Method and system for separating plastics from waste streams

Abstract

A method for separating and collecting plastics from a waste stream, comprising the steps of size separating the waste material, grinding the material, and separating the material at a specific density of 1.0 to 1.1 SG. A system is included herein. PP and PE are separated from the waste stream.

Description

[Technical field]

[0001] This application relates to separating various materials in a waste stream (e.g., ASR or ESR). This application also relates to removing plastics from the waste stream. This application also relates to material separation, where plastics from the waste stream are separated from waste plastic materials and other materials. [Background technology]

[0002] Recycling of waste materials is highly desirable from many standpoints, including economic and ecological standpoints. Properly sorted recyclable materials can often be sold at a substantial profit. Because many of the more valuable recyclable materials do not biodegrade in a short period of time, their recycling significantly reduces the burden on local landfills and ultimately the environment.

[0003] Most of the plastics supplied by manufacturers today ends its life in landfills or incinerators simply because the technology has not been available to recover it economically. Durable consumer goods such as automobiles, appliances, and electronics account for over one-third of the plastics in municipal solid waste. Durable consumer goods are increasingly being collected and partially recycled at the end of their useful lives to avoid disposal costs and potential penalties, and to recover metals and other marketable raw materials.

[0004] Automobile shredder residue (ASR) and electronic waste shredder residue (ESR) feedstocks are highly diverse and include rubber, wood, metal, wire, circuit boards, foam, glass, and other non-plastics. If the plastic materials are to be recycled, they must be separated into multiple product and by-product streams. In general, recycling processes need to be applied to a variety of plastic-rich streams originating from post-industrial and post-consumer sources to be commercially useful.

[0005] Different grades of a given plastic type may be compatible. Some grades can commonly be melt mixed to create new materials with different property profiles. A variety of plastics may be included in the waste stream. Some such plastics include polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polystyrene (PS), including high impact polystyrene (HIPS), and polyvinyl chloride (PVC). These materials are more valuable if separated into at least "light" plastics (PP and PE) and "heavy" plastics (ABS and PS). Also, some plastics, such as PVC, and some PP, such as talc-filled and glass-filled PP, are undesirable. To increase the value of the separated plastics, the undesirable plastics should be removed from the mixture to create a more homogenous material.

[0006] Many processes for identifying and separating materials are known in the art. However, not all processes are effective at recovering plastics, and the sequencing of these processes is a factor in developing a cost-effective recovery process. Thus, there is a constant need for improved methods and systems for collecting plastics from waste streams. Summary of the Invention

[0007] One embodiment includes a method for collecting plastics from a waste stream. The method may include size separating waste material from the waste stream into a first undersized material and a first oversized material at 19-25 mm, grinding the first undersized material into a first residue by mechanical grinding, sizing the first residue into a second undersized material and a second oversized material, separating the second oversized material with a specific density of 1.0-1.1 SG into a first heavy fraction and a first light fraction, separating the first light fraction above 4 mm into a third sized material and a third oversized material, and collecting the third oversized material. The third oversized material is greater than 90% PP and PE.

[0008] Another embodiment includes a system for separating and collecting plastics from a waste stream having a feeder with waste material, a first screen for separating material less than 25 mm into a first sized material and a first oversized material, a crusher for grinding the sized material into a first retentate by mechanical grinding, a second screen for sizing the first retentate into a second smaller material and a second oversized material, a first density separator for the second oversized material at a specific density of 1.0-1.1 SG into a first heavy fraction and a first light fraction, a third screen for separating the first light fraction greater than 8 mm into a third sized material and a third oversized material, and a collector for the third oversized material, where the third oversized material can be greater than 90% PP and PE.

[0009] Another embodiment includes a system for separating and collecting plastics from a waste stream, the system including a first screen for separating materials smaller than 25 mm into a first sized material and a first oversized material, a crusher for crushing the sized material into a first residue by mechanical crushing, a second screen for sizing the first residue into a second sized material and a second oversized material, a first density separator for the second oversized material at a specific gravity of 1.0-1.1 SG into a first heavy fraction and a first light fraction, a third screen for separating the first light fraction greater than 8 mm from the waste stream into a third sized material and a third oversized material, and a collector for the third oversized material. The third oversized material can be greater than 90% PP and PE.

[0010] Another embodiment includes a system having a third density separator for separating the second sized material at a specific density of 1.2 SG into a third heavy fraction and a third light fraction.

[0011] Another embodiment includes a system having a fourth screen for separating the third light fraction at 0.5 mm into a fourth sized material and a fourth oversized material, the fourth oversized material being essentially ABS and PS. [Brief description of the drawings]

[0012] [Figure 1] 1 is a flow diagram of one embodiment of the present invention. [Diagram 2] 4 is a flow diagram of another embodiment of the present invention. [Diagram 3] 1 illustrates an exemplary system in accordance with certain embodiments of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Exemplary embodiments of the present invention provide methods and systems for separating plastics from waste materials. Such embodiments provide processes and systems for separating plastics using multiple processing steps, which may result in a light plastic stream and a heavy plastic stream. The methods include defining configurations for preparing recycled plastic products. Additionally, certain methods and systems may enable the removal of undesired plastics and non-plastics from the stream to produce a single plastic type product. Certain embodiments provide cost-effective and efficient methods and systems for recovering plastics from waste streams, such as materials found in recycling processes including polypropylene (PP), polyethylene (PE), acrylonitrile-butadiene-styrene (ABS), and polystyrene (PS), in a manner that facilitates revenue recovery while also reducing landfill requirements.

[0014] The initial waste stream contains a certain amount of rubber, wood, metal, wire, circuit boards, foam, glass, and other non-plastics. A size reduction method and system configured to implement a process has been developed so that the plastic-rich feed stream can be separated into multiple product and by-product streams. The method and system can be applied to a variety of plastic-rich streams originating from post-industrial and post-consumer sources. These streams can include plastics from office automation equipment (printers, computers, copiers, etc.), white goods (refrigerators, washing machines, etc.), household appliances (televisions, video cassette recorders, stereos, etc.), automotive shredder residues, packaging waste, household waste, construction waste, and industrial molding and extrusion scrap. This material can be processed by certain embodiments of the present invention.

[0015] Certain embodiments allow for the purification or separation of materials from waste streams to remove undesirable plastics and non-plastics from a stream of multiple plastic type families. Plastics from more than one consumer durable source may be included in the mixture of materials fed to a plastic recycling plant. Exemplary plastics include acrylonitrile-butadiene-styrene (ABS), high impact polystyrene (HIPS), polystyrene (PS), polypropylene (PP), polyethylene (PE), polycarbonate (PC), polyamide (PA), polymethyl methacrylate (PMMA), polyvinyl chloride (PCV), polyether ether ketone (PEEK), polysulfone (PSU), polyoxymethylene (POM), and others. Plastic-containing materials can be separated into heavy plastics from light plastics. After the materials are separated, the purified plastics can be concentrated, extruded, and pelletized.

[0016] Exemplary embodiments provide systems and methods for collecting materials such as plastics. In one aspect of the invention, a method is provided for collecting various plastics from waste. The method includes the steps of (a) removing waste material from the waste material; (b) sieving or screening the waste material based on size less than 25 mm; (c) grinding or crushing the waste; (d) introducing at least one gravity separation at a specific gravity or SG of about 1.0 (e.g., in the range of 1.0 SG to 1.1. SG); and (e) collecting the desired various plastics throughout the process. The various materials collected throughout the process may be discarded or may be processed using other methodologies.

[0017] As shown in Figure 1, the process 10 can begin with a waste stream or feed material that is initially screened to a size of less than 25 mm (20). For example, a useful multi-stage screen can pass waste material of about 25 millimeters (mm) or less and can pass material of about 17 mm or less. The screen sizes can vary, for example, one screen can be 10 mm and another screen can be 50 mm. Sizing or screen size can be optimized accordingly.

[0018] After the waste material is initially screened (20), the material is ground, crushed, or otherwise comminuted in this step 30. The waste material is comminuted, for example, by any combination of crushing, shredding, to separate the plastic material from the waste material. In one embodiment, the waste material is crushed in a hammer mill to produce a powder and larger plastic pieces. The powder may be separated from the stream by screens, sieves, shaker tables, classifiers, combinations thereof, and / or other known mechanisms. In one embodiment, the waste material is comminuted using a ball mill or rod mill.

[0019] After the grinding step 30, the material is separated (40) into a first heavy fraction and a first light fraction with specific densities between 1.0 and 1.1 SG.

[0020] After the material is crushed and separated by density, the larger pieces are screened (50) to separate and collect material in the 4mm to 8mm range. In one example, the material is cut or sized at 4mm, 5mm, 6mm, 7mm, 8mm, or between. In one example, the material is cut or sized at 6mm or greater. The larger material may be greater than 65%, 70%, 80%, 85%, 90% PP and PE and collected accordingly (60).

[0021] The method and system can include multiple size reduction steps. Size reduction typically involves one or more processes at the front end of a plastic recycling plant that are configured to accomplish a variety of tasks. Size reduction can be performed to remove metals that may damage size reduction process equipment or adversely affect downstream separation processes, to reduce the plastic particle size so that much of the non-plastic material is liberated, to create a relatively narrow particle size distribution, and possibly to stabilize or clean the composition of the material sent to downstream processes.

[0022] As shown in FIG. 2, one exemplary process 200 includes an ASR or ESR feedstock 210 as an initial starting material that may be pre-processed. Initially, the feedstock is cut or sized at 200 mm, 100 mm, 50 mm, 25 mm or less (220). In one example, the feedstock entering the process is less than 200 mm. In another example, the feedstock entering the process has a size between 0.1 mm and 25 mm. The material may contain rubber, wood, metal, wire, circuit boards, foam, glass, and other non-plastics, any or all of which may be reprocessed (225). The material less than 25 mm is then ground (230), for example, by a ball mill or rod mill. The material from the grinding step 230 may be screened, for example, at 0.3 to 0.5 mm, and the unders may be discarded or used as media (245). The overs are then processed in a first gravity separation stage 250 to separate out those with a SG or specific gravity of about 1.0-1.2 SG, which may involve flotation in water. The heavies or heavier materials 255, having a SG greater than 1.0 to 1.2, may be further processed as such materials may contain valuable elements or be discarded as waste (ABS / PS 257 or metal / glass 258).

[0023] The light materials from the first gravity separation may be screened or cut or sized at 2 mm or 8 mm, for example, 4 mm, 6 mm, or 8 mm (260). Sizing may be performed to produce a sized waste stream having a particular desired particle size distribution to facilitate density separation and to produce an intermediate stream concentrated in particular recyclable materials. The materials or overs from the size separation include PP and PE (270).

[0024] Those skilled in the art will recognize that the ground waste stream can be analyzed to determine a size cutoff where a fraction of the stream separates different types of materials into different streams while concentrating similar types of waste into a somewhat concentrated stream. Additionally, the sized waste stream can be optimized for density separation by creating a sized waste stream with a narrow distribution of particles. In one example, the material is screened at 19 mm. The undersized material from the screen can be further processed as these materials contain valuable elements. The overs can include a mixed plastic stream, which can be subjected to further purification steps to remove rubber and wood and separate the plastics by type to achieve the desired composition, e.g., the compositional purity described above. Suitable examples of size separators that can be used in the method of the present invention include disc screen separators with rubber or steel discs, finger screen separators, trommel screen separators, vibrating screen separators, waterfall screens, vibrating screens, flower disc screens, and / or other size separators.

[0025] Materials that are smaller than the screen size can be crushed or sheared. Generally, grinding is a process in commercial mining operations where larger pieces of ore are broken down into fine particle size particles, i.e., fines. Useful minerals are extracted from the fines. The grinding process is carried out in one or more means for crushing the ore, such as ball mills, rod mills, autogenous mills, pebble mills, high pressure attritor mills, bumstone mills, vertical shift impactor mills, tower mills, etc. Ball mills, rod mills, and high pressure attritor roll mills can include specific embodiments. Such grinding processes do not grind or crush plastics in the grinder.

[0026] The material from the ball mill or grinding stage can be processed in a second density separation stage. During this stage, the material is separated at a SG of 1.2 or in the range of about 1.0-1.3 SG. In one example, the material below about 1.2 or the light material is screened at 4mm-8mm, e.g., 4mm, 6mm, 8mm, or therebetween. In another example, the light material is about 1.2 or 1.2, or the light material is screened at 4mm-8mm or 5mm-7mm, or at 6mm. The under or undersized material of about 1.0-1.3 SG can contain wood, fluff, and generally less valuable materials, or materials less desirable for PP / PE recycling or post-processing.

[0027] The heavies from the first gravity separation are separated using a second gravity separation at about 1.2SG. The heavies from the third separation are metals and glass. The lights are ABS and PP, which are valuable and reduce landfill waste. The heavies include metals, glass, and brominated plastics, which can be further processed to obtain valuable materials.

[0028] Density separation can include froth flotation or other methods that facilitate separation of plastics of similar density. Froth flotation can be used in combination with other separation methods to achieve the desired purity. Other density separation techniques are known in the art.

[0029] The density separation process may also be performed by a system and method called a falling velocity separator or a jig. Density differential modification is a method that facilitates the separation of plastics of similar density.

[0030] 3 illustrates an exemplary system 300 according to one embodiment. In this embodiment, waste material stored in a feeder 310 is screened with a first screen 320 to separate material between 19mm and 25mm, or to cut / size the material at 19mm or 25mm into a first sized material and a first oversized material. The system includes (a) a grinder (e.g., ball mill or rod mill) 330 for grinding the sized material by mechanical grinding into a first residue, (b) a second screen 340 for sizing the first residue into a second sized material and a second oversized material, (c) a first density separator 370 with a specific density of 1.0-1.1 SG for separating the second oversized material into a first heavy fraction and a first light fraction, (d) a third screen 360 for separating the first light fraction between 0.3 mm and cutting / sizing into sized material and oversized material at 3 mm and 8 mm, and (e) a collector of oversized material (overs) (not shown). The 4 mm-25 mm sized material, less than 1.2 SG, can be more than 90% PP and PE 365. The oversized material or overs is generally non-plastic material, fluff, and other materials 367.

[0031] The system may also include a second density separator 375 for separating or sizing the second sized material at a specific density of 1SG into a second heavy fraction and a second light fraction. This second density separator 375 may also be a reverse thickener or a screw.

[0032] The system may also include a third density separator 380 for separating or sizing the second sized material at a specific density of 1.2 SG into a third heavy fraction and a third light fraction.

[0033] The system may also include a fourth screen 390 for separating the third light fraction of 0.3 mm to 0.50 mm into a fourth smaller material and a fourth larger material, the fourth larger material being substantially ABS and PS. The system may also include a fourth sized material of a 1.2 SG fraction. The 1.2 SG light fraction results in a 1.0 to 1.2 SG cut material. This material may be dewatered and screened with a 0.3 mm or 0.5 mm screen, and the product may be ABS / PS plastic 395, which is valuable and recyclable.

[0034] There are methods for separating materials by density. Such methods are typically characterized by the use of liquids as a suspending medium to separate plastics by buoyancy differentials, using components such as settling tanks, gravity thickeners, and hydrocyclones.

[0035] With respect to waste streams, certain embodiments can be used to process waste materials or recyclable materials that contain concentrations of plastics greater than 15%, or 25%, 35%, 45%, and / or 50%. This means that as long as there is a good concentration of plastics (as low as 20% or more), the system can properly separate the materials. Household waste that is pre-sorted into a "plastics and non-plastics" stream is a good example. Typically, household waste that is not landfilled can be pre-sorted at a recycling facility where a plastic separate is produced. This plastic concentrate is an example of a "good feed material." Municipal waste containing plastics is an exemplary waste stream material.

[0036] Plastic recycling processes can utilize several separation processes sequenced to optimize efficiency and create valuable combinations of products. The sequence can depend on the source, particle size, and characteristics of the waste plastic material. In a particular implementation, some operations can be repeated if needed to achieve a desired purity or if operations are required for different reasons at different stages of the process.

[0037] Although specific embodiments of the present invention have been described in detail above, these descriptions are merely illustrative. Therefore, it should be understood that many aspects of the present disclosure have been described above by way of example only, and are not intended as necessary or essential elements of the present disclosure unless expressly stated otherwise. In addition to the above, various modifications of the disclosed aspects of the exemplary embodiments, and equivalent processes corresponding thereto, may be made by those skilled in the art having the benefit of this disclosure without departing from the spirit and scope of the present invention as defined in the following claims, and the scope should be accorded the broadest interpretation so as to encompass such modifications and equivalent structures.

Claims

1. 1. A method for separating and collecting plastics from a waste stream, comprising: a. providing a waste material from the waste stream, the waste material comprising mixed polymers and contaminants; b. separating said waste material by size into a first smaller material and a first larger material using a size range between 19 mm and 25 mm; c. mechanically grinding the first undersized material into a first residue using a grinding system to optimize particle size distribution; d. further sizing the washed first retentate into a second smaller material and a second larger material using an advanced screening unit with real-time particle size monitoring; f. separating the second larger material using a density-based separation process with a liquid medium adjusted to a specific density range of 1.0 to 1.1 SG, resulting in a first heavy fraction and a first light fraction; g. further separating the first light fraction into a third smaller material and a third larger material at a size threshold of greater than 4 mm using high speed vibration screening; h. collecting said third larger material, wherein the third larger material comprises greater than 90% by weight polypropylene (PP) and polyethylene (PE).

2. The method of claim 1, further comprising subjecting the collected third larger material to further processing including refining and pelletizing to produce high purity plastic pellets suitable for reuse in the manufacture of plastic products.

3. The method described in claim 1, wherein the cleaning process in step (d) uses a combination of ultrasonic cleaning and agitation to dislodge the polymer from embedded contaminants.

4. The method of claim 1, wherein the density-based separation in step (f) uses a liquid medium with continuous variable density control using a feedback loop from a real-time density sensor.

5. The method of claim 1, wherein the density separation step is carried out using a liquid medium maintained at a specific gravity of 1.0 to separate light weight plastics from heavier materials.

6. The method of claim 1, wherein the collected plastics in step (h) are automatically sorted by polymer type using near-infrared (NIR) spectroscopy prior to palletization.

7. A system for separating and collecting plastics from a waste stream, comprising: a. a waste material feeder configured to provide a mixed waste material to a downstream process; b. a size separation unit for separating the waste material into a first smaller material and a first larger material within a size range of 19 mm to 25 mm; c. a grinding unit designed to control the particle size of the first smaller material; d. A second sizing unit equipped with an adjustable screen and classifier with real-time monitoring of particle size distribution; e. a density-based separation unit configured to separate materials in the specific density range between 1.0 SG and 1.1 SG, the density-based separation unit including a liquid media reservoir and an automated density adjustment system; f. a second size separation unit for screening the first light fraction at a threshold value greater than 4 mm; g. a collection system for collecting plastics, the collection system being designed to ensure that the collected material contains greater than 90% by weight PP and PE.

8. The system described in claim 7, wherein the density separation unit is configured to operate with a liquid medium precisely maintained at a specific gravity of 1.0 to separate lightweight plastics from denser materials.

9. The system of claim 7, wherein the density-based separation unit (e) includes a variable density liquid medium that is adjusted using automated feedback from an in-line sensor.

10. The system of claim 7, further comprising a near-infrared (NIR) spectroscopy unit for polymer type sorting prior to pelletization.

11. The system of claim 7, wherein the cleaning unit (d) includes a water purification and recycling subsystem to minimize water usage.

12. The system of claim 7, wherein the system is configured for continuous operation with variable feed rates and adaptive control for handling waste material compositions.

13. A method for separating plastics from waste materials, the method comprising: a. screening the waste material at a size threshold between 19 mm and 25 mm to generate a first undersized fraction and a first oversized fraction; b. grinding the first smaller fraction into a residue using a ball mill, rod mill, or hammer mill to liberate plastic from non-plastic materials; c. density separating the retentate at a specific gravity between 1.0 SG and 1.1 SG to generate a first light fraction and a first heavy fraction; d. screening the first light fraction in the 4 mm to 8 mm size range to produce a second smaller fraction and a second larger fraction; e. collecting said second larger fraction comprising greater than 90 wt.% of a mixture of polypropylene (PP) and polyethylene (PE) for downstream recycling; f. Optionally, extruding and pelletizing the collected plastic to produce high purity plastic pellets for reuse.

14. The method of claim 13, wherein the density separation process utilizes a liquid medium having an adjustable specific gravity between 1.0 SG and 1.1 SG that is dynamically controlled through a feedback loop with an in-line density sensor.

15. The method of claim 13, wherein the density separation step utilizes a froth flotation or velocity separation process to further refine plastics of similar density, allowing removal of non-plastics such as wood and glass.

16. The method described in claim 13, wherein the screening step further includes a step of using a vibrating screen with variable frequency adjustment to optimize separation of materials at a specified size threshold.

17. The method of claim 13, wherein the density separation process includes the use of a cascade water flow system to enhance separation of plastic from non-plastic materials.

18. A system for separating plastics from waste materials, the system comprising: a. a screening unit configured to separate waste material into a first smaller fraction and a first larger fraction at a size threshold between 19 mm and 25 mm; b. a grinding unit, comprising a ball mill or a rod mill, for processing the first smaller fraction into a residue having a narrow particle size distribution; c. a density separation unit configured to separate the retentate in a specific gravity range of 1.0 SG to 1.1 SG to produce a first light fraction and a first heavy fraction; d. a second screening unit designed to process the first light fraction into a second smaller fraction and a second larger fraction in the size range between 4 mm and 8 mm; e. a collecting unit for collecting said second larger fraction comprising more than 90% polypropylene (PP) and polyethylene (PE); f. A control system with real-time monitoring sensors for particle size, density, and process efficiency to optimize material collection.

19. The system described in claim 18, wherein the density separation unit includes a liquid medium tank having an adjustable density controlled by automated feedback from an in-line sensor.

20. The system described in claim 19, further comprising a waste material dewatering unit positioned downstream of the density separation unit configured to remove excess liquid from the separated plastics prior to collection or further processing.

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