Systems and methods for recycling wet waste materials - Patents.com

Abstract

A system and method for recycling wet wipes or products containing wet plastics is provided. The recycling process may include processing the decomposed wet waste material into molten polymer using a dewatering degassing volumetric extruder. The recycling process may further include dewatering, degassing, and volumetrically decomposing the decomposed wet waste material and the molten polymer being processed in the dewatering degassing volumetric extruder, removing gas and waste material residue from the dewatering degassing volumetric extruder, and capturing large residue particles.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application and the presently disclosed subject matter claim the benefit of U.S. Provisional Patent Application No. 63 / 280,973, filed November 18, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The subject matter of the present disclosure relates to systems and methods for recycling wet waste materials, and in particular to systems and associated methods for processing the waste materials through a recycling process line that includes recycling process machinery designed to take in wet waste materials, such as wet wipe cloths and wet plastic waste, and convert the wet waste materials, such as wet wipe cloths, into recycled plastic. [Background technology]

[0003] Wet wipe products are available for use in a variety of products that may include baby wipes, hand wipes, cosmetic wipes, kitchen wipes, medical wipes, antibacterial or cleansing wipes, other wipes, and the like. A single manufacturer of wet wipe products may generate approximately 300 to 500 tons of post-production waste per month. Currently, this waste is disposed of in landfills and incinerators. Post-consumer wet wipe waste is substantially larger in volume compared to post-production waste. Additionally, post-consumer wet wipe waste is significantly more difficult to recycle compared to post-production waste. There are various concerns regarding the post-consumer waste regarding the contamination levels and recovery of wipes. As such, a large portion of the post-consumer wet wipe waste ends up in landfills.

[0004] In general, wet wipe products are usually made of nonwoven fabrics. About 90% of the nonwoven fabrics produced contain plastics or polymers, especially in the form of extruded polymer fibers that are bonded to form a nonwoven fabric. For example, these nonwoven fabrics may include spunbond nonwoven fabrics, spunlace nonwoven fabrics, meltblown nonwoven fabrics, flash spun nonwoven fabrics, needle punched nonwoven fabrics, other short and / or continuous fiber nonwoven fabrics bonded with different bonding materials, techniques, and methods, etc. About 10% or less are produced with biodegradable material technology. Wet wipe fabrics may be made from polymer filaments bonded with natural fibers. For example, in some embodiments, the polymer content may range from 15% to 75% containing polypropylene (PP) or polyethylene terephthalate (PET). Other polymers may also be used, but less frequently. The fiber content may also contain natural fibers, such as rayon, wood pulp, cotton, and other natural fibers, ranging from 15% to 75% depending on the manufacturing design formula.

[0005] Wet wipes are designed to absorb and maintain high levels of moisture (lotion) content. Design load levels can range from 1% to 700% (by substrate weight) depending on the manufacturing design for their wet wipe product application. The moisture content in a wet wipe fabric is determined by the surface moisture content. In addition , which is considered to be the internal moisture content.

[0006] Due to their high loading levels of moisture content, wet wipes are challenging to recycle using traditional methods. In many cases, the moisture in wet wipes can adversely affect and damage traditional recycling processes. Additionally, traditional recycling methods and processes are unable to effectively treat the moisture content of wet wipes so that a reusable or treatable product can be produced. Wet wipe fabrics can contain moisture or lotion that is beneficial to their original intended use. For example, lotion ingredients can contain antimicrobial agents, fragrances, citric acid, PEG-40 hydrogenated castor oil, sodium citrate, sorbitan caprylate, sodium benzoate, disodium EDTA, bis-PEG / PPG-16 / 16, PEG / PPG-16 / 16, dimethicone, xanthan gum, pentadecalactone, dipropylene glycol, and caprylic / capric triglyceride. However, traditional recycling methods and processes are not designed to effectively use, treat, and / or remove these ingredients during the recycling process. As such, these wet wipes have generally been excluded from collection for conventional recycling methods and processes, and as such, there are currently no recycling processes for post-production or post-consumer wet wipe waste.

[0007] Therefore, there is a need to provide a recycling process for post-production or post-consumer wet wipe waste that provides useful materials that can be reused in other applications. Summary of the Invention

[0008] The main part of this disclosure is a wet wipe. product or products containing wet plastic or wasteIn particular, the present disclosure relates to a system and associated method for processing the waste material through a recycling process line that includes recycling process machinery designed to take in wet wipe fabrics and / or wet plastic waste and convert the wet wipe fabrics into recycled plastic.

[0009] One or more objects of the subject matter of the disclosure have been set forth above and are achieved in whole or in part by the subject matter of the disclosure, while other objects will become apparent as the description proceeds when considered in conjunction with the accompanying drawings as best explained below.

[0010] A full and enabling disclosure of the subject matter of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth more particularly in the remainder of the specification, including references to the accompanying drawings, in which: [Brief description of the drawings]

[0011] [Figure 1] 1 illustrates a side view of one embodiment of a dehydration, degassing, volume reduction extruder system that may be used in one embodiment of a wet wipe recycling system according to the subject matter of the present disclosure. [Figure 1A] 2 illustrates a vertical cross-sectional view of an embodiment of the dehydration, degassing, volume reduction extruder system of FIG. 1 that may be used in one embodiment of the wet wipes recycling system according to the subject matter of the present disclosure. [Figure 1B] 2 illustrates a vertical cross-sectional view of an embodiment of the dehydration, degassing, volume reduction extruder system of FIG. 1 that may be used in one embodiment of the wet wipes recycling system according to the subject matter of the present disclosure. [Figure 1C] 2 illustrates a vertical cross-sectional side view of an embodiment of the dehydration degassing volume reduction extruder system of FIG. 1 showing a solid stage degassing member and a melt stage degassing member that may be used in one embodiment of the wet wipe recycling system according to the subject matter of the present disclosure. [Diagram 2]2 illustrates a side view of one embodiment of a screw used in the dehydration, degassing, volumetric reduction extruder system of FIG. 1 that may be used in one embodiment of the wet wipes recycling system according to the subject matter of the present disclosure. [Figure 3A] 3 illustrates a side view of an embodiment of the dehydrating, degassing, volumetric reduction extruder system of FIG. 1 with translucent walls to illustrate the arrangement of the screws of FIG. 2 in one embodiment of an extruder barrel according to the subject matter of the present disclosure. [Figure 3B] FIG. 2 illustrates a vertical cross-sectional view of a portion of the embodiment of the dewatering, degassing, volume reduction extruder system of FIG. 1 showing one embodiment of a bearing die housing and adapter where the discharge screw is connected to the main screw in accordance with the subject matter of the present disclosure. [Figure 4] FIG. 1 illustrates a schematic side view of one embodiment of a liquid ring vacuum pump system used in one embodiment of a wet wipe recycling system according to the subject matter of the present disclosure. [Figure 4A] FIG. 1 illustrates a perspective view of one embodiment of a liquid ring vacuum pump used in one embodiment of a wet wipe recycling system according to the subject matter of the present disclosure. [Figure 4B] FIG. 1 illustrates a perspective view of one embodiment of a liquid ring vacuum pump used in one embodiment of a wet wipe recycling system according to the subject matter of the present disclosure. [Figure 5A] FIG. 1 is a schematic side view of an embodiment of a wet wipe waste recycling system used to produce wet wipe plastic composite products or pellets according to the subject matter of the present disclosure. [Figure 5B] FIG. 1 illustrates a schematic side view of an embodiment of a wet wipe waste recycling system used to produce wet wipe plastic composite products or pellets according to the subject matter of the present disclosure. [Figure 5C] FIG. 1 illustrates a schematic side view of an embodiment of a wet wipe waste recycling system used to produce wet wipe plastic composite products or pellets according to the subject matter of the present disclosure. [Figure 5D]FIG. 1 illustrates a schematic side view of an embodiment of a wet wipe waste recycling system used to produce wet wipe plastic composite products or pellets according to the subject matter of the present disclosure. [Figure 6A] FIG. 1 illustrates a schematic side view of an embodiment of a wet wipe waste recycling system used to produce hard shell lightweight plastic pellets in accordance with the subject matter of the present disclosure. [Figure 6B] FIG. 1 illustrates a schematic side view of an embodiment of a wet wipe waste recycling system used to produce hard shell lightweight plastic pellets in accordance with the subject matter of the present disclosure. [Figure 6C] FIG. 1 illustrates a schematic side view of an embodiment of a wet wipe waste recycling system used to produce hard shell lightweight plastic pellets in accordance with the subject matter of the present disclosure. [Figure 6D] FIG. 1 illustrates a schematic side view of an embodiment of a wet wipe waste recycling system used to produce hard shell lightweight plastic pellets in accordance with the subject matter of the present disclosure. [Figure 7] 1 illustrates a simplified flow chart showing the input and output materials of one embodiment of a wet wipe waste recycling process according to the subject matter of the present disclosure. [Figure 8] 1 illustrates a simplified flow chart showing output materials of one embodiment of a wet wipe waste recycling process used to form recycled products and articles according to the subject matter of the present disclosure. [Figure 9] FIG. 1 illustrates a diagram showing an embodiment of another output material of an embodiment of a wet wipe waste recycling process according to the subject matter of the present disclosure. [Figure 10] FIG. 1 illustrates a simplified flow chart showing the Hydrapulper / Hydropulp plastic waste input materials and output materials and products of one embodiment of the wet plastics recycling process according to the subject matter of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Repeat use of reference characters in the present specification and drawings indicates the main part of the disclosure. Same? or is intended to represent similar features or elements.

[0013] Reference will now be made to embodiments of the subject matter of the present disclosure, one or more examples of which are set forth below. Each example is provided for the purpose of illustrating the subject matter of the present disclosure, and is not intended to limit the present invention. Indeed, it will be apparent to those skilled in the art that various modifications and variations can be made to the subject matter of the present disclosure without departing from the scope or spirit of the subject matter of the present disclosure. For example, features illustrated or described as one embodiment can be used in another embodiment to produce yet another embodiment. It should be understood by those skilled in the art that this discussion is merely a description of exemplary embodiments and is not intended as a limitation of the broader aspects of the subject matter of the present disclosure, which broader aspects are embodied in the exemplary configurations.

[0014] Terms such as first, second, right, left, front, back, top, bottom, etc. may be used herein to describe various features, elements, components, regions, layers, and / or sections, but these features, elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are used only to distinguish one feature, element, component, region, layer, or section from another feature, element, component, region, layer, or section. Thus, a first feature, element, component, region, layer, or section described below may be referred to as a second feature, element, component, region, layer, or section without departing from the teachings of the present disclosure herein.

[0015] Similarly, when a feature or element is described in this disclosure as "on" or "above" another feature or element, it should be understood that the features or elements may be in direct contact with one another or have other features or elements between them, unless expressly stated otherwise. Thus, these terms merely describe the relative positions of the features or elements with respect to one another, and do not necessarily mean "on top of," since a relative position of above or below depends on the orientation of the device relative to the viewer.

[0016] Herein, embodiments of the subject matter of the present disclosure are described with reference to schematic illustrations of possible idealized embodiments. Thus, changes in the shape and / or location of features, elements, or components within the illustrations are expected, for example, but not limited to, as a result of user intent, manufacturing techniques, and / or tolerances. The shapes, sizes, and / or locations of features, elements, or components illustrated in the drawings may further be enlarged, minimized, exaggerated, shifted, or simplified to facilitate the description of the subject matter disclosed herein. Thus, the features, elements, or components illustrated in the drawings are schematic in nature, and their shapes and / or locations are not intended to illustrate the exact configuration of the subject matter, and are not necessarily intended to limit the scope of the subject matter disclosed herein, unless otherwise specified herein.

[0017] Ranges and limits mentioned herein should be understood to include all ranges (i.e., subranges) located within the stated limits. For example, the range of about 100 to about 200 also includes the ranges of 110 to 150, 170 to 190, 153 to 162, and 145.3 to 149.6. Furthermore, the limit of up to about 7 also includes the limits of up to about 5, up to 3, and up to about 4.5, as well as ranges within the limits, such as from about 1 to about 5, and from about 3.2 to about 6.5.

[0018] As used herein, the term "polymer" generally includes, but is not limited to, homopolymers, copolymers (e.g., block copolymers, graft copolymers, random copolymers, alternating copolymers, etc.), and terpolymers, as well as blends and modifications thereof. Furthermore, unless otherwise limited, the term "polymer" is intended to include all possible geometric configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and random symmetries.

[0019] The term "plastic" or "thermoplastic" is used herein to mean any material formed from a polymer that softens and flows when heated, and such a polymer can be heated and softened many times without undergoing a fundamental change in properties, provided the heating is below the decomposition temperature of the polymer. Examples of thermoplastic polymers include, by way of illustration only, polyolefins, polyesters, polyamides, polyurethanes, acrylic ester polymers and copolymers, polyvinyl chloride, polyvinyl acetate, and the like, and copolymers thereof.

[0020] As used herein, the term "moisture-containing waste material" includes wet wipe products such as moisture-containing woven and moisture-containing nonwoven fabrics with or without polymers, as well as moisture-containing plastic waste materials such as hydrapulper / hydropulp waste, moisture-containing plastic film, moisture-containing shredded plastic, and also moisture-containing waste materials containing natural or synthetic rubber.

[0021] The main body of the present disclosure relates to a system, an apparatus, and a method for recycling water-containing waste materials, such as wet wipe cloths. The waste wet wipe material can be sent through a custom-designed recycling wet wipe machine. The system and the apparatus can convert the waste wet wipes into pellet form. The recycled wet wipes (pellet form) can be suitable for many applications in the plastics industry.

[0022] The systems, devices, and methods disclosed herein can provide a way to recycle wet wipes and water-containing plastic waste and convert them into wet wipe plastic composites (WWPCs). The possibility exists of using WWPCs instead of wood plastic composites (WPCs). Wood plastic composite (WPC) materials are widely used in the plastics industry, including extrusion profile applications for deck lumber, deck rails, fences, and components for doors and windows. WPCs are also used in plastic injection molding and other forms of molding applications. Products made with WPCs are durable and require low maintenance. The lifespan of products made with WPCs is two to three times longer compared to products made from natural wood. WPC materials require approximately a 50:50 mixture of thermoplastic polymers and wood particles (wood flour or wood fiber). The wood flour or wood fiber must be dry before the raw material can be used in the WPC manufacturing process. Common plastics used in WPCs are polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), and polyethylene (PE, LDPE, and HDPE). Recycled polymers are also frequently used in the WPC process. Fibers used in WPCs have particle sizes ranging from 177 microns to 2000 microns. The choice of fiber specification depends on the product quality requirements. The process of compounding wood fiber with plastic requires a twin screw extruder and aggressive screw mixer design configuration. The WPC manufacturing process requires additives such as waxes, coupling agents, and pigments. These additives aid in the process of mixing, bonding / adhesion, and product surface appearance. The addition of wood fiber to the polymer improves flex modulus properties while reducing the percentage of polymer, helping to reduce costs.

[0023] The process of compounding WWPC is simpler compared to the WPC process. Wet wipe fabrics contain natural fibers with a uniform particle size distribution, generally smaller than wood flour and wood fibers. Wet wipes are made with fibers and polymers already combined into the form of a fabric, and the fibers that are added have a smaller particle size. The WWPC process can be accomplished using a single screw extruder. A twin screw extruder can also be used for the WWPC process, but is not necessary. It cannot be said that moisture in wet wipes has a negative effect on the recycling process. Wet wipe fabrics are ,water The WWPC contains a 50% or 100% recycled wet wipes or lotion (lotion ingredients may contain antimicrobials, fragrances, citric acid, PEG-40 hydrogenated castor oil, sodium citrate, sorbitan caprylate, sodium benzoate, disodium EDTA, bis-PEG / PPG-16 / 16, PEG / PPG-16 / 16, dimethicone, xanthan gum, pentadecalactone, dipropylene glycol, and caprylic / capric triglyceride). Many of these ingredients can help the WWPC manufacturing process improve throughput, material dispersion / mixing, bonding, and product surface appearance. The operating costs for manufacturing WWPC can be significantly reduced compared to the WPC manufacturing process. The WWPC manufacturing process uses recycled wet wipe fabrics containing fiber and plastic compared to the WPC manufacturing process, which requires various raw material inputs.

[0024] Compared with WPC, WWPC has many advantages. For example, the manufacturing cost of WWPC can be lower because of the source of raw materials. The process of compounding WWPC can also be simpler because of the uniform layer of fiber and polymer in wet wipe fabric and the small size of fiber particles. WWPC can have higher water resistance compared with WPC. The lower water resistance of WPC makes it more hygroscopic, which in turn makes it more susceptible to mold and decay. WWPC can be made of recycled materials (fiber and polymer), which is more sustainable and environmentally friendly.

[0025] The systems, devices, and methods disclosed herein can remove the moisture content in wet wipe waste in a controlled manner that allows for recycling of the wet wipes.

[0026] Recycled input material (wet wipes) may generally be received in the form of bales from post-production suppliers. Wet wipes contained in the same bale may have different levels of moisture content. It is estimated that the top of the bale may contain a moisture content of 20-100% of the substrate weight. The middle portion of the bale may contain a moisture content of 100-200% by substrate weight, and the bottom may contain a moisture content of 200-500% or more by substrate weight. Machines such as film densifiers, tumble dryers, pellet mills or press mills have been used to test for removing moisture content in wet wipe fabrics. Film densifiers, also known as plastic agglomerators, and other similar machines such as cutter compactors can be used to cut or shred the film into smaller particles. For example, such machines use high-speed rotating blades or knives to shred the film particles into small pieces. At the same time, the rotating blades / knives can generate heat through friction due to high speed rotation. The heat friction can help the film dry (if it contains moisture) and simultaneously reduce the size of the film. Due to the high moisture content in the wet wipes, these machines did not effectively process the wet wipes on their own. The high moisture content of the wet wipes prevented the heat friction from building up to a high enough temperature to dry out or shrink the wet wipe fabric.

[0027] Tumble dryers are dryers in which the material flows through a large rotating horizontal screen drum. During this process, heated air circulates through the dryer drum to dry the material. Again, due to the high moisture content in the wet wipes, these dryers did not effectively process the wet wipes on their own. The heated air was not sufficient to evaporate the moisture content to achieve satisfactory drying of the material. During testing of these dryers, dust particles from the wet wipe fabric contaminating the air heating system were also an issue.

[0028] Pellet mills or press mills use rotating rollers on a die surface. The rollers crush and compress the material through the die holes. Heat generated by the friction of the rollers rotating at high speed against the material softens the material and reduces its volume. Again, due to the high moisture content in the wet wipes, these pellet mills or press mills did not effectively process the wet wipes alone. During testing, the moisture content prevented the thermal friction from building up, worsening the slippage of the die holes and causing the rollers to seize.

[0029] 1-3A, a dehydration, degassing and compaction (DDC) extruder system, generally designated 100, is provided for removing liquids and gases from waste wet wipes being processed and compacting the waste into molten polymer in order to remove the moisture content inside the wet wipe fabric from the wet wipe waste. Thus, the DDC extruder system 100 performs three main functions: dehydration, degassing, and compaction of the waste. The special dehydration and degassing structure in the DDC extruder system 100 allows the extruder system 100 to remove the internal moisture content in the waste wet wipe fabric. In the same process, the DDC extruder system 100 compacts the lightweight fabric into molten polymer before it is discharged from the DDC extruder. The molten polymer stage increases the density of the material and provides better throughput for the process. Although described with respect to the processing and recycling of wet wipe materials, the DDC extruder system described herein may be used in other applications such as nonwoven fabrics, hydropulp plastics, hydrous plastic films, plastic films, and hydrous flake plastics. In particular, the DDC extruder systems disclosed herein may be used in recycling materials that contain high internal moisture content and / or high surface moisture content.

[0030] The DDC extruder system 100 may include a motor 500, pulleys / belts 501, and gearbox 502 used to control the rotation of a specially designed extruder screw 504, as shown in Figures 1 and 1A. The DDC extruder system 100 may include a hopper 503 for feeding the system 100, a main barrel 505 with a heater 506 attached, a bearing housing 510, an adapter 511, and a barrel 515, as shown in Figures 1, 1A, and 1B. The main barrel 505 may include an internal chamber 505A having a compression dewatering section 505B and a heated degassing volume reduction section 505C following the compression dewatering section 505B. The extruder screw 504 may include a dewatering degassing compression screw section 504A and a discharge screw section 504B. The dewatering degassing compression screw section 504A of the extruder screw 504 may be configured to rotate within the internal chamber 505A of the main barrel 505. In some embodiments, the extruder screw 504 can be a one-piece screw. In some embodiments as shown, the dehydrating degassing compression screw section 504A of the extruder screw 504 can include a main extruder screw 521 and the discharge screw section 504B can include a discharge extruder screw 512 connected to the main extruder screw 521.

[0031] Rotation of the dehydration degassing compression screw section 504A of the extruder screw 504 within the internal chamber 505A can facilitate removal of liquid from the wet waste material being processed, compression of the wet waste material, and melting and degassing the wet waste material as the heater 506 heats the main barrel 505. The die 513 can be positioned at the end of the main barrel 505. The die 513 can be configured with one or more flow passages 513A to restrict the flow of the material being processed within the main barrel 505. The die 513 with the small flow passages 513A can create back pressure and thermal friction to help melt the wet waste material being processed into molten polymer. The molten polymer material flowing from the die 513 can flow into a pre-discharge flow passage 511A configured to receive the molten polymer flowing from the die. The pre-discharge flow passage 511A is heated to further aid in heating and degassing the molten polymer. The discharge barrel 515 can be connected to the pre-discharge flow passage 511A. The discharge barrel 515 may include an internal chamber 515A in which the discharge screw section 504B of the extruder screw 504 resides to receive the molten polymer, and a discharge port 515B for discharging the molten polymer. A hood 515C with a vacuum line (not shown) attached may cover a portion of the discharge port 515B to remove additional gases and vapors as the molten polymer 011 flows out of the discharge port 515B.

[0032] To facilitate the conversion of the water-containing waste material into molten polymer, gas, vapor, and / or material residues need to be removed from the extruder system 100 to increase the rate and opportunity for the water-containing waste material to remove moisture and melt the polymer therein. To that end, one or more degassing ports 507A are provided on the main barrel 505 to remove gas or vapor released by the molten polymer generated from the waste material being processed in the main barrel 505. These one or more degassing ports 507A may be considered solid stage degassing ports. Additionally, one or more degassing ports 508A may be provided engaging the pre-discharge passage 511A to remove gas or vapor released by the molten polymer flowing into the pre-discharge passage 511A from the die 513. These one or more degassing ports 508A may be considered melt stage degassing ports. Additionally, in some embodiments, to facilitate the conversion of the water-containing waste material into molten polymer, a polymer resin may be added to the extruder system 100. In some embodiments, where the water-containing waste material has a lower polymer content, such as, for example, certain wet wipe products, additional polymer may be added, as described below.

[0033] Referring to FIG. 1, FIG. 1A, FIG. 1B, and FIG. 1C, the inputted water-containing waste material is fed into the DDC extruder hopper 503, and then the dehydration degassing compression screw section 504A of the extruder screw 504 conveys the material for compression and dehydration in the first stage S1 of the screening section of the barrel 505. In the second stage S2 of the section of the barrel 505 where the heater 506 is present, the material is heated and conveyed to the die. The material is compressed and pulverized into molten polymer between the die and the kneading paddles of the dehydration degassing compression screw section 504A of the extruder screw 504. The material is first degassed using one or more degassing ports 507A arranged in the main barrel 505. For example, the one or more degassing ports 507A can be arranged in the heated degassing volume reduction section 505C of the main barrel 505.

[0034] Each of the one or more solid stage vents 507A may have a corresponding solid stage vent stuffer 507 that may be configured to prevent backflow of material from the degassing port 507A. FIG. 1C illustrates three solid stage vents 507A and three solid stage vent stuffers 507 engaging the three solid stage vents 507A. As shown in FIG. 1C, each of the solid stage vent stuffers 507 may have a steam exhaust line 522 extending therefrom. Each solid stage vent stuffer 507 may be configured to prevent waste material being processed from flowing into the steam exhaust line 522. A transfer blower 516 may be provided and connected to the steam exhaust line 522 of each solid stage vent stuffer 507. The transfer blower 516 may be configured to supply air through the steam exhaust line 522 to transport steam and residual material particles through the steam exhaust line 522 if any material particles pass through the respective solid stage vent stuffer 507. The cyclone system 517 may be connected to a steam exhaust line 522. The cyclone system 517 may be configured to separate material particles from steam provided to the cyclone system 517 by the respective steam exhaust line 522. This allows the vent stuffer transfer blower 516 to convey material and gases that may pass through the solid stage vent stuffer 507 to the cyclone system 517, where the solid material is separated and sent to the cyclone system discharge outlet 519. The recovered solid material may be reintroduced into the extruder system 100 at some point or may be otherwise disposed of. The cyclone system 517 may include a cyclone system transfer blower 518 that increases air velocity to transport gases through the exhaust outlet 520. Removing gases, steam, and residues through the solid stage degassing outlet 507A may increase the effectiveness of the extruder system 100 in producing molten polymer from aqueous waste material having a high fluid or moisture content, such as wet wipe waste material.

[0035] 1B, in a portion of the barrel 505, material is discharged from a die 513 into a pre-ejection flow path 511A, which may be defined in an adapter 511 attached to the barrel 515. The molten polymeric material may be degassed using one or more melt stage vents 508A, which may be in fluid communication with the pre-ejection flow path 511A. For example, one or more melt stage vents 508A may be disposed in the adapter 511, which may help define the pre-ejection flow path 511A.

[0036] Each of the one or more melt stage vents 508A may have a corresponding melt stage vent stuffer 508 that may be configured to prevent backflow of material from the vent 508A. As shown in FIG. 1C, each of the one or more melt stage vent stuffers 508 may be connected to the melt stage vent 508A and connected to a vacuum line 014. Each melt stage vent stuffer 508 may be configured to prevent molten polymer in the pre-discharge flow path 511 from flowing into the vacuum line 014 and allow only gas or vapor to flow into the vacuum line 014 that connects to the degassing system 102. As described above, removing gas, vapor, and residue through the melt stage vent 508A may also increase the effectiveness of the extruder system 100 in producing molten polymer from aqueous waste material having a high fluid or moisture content, such as wet wipe waste material.

[0037] The solid stage vent stuffer 507 and the melt stage vent stuffer 508 may have a similar structure. Each vent stuffer 507, 508 may include a motor, a support frame, a shaft coupling, a barrel, a screw, a gas / vapor inlet, and a gas / vapor outlet, with the motor being coupled to the screw via the shaft coupling, as described in more detail below. The screw of each vent stuffer 507, 508 may rotate unidirectionally within the barrel to prevent material from entering the gas / vapor inlet of the respective vent stuffer, while gas or vapor may exit from the gas / vapor outlet.

[0038] In the fourth stage S4 within discharge barrel 515, the material is conveyed and discharged from DDC extruder system 100 by discharge screw section 504B of extruder screw 504, i.e., discharge screw 512. Discharge barrel 515 may be heated by heater 506 to facilitate further processing of the molten polymer as it is conveyed by discharge screw 512.

[0039] The extruder screw 504 will be described below as two connected screws 521, 512. The main extruder screw 521 and the discharge screw 512 of the extruder screw 504 illustrated in Figures 1A and 1B are shown in more detail in Figure 2. The screw 521 may comprise a shaft 600 for the attachment of a gearbox 502 for rotating the screw 521 in the barrel 505 and the discharge screw 512 in the barrel 515. An electric motor 500 and a pulley 501 drive the gearbox 502. The screw 521 may comprise a first stage (stage 1) with a dewatering zone. In particular, the screw 521 may comprise a long screw pitch 601 with a double start flight with a first flight 606 and a second flight 607, and a deep screw flight channel 602 forming a section of the dewatering zone. This section is specifically designed to be used to convey wet wipe fabrics, which are a low-density, lightweight material. The screw 504 may further comprise a tapered section 603 without screw flights at the rear part of the first stage forming the dewatering zone. This design allows for compressing the material for dewatering. The screw 521 may comprise a second stage (stage 2) forming a heating and mixing zone. In the first section of the second stage, the screw 521 may comprise a first flight. 616 and the second flight 617The screw 521 may have a short screw pitch 604 with double start flights with a shallow screw flight channel 605. This section of the screw 504 is designed to create a uniform flow and allows heat transfer from the barrel to the material. The screw 521 may also have a double start flight screw design with kneading paddles 608, 609, which perform grinding and mixing of the material on the die 513 to turn the material into molten polymer. The screw 521 may further have a connector shaft 610. The connector shaft 610 may be coupled to a screw adapter 611 that attaches the screw 521 to the discharge screw 512. The discharge screw 512 may have a short screw pitch 612 and shallow screw flight channel 613. This section of the discharge screw 512 may be designed to create a uniform flow and allows heat transfer from the barrel to the material, which reduces the volume to molten polymer before being discharged from the discharge port 515B.

[0040] figure 3A5, a stage of the screw 521 and a section of the barrel 505 are shown. The barrel 505 may include a first barrel section 800 that is a dewatering barrel. The first barrel section 800 may include a drain hole 804 that allows liquid or mixed citric acid 810 to escape from the first barrel section 800 while the material is being compressed. The first barrel section 800 may include a breaker bar 802 that acts as a flow disruptor that may prevent the material from binding to the barrel due to the outward force resulting from the rotation of the screw. The barrel and screw tolerances 803 in this section of the barrel 505 may allow backflow of the material to prevent the material from being over-compressed and to prevent the drain hole 804 from becoming blocked. The barrel 505 may include a second barrel section 801 that may include the beginning for a first material heating zone with a heater 506. The first barrel section 801 may further include a breaker bar 805 that acts as a flow disruptor that may prevent material from binding to the barrel due to outward forces resulting from the rotation of the screw. The barrel and screw tolerances 806 in this section of the barrel 505 may further allow for backflow of material to prevent the material from being over-compressed. The second barrel section 801 may also include a breaker bar 805 that may function as a flow disruptor that may prevent material from being over-compressed due to outward forces resulting from the rotation of the screw. 3B The second barrel element 801 may include a vent stuffer 507, which is shown in more detail in FIG. 3B 5. The screw 521 may be mounted on a bearing die housing 510 shown in FIG. The bearings 514 and die 513 may be mounted on the bearing die housing 510. The bearings 514 support the rotational motion of the screw 521. The die 513 restricts the flow of material while at the same time creating back pressure and thermal friction to help melt the material into molten polymer. The bearing die housing 510 may be mounted on an adapter 511 shown in FIG. 3B1 and 2. The adapter 511 may be attached to a barrel 515, which may include two barrels 807, 808. The barrels 807, 808 may continue to heat the material using heaters 506 (see FIGS. 1 and 1A) positioned around the barrels 807, 808 to create a zone for better mixing and volume reduction of the material before it is dispensed.

[0041] figure 3BReferring to FIG. 1, the vent stuffer 507 may include a motor 900, a support frame 901, a shaft coupling 902, a packing seal 903, a barrel 904, a material gas vapor outlet 905, a transfer inlet 908, and a screw 906. The motor 900 is mounted to the support frame 901. The shaft coupling 902 is coupled between the shaft of the motor 900, the screw 906, and the gas vapor inlet 907. The packing seal 903 prevents gas from escaping the DDC extruder system 100. The screw 906 is mounted within the barrel 904. The speed rotation of the screw 906 prevents material from escaping the barrel 801. The vent stuffer 508 may include a motor 910, a support frame 911, a shaft coupling 912, a packing seal 913, a barrel 914, a gas vapor outlet 915, and a screw 916, a gas vapor inlet 917 on an adapter 511. The motor 910 is mounted on the support frame 911. The shaft coupling 912 is coupled between the shaft of the motor 910 and the screw 916. The packing seal 913 prevents gas from escaping the DDC extruder system 100. The screw 916 is installed in the barrel 914. The speed rotation of the screw 916 prevents the material from flowing into the degassing line, while the gas can be vacuumed through the vent port 915. The bearing die housing 510 may include a heater 506 for the material heating zone 2. The heating zone 2 helps melt the material in the die 513 when the die 513 is cold during initial operation of the DDC extruder system 100. Heating zone 2 also allows for temperature acceleration of die 513 to improve mixing and melting of the material. Adapter 511 accommodates heater 506 (FIGS. 1 and 2) for material heating zone 3. 1A 3. Heating zone 3 can melt the solid polymer in the adapter during initial operation of DDC extruder system 100. Adapter 511 compresses and directs the polymer melt stream from die 513 to discharge barrel 807 shown in FIG.

[0042] The DDC extruder system 100 may include a degassing system that may include a vacuum pump. Referring to FIG. 4, the degassing system 102 may include a steam inlet 700 for the DDC extruder system 100 and a steam inlet 701 for the compound extruder having steam control valves 702, 703, a vacuum gauge 704, a trap system 705, and liquid control valves 706, 707. The degassing system 102 includes a motor 708, a liquid ring vacuum pump 709, a process liquid line 710, a liquid gas discharge line 711, a heat exchanger 712, a cooling water inlet 713, a cooling water return 714, a separation tank 715, a water fill replenishment 716, a process liquid 717, a drain valve 718, a separation tank inlet 719, a pressure temperature gauge 720, a gas discharge port 721, a level switch 722, a level inspection sight glass 723, a liquid level control valve 724, a pneumatic liquid level relief valve 725, a discharge liquid level safety Drain line 726, Discharge liquid overflow Drain line 727, liquid, mixed citric acid 728 may be included along with other components shown in FIG. 4. The DDC extrusion process may generate very large amounts of steam. Therefore, a vacuum pump system may be used to remove the gas. The vacuum pump may be a liquid ring vacuum pump system. In some embodiments, the medium used in the liquid ring vacuum pump is water. A liquid ring vacuum pump may provide extremely superior performance for at least several reasons. A liquid ring pump may be self-cleaning to minimize the buildup of internal pump residues. If the high temperature steam condensation is done inside the pump, the condensation is compatible with the medium used in the vacuum process. Therefore, there is no problem of lubricant contamination as with a dry vacuum pump. The bearings may be installed externally and lubricated with grease. The bearings have no points of contact with steam or vapor. Therefore, there is no problem of bearing seizure or lubricant contamination. Condensate from the wet wipe may be used as a seal liquid and cooling medium for the liquid ring vacuum pump system.

[0043] 4A and 4B show one embodiment of the liquid ring vacuum pump 106. The working principle of the degassing system 102 shown in FIG. 4 is to let the gas and residue (produced from the DDC extruder and the compound extruder) flow into the trap system. The trap system can capture large residual particles from the steam before the steam flows into the vacuum pump. After the steam flows into the vacuum pump, the steam is compressed and condensed by the liquid circulation. The liquid in the vacuum pump process is cooled by a heat exchanger through an external medium. The liquid and gas are then discharged from the vacuum pump into a separation tank. The separation tank separates the liquid from the gas, and the gas can be discharged from the separation tank through a discharge exhaust pipe. The separation tank can be designed to hold a sufficient amount of liquid to recirculate the cooling loop in the pump. The separation tank can be adapted to include a high level tank overflow safety valve. When the tank level reaches the normal overflow level, the liquid flows through the tank overflow to maintain the tank level. In some cases, if the liquid level rises continuously, such as when the overflow tube becomes blocked or clogged, the safety pneumatic valve will open every time the liquid level reaches a high level.

[0044] The present disclosure can further provide a plastic foaming process that can create a cellular structure in the molten plastic. The standard method used in the plastic foaming process is to use a directly injected gas and a chemical foaming agent. The direct injection gas process uses gases such as nitrogen, carbon dioxide, pentane, or butane. The gas is directly injected under high pressure into the extruder process and mixed with the polymer. The combination of the gas and the polymer creates a cellular structure or foamed polymer. The chemical foaming agent process can add a small amount of a special compound foaming agent (in solid form) to the polymer melt. The foaming agent decomposes during the extrusion process and releases an expanding gas to create a foamed polymer. Plastic foaming has different properties. Therefore, plastic foaming is used in different application areas.

[0045] As disclosed herein, wet wipe fabrics (nonwoven fabrics) can include a uniform layer of fibers and polymers, such as thermoplastic polymers. The fibers can absorb and maintain an internal moisture content. The DDC extruder system and associated processes disclosed herein take advantage of these fabric properties to absorb and maintain an internal moisture content with H2O gas. Use This technology can be used to make hard shell lightweight plastic (HSLP) pellets. This technology can also be used for other processes such as profile extrusion processes.

[0046] FIG. 5A illustrates one embodiment of a system and process (generally designated 104) for recycling wet wipe products. Wet wipe waste may be provided in bales, for example as baled industrial wet wipe waste. Each bale 001 may have a size of, for example, about 60 inches (152.4 cm) by 32 inches (81.28 cm) by 32 inches (81.28 cm). The bales 001 are provided to a hopper of a first shredder 002, which may shred and break down the compressed wet wipe fabric (material) contained in the bale 001 into more manageable sized wet wipe waste pieces WP1 before discharging the material evenly onto a first belt conveyor 003. As an example, in some embodiments, the wet wipe waste pieces WP1 may have a nominal size of approximately 8 inches (20.32 cm) by 4 inches (10.16 cm) by 2 inches (5.08 cm) or less when the wet wipe waste pieces WP1 exit the first shredder 002. The first belt conveyor 003 may transport the wet wipe waste pieces WP1 through a metal detector system 004. If metal is detected, the system 004 stops the wet wipe recycling system 104 and sounds an alarm. The first belt conveyor 003 may feed the material to a second shredder 005. The second shredder 005 may shred and break down the wet wipe waste pieces WP1 from the first shredder 002 into smaller sized wet wipe waste pieces WP2 before discharging them evenly onto the second belt conveyor 006. Wet wipe waste piece WP2 is smaller in size than wet wipe waste piece WP1. For example, in some embodiments, wet wipe waste piece WP2 may have a nominal size of approximately 8 inches (20.32 cm) by 1 inch (2.54 cm) by 0.5 inches (1.27 cm).

[0047] The second belt conveyor 006 transports the wet wipe waste pieces WP2 to a third shredder 007, which can shred and break down the wet wipe waste pieces WP2 from the second shredder 005 into smaller sized wet wipe waste pieces WP3. For example, in some embodiments, the wet wipe waste pieces WP3 can have a nominal size of approximately 1 inch (2.54 cm) by 0.5 inch (1.27 cm) by 0.5 inch (1.27 cm). Thus, generally speaking, the wet wipe waste pieces WP3 are of size 008 that leads to feeding into the DDC extruder system 010 as described above. The shredder can be single-axis, twin-axis, triple-axis, or quadruple-axis.

[0048] The wet wipe waste pieces WP3 are then discharged from the third shredder 007 onto a third belt conveyor 009 which can then transport the wet wipe waste pieces WP3 to a DDC extruder system 010. The DDC extruder system 010 can then process the wet wipe waste pieces WP3 by compressing to remove water and / or liquids, mixing citric acid 728, and the vent stuffers 507, 508 degassing and reducing the volume of the wet wipe waste material into a wet molten polymer. The transfer blower 516 conveys the material and gases that may pass through the vent stuffer 507 to a cyclone system 517. The cyclone system 517 separates and sends the solid material to a discharge outlet 519, and the transfer blower 518 increases the air velocity to transport the gases / vapors through an exhaust outlet 520. The DDC extruder system 010 can discharge the molten polymer 011 into a compounding extruder system 012 for further processing. While the molten polymer 011 is being discharged, residual gases in the molten polymer are vented to the atmosphere before entering the compounding extruder system 012. At this point in the processing system 104, feeders 016, 017, 018 can supply additives, colorants, and booster resins to the compounding extruder system 012 as needed or desired for the final recycled product based on the recipe requirements.

[0049] The compounding extruder system 012 can complete the process in two stages. In the first zone of the compounding extruder system 012, the compounding extruder system 012 can continuously mix the molten polymer, including the fibers and polymer, with the additives, colorants, and booster resins simultaneously. In the second stage of the compounding extruder system 012, the compounding extruder system 012 can degas the polymer and pump it through a screen changer 019. Degassing System 102 A pump (which may be, for example, a vacuum pump system in some embodiments) can vent steam / gas during processing of both the DDC extruder system 010 via line 014 and the compound extruder system 012 via line 013. The compound extruder system 012 may comprise single screw, twin screw, and ring type extruders used in the wet wipes recycling process. By using a two-stage extruder layout concept including the DDC extruder system 010 and the compound extruder 012 for the wet wipes recycling process, the molten polymer is processed in a manner conducive to recycled materials having high moisture content. By using both the DDC extruder system 010 and the compound extruder 012, the molten polymer can be vented to the atmosphere and residual gas can escape from the molten polymer. Such a two-stage process line may further allow additives, colorants, and booster resins to be fed to the molten polymer in the compound extruder system 012 after the wet wipes waste material has been processed to a molten polymer state. In some embodiments, the operating principles of a DDC extruder can be combined with those of a compound extruder into a single stage wet wipe recycling process, reducing the space and components of the wet wipe recycling apparatus, and reducing power consumption and maintenance costs.

[0050] The screen changer 019 can filter the molten polymer 011 to remove contaminant particles from the polymer 011. The screen changer 019 can include a slide plate, single bolt, dual bolt, rotary, belt, or filter drum screen changer. The polymer 011 can then be discharged to a pelletizer system 020, which can include a pelletizer cutting chamber 024 that cuts the molten polymer 011 into small pieces. The pelletizers include, but are not limited to, underwater pelletizers, strand cut pelletizers, watering pelletizers, hot air or hot face pelletizers, etc. Process water from the water pump 021 flows through a heat exchanger 022 to adjust the water temperature of the process water and is then pumped through a process water line 023 to collect the cut pellets in the cutting chamber 024. The process water solidifies the molten polymer 011 into a solid form (pellet form) during the cutting process. The slurry of process water and pellets can then be pumped from the cutting chamber 024 through a line 025 and through an agglomerate catcher 026 to the centrifugal dryer 027. The agglomerate catcher 026 can prevent and remove any large particle size agglomerates from entering the centrifugal dryer 027 to prevent damage within the centrifugal dryer 027. The centrifugal dryer 027 can separate the pellets from the process water, which can be discharged from the centrifugal dryer 027 to a water tank 028 so that it can be reused. The blower 029 can generate a countercurrent air flow to allow a longer pellet residence time in the centrifugal dryer 027. At the same time, the blower 029 can remove surface moisture from the pellets, after which the pellets 030 can be discharged from the centrifugal dryer 027.

[0051] Referring to FIG. 5B, another embodiment of a system for recycling wet wipe products, generally designated 108, is shown. The recycling system 108 is similar to the embodiment of the recycling system 104, but instead of a series of three shredders, the system 108 may include a single shredder 002. Compared to the shredder system shown in FIG. 5A, the single shredder 002 of the system 108 in FIG. 5B has more horsepower and a screen through which the processing material WP4 ​​must pass after the individual pieces of the processing material WP4 ​​become small enough. The screen pushes the waste wet wipe material into the shredder rollers of the shredder 002 multiple times. Having a single shredder 002 can save space, but more horsepower is required for the single shredder 002 to push the processing material WP4 ​​through the screen.

[0052] Referring to FIG. 5C, another embodiment of a system for recycling wet wipe products, generally designated 110, is shown. The recycling system 110 is similar to the embodiment of the recycling system 104, except that the compound extruder system 012 of the recycling system 104 of FIG. 5A is not present in the recycling system 110. In the recycling system 110, feeders 016, 017, 018 can feed additives, colorants, and booster resins to the DCC extruder system 010 as needed or desired to achieve the final recycled product based on the formula requirements. Similarly, referring to FIG. 5D, another embodiment of a system for recycling wet wipe products, generally designated 112, is shown, which is a mixed form of the recycling system 108 shown in FIG. 5B and the recycling system 110 shown in FIG. 5C. The system 112 may have a single shredder 002 and use only the DDC extruder system 010 without a compound extruder system so that feeders 016, 017, 018 can supply additives, colorants, and booster resins to the DCC extruder system 010 as needed.

[0053] Referring to Figures 6A-6D, there are shown embodiments of wet wipe recycle systems 114, 116, 118, 120 that can be used to make hard shell lightweight plastic (HSLP) pellets in a process similar to that of the wet wipe recycle system for making WWPC pellets shown in Figures 5A-5D. However, WWPC pellets are solid while HSLP pellets have a porous structure. In particular, during the pelletization stage by the cutting chamber 024 and pelletizer system 020, the process water solidifies the molten polymer 011 on the outside into a hard pellet form. However, due to the porous structure of the HSLP pellets, moisture is absorbed into the pellets during this stage. After passing through the centrifugal dryer 027 in the wet wipe recycle system 114, 116, 118, 120, the pellets flow into the tumbler dryer 031, which is used as an additional pellet drying device to reduce the moisture content of the pellets. The pellets flow through a rotating screen drum in a tumbler dryer 031, and a blower 032 circulates heated air 033 through the pellets to further dry them, so that the final dried pellets are discharged from the tumbler dryer exit. 34 The recycled wastewater has a lower moisture content when discharged from the tumble dryer. Other than the addition of a tumble dryer to the system, recycling system 114 of FIG. 6A has a similar configuration to recycling system 104 of FIG. 5A. Similarly, recycling system 116 of FIG. 6B has a similar configuration to recycling system 108 of FIG. 5B, and recycling system 118 of FIG. 6C has a similar configuration to recycling system 110 of FIG. 5C. Additionally, recycling system 120 of FIG. 6D has a similar configuration to recycling system 112 of FIG. 5D.

[0054] Thus, as described above, disclosed herein are extruder systems, recycling systems, apparatus, and associated methods for recycling wet wipe waste materials. As described herein, post-production wet wipes and post-consumer wet wipe waste 10 (which may be provided to a recycler in bales or other bulk) may be recycled into wet wipe plastic composites (WWPC) in the form of pellets 12 in some embodiments shown in FIG. 7, or hard shell lightweight plastics (HSLP) in the form of pellets 18 shown in FIG. 9. The wet wipe plastic composites (WWPC) produced by the recycling apparatuses, systems, and methods described herein may be used as a replacement for wood plastic composite (WPC) profiles. For example, profiles made from WWPC pellets 12 as shown in FIG. 8 may be used to form replacement lumber 14 as a replacement for wood lumber and other wood replacement components, including replacement lumber made from other polymer wood composites. For example, WWPC pellets may be used to manufacture anti-fence components 16, including anti-fence posts, stakes, rails, and caps. WWPC can also be used to manufacture other posts, decks, trim and moldings. Additionally, WWPC can be used to manufacture furniture such as outdoor picnic tables and outdoor chairs. Essentially, WWPC can be used in manufacturing any injection molded product including but not limited to pallets, trash cans, auto parts, electronic parts, etc. Wet wipe fabrics and non-woven fibers can be used to increase the flexural modulus properties of plastics.

[0055] The extruder system, recycling system, apparatus, and associated methods for recycling wet wipe waste materials described herein can be used to create hard shell lightweight plastic (HSLP) pellets from wet wipe fabrics and other nonwoven fabrics, which can utilize the uniform layers of fibers and polymers in the fabric and the internal moisture content in the fabric. For example, the internal moisture content (H2O gas) of the fabric can be reduced by 100%. blowHSLP pellets can be used to form or produce aggregates in concrete, bean bags, packaging materials, filtration applications, etc. The internal moisture content of fabrics (especially H2O gas) can be reduced by blow The technology used as an additive can be applied to extrusion profile processes to create lighter weight profiles. Similarly, the recycling systems and processes disclosed herein can utilize the uniform layers of fibers and polymers in wet wipe fabrics in forming lighter weight extrusion profile parts.

[0056] The extruder system, recycling system, apparatus, and associated methods for recycling wet wipe waste material described herein can be used to make recycled plastic pellets and lumber from hydropulper / hydropulp plastic waste material, as shown in FIG. 10. The hydropulper / hydropulp waste material can include plastic coated paper, or laminated composites including paper or paperboard with a plastic layer or treatment on the surface. This type of paper is commonly used in the food and beverage packaging industry. The hydropulper / hydropulp waste material 20 has similar moisture content characteristics as the wet wipe waste material. The hydropulper / hydropulp waste material 20 can be from 20% to 80% or more. and The hydropulper / hydropulp plastic waste 20 may contain moisture levels between 10% and 50% waste paper material. Using the extruder system, recycling system, apparatus, and related methods described above, the hydropulper / hydropulp waste material 20 may be converted into recycled plastic pellets 22 which may then be heated and extruded in a desired form, such as replacement lumber 24, for other useful components.

[0057] Thus, as disclosed above, the present disclosure further provides a recycling process for recycling water-containing waste materials. The recycling process may include disintegrating the water-containing waste materials being processed using one or more shredders, and processing the disintegrated water-containing waste materials into molten polymer using a dehydration degassing volumetric extruder. The recycling process may further include dehydrating, degassing, and volumetrically reducing the disintegrated water-containing waste materials and molten polymer being processed in the dehydration degassing volumetric extruder, removing gas and waste material residue from the dehydration degassing volumetric extruder, and capturing large residue particles.

[0058] The present disclosure further provides a recycling system for recycling wet wipe waste material. The recycling system may include a dehydration degassing volumetric extruder for receiving the decomposed wet wipe waste material. The dehydration degassing volumetric extruder may be configured to dehydrate, degas, and decompose the wet wipe waste material received from the shredder into a molten polymer. The recycling system may further include a solid stage degassing port on the dehydration degassing volumetric extruder to remove gas or vapor released by the molten polymer generated from the waste material being processed in the dehydration degassing volumetric extruder. In some embodiments, the recycling system may include one or more shredders for decomposing the wet wipe waste material being processed to feed the dehydration degassing volumetric extruder.

[0059] For example, as described above, the present disclosure provides an extruder system for recycling water-containing waste. The extruder system may include a main barrel including an internal chamber having a compression dewatering section and a heating degassing volume reduction section following the compression dewatering section. An extruder screw may be provided. The extruder screw may include a dewatering degassing compression screw section as well as a discharge screw section. The dewatering degassing compression screw section of the extruder screw is configured to rotate within the internal chamber of the main barrel. The extruder system may further include a solid stage degassing port positioned on the main barrel and engaging the internal chamber of the main barrel to remove gas or vapor released by molten polymer generated from the waste material being processed in the main barrel. Furthermore, the extruder system may include a die positioned at the end of the main barrel and a pre-discharge flow path for receiving the molten polymer flowing out of the die. The die may include one or more flow paths and may be configured to restrict the flow of the material being processed in the main barrel to create back pressure and thermal friction to aid in melting the waste material being processed into molten polymer. The pre-discharge flow path may be configured to heat and degas the molten polymer. Additionally, the extruder system may include a discharge barrel connected to the pre-discharge flow path, the discharge barrel may include an internal chamber in which a discharge screw section of the extruder screw may reside for receiving the molten polymer, and a discharge opening for discharging the molten polymer.

[0060] In some embodiments, the extruder system may include a melt stage vent engaging the pre-discharge flow path to remove gases or vapors released by molten polymer generated from the waste material being processed in the pre-discharge flow path. In some embodiments, the extruder system may include a solid stage vent stuffer connected to the solid stage vent. The solid stage vent stuffer may have a steam exhaust line extending therefrom and may be configured to prevent the waste material being processed from flowing into the steam exhaust line. In some embodiments, the extruder system may include a transfer blower connected to the steam exhaust line of the solid stage vent stuffer. The transfer blower is configured to supply air through the steam exhaust line to convey the vapors and material particles through the steam exhaust line if any material particles pass through the solid stage vent stuffer. In some such embodiments, the extruder system may include a cyclone system connected to the steam exhaust line. The cyclone system is configured to separate the material particles from the vapors supplied to the cyclone system by the steam exhaust line. In some embodiments, the extruder system may include a melt stage vent stuffer connected to the melt stage vent. The melt stage vent stuffer may be connected to the vacuum line and configured to prevent molten polymer in the pre-eject flow path from entering the vacuum line and allow only gas or vapor to enter the vacuum line.

[0061] These and other modifications and variations to the subject matter of the present disclosure may be implemented by those skilled in the art without departing from the spirit and scope of the subject matter of the present disclosure, which is more particularly described in the above description and the appended claims herein. In addition, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those skilled in the art will appreciate that the foregoing description is merely exemplary and is not intended to limit the subject matter.

Claims

1. 1. An extruder system for recycling wet waste materials, the extruder system comprising: a main barrel having an internal chamber having a compression and dehydration section and a heating and degassing volume reduction section following the compression and dehydration section; an extruder screw including a dehydrating degassing compression screw section and a discharge screw section, the dehydrating degassing compression screw section of the extruder screw configured to rotate within an internal chamber of the main barrel; a solid stage vent positioned on said main barrel and engaging an interior chamber of said main barrel for removing gases or vapors released by molten polymer produced from waste material being processed in said main barrel; a die positioned at an end of the main barrel, the die including one or more flow passages and configured to restrict the flow of material being processed in the main barrel to create back pressure and thermal friction to assist in fusing the material being processed into a molten polymer; a pre-discharge channel for receiving molten polymer exiting the die, the pre-discharge channel configured to heat and degas the molten polymer; a discharge barrel connected to the pre-discharge flow path, the discharge barrel having an internal chamber in which a discharge screw section of the extruder screw resides for receiving the molten polymer, and a discharge opening for discharging the molten polymer; An extruder system comprising:

2. 10. The extruder system of claim 1, further comprising a hopper for feeding wet wipes waste material into the interior chamber of the main barrel above the dewatering degassing compression screw section of the extruder screw.

3. 2. The extruder system of claim 1, wherein the dehydrating, degassing, compressing screw section of the extruder screw comprises a main extruder screw, and the discharge screw section comprises a discharge extruder screw connected to the main extruder screw.

4. The main extruder screw A shaft, a first stage having a first section with a double start flight screw flight around the shaft with a long screw pitch and a deep screw flight channel, and a second section with a tapered shaft surface without any screw flights; a second stage comprising a first section having a double start flight screw flight with a short screw pitch and a shallow screw flight channel around a thicker portion of the shaft, the second stage screw flights terminating in a kneader paddle; an end connector shaft extending outwardly from a second stage of the extruder screw beyond an end of the main barrel; The extruder system of claim 3 comprising:

5. 5. The extruder system of claim 4, wherein the discharge extruder screw is positioned within the interior chamber of the discharge barrel, the discharge extruder screw comprising a discharge screw shaft and a single start screw flight about the shaft having a short screw pitch and a shallow screw flight channel.

6. 6. The extruder system of claim 5, wherein when the main extruder screw is installed within the internal chamber of the main barrel, a first stage of the main extruder screw is aligned with a dewatering section of the main barrel and a second stage of the main extruder screw is aligned with a heated degassing volume reduction section of the main barrel.

7. 7. The extruder system of claim 6, wherein the dewatering section of the main barrel includes a drain hole for draining liquid being extracted from waste material being compressed by the main extruder screw.

8. 8. The extruder system of claim 7, wherein the main barrel comprises a breaker bar positioned along an internal chamber within the dewatering section proximal to the main extruder screw.

9. 7. The extruder system of claim 6, wherein the heated degassing volume reduction section of the main barrel comprises band heaters for transferring heat from the main barrel to the waste material being processed.

10. 10. The extruder system of claim 1, further comprising a melt stage vent engaging said pre-discharge flow passage for removing gases or vapors released by molten polymer produced from waste material being processed in said pre-discharge flow passage.

11. 11. The extruder system of claim 10, further comprising a solid stage vent stuffer connected to the solid stage vent, the solid stage vent stuffer having a steam exhaust line extending therefrom and configured to prevent waste material being processed from entering the steam exhaust line.

12. 12. The extruder system of claim 11, further comprising a transfer blower connected to a steam exhaust line of the solid stage vent stuffer, the transfer blower configured to supply air through the steam exhaust line to transport steam and material particles through the steam exhaust line as any material particles pass through the solid stage vent stuffer.

13. 13. The extruder system of claim 12, further comprising a cyclone system connected to the steam exhaust line, the cyclone system configured to separate material particles from steam supplied to the cyclone system by the steam exhaust line.

14. 12. The extruder system of claim 11, further comprising at least one melt stage vent stuffer connected to the melt stage vent, the melt stage vent stuffer being connected to a vacuum line and configured to prevent molten polymer in the pre-discharge flow path from entering the vacuum line and to allow only gas or vapor to enter the vacuum line.

15. 15. The extruder system of claim 14, wherein the solid stage vent stuffer and the melt stage vent stuffer each comprise a motor, a support frame, a shaft coupling, a barrel, a screw, a gas / vapor inlet, and a gas / vapor outlet, the motor being coupled to the screw via a shaft coupling such that the screw rotates within the main barrel to prevent material from entering the gas / vapor inlet of the respective vent stuffer and to allow gas or vapor to exit through the gas / vapor outlet.

16. The extruder system comprises: a bearing die housing connected to an end of the main barrel, through which an end connector shaft of the main extruder screw extends and in which the die is positioned; a bearing positioned within the bearing die housing on an end connector shaft of the main extruder screw, the bearing being configured to integrate the connector shaft of the main extruder screw with the bearing die housing and to maintain rotational motion of the main extruder screw; a discharge screw adapter engaged with the bearing, the discharge screw adapter configured to couple the main extruder screw and the discharge extruder screw such that rotation of the main extruder screw rotates the discharge extruder screw; an adaptor, the pre-eject passageway downstream of the die, the adaptor being connected to the bearing die housing; Further equipped with 6. The extruder system of claim 5, wherein the bearing die housing is configured for heating polymer exiting the die and for integrating the bearing and the die.

17. 17. The extruder system of claim 16, wherein the shaft of the main extruder screw in the second section of the first stage of the screw is frusto-conical in shape such that the diameter of the shaft expands along the length of the screw, thereby compressing the wet wipes waste material being processed and removing liquid without the shaft having screw flights.

18. 17. The extruder system of claim 16, wherein the shaft of the screw in the first section and the second section of the second stage of the screw has a larger diameter than the shaft of the screw in the first section of the first stage.

19. 17. The extruder system of claim 16, wherein the main extruder screw is configured with kneading paddles at the ends of the double start flight screw flights to pulverize and compress waste material on the die.

20. The extruder system of claim 16, wherein the one or more flow paths comprise multiple flow paths in the die, the multiple flow paths comprising at least one of circular or elliptical holes to restrict the flow of material while at the same time creating back pressure and thermal friction to assist in melting the waste material into molten polymer.

21. 17. The extruder system of claim 16, wherein the bearing die housing comprises a chamber for securing the bearing and die.

22. 22. The extruder system of claim 21, wherein the bearing die housing comprises a section of the bearing die housing to which at least one of an electric heater, an oil heater, or a steam heater is secured.

23. 17. The extruder system of claim 16, wherein the bearing die housing comprises multiple flow passages that allow molten polymer to flow from the die to the adapter.

24. The extruder system of claim 16, wherein a melt stage vent extends through the adapter to allow gas or vapor to escape from the pre-discharge flow path.

25. 17. The extruder system of claim 16, wherein at least one of an electric heater, an oil heater, or a steam heater is secured to one section of the adapter.

26. 17. The extruder system of claim 16, wherein the discharge barrel comprises two barrel elements secured together to form the discharge barrel with a first barrel element and a second barrel element, and when the discharge extruder screw rotates, heating and mixing of the molten polymer occurs within the discharge barrel.

27. 17. The extruder system of claim 16, wherein at least one of an electric heater, an oil heater, or a steam heater is secured to the first barrel element and the second barrel element of the discharge barrel.

Images