System and method for recycling glass fibers

Abstract

A system for regenerating glass fibers from a feedstock material is provided that includes a chamber for holding the feedstock material in a low-oxygen environment and a pyrolysis apparatus having a distributed heat source for heating the feedstock material. The distributed heat source uniformly heats the feedstock material, thereby converting it into glass fibers.

Description

[Technical field]

[0001]

[0001] The embodiments disclosed herein relate to recovering glass fibers from feedstock materials, and more particularly, to a system and method for recovering glass fibers by powering a pyrolyzer with gases released by the pyrolyzer.

[0002] [Overview]

[0002] Glass fiber reinforced plastics (GFRP) are commonly used in building materials, especially in vehicles and structures such as boats and windmills. These vehicles and structures age or fall out of use. For example, since the late 1960s, 95% of boats under 24 metres have been made from GFRP, which has a useful lifespan of 30-40 years. This means that GFRP boats over 20 years old are reaching the end of their life cycle and need to be disposed of. Recreation boating federations estimate that the number of boats destined for recycling in Canada alone could be as high as about 6 million units.

[0003]

[0003] Disposal costs are high, which may lead owners to keep fiberglass vehicles and structures which incur storage costs. Alternatively, owners may dispose of them in unsightly and / or illegal ways. Even if the vehicles and structures are disposed of responsibly, disposal methods are limited to crushing and landfilling, or burning in cement kilns, due to the challenges of separating the resin from the glass fibers of GFRP. Both of these disposal methods are expensive and have significant environmental consequences.

[0004]

[0004] In recent years, pyrolysis has been used successfully to separate the resins of GFRP feedstock materials, leaving behind carbon dust and chopped glass fibers. These systems require uniform distribution of heat in the pyrolyzer to avoid high temperature gradients, which can destroy the recovered product, reduce process efficiency, and / or cause serious breakdowns in the system. Agitation of the feedstock materials, often by tumbling or stirring, is typically used to distribute heat from a point source in the pyrolyzer. Unfortunately, this agitation typically reduces the quality of the glass fibers produced due to the forces and friction experienced by the fibers and the cyclic bending of the glass fibers. Furthermore, there are high costs associated with this pyrolysis method, particularly related to the time required in the pyrolysis chamber.

[0005]

[0005] Therefore, there is a need for improved systems and methods for recovering glass fibers from raw materials, particularly those that better maintain the quality of the glass fibers and / or recover gases released during pyrolysis and use those gases to power the pyrolysis equipment. Summary of the Invention

[0006] A system for regenerating glass fibers from a feedstock material is provided. The system includes a chamber for holding the feedstock material in a low-oxygen environment and a pyrolysis apparatus having a distributed heat source for heating the feedstock material. The distributed heat source uniformly heats the feedstock material to reduce it into glass fibers.

[0007]

[0007] The chamber can further include a workpiece planarization device for planarizing the workpiece material during heating. The volume of the low-oxygen environment can be reduced when the workpiece material is planarized. The workpiece planarization device can include a distributed heat source, and the distributed heat source can move with the workpiece planarization device.

[0008]

[0008] A low oxygen environment can be caused by a vacuum.

[0009]

[0009] The system may further include a collector for collecting gases released as the feedstock material is heated.

[0010]

[0010] The system may further include a condenser for recovering oil from the gas.

[0011]

[0011] The system may further include a power system fueled by the gas, the power system powering the pyrolysis device.

[0012]

[0012] The system may further include a storage system for storing gases released by the pyrolysis device.

[0013]

[0013] The distributed heat source may be a gas burner.

[0014] The distributed heat source may be an electric heating element.

[0015]

[0015] The system may further include a filter for removing solid particles from the emitted gas.

[0016]

[0016] The system may further include multiple chambers for pyrolyzing multiple base materials and a vacuum control mechanism for controlling the low-oxygen environment in one or more of the chambers independently of the low-oxygen environment in other of the multiple chambers.

[0017]

[0017] The system may further include multiple chambers for pyrolyzing multiple base materials and a temperature control mechanism that controls the temperature in one or more of the chambers independently of the temperatures in other of the multiple chambers.

[0018]

[0018] A method for regenerating glass fibers from a feedstock material is provided, the method including the steps of maintaining the feedstock material in a low-oxygen environment, uniformly heating the feedstock material in the low-oxygen environment, and converting the feedstock material into glass fibers.

[0019]

[0019] The method may further include the step of collecting gas released as the feedstock material is heated.

[0020]

[0020] The method may further include the step of powering a pyrolysis device with the gas to provide heat to the feedstock material.

[0021]

[0021] The method may further include the step of condensing the gas to recover oil released from the stock material.

[0022] The method may further include independently controlling one or more of the temperature and oxygen level of the one or more chambers.

[0023]

[0023] The method may further include the step of planarizing the blank material during heating.

[0024]

[0024] The method may further include the step of adhering the feedstock material to a stationary surface during pyrolysis.

[0025]

[0025] The method may further include the steps of heating the glass fibers in an atmospheric environment and removing the carbon coating from the glass fibers.

[0026]

[0026] The method may further include the step of subjecting the glass fibers to a surface treatment to reduce the coefficient of friction at the surface of the glass fibers.

[0027]

[0027] The method may further include the step of tumbling the glass fibers to randomize the orientation of the glass fibers.

[0028]

[0028] The drawings included herein are intended to illustrate various examples of the articles, methods and apparatus herein. [Brief description of the drawings]

[0029] [Figure 1] FIG. 1 is a block diagram of a pyrolysis system, according to one embodiment. [Diagram 2] FIG. 2 is a diagram of the pyrolysis system of FIG. 1, according to one embodiment. [Diagram 3] FIG. 2 is a diagram of the pyrolysis system of FIG. 1, according to one embodiment. [Figure 4] FIG. 2 is a schematic perspective view of the pyrolysis system of FIG. 1, according to one embodiment. [Diagram 5] FIG. 5 is a schematic side view of the pyrolysis apparatus of FIG. 4 in an open configuration, according to one embodiment. [Figure 6] 6 is a side cross-sectional view of the pyrolysis apparatus of FIG. 5 in a closed configuration, according to one embodiment. [Figure 7A] 1 is a cross-sectional block diagram of a planarization apparatus, according to one embodiment. [Figure 7B] 1 is a cross-sectional block diagram of a planarization apparatus, according to one embodiment. [Figure 8A] 1 is a photograph of a feedstock material, according to one embodiment. [Figure 8B] 1 is a photograph of a feedstock material, according to one embodiment. [Figure 9] 1 is a photograph of glass fibers after pyrolysis, according to one embodiment. [Figure 10] 1 is a photograph of glass fibers after pyrolysis, according to one embodiment. [Figure 11] 1 is a flow chart of a method for recycling glass fibers, according to one embodiment.

[0030] [Detailed Description]

[0029] Various apparatus or processes are described below to provide examples of each of the claimed embodiments. The embodiments described below are not intended to limit the claimed embodiments, and any claimed embodiment may include a process or apparatus different from those described below. A claimed embodiment is not limited to an apparatus or process having all of the features of any one of the apparatus or process described below, or to features common to some or all of the apparatus described below.

[0031]

[0030] Referring to FIG. 1, a diagram illustrates a pyrolysis system 100 for recovering glass fibers from a feedstock material 102, according to one embodiment.

[0032]

[0031] The feedstock material 102 can be any material that separates into gases 104 and solid residues when heated in the pyrolyzer 106. The feedstock material 102 can be GFRP, which leaves a solid residue containing glass fibers after heating in the pyrolyzer 106. The feedstock material 102 can include one or more of a sandwich structure GFRP or a glass fiber / polymer composite. These GFRPs are typical building materials for boats and wind turbines, many of which require environmental and cost-effective disposal / recycling solutions.

[0033] The pyrolysis system 100 includes a pyrolyzer 106. The pyrolyzer 106 is configured to heat the feedstock material 102 to separate the feedstock material 102 into solid residue and gases 104. The feedstock material 102 may be limited based on the size of the pyrolyzer 106.

[0034]

[0033] The pyrolysis system 100 includes a chamber 108 that holds the feedstock material 102 in a low-oxygen environment. The pyrolysis system 100 includes a pyrolysis device 106 having a distributed heat source 103 for heating the feedstock material 102. The distributed heat source 103 uniformly heats the feedstock material 102 to convert the feedstock material 102 into glass fibers.

[0035]

[0034] The distributed heat source 103 provides uniform heat throughout the length of the workpiece 103. The chamber 108 holds the workpiece 102 such that the workpiece 102 receives heat that is evenly distributed throughout the distributed heat source 103, without any concentration of heat in any area of ​​the chamber 108 or on the workpiece 102. The shape of the distributed heat source 103 corresponds to the shape of the workpiece 102 and / or the shape of the chamber. For example, if the workpiece 102 is elongated and relatively flat, then the chamber 108 is elongated and flat and the distributed heat source 103 is also elongated and flat.

[0036] The pyrolysis apparatus 106 may include multiple chambers 108. Each chamber 108 may be at a level of the pyrolysis apparatus 106 relative to the other chambers. In one embodiment, the heat provided to the chambers at each level is individually controlled. This individual control results in individually controlled heating zones. This maximizes the payload by providing multiple levels of pyrolysis of the feedstock material 102.

[0037]

[0036] The pyrolysis unit 106 may include expansion joints that are installed to relieve thermal expansion stresses from the piping system.

[0038]

[0037] During pyrolysis, the oxygen control system 118 provides and maintains a low-oxygen environment in the chamber 108. The low-oxygen environment prevents combustion of the feedstock material 102 during pyrolysis, whereby components of the feedstock material 102 evaporate rather than burn. The oxygen control system 118 can provide and maintain this low-oxygen environment by creating one or more environmental conditions, including a vacuum or a neutral atmosphere. If the low-oxygen environment is achieved by a vacuum, the oxygen control system 118 provides a pressure of 10 mbar or less. If the low-oxygen environment is achieved by a neutral atmosphere, the oxygen control system 118 evacuates the oxygen in the chamber 106 by supplying a neutral gas to replace the oxygen. The neutral gas can include nitrogen. The neutral gas can be supplied by a pipe feedthrough. The pipe feedthrough can be a DN20 ISO mm pipe feedthrough.

[0039]

[0038] The chamber 108 may be sealed with a double seal system to prevent air (oxygen) leaking into the system. The less air leaks, the better the quality of pyrolysis achieved and the minimized risk of fire and / or explosion.

[0040]

[0039] The chamber 108 can further include a leak detection system. The leak detection system can alert an operator in case of a leak. The leak detection system can also control the pyrolyzer to avoid problems such as fire and / or explosion in case of a leak. The control can include shutting down the heat source of the pyrolyzer 106.

[0041]

[0040] The pyrolyzer 106 may further include an explosion hatch. The explosion hatch is designed to be a weak connection in the event of an explosion. The explosion hatch may be located at the top, bottom, or both of the pyrolyzer. The explosion hatch may include a connecting bolt. The connecting bolt connects the explosion hatch to the pyrolyzer 106. During an explosion, the connecting bolt may deform and / or displace. This deformation / displacement acts as a pressure relief valve in the event of an explosion.

[0042] The pyrolysis system 100 captures gases 104 released during pyrolysis to power a pyrolyzer 106. The gases 104 are released from the pyrolyzer 106 to a collector 110 that collects the gases 104. The collector 110 can further process the gases into fuel 112 for a power system 114.

[0043] The power system 114 converts the fuel 112 into a power source 116 for the pyrolyzer 106. The power system 114 directs the power source 116 towards the pyrolyzer 106. In some configurations, components of the power system 114 may be housed within the pyrolyzer 106.

[0044]

[0043] The pyrolyzer produces gas 104 during the pyrolysis process as the resin of the feedstock material 102 is separated from the glass fibers. During pyrolysis, the resin components are vaporized by heat provided by the distributed heat source 103 to the pyrolyzer 106 by the power system 114. The pyrolysis operating temperature ranges from 300°C to 700°C. In one embodiment, the nominal operational operating temperature is maintained at 550°C. The pyrolyzer 106 can further heat the feedstock material 102 for a processing time of 4 hours. The processing time can include a ramp-up time of 40 minutes during which the temperature of the feedstock material 102 is gradually increased. The heating power can be calculated to be a minimum of 100 kW. With this heating power, the temperature can be increased from 400°C to the nominal temperature of 500 kg of GFPR in 40 minutes. The remaining 3 hours and 20 minutes are generally referred to as the processing time. The components of resin produced during evaporation, and the proportion of resin components in the composition of gas 104, depend on the temperature maintained within chamber 108 by distributed heat source 103 during pyrolysis.

[0045]

[0044] Higher temperatures can produce more desirable molecules in a shorter time. For example, higher temperatures produce a higher proportion of non-condensable gases such as H2, CH4, and C2H6 molecules, C3-containing molecules such as propane, C4-containing molecules such as butane, and lower proportions of CO, CO2. Higher temperatures also produce a higher proportion of gases that can be condensed into a liquid phase, such as benzene, toluene, styrene, and ethylbenzene. However, the higher the temperature maintained in the chamber 108, the higher the power consumption of the pyrolyzer 106. Thus, the power consumed by the pyrolyzer 106 is balanced against the usefulness and desirability of the components produced, both as fuel 112 for the power system 114 and as market prices for other components.

[0046]

[0045] Referring now to FIG. 2, there is shown a schematic cross-sectional view of an electropyrolysis system 200 according to one embodiment of the pyrolysis system 100 of FIG.

[0047] The pyrolysis device 202 of the electro-pyrolysis system 200 includes a first chamber 204 in which the feedstock material 206 is placed. The height of the first chamber 204 may be configured to maximize the height of the feedstock material 206 that may be accommodated without significantly sacrificing efficiency or risking exposing the first chamber 204 to thermal gradients that would promote failure of the pyrolysis device 202.

[0048] In one embodiment, the first chamber 204 is oriented horizontally and the blank 206 is located on a bottom surface 207 of the first chamber 204. In another embodiment, the first chamber 204 is oriented vertically such that the blank 206 is suspended within the first chamber 204 by a hanger.

[0049]

[0048] The first chamber 204 includes an electric heating element (such as an example of the distributed heating element 103 of FIG. 1) to provide uniform heat to the first chamber 204. The heating element 208 can include an electrical resistive element that converts electrical power 209 to heat the first chamber 204. The resistive element can be a resistive wire. The resistive wire can be embedded in the heating element 208 in an even, closely packed pattern. This pattern provides heat that is distributed homogeneously throughout the heating element 208. This distribution of heat minimizes thermal gradients in the first chamber 204, thereby improving efficiency and allowing pyrolysis of the feedstock material 206 while reducing the risk to the pyrolysis equipment caused by thermal gradients.

[0050] The electric heating element 208 is powered by electrical power provided by a power system 210 through lines 212. In one embodiment, the heating element 208 is disposed on a bottom surface 207 of the first chamber 204. In a further embodiment, the heating element 208 is disposed on a top surface 213 of the first chamber 204. In a further embodiment, the heating element 208 is disposed on both the bottom surface 207 and the top surface 213 of the first chamber 204.

[0051]

[0050] The first chamber 204 further includes a heat exchange element 214 for providing heat to the first chamber 204. The heat exchange element 214 is supplied with heat by exhaust fumes 216 of the power system 210 through a power system exhaust 218. In one embodiment, the heat exchange element 214 is disposed on a bottom surface of the first chamber 204. In a further embodiment, the heat exchange element 214 is disposed on a top surface 213 of the first chamber 204. In a further embodiment, the heat exchange element 214 is disposed on both the bottom surface 207 and the top surface 213 of the first chamber 204.

[0052]

[0051] The first chamber 204 includes a vent 220 through which gas 222 exits the first chamber 204 and is released to a collector 224. The vent 220 is a one-way valve that maintains the low oxygen environment of the first chamber 204.

[0053]

[0052] The pyrolysis apparatus 202 can include additional chambers 226 similarly configured to process multiple feedstock materials simultaneously. The additional chambers 226 are disposed within the pyrolysis apparatus 202 such that the first chamber 204 and / or the additional chambers 226 benefit from the heat provided to the other chambers. This arrangement can reduce temperature gradients in each of the first chamber 204 and / or the additional chambers 226.

[0054] The recovery vessel 224 includes a condenser 228 for separating the oil 230 from the non-condensable gases 232 present in the gas 222 discharged from the pyrolysis vessel 202, and a storage vessel 234 for receiving the non-condensable gases 232. The condenser 228 receives the gas 222 from the pyrolysis vessel 202 through a condenser inlet 236. The gas 222 passes through the condenser 228, which may be cooled by water flowing in a cooling device. The gas 222 is condensed as it passes through the condenser 228. By condensing the gas 222, the gas 222 is separated into condensed oil 230, which is condensed to a liquid phase, and non-condensable gases 232. The condenser may be open at the top and / or include a drain at the bottom to facilitate cleaning.

[0055]

[0054] The condensed oil 230 drips into an oil container 238 at the base of the condenser 228. Here, the collected oil 230 is available for use in external applications, such as as a fuel or as a precursor to chemical compounds based on the molecules present in the oil, such as plastics. The oil container 238 can house a distribution pump for pumping the oil to their intended use. The distribution pump can further include a level indicator and a temperature indicator. The remaining non-condensable gases 232 are discharged from the condenser 228 through a condenser outlet 240 where they are received by a storage container 234. The storage container 234 stores the non-condensable gases 232 until they are needed by the power system. The storage container 234 can include a vent to atmosphere.

[0056]

[0055] The power system 210 includes a gas generator 242 that is powered by burning non-condensable gases 232 to generate electricity 209. The electricity 209 operates an electric heating element 208 to provide heat for the pyrolyzer 202. The electricity 209 provided to the electric heating element 208 may be controlled by a control system that controls the heat provided to each of the first chamber 204 and / or additional chambers 226 together and / or independently.

[0057] A by-product of the operation of the gas generator 242 is a hot gas exhaust 216, which is piped to a heat exchanger 214 that can also provide heat for the pyrolyzer 202. The hot gas exhaust 216 provided to the heat exchanger 214 can be controlled by a control system that controls the heat provided to each of the first chamber 204 and / or additional chambers 226 together and / or independently.

[0058]

[0057] Referring now to Figure 3, a schematic cross-sectional view of a gas burner pyrolysis system 300 is shown, according to one embodiment.

[0059]

[0058] The pyrolysis apparatus 302 provides uniform heat to the chamber 304 by a gas burner 306 (an example of the distributed heating element 103 of FIG. 1). The gas burner 306 includes outlets 307 that distribute a gas mixture 308 that is fed to the gas burner 306. The outlets 307 may be evenly spaced and closely packed such that when the burner is ignited, a flame 309 provides heat to the chamber 304 and the heat is distributed homogeneously throughout the gas burner 306.

[0060]

[0059] The gas burners 306 are fueled by a gas mixture 308 provided by a power system 310. The power system 310 includes an inlet 312 that receives a non-condensable gas 314 from a collector 318 and an external gas 320, such as oxygen. The inlet 312 regulates the mixture of the non-condensable gas 314 and the external gas 320 to create the gas mixture 308. The inlet further regulates the flow rate of the gas mixture 308 to one or more gas burners 306. In a further embodiment, a distribution valve may regulate the flow rate to the gas burners 304 independently or in groups. The distribution valve may be part of a control system that regulates the temperature in the chamber 304.

[0061] The collector 318 includes a condenser 322 that separates the gas 326 released by the pyrolyzer 302 into oil 324 and non-condensable gases 314. The collector 318 further includes a storage tank 328. The storage tank 328 receives the non-condensable gases 314 from the condenser 322 and stores it until it is released to the power system 310.

[0062]

[0061] Referring now to Figure 4, there is shown a schematic perspective view of a pyrolysis system 400 according to one embodiment. The pyrolysis system 400 may be the pyrolysis system 100 of Figure 1.

[0063]

[0062] The pyrolysis system 400 is configured to be mounted within a shipping container (e.g., an open-sided 20 ft high cube). In this embodiment, the feedstock material 402 can be up to one or more of 1.5 m wide, 2.5 m long, and 15 cm high. The height of the feedstock material 402 is primarily due to the curvature of the feedstock material 402. The pyrolysis apparatus 406 has a loading capacity of 500 kg of feedstock material 402 per batch.

[0064]

[0063] The pyrolysis system 400 may further include an air cooling system 408. The air cooling system 408 provides cooling to a heat exchanger of the pyrolysis unit 406. The air cooling system 408 may be rotatably coupled to a door of the pyrolysis system 400.

[0065]

[0064] The pyrolysis system 400 may be made of corrosion resistant stainless steel. The material of the pyrolysis system 400 is of a suitable high temperature class, such as MA253 (EN 1.4835).

[0066]

[0065] The pyrolysis system 400 may further include a power cabinet 410. The pyrolysis system 400 is connected to a power system through the power cabinet 410. The power cabinet 410 may be operated with 250 amp, 400 volt three-phase power. The power cabinet 410 may be fused to handle a furnace of estimated power, such as 125 kW. The power cabinet 410 may include a human machine interface (HMI) panel. The HMI panel may be a 10" panel. The HMI panel may be attached to the door of the power cabinet 410. The power cabinet 410 may be configured to provide 220VAC AC for powering components of the pyrolysis system 400, such as lighting and power outlets, for convenience.

[0067]

[0066] The pyrolysis system 400 may further include a control system cabinet 412. The control system cabinet 412 may be the same cabinet as the power system cabinet 410. The control system cabinet 412 includes cables for the logic and sensors of the pyrolysis system 400. The control system cabinet 412 may include an HMI panel for the control system. The control system cabinet 412 may further include a wireless controller. The wireless controller transmits information collected by the sensors of the pyrolysis system, such as control displays, furnace operation information, temperature in the chamber, time to finish, alarms, etc. The wireless controller may transmit the information to a local display (within the pyrolysis system 400) or externally. The wireless controller may transmit to one or more of a forklift truck and a field work station. The wireless controller may have a free outdoor range of about 1 km. The information may be provided by the wireless controller to a cloud server. The cloud server may store and protect the information. The cloud server may have a web interface to access the information. The web interface may require security clearance or authentication of a security clearance level to access information. The control system cabinet 412 may include an Internet connection. The Internet connection may be used for business calls. The Internet connection may be configured to provide updates to the programmable logic controller of the pyrolysis system 400. The Internet connection may be one or more of 4th and 5th generation (and higher) cellular service. The control system cabinet may further include a Global Positioning System (GPS) tracker.

[0068]

[0067] Referring now to Figure 5, there is shown a schematic side view of a pyrolysis apparatus 500 in an open configuration, according to one embodiment. The pyrolysis apparatus 500 may be the pyrolysis apparatus 106 of Figure 1.

[0069]

[0068] The pyrolysis apparatus 500 includes a rack system 501. The rack system 501 provides feedstock materials 502a-502g to a chamber, such as chamber 108 of FIG. 1. The feedstock materials 502a-502g are collectively referred to as feedstock materials 502. The rack system 501 allows the feedstock materials 502 to be quickly and safely slid, rolled, loaded, and / or inserted into a furnace. The rack system 501 may be loaded with the feedstock materials 502 by one or more of a crane, a fork lift truck (FLT), and manual loading.

[0070]

[0069] The rack system 501 may be spring loaded so that it presses lightly against the hot shelf of the pyrolyzer when the furnace is closed. The rack system 501 may be made of stainless steel. The stainless steel may be 316-L quality. The rack system 501 may include wheels to move the rack system 501 in and out of the furnace. In one embodiment, brass or copper bushings are used for the wheels.

[0071]

[0070] The rack system 501 includes a rack frame 506. The rack frame 506 provides a structure for the rack system 501. The rack frame is coupled to wheels.

[0072]

[0071] Rack system 501 includes at least one of racks 508a-508g. Racks 508a-508g are referred to collectively and generally as racks 508. Racks 508 may also be referred to as shelves. Racks 508 are coupled to rack frame 506 such that rack 508 is positioned within a pyrolysis chamber when rack frame 506 is inserted into a furnace.

[0073]

[0072] The connection of the racks 508 to the rack frame 506 can be removable so that the racks 512 can be removed and replaced. The replacement rack can be the rack 508 (i.e., after removal), or a second rack 508. For example, there can be at least two sets of racks 508. With two sets of racks 508, one set can be cooled, drained, and / or loaded while the other is in operation. In one embodiment, the rack system 501 includes a rack 508 for each chamber of the pyrolyzer 500. It is not necessary for the entire set of racks 508 to be attached to the rack frame 506 of the pyrolyzer 500 to be in operation.

[0074]

[0073] The pyrolysis apparatus 500 includes an exhaust gas feedthrough 510. The exhaust gas feedthrough 510 may terminate at the top of a chimney 512. The exhaust gas feedthrough 510 may be located at the back or side of the pyrolysis apparatus 106 of FIG. 1. The exhaust gas feedthrough 510 may include one or more of a valve, a pressure detection sensor, and a gas flow meter. These slow the gases exiting the furnace for as long as possible, thereby maximizing the reaction of the gases and the production of gas spices.

[0075]

[0074] The pyrolysis apparatus 500 further includes a door 514. The door 514 is rotatably coupled to the pyrolysis apparatus 500 at a bottom edge 516. The door 514 can rotate about the bottom edge such that the door contacts the floor surface 516 when the pyrolysis apparatus is in the open configuration. When the door 514 is in the open configuration, the door can provide the rack system 501 with a stable surface to roll or slide on.

[0076]

[0075] The door 514 can include rails 516. The rails 516 are configured to receive and guide the wheels of the rack system.

[0077]

[0076] The pyrolysis apparatus 500 further includes at least one motorized cylinder 518. The motorized cylinder 518 transitions the door 514 between an open configuration and a closed configuration. The motorized cylinder 518 is coupled to a side 520 of the pyrolysis apparatus and to a side of the door 520.

[0078]

[0077] Referring now to Figure 6, there is shown a schematic cross-sectional view of a pyrolysis device 600 in a closed configuration, according to one embodiment. The pyrolysis device 600 may be the pyrolysis device 106 of Figure 1.

[0079]

[0078] The pyrolysis apparatus 600 may be insulated. Insulation 602 may surround the pyrolysis apparatus 600. The insulation 602 is of a thickness to allow for safe operation of the pyrolysis apparatus 600 in accordance with standards.

[0080]

[0079] The insulation 602 may include multiple layers. The insulation 602 may include an inner layer 604 adjacent to an inner surface 606 of the pyrolyzer 600. The inner layer 604 may be of a high temperature material, such as ceramic or glass. The insulation 602 may further include an intermediate layer 608. The intermediate layer 608 is located outside the inner layer 604. The intermediate layer 608 may be of stone, wool or a similar material. The insulation 602 may further include an outer layer 610. The outer layer 610 is located outside the inner layer 604 and / or the intermediate layer 608. The outer layer 610 may be of a material conforming to class standards ~55°C.

[0081]

[0080] The bottom of the pyrolysis device 600 can include sloping sides that slope towards the valve, allowing cleaning of soot, ash, dust or other particles. The bottom valve can have a redundant closing system.

[0082]

[0081] The pyrolyzer 106 may further include one or more weighing scales 612a, 612b. The weighing scales 612a, 612b may measure one or more of the weight of the raw material handled and the accumulated and / or stored amount of pyrolysis oil collected from the system. The weighing scales 612a, 612b may be located under the pyrolyzer 600. The weighing scales 612a, 612b may be located under the legs of the pyrolyzer 600. In a further embodiment, the legs of the pyrolyzer may include load cells that act as the weighing scales 612a, 612b.

[0083] 7A and 7B, there is shown a cross-sectional block diagram of a planarization apparatus in a first position 700 and a second position 701, respectively. When the feedstock material 702 is placed in the pyrolysis apparatus chamber 704 without the planarization apparatus, the feedstock material 702 typically does not lie flat at the bottom of the chamber 704. As pyrolysis progresses and the feedstock material 702 softens, the feedstock material 702 collapses under its own weight. This collapse often causes the feedstock material 702 to fold back on itself, thereby reducing the quality, uniformity and configuration of the resulting glass fibers 706.

[0084]

[0083] The planarization apparatus 700, 701 planarizes the feedstock material 702 between an upper plate 708 and a lower plate 710 during pyrolysis. The planarization apparatus 700 promotes the production of high quality glass fibers 706 that are uniform and straight.

[0085]

[0084] The lower plate 710 may be stationary. The lower plate 710 may be the bottom of the chamber 704.

[0086]

[0085] The planarization apparatus 700 includes a first hinge 712 and a second hinge 714 joining first and second sides of the upper and lower plates 708 and 710, respectively. The first hinge 712 and the second hinge 714 are on opposite sides of the upper and lower plates 708 and 710. As pyrolysis progresses, the first hinge 712 and the second hinge 714 move the upper and lower plates 708 and 710 closer to each other. The closing of the first hinge 712 and the second hinge 714 may be passive in that it is caused by the weight of the upper plate 708. Alternatively, the first hinge 712 may be driven by a spring or motor actuator to facilitate closing. The planarization apparatus 700 may include additional hinges joining one or more of the first side, second side, or other side of each of the upper plate 708 and the lower plate 710.

[0087]

[0086] The upper plate 708 and / or the lower plate 710 may be made from a material, such as a metal, that promotes even distribution of heat throughout the blank material 702 and / or that is heated by an inductive heating element. Thus, the planarization apparatus 700 may further promote more efficient heating.

[0088]

[0087] The upper plate 708 and / or lower plate 710 may include a heating element 716, such as heating element 208 of FIG. 2. The heating element 716 maintains a more consistent separation from the feedstock material 702 than the stationary heating element 208 of FIG. 2 as the feedstock material 702 flattens. Maintaining a consistent separation from the feedstock material 702 reduces the temperature required to achieve the same result as heating the space required by the original shape of the feedstock material 702 throughout pyrolysis. Additionally, it is desirable to maintain the smallest amount of separation possible between the upper plate 708 and / or lower plate 710 and the feedstock material 702. This consistent minimum separation can, in turn, reduce the power required by the pyrolysis apparatus 202 of FIG. 2, thereby increasing efficiency.

[0089]

[0088] The flattening apparatus 700 may be configured to be stackable with other flattening apparatuses. The flattening apparatus may further be configured to minimize the volume that the flattening apparatus 700 occupies when empty. A stackable, volume-minimized flattening apparatus minimizes the volume that the flattening apparatus 700 occupies during shipping.

[0090]

[0089] Referring now to Figure 8A, a photograph of a blank material for a sandwich structure 800 is shown, according to one embodiment. The blank material 800 is used, among other things, in constructing the hulls of water vehicles, many of which have recently reached or are reaching the end of their usable life cycle. These hulls provide an abundant source of blank material for the sandwich structure 800. The blank material for the sandwich structure 800 includes glass fibers 802 and resin 804 that are separated by heating in the pyrolyzer 106 of Figure 1.

[0091]

[0090] Referring now to Figure 8B, a photograph of a standard fiberglass / polymer stock material 810 is shown, according to one embodiment. This fiberglass / polymer stock material 810 is used, among other things, in constructing wind turbine blades. Each of these wind turbine blades consists of a large amount of material, creating enormous disposal costs and challenges at the end of their usable life cycle. Their size typically provides an abundant source of fiberglass and / or polymer stock material 810, at one site. The fiberglass / polymer stock material 810 includes glass fibers 812 and resin 814 that are separated by heating in the pyrolyzer 106 of Figure 1.

[0092]

[0091] Referring now to Figure 9, there is shown a photograph of remnants 900 of the feedstock material of Figures 3a and 3b remaining after pyrolysis is complete. Sandwich remnants 902 are remnants from the feedstock material of sandwich structure 500 of Figure 8A. Fiberglass / polymer remnants 904 are remnants from the fiberglass / polymer feedstock material 510 of Figure 8B. Sandwich remnants 902 and fiberglass / polymer remnants 904 include glass fibers coated with carbon black.

[0093]

[0092] Referring now to Figure 10, there is shown a photograph of primarily glass fibers 1000 remaining after oxidation of the residue 900 of Figure 9 in a conventional furnace. The oxidation burns off the carbon black 906 from the residue 900 of Figure 9, essentially leaving behind the glass fibers 900. Depending on the time and temperature of oxidation, some of the carbon black 906 may remain on the glass fibers 900.

[0094]

[0093] Referring now to Figure 11, a flow diagram of a method 1100 for recycling glass fibers is shown, according to one embodiment. The method 1100 separates glass fibers from a feedstock material and further prepares them for use in GFRP. The method 1100 may be implemented using the pyrolysis system 100 described with reference to Figures 1-7B. The method 800 may process 500 kg of feedstock material per run. Each run may take 4 hours to process. If the operation consists of two 8 hour shifts per day, a total of four runs may be processed per day, totaling up to 2000 kg of feedstock material.

[0095] At 1102, a feedstock material such as GRP is prepared and loaded into a pyrolysis chamber. The pyrolysis chamber is typically of limited size smaller than the container or structure into which the feedstock material will take shape. The feedstock material is obtained from the originating container or structure by cutting into feedstock pieces that fit into the chamber. This can be done at the location where the container or structure exists, or after it has been transported to the pyrolysis system. Alternatively, the pyrolysis method may be deployed at the location housing the container or structure, thereby eliminating the need for further transport. After cutting, the feedstock pieces are loaded into the chamber for pyrolysis.

[0096]

[0095] If a planarizing device is used, the blank material is loaded into the planarizing device, which may be loaded while inside the chamber, or may be loaded externally and then loaded into the chamber as a unit.

[0097] At 1104, a low-oxygen environment is created in the pyrolysis chamber housing the feedstock material. The low-oxygen environment prevents or reduces combustion of the feedstock material during pyrolysis, whereby components of the feedstock material evaporate rather than burn. The low-oxygen environment may be created by establishing one or more environmental conditions including a vacuum or a neutral atmosphere. If the low-oxygen environment is achieved by a vacuum, a pressure of 10 mbar or less is maintained during pyrolysis. If the low-oxygen environment is achieved by a neutral atmosphere, the oxygen in the chamber is evacuated by introducing a neutral gas, e.g., nitrogen, into the chamber to replace the oxygen.

[0098] At 1106, the chamber is heated to separate the feedstock material into gases and residue (e.g., glass fibers). The operating temperature for heating is typically in the range of 300° C. to 700° C. In one embodiment, a nominal operational temperature of 550° C. is maintained. The pyrolysis apparatus may further heat the feedstock material for a processing time of 4 hours. The processing time may include a ramp-up time of 40 minutes during which the temperature of the feedstock material is gradually increased. The heating power may be calculated to be a minimum of 100 kW. With this heating power, the temperature can be increased from 400° C. to the nominal temperature for 500 kg of GFPR in 40 minutes. As mentioned above, the remaining 3 hours and 20 minutes constitute the processing time.

[0099]

[0098] This heating causes some of the raw material to evaporate, thereby producing gas. The composition of the gas produced during evaporation depends on the temperature maintained during pyrolysis. Higher temperatures generally produce more desirable molecules in a shorter time. For example, higher temperatures produce a higher proportion of non-condensable gases such as H2, CH4, C2H6 and C2H6 molecules, and a lower proportion of C3-containing molecules such as CO, CO2, propane, and C4-containing molecules such as benzene. Higher temperatures also produce a higher proportion of gases that can be condensed into a liquid phase, such as benzene, toluene, styrene, and ethylbenzene. However, the higher the temperature maintained during pyrolysis, the more power is consumed. Thus, the power consumed is balanced against the usefulness and desirability of the components produced, both as fuel for the power system and as market prices for other components. Heating is continued until gas is no longer produced at the selected temperature.

[0100] At 1108, the gas is collected and stored as fuel for the pyrolysis unit. The method can further include condensing the gas to separate it into oil, which is condensed to a liquid phase, and non-condensable gases, which are to be consumed separately.

[0101]

[0100] At 1110, the gas is converted to heat for the pyrolysis device. The conversion may be done by using the gas as a fuel or as part of a fuel to generate power. The power can then run electric and / or induction heating elements. Alternatively, the conversion may be done by using the gas as a fuel or as part of a fuel for a gas burner. Alternatively, the conversion may be done by using the gas as a fuel for other purposes to generate hot exhaust gases. The hot exhaust gases may be used to heat a heat exchanger. The conversion may also be done by combining the above methods and / or other methods of generating heat from the gas.

[0102]

[0101] The residue is removed from the pyrolysis device at 1112. The removal of the residue 1112 may occur after the residue is heated in standard atmosphere 1114 if the heating in standard atmosphere 1114 occurs within the pyrolysis device.

[0103] At 1114, the residue (e.g., glass fibers coated with carbon black) is cleaned. The residue is heated in an air environment at a temperature ranging from 300° C. to 700° C. The heating cleans the glass fibers of carbon black by burning off any coating. The residue may be cleaned at a temperature of about 500° C. for 4 hours. Heating may be performed within the pyrolysis chamber or in an external furnace.

[0104]

[0103] At 1116, the surface of the glass fiber may be manually cleaned to remove any particulate matter that has not been burned off. Manual cleaning may include one or more of: immersing the glass fiber in an ultrasonic bath containing a solvent, oxidizing or reducing organic residues on the glass fiber with a plasma, such as O2 plasma or hydrogen plasma, or hydrolysis, such as with boiling water or hydrogen peroxide.

[0105]

[0104] At 1118, a lubricant is applied to the glass fibers. Friction can cause the fibers to wear during handling. This wear reduces the quality of the fibers. The lubricant allows the fibers to slide along one another during handling. The sliding reduces degradation of the glass fibers, thereby maintaining the quality of the glass fibers. The lubricant can be applied in the gas phase or as a chemical solution in a solvent. Applying the lubricant as a chemical solution may be preferred when processing large quantities of fibers, as it is easier to implement. The lubricant may be one or more of octadecyltrichlorosilane, teflon-terminated cholorsilane, or any silane that can be covalently attached to the surface of the glass fibers to provide lubricity.

[0106]

[0105] At 1120, the glass fibers can be tumbled to randomize the orientation of the glass fibers. In some applications, random glass fiber orientation provides a desired quality in the construction of GFRP. By tumbling the glass fibers, this orientation is achieved. In other applications, a current orientation, or one that can be more easily achieved with fibers derived from a current orientation, may be desired. In these applications, tumbling may be omitted.

[0107]

[0106] At 1122, an adhesion promoter is applied to the surface of the glass fibers. The glass fibers are regenerated to form a final GFRP that differs in one or more of the morphology, composition, and quality of the GFRP blank material from which the glass fibers were previously constructed. The adhesion promoter promotes the adhesion of the resin to the glass fibers of the final GFRP. The adhesion promoter may be applied in the gas phase or in a solvent as a chemical solution. Which adhesion promoter is applied to the glass fibers depends on the resin of the final GFRP. The adhesion promoter may be one or more of an epoxy silane or an amino silane, such as amma-aminopropyl triethoxy silane, gamma-aminopropyl methyl diethoxy silane, gamma-aminopropyl dimethyl ethoxy silane, where aminopropyl triethoxy silane may be applied for epoxy polymer resins. Methacryl silanes such as gamma-methacryloxypropyl trimethoxy silane may be used for polyester and vinyl ester resins. Generally, silane coupling agents, with appropriate molecular termination, can be applied to glass fibers to promote adhesion with polymer resins.

[0108]

[0107] Although the above description provides examples of one or more devices, methods, or systems, it will be apparent to one of ordinary skill in the art that other devices, methods, or systems may fall within the scope of the claims.

Claims

1. A system for recycling glass fibers from raw materials, comprising: a chamber for holding the feedstock in a low-oxygen environment; a pyrolysis device having a distributed heat source for heating the feedstock material, the distributed heat source uniformly heating the feedstock material to convert it into the glass fibers; a rack system configured to load and unload the feedstock material into the pyrolysis device; and Equipped with the pyrolysis apparatus includes a door, and the rack system is at least partially supported by an inner surface of the door during loading and unloading. system.

2. the chamber further comprising a workpiece planarizer for planarizing the workpiece during heating; The system of claim 1 .

3. The volume of the low-oxygen environment is reduced when the base material is planarized; or the workpiece material planarizing apparatus includes the distributed heat source, and the distributed heat source moves with the workpiece material planarizing apparatus; The system of claim 2 .

4. Further comprising a collector for collecting gases released when the base material is heated. The system of claim 1 .

5. Further comprising a condenser for recovering oil from the gas; or a power system fueled by the gas to power the pyrolysis device, and a storage system for storing the gas released by the pyrolysis device. The system of claim 4.

6. The distributed heat source is a gas burner, or the distributed heat source is an electric heating element; or further comprising a filter for removing solid particles from the emitted gas; The system of claim 1 .

7. Further comprising a plurality of chambers for pyrolyzing a plurality of raw material materials, and a vacuum control mechanism for controlling the low-oxygen environment in one or more of the plurality of chambers independently of the low-oxygen environment in other of the plurality of chambers; or a plurality of chambers for pyrolyzing a plurality of feedstock materials; and a temperature control mechanism for controlling the temperature in one or more of the plurality of chambers independently of the temperature in other chambers of the plurality of chambers. The system of claim 1 .

8. The rack system includes a plurality of racks, or the rack system further comprises a rack frame configured to support at least one rack, the rack being removable from the rack frame. The system of claim 1 .

9. The door includes a rail, the rail configured to receive and guide wheels of the rack system. The system of claim 1 .

10. The pyrolysis apparatus further comprises an explosion hatch, the explosion hatch being configured to become a weak link in the event of an explosion; or Further comprising a power cabinet operated by 250 amp, 400 volt three-phase power; or a control system cabinet configured to wirelessly control the pyrolysis device based on at least one information from at least one sensor; or The pyrolysis device is insulated by a thermal insulation material, and the thermal insulation material is layered. The system of claim 1 .

11. A method for regenerating glass fibers from raw materials, comprising: loading the feedstock material into a rack system, wherein the rack system is at least partially supported by an interior surface of a pyrolysis apparatus door during loading; maintaining the feedstock in a low-oxygen environment; uniformly heating the feedstock material in the low-oxygen environment; converting said base material into said glass fiber; bringing the feedstock material together with the rack system into the reduced-oxygen environment by moving at least a portion of the rack system into the reduced-oxygen environment of the pyrolysis apparatus; removing at least a portion of the rack system from the reduced-oxygen environment of the pyrolysis apparatus, thereby removing the feedstock material along with the rack system from the reduced-oxygen environment; removing the rack system, wherein the rack system is at least partially supported by an inner surface of the door during removal. method.

12. The method of claim 1, further comprising the step of collecting gases released when the feedstock material is heated. The method of claim 11.

13. The method further comprises the step of powering a pyrolysis device with the gas to heat the raw material; or further comprising condensing the gas to recover oil released from the stock material. The method of claim 12.

14. The method according to claim 1, further comprising the step of independently controlling one or more of the temperature and oxygen level of one or more chambers; or further comprising the step of flattening the blank during heating; or or further comprising adhering the feedstock material to a stationary surface during pyrolysis; or further comprising the steps of heating the glass fibers in an atmospheric environment and removing the carbon coating from the glass fibers; or further comprising the step of subjecting the glass fibers to a surface treatment to reduce the coefficient of friction at the surface of the glass fibers; further comprising the step of tumbling the glass fibers to randomize the orientation of the glass fibers. The method of claim 11.

15. The rack system further comprises a rack frame configured to support at least one rack, the rack being removable from the rack frame, and the step of loading the rack system further comprises loading the rack with raw material and attaching the rack to the rack frame. The method of claim 11.

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