size, the shorter the residence time of the material to be ground in the hammer mill. The smaller the sieve or the maximum grain size, the longer the residence time of the material to be ground in the hammer mill, as greater comminution is required to pass through the sieve. This also means that the fine fraction, i.e. the proportion of particles with a very small grain size that is also significantly below the target grain size of the target fraction, varies depending on the sieve size used. With a larger sieve and thus a shorter residence time, the fine fraction is smaller, whereas with a smaller sieve and a longer residence time, it is larger.

[0014] According to this process variant, two separate fractions are generated at the screening device: the second particle fraction, which contains particles that form the recyclate and are equal to or smaller than the target particle size, and the third particle fraction, which contains particles that are larger than the target particle size. The second particle fraction can either be used as the final target fraction, or it can be further classified, as will be discussed below. The third particle fraction can also be reused if desired, as will be discussed in more detail below.

[0015] According to a further development of the invention, the maximum grain size of the first particle fraction can be 5 mm, in particular 4 mm. This means that the sieve of the hammer mill has a corresponding sieve width of 5 mm, in particular 4 mm. A bar grid sieve can preferably be used for classification, which provides a sufficiently large sieve surface area, enabling a reduction in the residence time of the particles in the hammer mill. While a maximum grain size of < 4 mm is conceivable in principle, the fine fraction, i.e., the proportion of particles with a grain size significantly smaller than the target grain size, then increases considerably.

[0016] Here, too, the target grain size should be 1.0 mm, especially 0.8 mm. This is especially true if the recycled particles are to be added to a quartz composite casting compound as an additive for the production of new molded parts. Again, in this process variant, the target grain size essentially corresponds to the maximum filler grain size of the inorganic or organic fillers present in the new molded part.

[0017] As described, this second process variant according to the invention produces a third particle fraction that contains particles larger than the maximum target grain size of the second particle fraction. It is preferable to return this third particle fraction to the hammer mill for further comminution. This means that these still-too-large particles are processed and comminuted again in the hammer mill until they have a grain size that is in the range of the target grain size or smaller, so that they are added to the second particle fraction in the downstream screening step in the screening device. This means that the third particle fraction is recycled, which can also be repeated several times, so that, starting from an added fill quantity of molded parts, a yield of particulate recyclate of almost 100% is possible.

[0018] As described above, the crushed particles of the first particle fraction must be transferred from the hammer mill to the screening device, and the particles of the third particle fraction must be transferred from the screening device back to the hammer mill. This transfer can be done manually, i.e., the material is manually transported by an operator from the hammer mill to the screening device, or from the screening device to the hammer mill, and fed there.

[0019] Preferably, however, automatic transport takes place via a suitable transport device. Such a transport device for transferring the first particle fraction can be, for example, a conveyor belt, such as a Z-conveyor, which carries the first particle fraction from the hammer mill to the screening device. A Z-conveyor is expedient because at the hammer mill, the first particle fraction is preferably drawn off downwards, while it is fed to the screening device from above, with the corresponding second and third particle fractions in turn preferably being drawn off from below at the screening device.

[0020] A conveyor belt, such as a vibrating chute or similar, can also be provided to transport the third particle fraction from the screening device back to the hammer mill.

[0021] If, for example, the third particle fraction is transported manually, the third particle fraction can be collected in a correspondingly large storage container, for example a big bag, and the filled storage container can then be transported to the hammer mill via a corresponding means of transport such as a pallet truck or the like, for example to a conveyor belt starting close to the ground, via which the material to be ground is transported upwards to the feed of the hammer mill.

[0022] The operation of the hammer mill and the screening device can essentially be continuous. This means that pre-shredded shaped parts and, if provided, particles of the third particle fraction are continuously fed to the hammer mill, and particles are continuously removed and also continuously fed to the screening device, where they are continuously screened into the appropriate fractions. Such a continuous process can therefore operate at a remarkably high throughput. Alternatively, an intermittent process can of course also be provided, in which only a specific amount of ground material is processed without the continuous addition of new ground material. This only occurs when the fed ground material has been completely processed.

[0023] As described, a second particle fraction is separated from the first particle fraction in the screening device using a sieve, which can be a mesh sieve or similar. This second particle fraction contains particles whose grain size corresponds at most to the target grain size, but which can also be smaller or significantly smaller, meaning that the second particle fraction also has a correspondingly high fines fraction, i.e. very fine particles with a very small grain size. If the target grain size is, for example, 1.0 mm or 0.8 mm, the second fraction also contains particles with grain sizes of only 0.2 mm, 0.1 mm or even finer, right down to powdery particles, which ultimately can no longer be described as granules. In principle, the second particle fraction, i.e. the target fraction, can also contain the fines fraction, for example as an additive for a casting compound.However, if the fine fraction is not desired, an expedient development of the invention provides that in the screening device or a further screening device, a fourth particle fraction with a maximum grain size smaller than the target grain size is formed from the second particle fraction by screening and removed, so that a fifth particle fraction containing the particles forming the recyclate remains and is removed. In the screening device, the second particle fraction is further classified in a second screening level. This is separated into a fourth particle fraction containing the undesired fine fraction to be removed, and a fifth particle fraction, which then corresponds to the final target fraction.For this purpose, a maximum grain size of the fourth particle fraction, i.e. the fine fraction, is defined using an additional sieve, e.g. a mesh sieve, so that this fourth particle fraction only contains particles that have this grain size or that are even finer. The final fifth particle fraction, i.e. the target fraction, then only contains recyclate particles whose grain size lies in the range between the target grain size and the maximum grain size of this second sieve level. Thus, the target fraction ultimately contains no or only a negligible fine fraction, which can have advantages with regard to the rheology of the casting compound to which the recyclate particles are added. If both sievings take place in a common sieving device, corresponding downstream sieving stages are provided. If two separate sieving devices are used, these can, for example,be connected via a transport device via which the second particle fraction is automatically transported to the second screening device.

[0024] The maximum grain size of the fourth particle fraction should be 0.1 mm, especially 0.2 mm. The larger this maximum grain size, the smaller the range of grain sizes of the final recycled particles.

[0025] According to the invention, mesh sieves having a defined mesh size are used for sieving the first particle fraction and / or for sieving the second particle fraction, which enables appropriate separation and classification of the fractions.

[0026] Particularly preferred starting materials for the process according to the invention are molded parts that contain inorganic and / or organic filler particles embedded in a polymer matrix with a proportion of ≥ 60 percent by weight (wt.%), in particular ≥ 65 wt.%. The molded parts should therefore contain a minimum proportion of inorganic and / or organic filler particles, which should be at least 60 wt.%, but preferably higher. This means that the proportion of polymer matrix should not be too high, since the aim is to recycle fillers, in particular, via the recyclate, i.e., to add recycled fillers to a casting compound for the new production of molded parts.

[0027] In addition to comminuting differently colored composite materials, the described process can also be used to preferably comminute molded parts with essentially the same color together in the hammer mill. This means that the recyclate particles of the target fraction can ultimately also have a uniform color. As explained, molded parts, including recycled molded parts, usually contain color pigments that give them an individual color. These color pigments are usually added to the casting compound via a color paste during new production. Since the new parts are also intended to have a specific color, and since the recyclate particles inevitably also contain color pigments, it must be ensured that the recyclate particles do not change the target color of the new molded part defined by the color paste.Therefore, according to the invention, only pure-type molded parts, i.e., molded parts of the same color, are preferably crushed together, so that the recycled particles have a uniform color. Of course, the molded parts do not have to be completely identical in color; rather, molded parts that vary slightly in color can also be processed together, for example, anthracite gray molded parts together with black molded parts or similar. Of course, the ratio of the number of molded parts with different colors ultimately determines the final mixed color.

[0028] The pre-shredded, usually irregularly shaped molded parts should preferably have a maximum length of approximately 40 cm, especially approximately 30 cm. The molded parts can be produced either by manually crushing the molded parts to be recycled or by means of a suitable pre-shredding process, for example, using a roller compactor in a container or the like, where the molded parts are crushed accordingly using a heavy roller.

[0029] The molded parts themselves can be fed into the hammer mill either manually or automatically using a transport device such as a conveyor belt.

[0030] Various quartz composite moldings can be used as molded parts to be processed. Preference is given to processing molded parts that correspond to the molded parts to be produced, since the material composition of the old molded parts essentially corresponds to that of the new molded parts to be produced. Therefore, if kitchen sinks are to be produced as new molded parts, then according to the invention, kitchen sinks should also be used as old molded parts within the scope of the inventive method. If such kitchen sinks are produced from different casting compound compositions, i.e. the kitchen sinks consist of different material compositions, it is also conceivable that only old kitchen sinks whose material composition corresponds to that of the new kitchen sink to be produced are used to produce the recyclate to be added to the casting compound. However, this further specification is not mandatory.

[0031] Furthermore, the invention relates to the use of a particulate recyclate according to claim 16.

[0032] Further advantages, features, and details of the invention will become apparent from the exemplary embodiments described below and from the drawings. In the drawings: Fig. 1 is a schematic diagram of an apparatus for producing a particulate recyclate from quartz composite according to the method according to the invention, Fig. 2 is a flow chart to explain the method according to the invention, Fig. 3 is a diagram showing the grain size distribution of three different milling materials, Fig. 4 is a diagram showing the influence of grain size on the product discharge through a sieve or an outlet gap, Fig. 5 is a diagram showing the grain size distribution in various successive grinding steps, and Fig. 6 is a diagram showing the grain size distribution of successively ground milling materials, each taken from a previous grinding process.

[0033] Fig. 1shows a device 1 for producing a particulate recyclate from quartz composite. The device 1, which is purely a schematic representation, comprises a first transport device 2, for example, a belt conveyor, onto which transport device 2 pre-shredded molded parts 3 are placed. These pre-shredded molded parts 3 are fragments of a quartz composite molded part and, like this molded part, consist of a polymer matrix with embedded inorganic and / or organic filler particles and usually also color pigments. The molded parts shredded to form the molded parts 3 are, for example, no longer used or unusable kitchen sinks.

[0034] By means of the first transport device 1, the shaped pieces 3 are transported to a hammer mill 4, where they are crushed by the rotating hammer or impact mechanism. The shaped pieces 3 are crushed by the rotating hammers, meaning that the crushing process is achieved by the introduction of impact energy. Due to the relatively high rotation speed of the rotor or hammers of several tens of meters per second, the crushed pieces are also thrown against the mill wall, where they also break.

[0035] InThe hammer mill 4 incorporates a screen (not shown in detail), which can be used to separate a first particle fraction with a maximum grain size larger than the target grain size of the particles forming the recyclate. This means that particles with a grain size that corresponds to the maximum grain size defined by the screen or that is smaller than this maximum grain size fall through this screen, for example a bar grate screen. The particles that do not fall through the screen remain in the hammer mill and continue to be impacted and thus crushed until they too can pass through the screen.

[0036] The first particle fraction is then transported to a screening device 6 by a second transport device 5, in the example shown a Z-conveyor with a corresponding conveyor belt, and fed to the screening device 6. There, the first particle fraction is screened in at least one screening level to form a second particle fraction containing the particles forming the recyclate. These particles of the second particle fraction have a grain size equal to or smaller than the target grain size. Furthermore, a third particle fraction is formed, which contains the particles that are larger than the target grain size.This means that in the screening device 6, a classification of the relatively coarse first particle fraction takes place in order, on the one hand, to form a particle volume containing the particles which ultimately lie in the target particle size range or are smaller, and to form a third particle fraction containing particles which are larger than this target particle quantity.

[0037] In the embodiment shown, the second particle fraction can be introduced from the screening device 6 into a receiving container 7 provided for removal, e.g. on a lifting truck shown, and collected there until a certain filling level is reached, after which this second particle fraction is finally removed and fed for further use, e.g. as an additive to a casting compound for the production of new kitchen sinks.

[0038] The third particle fraction is also collected in a suitable receiving container 8. Since this third particle fraction consists of particles that do not fall within the target grain size range, and are therefore still too large, they are fed to the first transport device 2, as shown by the dashed line 9 indicating a transport path, where they are fed back into the hammer mill 4 to be ground again. This means that the third particle fraction that is too large is returned. Through the renewed grinding, a sufficiently large proportion of the particles is further reduced in size so that these particles then lie within the target grain size range and subsequently fall into the second particle fraction. This return of the third particle fraction to the first transport device 2 can be done manually, for example by pulling the lifting truck shown here, via which the receiving container 8 can be moved.Alternatively, instead of the receiving container 8, a further transport device, for example a vibrating trough or a conveyor belt, can be provided, onto which the particles of the third particle fraction fall or are placed, so that they are automatically returned to the first transport device 2.

[0039] Of course, the second particle fraction, i.e. the target fraction, can also be placed on a conveying device such as a conveyor belt instead of in the shown receiving container 7, by means of which it is transported, for example, to a distant packaging station or the like.

[0040] As described above, in the exemplary embodiment shown, the screening device 6 comprises only one screening level, via which the first particle fraction is separated into the second and third particle fractions. As stated, the second particle fraction contains particles that have a maximum of the target particle size, but which can of course also be smaller, down to a fine fraction with a minimal particle size, i.e., particle sizes smaller than 0.2 or 0.1 mm. This fine fraction can remain in the second particle fraction as long as it does not interfere with subsequent processing. However, it can also be separated if necessary. For this purpose, the screening device has a second screening level in which the second particle fraction is screened again to form a fourth particle fraction that contains only the fine fraction, and a fifth particle fraction, which then becomes the final target particle fraction.This additional sieving level, which, like the first sieving level, is formed by means of a mesh sieve or similar, defines a maximum grain size that is smaller than the target grain size. This means that the fourth particle fraction, i.e. the fines fraction, only contains particles that have this maximum grain size or are smaller, i.e. the entire fine fraction down to the powder. In contrast, the fifth particle fraction only contains particles that are smaller than or equal to the target grain size and larger than this maximum grain size of the second sieving level. The fourth and fifth particle fractions are then removed accordingly. While the fifth particle fraction, i.e. the target fraction, is recycled, the fourth particle fraction, i.e. the fines fraction, can be discarded. This means that in the . Fig. 1In the device shown, two such containers are provided instead of one receiving container 7. One receiving container receives the fourth particle fraction, i.e., the fine and ultrafine fraction, while the other exception container receives the final fifth particle fraction.

[0041] The maximum grain size of the first particle fraction, as defined by the sieve of hammer mill 4, is 5 mm, for example, and especially 4 mm. The gap width of the sieve should not be smaller, as otherwise the fine fraction will become too large during the grinding process.

[0042] The target grain size, which is defined by the first screening level of the screening device 6, should be approximately 1.0 mm, preferably approximately 0.8 mm.

[0043] The maximum grain size, which defines the fine fraction, should be approximately 0.1 mm, preferably approximately 0.2 mm. This results in the grain size of the particles comprising the final fourth particle fraction, i.e., the target fraction, being ≤ 1.0 mm and > 0.1 mm, preferably ≤ 0.8 mm > 0.2 mm.

[0044] Fig. 2 shows a flow chart that shows the individual process steps in principle, as well as the resulting particle fractions.

[0045] In step S1, the material to be ground, i.e. the pre-shredded shaped pieces 3, is placed on the first transport device 2 and fed to the hammer mill 4.

[0046] In step S2, the feed material is ground in the hammer mill 2. This grinding leads to the formation of the first particle fraction PF1.

[0047] This first particle fraction PF1 is then withdrawn from the hammer mill via the sieve of the hammer mill 4 in step S3 and fed via the second transport device 5 to the sieve device 6 and fed there.

[0048] In step S4, the first particle fraction PF1 is sieved in the sieving device 6, forming the second particle fraction PF2 and the third particle fraction PF3. For this purpose, the sieving device 6 has a first sieve, for example a mesh sieve or the like, forming a first sieving plane, via which the target grain size is defined. This is, for example, 1.0 mm, 0.9 mm, or 0.8 mm, depending on the desired maximum target grain size of the final recyclate. This means that the second particle fraction PF2 contains particles with a grain size equal to or smaller than the target grain size of, for example, 1.0 mm or 0.8 mm.

[0049] In contrast, the third particle fraction PF3 comprises only particles that are larger than the target grain size, i.e., particles with a grain size greater than 1.0 mm or 0.8 mm. This third particle fraction PF3 is then automatically fed back to the first transport device 2, for example, via a transport device, in step S5, so that it is fed back to the hammer mill 4 in step S1, where these still relatively large particles are ground again and returned to the grinding and screening circuit.

[0050] As explained, the second particle fraction PF2 contains particles that are smaller than or at most equal to the target grain size. It therefore also includes a corresponding fine fraction, i.e., particles that are much smaller. To separate this fine fraction, as illustrated by step S6, the second particle fraction PF2 is sieved by means of the sieving device 6 in a second sieve level using a second sieve, for example, a mesh sieve or the like, to form a fourth particle fraction PF4 and a fifth particle fraction PF5. The sieve width of the sieve of this second sieve level, in turn, defines a maximum grain size, for example, 0.1 mm or 0.2 mm, which ensures that the undesired fine fraction is sieved out. This means that the fourth particle fraction PF4 contains only very fine particles, which form the fine fraction.

[0051] In contrast, the fifth particle fraction PF5 contains only particles within the desired particle size range, which is defined upwards by the target particle size, i.e., the preferred particle size, and downwards by the maximum particle size, at which the fine fraction begins. The fifth particle fraction PF5 therefore contains, for example, only particles that are ≤ 0.8 mm and > 0.2 mm.

[0052] In step S7, the fourth particle fraction is removed and can, for example, be discarded if the fine fraction cannot be recycled in any other way. The final fifth particle fraction PF5, which can be further processed as recyclate, is subsequently removed according to step S6, for example, after it has been collected in a receiving container or by means of a transport device or similar.

[0053] As part of the investigations, various quartz composite materials were ground using a hammer mill and the grinding result was determined.

[0054] In a first experiment, the grinding behavior of three different quartz composite compositions was investigated. The starting material was three quartz composite kitchen sinks from the applicant, each made of different quartz composites.

[0055] One sink was made of the applicant's material known under the brand name Cristalite ®<, the second sink was made of the applicant's material known under the brand name Cristadur ®<, and the third sink was made of the applicant's material known under the brand name Cristadur ®< Green Line.

[0056] In addition to the polymeric binder that forms the polymer matrix and is based on MMA, as well as color pigments, the sinks made of Cristadur ®< material also contain an inorganic filler in the form of quartz sand in a proportion of 68 - 75 percent by weight.

[0057] In addition to the polymeric binder matrix and color pigments, the sink made of Cristalite ®< material contains an inorganic filler in the form of quartz sand at a proportion of 70 - 75 percent by weight.

[0058] The sinks were pre-crushed into molded fragments, meaning the sinks were pre-crushed, with the fragments not exceeding 30 cm in length. To ensure sufficient material was processed, several identical sinks of each type were crushed.

[0059] A Gebr. Jehmlich GmbH HM 672 hammer mill was used to grind the material. It operates on the principle of impact and impact. The rotating hammers impact the material in the grinding chamber. Once the required fineness is achieved, the material exits the grinding chamber through a bar screen. The bar screen had a gap width of 4 mm, which limited the proportion of larger particles passing through the screen.

[0060] In this hammer mill, the various material types were ground. Milling continued until all the material fed into the mill had been ground.

[0061] The result of the grain size distribution of the three different grinding materials is shown in Figure 3 shown.

[0062] The particle size is given in mm along the abscissa, and the respective proportion in mass percent along the ordinate.

[0063] The curve marked I indicates the particle distribution for the material Cristalite ®<, the curve marked II the distribution for the material Cristadur ®< and the curve marked III the distribution for the material Cristadur ®< Greenline.

[0064] It can be seen that the resulting milled material of all compositions examined exhibits a comparable grain size distribution. A first peak appears in the range between approximately 3.0 and 1.0 mm, and a second peak appears in the range between 0.3 and 0.06 mm.

[0065] Clumping or briquetting of the respective material in the hammer mill did not occur with any of the materials examined, which means that the entire material fed into the mill could be ground and removed via the sieve.

[0066] For the production of new molded parts, i.e., new kitchen sinks made from the respective Cristalite ® or Cristadur ® materials, inorganic fillers, primarily quartz sand, with a maximum grain size of approximately 0.8 mm are preferred. For this reason, the respective particle fraction with a grain size of ≤ 0.8 mm is suitable within the resulting millbase, as shown above.

[0067] The milling yield of the grinding tests shown in the diagram above with a particle size ≤ 0.8 mm is shown in the following table: material Cristalite ®< Cristadur ®< Cristadur ®< Greenline Yield approx. (%) 60 48 45

[0068] This means that any material can be crushed in the first grinding step to such an extent that it already contains a sufficiently high proportion of particles that have a certain target grain size or are smaller.

[0069] In a further experiment, the influence of the outlet opening on the residence time of the material in the mill and the resulting particle size distribution of the material to be ground was investigated. The experiments were conducted on an HA800 hammer mill from Erdwich Zerkleinerungssysteme GmbH with a variable outlet gap instead of a bar grate screen for product discharge. The outlet gap width was 3 mm. By having only a single outlet gap with a smaller opening width for product discharge, the residence time of the material in the mill was significantly increased. The results are shown in Figure 4 shown.

[0070] The abscissa represents the particle size in mm, i.e., the grain size, while the ordinate represents the respective mass percentage of the ground material. The curve marked I indicates the particle size distribution for a bar screen width of 4 mm, while the curve marked II indicates the particle size distribution for an outlet gap opening of 3 mm.

[0071] It is evident that when using the 4 mm bar screen of the HM 672 hammer mill from Jehmlich, the proportion of particles with a grain size between 4.0 and 0.5 mm is significantly higher than in curve II with an outlet opening of 3 mm in the HM800 hammer mill from Erdwich. These relationships are reversed from a particle size of approximately 0.5 mm, meaning that the fines fraction is significantly higher during the inevitably longer grinding process with the single outlet opening of 3 mm than when grinding with a bar screen, where the material is discharged much sooner and the residence time is thus significantly shortened.

[0072] If we consider the particle fraction with a grain size of ≤ 0.8 mm, a higher yield of particles in the target grain size range can be achieved by grinding with a single exit slit and by extending the material's residence time in the hammer mill. An increase of up to 90% has been observed according to the diagram above. However, this also entails a significant increase in the proportion of fine material, with particles with a grain size of ≤ 0.2 mm, for example, being considered fine material. If an excessively high fines content is not desired, the sieve size must not be selected too small.

[0073] As mentioned above regarding the Figures 1 and 2As already described, the first particle fraction taken from the hammer mill 4 is screened in the screening device 6. A second and a third target fraction are formed, wherein, as described, the third target fraction contains particles with a grain size larger than the target grain size of the desired recyclate particles. This third particle fraction can be returned to the hammer mill 4 for further grinding.

[0074] In a further experiment, the efficiency of a second grinding process was investigated in relation to the yield of suitable material. This involved grinding the material to be ground a first time in the hammer mill, then classifying the first particle fraction in the screening device. The third particle fraction was then returned to the hammer mill and ground a second time, followed by classification in the screening device. A Cristalite ® quartz composite material was investigated.

[0075] The results are in Figure 5 shown. Here, too, the particle size distribution in mm is plotted along the abscissa and the respective percentage along the ordinate.

[0076] The curve marked I shows the particle or grain size distribution after the first grinding pass, the curve marked II shows the particle or grain size distribution after the second grinding pass, and the curve marked III shows the effective particle or grain size distribution after both grinding passes.

[0077] The first grinding step results in a grain size distribution in which a considerably large proportion of particles is already in the target grain size range, i.e. ≤ 0.8 mm.

[0078] In the second grinding run, the particle volume from the first grinding run that was > 0.8 mm is ground again in the hammer mill, meaning that the oversize particles from the first grinding run are fed in again. As shown by Curve II, this grinding run also produces a particle fraction with particles < 0.8 mm, as well as a particle fraction still containing larger particles. However, the comminution ratio in this second grinding run is lower than in the first grinding run.

[0079] However, it is shown that by recycling the upper grain, i.e. the third fraction according to the above description of the figure, a new yield of particles in the target grain size range is obtained.

[0080] This is also evident in the curve marked III, which shows the effective particle size distribution after two grinding passes. The vast majority of the milled material obtained after two grinding passes is already within the desired particle size range of ≤ 0.8 mm, and there primarily in the desired particle size interval between 0.8 and 0.2 mm. This means that by repeatedly reapplying the upper particle size, i.e., the third particle fraction, a continuous increase in yield can be achieved, up to almost 100%.

[0081] In addition to experiments using a hammer mill according to the invention, another grinding process for comminuting quartz composite molded parts was also investigated. In this case, multi-stage comminution was performed using a roller crusher and a roller mill. A four-stage grinding process was performed.

[0082] In the first grinding stage, pre-crushed shaped pieces with a maximum length of 30 cm were crushed using a jaw crusher of the type BB 400 / 250 from Merz Aufbereitungstechnik GmbH; the crusher gap was 20 mm.

[0083] In a second grinding stage, the material from the first grinding stage, which was drawn off via the crusher gap, was ground in a roller crusher with a pyramid cam profile of the type WBG 5 / 4 from Merz Aufbereitungstechnik GmbH; the crusher gap here was 1.0 mm.

[0084] The material to be ground from the second grinding stage, which had passed through the crusher gap, i.e. the fine fraction from grinding stage two, was then further ground in a roller mill of type WBP 6 / 4 from Merz Aufbereitungstechnik GmbH, the grinding gap was set to 1.5 mm.

[0085] In a fourth grinding stage, the material that had passed through the grinding gap in grinding stage three, i.e. the fine fraction obtained there, was then ground again in the roller mill, but the crusher gap was then set to 0.5 mm.

[0086] The individual grinding results were classified according to particle size, the results are shown in Figure 6 shown.

[0087] The curve marked I shows the particle size distribution of the ground material from the first grinding stage. The curve marked II shows the particle size distribution of the ground material from the second grinding stage. The curve marked III shows the particle size distribution of the ground material from the third grinding stage. The curve marked IV shows the particle size distribution of the ground material from the fourth grinding stage.

[0088] In the first grinding stage, the molded parts are only coarsely crushed due to the large crusher gap. Clearly, almost no particles are formed that are within the target particle size range, i.e., preferably ≤ 0.8 mm. The yield of recycled particles in the target particle size range is only approximately 0.3% of the total material fed in.

[0089] In the second grinding stage, only the fraction of the first grinding stage that passed through the crusher gap was ground. It is evident that further comminution is possible in the second stage, but even here, only an almost negligible particle fraction was found, which lies within the target particle size range of ≤ 0.8 mm. The yield of particles ≤ 0.8 mm was approximately 5.9%.

[0090] The portion of the material that passed through the crusher gap in the second grinding stage was then ground in the third grinding stage in a roller mill with a grinding gap of 1.5 mm. The result is shown by curve III.

[0091] Here, too, a high peak is observed in the grain size range between approximately 2.5 - 8 mm, in which almost all of the material is generated. In contrast, only a small fraction of particles was obtained, which lies in the target grain size range ≤ 0.8 mm.

[0092] In the fourth grinding stage, the particle fraction obtained in the third grinding stage that had passed through the crusher gap was then ground once more in the roller mill, but this time with a smaller crusher gap of 0.5 mm. The grinding result is shown by curve IV. Here, a broader particle size distribution is observed in the range ≤ 2.5 mm, which means that further comminution has taken place. The proportion of particles in the target particle size range ≤ 0.8 mm also increases. Nevertheless, the yield of material in the target particle size range is only approximately 46%. It can also be seen that the proportion of coarser material has increased slightly compared to the third grinding stage. This is due to briquetting that occurs in this shearing grinding process. The stuck, briquetted material has a larger particle size than the original material from the third grinding stage.

[0093] This means that at the end of the four-stage grinding process, only a fraction of the originally fed-in material can actually be recovered, as the quantity of processed material has been continuously reduced within each individual grinding stage, since only the portion passing through the corresponding sieve or gap was further processed. In order to even arrive at a grinding material that would result in a reasonably acceptable yield, three previous grinding processes were necessary. The material fed into this fourth grinding stage already had a considerably small maximum grain size, resulting from the third grinding stage with a crusher gap of 1.5 mm. Even when grinding this already extremely pre-crushed material (as mentioned, the starting material was the shaped parts with a length of approx. 30 cm fed into the first grinding stage), a yield of only approx.46% is achieved, which means that more than half of the ground material obtained is not within the target grain range.

[0094] Furthermore, clumping or briquetting of the ground material, i.e., the composite granules, was observed, both in the third grinding stage and in the fourth grinding stage, which ultimately leads to a significant deterioration in the yield of material in the target particle size range. As already explained, this clumping or briquetting results from the material being subjected to shear stress in the roller mill, which leads to significant heating and softening of the polymer matrix, i.e., the resin binder, and subsequently to particle sticking.

[0095] In contrast, the method according to the invention allows the formation of a considerably large target particle fraction in a single grinding step, starting from coarse, pre-shredded shaped pieces, preferably with a maximum length of 30 cm. This means that a fraction with particles that are, for example, ≤ 1.0 mm or ≤ 0.8 mm, depending on how the maximum target grain size is defined. In addition, the method according to the invention has the advantage that there is no briquetting, i.e. clumping, which means that the material not within the target grain size range can be re-ground without problems. A continuous, longer grinding process can also be carried out because the impact stress on the ground material does not result in a high energy input, unlike with shear stress, such as that used as a comminution process by the mill types described above.

[0096] Therefore, the process according to the invention using a hammer mill can be used to efficiently and economically produce a particulate recyclate made of quartz composite.

[0097] The resulting recyclate, which, as mentioned, preferably has a maximum grain size corresponding to the maximum grain size of the inorganic or organic filler, such as quartz sand, used in the production of a new molded part, particularly a kitchen sink, is extremely simple. It is merely necessary to pretreat the recyclate particles before incorporating them into the casting compound. As explained, the recyclate particles also contain, to a certain extent, the polymeric binder matrix, i.e., an acrylic matrix. Since the untreated recyclate particles are incorporated into the casting compound, they swell slightly in the monomeric acrylate contained therein, leading to an increase in the viscosity of the casting compound.To avoid changes in the rheological properties of the casting compound or an intermediate product, such as the color paste to which the recycled material can be added, the recycled particles simply need to be pre-swollen with a suitable amount of monomeric acrylate. This means that an appropriate amount of monomeric acrylate is added to the recycled granules, allowing the particles to swell. Swelling is usually complete after 24 hours at the latest. The swelling process can be monitored rheologically.

[0098] The recycled particles pretreated in this way are then added to the casting compound either directly as a standalone intermediate product or, for example, to the color paste, which is then added to the casting compound. The casting compound can then be processed like a conventional casting compound in mold casting, but contains a significant proportion of recycled, i.e., reused, fillers.

[0099] Although in the example in the screening device 6 both the first particle fraction is separated into the particle fractions PF2 and PF3 and the second particle fraction PF2 is also separated into the particle fractions PF4 and PF5, i.e. two screening stages are provided, it would also be conceivable to use a further separate screening device for the separation of PF2 into PF4 and PF5, to which the second particle fraction PF2 is fed from the screening device 6 via a transport device.

Claims

1. Process for producing a particulate recyclate from quartz composite by comminuting quartz composite mouldings composed of a polymer matrix with inorganic and / or optionally additionally organic filler particles embedded therein, in which precomminuted pieces of moulding are comminuted in a hammer mill (4) to form particles that form the recyclate, wherein a sieve is used to remove a first particle fraction (PF1) having a maximum grain size greater than the target grain size of the particles that form the recyclate from the hammer mill (4), and then, in a downstream sieving device (6), a second particle fraction (PF2) containing particles having a grain size equal to or less than the target grain size that form the recyclate is removed from the first particle fraction (PF1) and separated from a third particle fraction (PF3) containing particles larger than the target grain size.

2. Process according to Claim 1, characterized in that a sieve is used to remove a particle fraction comprising particles having a maximum target grain size that form the recyclate.

3. Process according to Claim 2, characterized in that the target grain size is 1.0 mm or 0.8 mm.

4. Process according to any of the preceding claims, characterized in that the maximum grain size is 5 mm or 4 mm.

5. Process according to any of the preceding claims, characterized in that the sieve for obtaining the first particle fraction (PF1) is a bar sieve.

6. Process according to any of the preceding claims, characterized in that the third particle fraction (PF3) is returned to the hammer mill (4) for further comminution.

7. Process according to any of the preceding claims, characterized in that the particles of the first particle fraction (PF1) that are comminuted in the hammer mill (4) are transferred to the sieving device (6) and / or the particles of the third particle fraction (PF3) from the sieving device (6) are returned to the hammer mill (4) manually or via a transport device.

8. Process according to any of the preceding claims, characterized in that, in the sieving device (6) or a further sieving device, a fourth particle fraction (PF4) having a maximum grain size less than the target grain size is formed from the second particle fraction (PF2) by sieving and removed, so as to leave a fifth particle fraction (PF5) containing the particles forming the recyclate which is removed.

9. Process according to Claim 8, characterized in that the maximum grain size of the fourth particle fraction (PF4) is 0.1 mm or 0.2 mm.

10. Process according to any of the preceding claims, characterized in that sieving of the first particle fraction (PF1) and / or sieving of the second particle fraction (PF2) is accomplished by using a mesh sieve in each case.

11. Process according to any of the preceding claims, characterized in that moulding pieces (3) comprising inorganic and / or filler particles embedded in a polymer matrix with a proportion of ≥ 60% by weight, especially of ≥ 65% by weight, are used.

12. Process according to any of the preceding claims, characterized in that the precomminuted moulding pieces (3) have a maximum length of 40 cm, especially of 30 cm.

13. Process according to any of the preceding claims, characterized in that the mouldings for formation of the moulding pieces (3) are automatically comminuted manually or by means of a comminution apparatus.

14. Process according to any of the preceding claims, characterized in that the moulding pieces (3) are fed automatically to the hammer mill (4) manually or by means of a transport device (2).

15. Process according to any of the preceding claims, characterized in that the mouldings used are sinks.

16. Use of a particulate recyclate, comprising the steps of: providing a recyclate produced according to Claim 1 or according to Claim 1 and any of Claims 2 to 15 and adding the recyclate as an admixture to a casting compound for production of a quartz composite moulding, in particular a sink.