Apparatus, system and method for separating and cleaning waste

Abstract

An apparatus (10) for separating and cleaning a feed material mixture including: a vertical column (16) having a top (56) and a bottom (58); a feed arrangement (60) adapted to provide the feed material mixture into the top (56) of the column (16); a fluid source (62) to provide a fluid flow including a liquid and air bubbles upwardly within the column (16) being counter current to the feed material mixture. The vertical column (16) being shaped to substantiality maintain a velocity of the fluid flow between the bottom (58) and the top (56) such that a first separated portion of the feed material mixture is separatable via a weir (59) from a second separated portion of the feed material mixture which descends from the bottom (58). A separation column (16) and a method (100) for separating and cleaning a feed material mixture is also disclosed.

Description

Apparatus, System and Method for Separating and Cleaning WasteRelated Applications

[0001] This application claims priority from Australian provisional patent application no. 2023902611 filed on 17 August 2023, the contents of which are incorporated by reference.Technical Field

[0002] The invention relates to an apparatus, a system, and a method for separating and cleaning waste such as building and construction waste.Background

[0003] Waste such as construction waste may include a variety of materials of different types, sizes, and densities. Such waste may include, but not limited to, rock, concrete, brick, wood, plastic, and fibrous material which may range in size, density and shape. Such waste may also include conglomerates of such materials and finer material such as sand and silt.

[0004] It is desirable reuse such construction waste. However, before reuse, the waste needs to be crushed, processed, and washed to remove undesirable material such as the plastic, fibrous material, wood, and fine material such as the sand and silt. The product material of crushed and cleaned rocks, concrete and bricks may then be reused such as for fill or foundational material.

[0005] Problems exist with the processing and washing of such crushed material including: the separation of denser materials such as fibrous material and wood from the desirable product material; the efficient use of water used for the cleaning; and the ability to effectively and efficiently process large volumes of such construction waste.

[0006] More specifically, in some instances the processing and washing of such crush material may use a water bath or slow-moving counter-current of water to encourage low density materials that naturally float such as soft wood and Styrofoam to float and be removed by various means and heavy product material such as rocks, brick, and concrete to sink and be recovered by various means.

[0007] However, the product recovered by these methods may be contaminated by materials that would normally sink in water (S.G. > 1) such as hard woods, sand, and porous material that has absorbed water. The contamination of the recovered material may prevent it from being recycled and re-used. Accordingly, there is a need to separate materials that would normally sink in water (S.G. > 1) such as hard woods, sand, and porous material that has absorbed water.

[0008] The invention disclosed herein seeks to overcome one or more of the above identified problems or at least provide a useful alternative.Summary

[0009] In accordance with a first broad aspect there is provided, an apparatus for separating and cleaning a feed material mixture, the apparatus may include a vertical column having a top and a bottom; a feed arrangement adapted to tangentially provide the feed material mixture into the top of the column; a fluid source adapted to provide a fluid flow including a liquid and air bubbles upwardly within the column between the bottom and top being counter current to the feed material mixture, wherein the vertical column is shaped to substantiality maintain a velocity of the liquid flow with air bubbles between the bottom and the top of the column such that a first separated portion of the feed material mixture is separatable via a weir at the top of the column from a second separated portion of the feed material mixture which descends from the bottom of the vertical column.

[0010] In an aspect, the vertical column has a substantiality constant cross-sectional area.

[0011] In another aspect, the vertical column is a generally straight sided cylindrical column, the cross section may be round, square or rectangular.

[0012] In yet another aspect, the liquid flow is liquid water into which course air bubbles are introduced.

[0013] In yet another aspect, the fluid source includes a first source of the fluid flow provided to the bottom of the column.

[0014] In yet another aspect, the fluid source further includes a second source of the fluid flow provided within the column.

[0015] In yet another aspect, the second source of the fluid flow is directed to flow toward to the top of the column.

[0016] In yet another aspect, the weir is provided toward a side of the top of the column and the feed arrangement is arranged to provide the feed material mixture toward an opposing side of the top of the column.

[0017] In yet another aspect, the feed arrangement is at least partially submerged to brake the feed material mixture before entering the column.

[0018] In yet another aspect, the feed arrangement includes a chute having a slope angled such that feed material mixture is dropped from substantially being stationary, or at a low velocity, into the top of the column.

[0019] In yet another aspect, a flow rate of the fluid flow is adjustable to control the separation between the first separated portion and the second separated portion.

[0020] In yet another aspect, the flow rate is adjustable such that the separation point between the first separated portion and the second separated portion is in the range of a specific gravity of about 1.0 to 1.8.

[0021] In yet another aspect, the feed material mixture includes materials of variable types, sizes and densities.

[0022] In yet another aspect, the feed material mixture includes materials having a size up to about 100mm in diameter.

[0023] In yet another aspect, the apparatus further includes a material transport arrangement below the column.

[0024] In yet another aspect, the material transport arrangement is a sloped screw having a screw inlet section arranged to receive the second separated portion of the feed material which descends from the bottom of the vertical column.

[0025] In yet another aspect, at least some of the fluid flow is directed to flow upwardly through the screw inlet section and into the bottom of the vertical column.

[0026] In yet another aspect, the apparatus includes a pump to substantially recycle liquid flow between the top and the bottom of the column.

[0027] In yet another aspect, the apparatus includes a further separation arrangement adapted to separate a third and a fourth separated portion from second separated portion.

[0028] In accordance with a second broad aspect there is provided, a separation column arrangement for separating and cleaning a feed material mixture, the arrangement including: a substantially vertical column having a top adapted to receive the feed material mixture toward a side of the top and a bottom; a fluid source adapted to provide an fluid flow upwardly within the column between the bottom and top and counter current to the feed material mixture, wherein the top includes a weir located toward an opposing side of the top relative to the side of the feed material mixture, the vertical column being shaped to substantiality maintain a velocity of the fluid flow between the bottom and the top of the column such that a first separated portion is separatable via the weir from a second separated portion of the feed material which descends from the bottom of the vertical column.

[0029] In accordance with a third broad aspect there is provided, a method for separating and cleaning a feed material mixture, the method including: tangentially providing the feed material mixture to a side of a top of a vertical column; directing an aerated fluid at a rate between a bottom of the vertical column and the top, the rate being adapted to separate the feed material mixture into first portion lifted by the feed material mixture and a second portion which sinks toward the bottom; collecting the first portion from a weir at the top; and tangentially moving and elevating the second portion relative to the bottom so as to provide a separated and cleaned product material.

[0030] Other aspects and features will become apparent from the description and drawings referenced below.Brief Description of the Figures

[0031] The invention is described, by way of non-limiting example only, by reference to the accompanying figures, in which;

[0032] Figure 1 is a perspective side view illustrating an apparatus for separating and cleaning waste;

[0033] Figures 2a to 2d respectively illustrate a side, a top, a first end and a second end of the apparatus;

[0034] Figure 3 A is a side view illustrating a separation arrangement of the apparatus;

[0035] Figure 3B is a detailed side view illustrating a separation arrangement of the apparatus;

[0036] Figure 4 is a process flow diagram illustrating a process and components of the apparatus; and

[0037] Figure 5 is a flow diagram illustrating an example method for separating andcleaning a feed material mixture.Detailed Description

[0038] Referring to Figures 1 to 4 there is shown an apparatus 10 for separating and cleaning a feed material mixture 12. The feed material mixture 12 may be, but not limited to, construction waste that may include rock, bricks, dirt, concrete, wood, fibrous material and dust. Other forms of waste such as street waste may also be used. The feed material mixture 12 may need to be prior crushed, such as by a crusher (not shown), to reduce its material size down to less than about 100mm is size and preferably less than about 80mm in size. It is noted that the apparatus 10 may be scaled up and down in size to suit different material sizes and types.

[0039] The feed material mixture 12 may include materials have different specific gravities. Generally, the desirable product materials have a higher specific gravity generally, but not limited to, being over about 1.0 to 1.8, and in some examples about 1.4. The apparatus 10 described herein has been developed to separate the desirable product materials (i.e cleaned brick, rock and concrete etc.) from other components of the feed material based on the specific gravity using at least a primary separation arrangement 14, show in Figure 3A, which is adapted to remove still relatively high specific gravity material from the feed material mixture 12 as will be further detailed below.

[0040] It is noted that whilst, for example, the primary separation arrangement 14, as best shown in Figure 3A, and its components such as a vertical separation column arrangement 16 are described in relation to the example apparatus 10 shown herein - the vertical separation column arrangement 16, for example, may find use in other applications and apparatuses and it is not limited for use only with the apparatus 10 herein described. Further, any sizing, flow rates and shapes have been provided for example purposes only and such sizing, flow rates and shapes may be adapted for specific applications, as need be.

[0041] Referring to Figures 1 to 2D, in this example, the apparatus 10 may be provided as a unit 18 that is substantially self-contained requiring an initial water supply to fill the tank 21 and electrical power via its electrical and control system 20. The unit 18 includes a base 19 and the tank 21 is supported by the base 19.

[0042] The apparatus 10 includes a material cleaning and separation arrangement 22, a feed material inlet 24 in which the feed material mixture is feed into the apparatus 10, a main product outlet 26 and further second and third product outlets 28, 30. The material cleaning and separation arrangement 22 includes the primary separation arrangement 14, shown best in Figure 3A, and a secondary and tertiary separation arrangement 32, 34. The components of the material cleaning and separation arrangement 22 are best shown and described in relation to Figure 4.

[0043] Figure 1 best shows the secondary separation arrangement 32 having a hydrocyclone 36 and an associated pump 38 and the tertiary separation arrangement 34 includes a hydrocyclone bank 40 and a further associated pump 42. It is noted that some examples may omit the secondary separation arrangement 32 depending on the type of feed material, and in these examples the the primary separation arrangement 14 may proceed straight to the tertiary separation arrangement 34. Both examples are contemplated herein

[0044] Referring to Figures 2A to 2D, the primary separation arrangement 14 includes a housing 44 which houses a material transport arrangement 46 which is provided in this example in the form of an angled screw or auger 48, shown best in Figure 3A, which moves the product material out of the water bath and to the main product outlet 26. The screw or auger 48 is powered by a motor 50. A main pump 52 is locate adjacent the tank 21 and the electrical and control system 20 which is used to provide a fluid flow to the primary separation arrangement 14 with water that has been recycled from the separation arrangements 14, 32 and 34. It is noted the locations of the pumps 52, 38 may change depending on the specific arrangement of the apparatus 10.

[0045] Referring now to Figures 3A and 3B, the primary separation arrangement 14 includes the vertical column arrangement 16 having generally vertical column 54having a top or top inlet 56 and a bottom or bottom outlet 58, a feed arrangement 60 adapted to tangentially provide the feed material mixture 12 into the top 56 of the column 54, and a fluid source 62 adapted to provide an fluid flow “F” upwardly within the column 54 between the bottom 60 and the top 56 being counter current to the feed material mixture 12. It is noted that the column 54 may be a section of a longer column or enclosure, and in such configurations the top is generally where the weir and material feed is located rather than the physical end point of any such longer column or enclosure. As such, the use of the terms top, bottom, side etc. herein should be construed to encompass such alternative configurations.

[0046] The vertical column 54 is shaped to substantiality maintain a velocity of the fluid flow “F” between the bottom 58 and the top 56 of the column 54 such that a first separated portion “FP” of the feed material mixture is separatable via a weir 59 at the top 56 of the column 54 from a second separated portion “SP” of the feed material mixture which descends to the bottom 58 of the vertical column 54.

[0047] In more detail, the feed material inlet 24 may include a chute 66 with a vibrator 68. The chute 66 is preferably relatively flat and tangentially arranged relative to the column 54 to slow the velocity of the feed material entering the vertical column 54. The chute 66 angle may be adjustable to the break coefficient of friction of the feed material with the most reduced angle possible. It is noted that in some examples the vibrator 68 may be omitted depending on the type of feed material. It is also noted that water may be injected onto the chute 66.

[0048] It is noted that the chute 66 and top 56 of the column 54 may be arranged so that the feed material entering the column 54 is at least partially submerged to slow or brake the feed material prior to moving from the chute 66 into the column 54. The chute 66 may also be located on a side 70 of the column 54 which is opposite to the side 71 of the weir 59. Such an arrangement promotes an upward flow of the first separated portion “FP” within the column toward the side 71 as indicated in Figure 3 A.

[0049] The vertical column 54 has a substantiality constant cross-sectional area and may be generally straight sided cylindrical column. The cross-sectional shape of thecolumn may be round, square or rectangular. This shape seeks to maintain the flow velocity substantially to the top 56 of the vertical column 54. Advantageously, this allows fluid in the vertical column 54 to carry therewith material of relatively high specific gravity such as being in the range of about 1.0 to 1.8, as noted above. The air bubbles within the liquid provides an additional lifting and agitation force, and also allows for a reduction in water usage.

[0050] The fluid flow is provided as a mixture of liquid water and air. The primary fluid flow is provided by first source being lower nozzles 72 located by a screw housing 74 below a lower end 76 of the screw 48 and a second source being upper nozzles 78 located at a side wall 80 of the column 54. The upper nozzles 78 may be directed upwardly to assist to promote the upward flow. The air may be mixed by an air blower (not shown) prior to the respective lower nozzles 72 and upper nozzles 78.

[0051] It is noted that the liquid and air are preferably injected via separate nozzles of the lower nozzles 72 and the upper nozzles 78. The air is generally provided as course bubbles. The liquid and air may be injected through one or many high pressure / flow nozzles 72, 78 to manipulate the flow pattern in the column and influence the settling and floating material.

[0052] The flow rate of the fluid flow is adjustable to control the separation between the first separated portion and the second separated portion. For example, the flow rate and air component may be varied such that the separation point between the first separated portion and the second separated portion is in the range of a specific gravity of about 1.0 to 1.8,

[0053] The lower end 76 of the screw housing 74 generally receives the second separated portion of the feed material which descends from the bottom 58 of the vertical column 54. The lower end 76 the screw housing 74 may be filled with fluid and material with a higher specific gravity. The flow of the fluid through this second separated portion ensures to remove material with a lower specific gravity, with the flow and bubbles from the air assisting to provide agitation and a lifting force.

[0054] The second separated portion is then moved via the screw 48 upwardly through the screw housing 74 to the main product outlet 26 that is provided in this example as an outlet chute 82. The screw 48 provides a cleaning and dewatering action to remove water as it moved up the screw housing 74.

[0055] Referring to Figure 4, the first separated portion “FP” of the feed material mixture passed over a weir 59 leading to a chute 61 and is then further processed by the second and tertiary separation arrangement 32, 34 which include the cyclone 36 and cyclone bank 40, respectively. The arrangement is configured to produce a third separated portion “TP” with lower specific gravity material at the output 28 and a fines “FINES” material at output 30. Water may be collected and reprocessed via sump 84, and a cleaned water stream may be provided form the cyclone bank 40 to the water tank 21. The tank water may then be reused.

[0056] It is noted that the process may run continuously, and the feed material input could be, for example, 10 to 100 tonnes per hour. The ability to produce cleaned material stripped from relatively high specific gravity contaminants such as hard wood and fibrous mater is advantageous and this stripped material may be further provided as a higher specific gravity product and a fines / silt product that may go to waste or be further processed.

[0057] It is also noted that whilst in this example the apparatus 10 is shown as a unit 18, it may also be provided as a system 90 having the same components provided separately.

[0058] Turning now to Figure 5, there is shown a method 100 for separating and cleaning a feed material mixture 12. The method 100 including at step 110, tangentially providing the feed material mixture 12 to a side 70 of a top 56 of a vertical column 54. The feed may be via the chute 66 and the flow velocity of the feed material is slowed down as much as possible which may involve the feed material being at least partially submerged before it falls from the chute 66.

[0059] At step 120, an aerated fluid is provided and directed at a flow rate between the bottom 58 of the vertical column 54 and the top 56, the flow rate being adapted to separate the feed material mixture 12 into the first portion lifted by the feed material mixture and the second portion which sinks toward the bottom 58. The amount of air and the flow rate may be adjusted to separate the material mixture 12 into the first portion and second portion based on specific gravity.

[0060] At step 130, the first portion may be collected from the weir 59 at the top 56. The first portion may be further processed by the second and tertiary separation arrangement 32, 34 and the fluid, in this example water, being separated and recycled to the tank 21.

[0061] At step 140, the second portion may be tangentially moved and elevated, by the screw 48, relative to the bottom 58 so as to provide the separated and cleaned product material 12 at the product outlet 30. The second portion being washed and dewatered during this movement and elevation.

[0062] Advantageously, there has been provided an apparatus, a system and a method for separating and cleaning a feed material mixture. The primary separation arrangement with the vertical column may have a relatively high upward fluid flow including water and air assists to separate materials with relatively high specific gravity that would not normally be separatable using such flow or floating methods. This provides a main product with a relatively high specific gravity, which in this example, may be useable clean material such as fragments of rock, brick and concrete.

[0063] Further advantageously, a secondary and tertiary separation arrangement are provided which provide second and third products, and a cleaned water stream that may be recycled into the tank. The apparatus may be operated continuously and may use the recycled water which is contained within the tank therefore not requiring external water treatment during normal operation.

[0064] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and"comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0065] The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.

[0066] While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein.

[0067] Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.

Claims

The claims defining the Invention are as follows:

1. An apparatus for separating and cleaning a feed material mixture, the apparatus including: a. a vertical column having a top and a bottom; b. a feed arrangement adapted to tangentially provide the feed material mixture into the top of the column; c. a fluid source adapted to provide a fluid flow including a liquid and air bubbles upwardly within the column between the bottom and top being counter current to the feed material mixture, wherein the vertical column is shaped to substantiality maintain a velocity of the fluid flow between the bottom and the top of the column such that a first separated portion of the feed material mixture is separatable via a weir at the top of the column from a second separated portion of the feed material mixture which descends from the bottom of the vertical column.

2. The apparatus according to claim 1, wherein the vertical column has a substantiality constant cross-sectional area.

3. The apparatus according to claim 2, wherein the vertical column is a generally straight sided cylindrical column.

4. The apparatus according to claim 1, wherein the fluid flow is liquid water into which course air bubbles are introduced.

5. The apparatus according to claim 1, wherein the fluid source includes a first source of the fluid flow provided to the bottom of the column.

6. The apparatus according to claim 5, wherein the fluid source further includes a second source of the fluid flow provided within the column.

7. The apparatus according to claim 6, wherein the second source of the fluid flow is directed to flow toward to the top of the column.

8. The apparatus according to claim 1, wherein the weir is provided toward a side of the top of the column and the feed arrangement is arranged to provide the feed material mixture toward an opposing side of the top of the column.

9. The apparatus according to claim 8, wherein the feed arrangement includes a chute having a slope angled such that feed material mixture is dropped from substantially being stationary, or at a low velocity, into the top of the column.

10. The apparatus according to any one of the previous claims, wherein a flow rate of the fluid flow is adjustable to control the separation between the first separated portion and the second separated portion.

11. The apparatus according to claim 10, wherein the flow rate is adjustable such that the separation point between the first separated portion and the second separated portion is in the range of a specific gravity of about 1.0 to 1.8.

12. The apparatus according to any one of the previous claims, wherein the feed material mixture includes materials of variable types, sizes and densities.

13. The apparatus according to any one of the previous claims, wherein the feed material mixture includes materials having a size up to about 100mm in maximum particle size.

14. The apparatus according to any one of the previous claims, wherein the apparatus further includes a material transport arrangement below the column.

15. The apparatus according to claim 14, wherein the material transport arrangement is a sloped screw having a screw inlet section arranged to receive the second separated portion of the feed material which descends from the bottom of the vertical column.

16. The apparatus according to claim 15, wherein the at least some of the fluid flow is directed to flow upwardly through the screw inlet section and into the bottom of the vertical column.

17. The apparatus according to any one of the previous claims, wherein the apparatus includes a pump arranged to substantially recycle liquid flow between the top and bottom of the column.

18. The apparatus according to any one of the previous claims, wherein the feed arrangement is at least partially submerged to brake the feed material mixture before entering the column.

19. The apparatus according to any one of the previous claims, wherein the apparatus includes a further separation arrangement adapted to separate a third and a fourth separated portion from second separated portion.

20. A separation column arrangement for separating and cleaning a feed material mixture, the arrangement including: a. a substantially vertical column having a top adapted to receive the feed material mixture toward a side of the top and a bottom; b. a fluid source adapted to provide a fluid flow upwardly within the column between the bottom and top and counter current to the feed material mixture, wherein the top includes a weir located toward an opposing side of the top relative to the side of the feed material mixture, the vertical column being shaped to substantiality maintain a velocity of the fluid flow between the bottom and the top of the column such that a first separated portion is separatable via the weir from a second separated portion of the feed material which descends from the bottom of the vertical column.

21. A method for separating and cleaning a feed material mixture, the method including: a. Tangentially providing the feed material mixture to a side of a top of a vertical column; b. Directing an aerated fluid at a rate between a bottom of the vertical column and the top, the rate being adapted to separate the feed material mixture into first portion lifted by the feed material mixture and a second portion which sinks toward the bottom;c. Collecting the first portion from a weir at the top; and d. Tangentially moving and elevating the second portion relative to the bottom so as to provide a separated and cleaned product material.

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