Systems and methods for processing combinations of liquids and particulate materials

Abstract

A system for processing a combination of liquid and particulate material is provided, wherein the particulate material comprises two or more types of particulate material that are equal to or greater than a minimum particle size and have different densities, at least two of which have a density greater than that of the liquid. The system includes a layering machine having a layering or screening chamber for holding the combination of liquid and particulate material, the layering or screening chamber having one or more side walls. The layering machine also includes a movable plate disposed within the layering or screening chamber, the movable plate having sieve openings smaller than the minimum particle size of the particulate material to be processed, thereby maintaining the particulate material above or on top of the movable plate. The layering machine further includes a drive system for moving the movable plate in a vertical upward and downward motion within the layering or screening chamber, thereby moving or processing the particulate material in the liquid. A method for processing a combination of liquid and particulate material is also provided. The particulate material may include or consist of polymeric particulate material.

Description

[Technical Field]

[0001] The present disclosure relates to systems and methods for processing a combination of liquid and particulate material, wherein the particulate material comprises two or more types of particulate material having different densities, at least two of the different types of particulate material having a density greater than the density of the liquid. The type of particulate material to be processed may be a polymeric particulate type, although other types of mixed particulate material may also be processed according to the disclosed methods and systems. [Background technology]

[0002] Plastic pollution is a widely discussed issue worldwide due to its potentially serious environmental impacts. Millions of tons of plastic are released into the environment each year, posing a risk of harm to both humans and the natural environment. Furthermore, the production of virgin plastics has a significant carbon impact, as the raw materials used in production are often fossil fuel-based. Plastic recycling is typically limited to single-type plastic products, as melting and recycling products made from several different types of plastic tends to produce polymer blends that exhibit structural weaknesses. As a result, plastics and their production place a significant strain on the global resources and environment. For this and other reasons, there is a need for improved plastic sorting and recycling.

[0003] Methods for separating plastics, particularly granular materials, typically utilize a sink-float technique, in which the granular material is submerged in a medium (typically a liquid) with a density higher or lower than that of the material to be separated, causing the material to float to the top or sink to the bottom of the medium. The material can then be removed from the medium. Depending on the material to be separated, the density of the medium can be such that two distinct fractions of the material are separated, one sinking to the bottom of the medium and the other floating to the top, thereby allowing both fractions to be removed. Similarly, in mining, a process called jigging is used in which granular material is placed on a grid or sieve in a column of media, and a separate device is used to agitate the column of media to aid in the separation of the different fractions of material, moving the granular material through the liquid and causing the denser material to settle on the grid or sieve. When a sieve or grid is used, heavier materials can be sieved through and settle to the bottom, while lighter materials will settle to the top of the sieve.

[0004] These methods can suffer from the problem of achieving insufficient particulate separation. Furthermore, it can be difficult to separate a mixture of particulate material consisting of several different fractions of material with different densities.

[0005] Therefore, there is a need for improved systems and methods for processing mixtures of particulate matter consisting of several different fractions of material having different densities, thereby achieving improved separation of the particulate matter. Summary of the Invention

[0006] It is an object of the present invention to provide an improved system and method for processing a mixture of particulate matter containing fractions of material having different densities, thereby achieving improved separation of the particulate matter.

[0007] The subject matter is a system for processing a combination of a liquid and particulate material, according to a first aspect, wherein the particulate material includes two or more types of particulate material that are equal to or larger than a minimum particle size and have different densities, at least two of the two or more types of particulate material having a density greater than the density of the liquid, the system comprising: a stratification or screening chamber for holding a combination of liquid and particulate material, the stratification or screening chamber having one or more side walls; a movable plate disposed within the stratifying or separating chamber, the movable plate having an outer edge disposed in close proximity to one or more side walls of the stratifying or separating chamber, any distance between the outer edge and the one or more side walls being smaller than the minimum particle size of the powder or granular material to be processed, and the movable plate being a plate sieve having sieve openings smaller than the minimum particle size of the powder or granular material to be processed, thereby maintaining the powder or granular material above or on the movable plate; This is achieved by providing a system comprising a layering machine having a drive system for moving a movable plate in a vertical upward and downward motion within a layering or screening chamber, thereby moving or manipulating powder or granular material in a liquid.

[0008] The type of granules processed can be a polymer granule type, but other types of mixed granules can also be processed.

[0009] At least two of the granular materials to be treated must be denser than the liquid so that the granular materials can sink in the liquid.

[0010] By moving a movable plate in a vertical upward and downward motion in the liquid in the stratification or separation chamber, the powder or granules are pushed upward in the liquid during the upward motion and settle during and after the downward motion, thereby achieving stratification of the powder or granules in the liquid based on density differences.

[0011] In a possible implementation of the first aspect, the movable plate is positioned above a bottom below a sidewall of the stratification or sorting chamber at a distance, thereby defining a lower chamber portion between an upper surface of the bottom and a lower surface of the movable plate, the lower chamber portion having a volume that changes with upward or downward movement of the movable plate within the stratification or sorting chamber. The stratifier may further include a fluid compensation system fluidly connected to the lower chamber portion and configured to deliver and receive liquid to and from the lower chamber portion when the volume of the lower chamber portion increases, and receive liquid from the lower chamber portion when the volume of the lower chamber portion decreases.

[0012] Thus, in a possible implementation of the first aspect, there is provided a system for processing a combination of a liquid and particulate material, the particulate material comprising two or more types of particulate material that are equal to or greater than a minimum particle size and have different densities, at least two of the two or more types of particulate material having a density greater than a density of the liquid, the system comprising: a stratification or screening chamber for holding a combination of liquid and particulate material, the stratification or screening chamber having one or more side walls; a movable plate disposed within the stratifying or separating chamber, the movable plate having an outer edge disposed close to one or more side walls of the stratifying or separating chamber, any distance between the outer edge and the one or more side walls being smaller than the minimum particle size of the powder or granular material to be processed, and the movable plate having sieve openings smaller than the minimum particle size of the powder or granular material to be processed, thereby forming a plate sieve for maintaining the powder or granular material above or on the movable plate, the movable plate being disposed at a distance above a bottom below the side wall of the stratifying or separating chamber, thereby defining a lower chamber portion between the upper surface of the bottom and the lower surface of the movable plate; a drive system for moving the movable plate in a vertical upward and downward motion within the stratification or sorting chamber, thereby varying the volume of the lower chamber portion; and a fluid compensation system fluidly connected to the lower chamber portion and configured to deliver and receive liquid from the lower chamber portion, whereby liquid can be supplied to the lower chamber portion when the volume of the lower chamber portion increases, and liquid can be received from the lower chamber portion when the volume of the lower chamber portion decreases. The granular material to be processed may be or may include a polymer granular material.

[0013] In a possible implementation of the first aspect, the upper part or top of the stratification or sorting chamber is configured to allow air to freely enter. In a preferred embodiment, the stratification or sorting chamber is open at the top.

[0014] By providing sieve openings in the movable plate, the movable plate can move up and down in the liquid when moving the powder or granules. However, some of the powder or granules may rest on the top of the movable plate and block the flow of liquid through some of the sieve openings, which may create a vacuum or negative pressure in the lower chamber portion when the movable plate is moved upward. To compensate for such a pressure drop, liquid is supplied from the fluid compensation system to stabilize the pressure in the lower chamber portion. When the movable plate is moved downward, overpressure may be created in the lower chamber portion, and liquid is supplied from the lower chamber portion to the fluid compensation system.

[0015] In a possible implementation of the first aspect, the drive system is configured to move the movable plate according to a stratification or sorting operation that includes a series of vertical upstrokes and vertical downstrokes through the liquid in the stratification or sorting chamber.

[0016] In a possible implementation of the first aspect, the drive system is configured to move the movable plate according to a predetermined sorting operation within the layering or sorting chamber.

[0017] In a possible implementation of the first aspect, the drive system is configured to pause the movement of the movable plate between completing its downward movement or downstroke and commencing its upward movement or upstroke.

[0018] In a possible implementation of the first aspect, the drive system is configured to maintain a pause of at least 0.5 seconds, such as at least 1 second or such as at least 1.5 seconds, between completing the downward movement or downstroke of the movable plate and starting the upward movement or upstroke.

[0019] In a possible implementation of the first aspect, the drive system can be configured to adjust the length of the pause between completing the downward movement or downstroke of the movable plate and starting the upward movement or upstroke.

[0020] In a possible implementation of the first aspect, the drive system can be configured to adjust the acceleration of the upward movement of the movable plate; and / or The drive system can be configured to adjust the speed of the upward movement of the movable plate.

[0021] In a possible implementation of the first aspect, the drive system can be configured to adjust the acceleration of the downward movement of the movable plate; and / or The drive system can be configured to adjust the speed of the downward movement of the movable plate.

[0022] In a possible implementation of the first aspect, the drive system can be configured to adjust the amplitude of the movement of the movable plate according to the ratio of the volume of the granular material to be separated to the volume of the liquid in the stratification or separation chamber.

[0023] In a possible implementation of the first aspect, the drive system is configured to control the amplitude of movement of the movable plate between a lower or rest position and a first maximum upper position.

[0024] In a possible implementation of the first aspect, the first maximum upper position is determined based on the amount of liquid and granular material in the stratification chamber, thereby ensuring that all of the granular material is covered by liquid when the movable plate reaches the first maximum upper position.

[0025] In a possible implementation of the first aspect, the drive system is reconfigurable to control the amplitude of the movement of the movable plate.

[0026] In a possible implementation of the first aspect, at least two types of granular material having a density greater than the density of the liquid have particle sizes within a defined range of ratio between the minimum particle size and the maximum particle size.

[0027] In a possible implementation of the first aspect, the defined range of ratios is between a 1:1 ratio and a 1:100 ratio between the minimum particle size and the maximum particle size.

[0028] In a possible implementation of the first aspect, the drive system can be configured to lift the movable plate upward to a discharge height, at which height at least some or all of the powder or granular material is lifted above the surface of the liquid in the stratification chamber.

[0029] In a possible implementation of the first aspect, the system further comprises a discharge system for discharging the granular material from the liquid in the stratification chamber.

[0030] In a possible implementation of the first aspect, the discharge system is configured to discharge a top layer of granular material lifted above the surface of the liquid in the stratification chamber.

[0031] In a possible implementation of the first aspect, the discharge system is configured to repeatedly discharge the top layer of granular material.

[0032] In a possible implementation of the first aspect, the system further comprises a density discrimination system for discriminating between granular materials of different densities.

[0033] In a possible implementation of the first aspect, the density discrimination system is configured to discriminate variations in density between fractions of particulate matter exiting the discharge system.

[0034] According to a second aspect, there is provided a method for treating a combination of a liquid and particulate material, the particulate material comprising two or more types of particulate material having different densities, the method comprising: providing a stratification or sorting chamber having one or more side walls; Supplying two or more types of powders and granules having different densities and a liquid to be used in the combination, wherein at least two of the two or more types of powders and granules have a density greater than the density of the liquid; combining the supplied granular material and the supplied liquid in a stratification or separation chamber; providing a series of upward and downward movements of particulate matter in a liquid, with a pause for at least some of the downward movements between the end of the downward movement for settling of the particulate matter in the liquid and the initiation of a new upward movement of the particulate matter in the liquid. The type of particulate matter processed may be a polymer particulate matter, although other types of mixed particulate matter may also be processed.

[0035] In a possible implementation of the second aspect, the sequential upward and downward movement of the granular material in the liquid follows a predetermined sorting action in a stratification or sorting chamber.

[0036] In a possible implementation of the second aspect, the pause period has a minimum length determined according to the ratio between the density of the liquid in the stratification chamber and the density of the granular material having the highest density.

[0037] In a possible implementation of the second aspect, the rest period before starting a new upward movement of the granules in the liquid is at least 0.5 seconds, such as at least 1 second or such as at least 1.5 seconds.

[0038] In a possible implementation of the second aspect, the series of upward and downward movements of the granular material in the liquid can be divided into at least first and second series of upward and downward movements; For at least a portion of the downward movement in both the first and second series of movements, there is a pause between the end of the downward movement for settling of the granular material in the liquid and the start of a new upward movement of the granular material in the liquid.

[0039] In a possible implementation of the second aspect, the rest period differs from the first sequence of movements to the second sequence of movements.

[0040] In a possible implementation of the second aspect, the first series of movements has an amplitude of upward movement that is different from the amplitude of upward movement of the second series of movements.

[0041] In a possible implementation of the second aspect, the first series of movements is performed before the second series of movements, and the rest period of the first series of movements is longer than the rest period of the second series of movements.

[0042] In a possible implementation of the second aspect, the first series of movements is performed before the second series of movements, and the amplitude of the upward movement of the first series of movements is greater than the amplitude of the upward movement of the second series of movements.

[0043] In a possible implementation of the second aspect, the first series of movements is performed before the second series of movements, and the total time for processing the combination of liquid and powder by the first series of movements is less than or equal to the total time for processing the combination of liquid and powder by the second series of movements.

[0044] In a possible implementation of the second aspect, the supplied powder or granule has a minimum particle size or larger.

[0045] In a possible implementation of the second aspect, the at least two types of granular material supplied, having a density greater than the density of the liquid, have particle sizes within a defined range of ratio between the minimum particle size and the maximum particle size.

[0046] In a possible implementation of the second aspect, a movable plate is provided and positioned within the stratification or separation chamber, the movable plate having an outer edge positioned adjacent to one or more side walls of the stratification or separation chamber, any distance between the outer edge and the one or more side walls being less than a minimum particle size of the granular material to be processed, and the movable plate is configured to maintain the granular material above or on top of the movable plate. The method according to the second aspect then comprises: The method may further comprise moving the movable plate in a vertical upward and downward motion within the stratification or separation chamber, thereby effecting said series of upward and downward motions of the particulate matter in the liquid.

[0047] In a possible implementation of the second aspect, the movable plate is a plate sieve having sieve openings smaller than the smallest particle size of the powder or granular material to be processed, thereby allowing the movable plate to move up and down in the liquid while maintaining the powder or granular material above or on top of the movable plate.

[0048] In a possible implementation of the second aspect, the movable plate is disposed above a bottom below a sidewall of the stratification or sorting chamber at a distance, thereby defining a lower chamber portion between an upper surface of the bottom and a lower surface of the movable plate, the lower chamber portion changing in volume due to upward or downward movement of the movable plate within the stratification chamber; A fluid compensation system is provided that is fluidly connected to the lower chamber portion and configured to deliver and receive liquid to and from the lower chamber portion, whereby liquid can be supplied to the lower chamber portion when the volume of the lower chamber portion increases due to upward movement of the movable plate, and liquid can be received from the lower chamber portion when the volume of the lower chamber portion decreases due to downward movement of the movable plate.

[0049] In a possible implementation of the second aspect, the movement of the movable plate is controlled to be between a lower or rest position and a predetermined first maximum upper position; The first maximum upper position is determined based on the amount of liquid and granular material in the stratification chamber, thereby ensuring that all of the granular material is covered by liquid when the movable plate reaches the first maximum upper position.

[0050] In a possible implementation of the second aspect, the distance between the lower position and the first maximum upper position is determined according to the ratio of the volume of the granular material to the volume of the liquid in the stratification chamber.

[0051] In a possible implementation of the second aspect, the defined range of ratios is between a 1:1 ratio and a 1:100 ratio between the minimum particle size and the maximum particle size.

[0052] In a possible implementation of the second aspect, the method further comprises a discharge process in which at least some or all of the treated granular material is separated from the liquid.

[0053] In a possible implementation of the second aspect, the granular material is lifted upward to a height at which at least some or all of the granular material is lifted above the surface of the liquid in the stratification chamber.

[0054] In a possible implementation of the second aspect, the movable plate is then moved upward to a discharge height to separate the powder from the liquid, at which height all of the powder is lifted above the surface of the liquid in the stratification chamber.

[0055] In a possible implementation of the second aspect, the discharge process includes removing from the stratification chamber a top layer of granular material that has been lifted above the surface of the liquid.

[0056] In a possible implementation of the second aspect, the discharge process includes repeatedly removing the top layer of granular material from the stratification chamber.

[0057] In a possible implementation of the second aspect, the method further comprises a density discrimination process for discriminating between granular materials of different densities.

[0058] In a possible implementation of the second aspect, the density process includes identifying variations in density between fractions of particulate matter removed from the stratification chamber during the discharge process.

[0059] In a possible implementation of the second aspect, a surfactant is added to or is part of the liquid provided for use in combining the liquid with the particulate material.

[0060] It should be understood that possible implementations of the method of the second aspect may be performed by using a system selected from one or more implementations of the first aspect.

[0061] According to a third aspect, there is provided a method for processing or sorting granular material comprising two or more materials having different densities, comprising the steps of: - providing a container including one or more side walls defining a stratification or sorting chamber; - combining the granular material to be separated and the liquid in the layering or separating chamber; - providing a movable plate within the layering or sorting chamber that substantially seals against one or more side walls of the layering or sorting chamber and that has an opening that is smaller than the minimum particle size of the granular material to be sorted; - moving a movable plate within said stratification or sorting chamber according to a predetermined sorting operation. The granular material to be treated or sorted may be or may include polymeric granular material.

[0062] It should be understood that possible implementations of the method of the third aspect may be performed by using a system selected from one or more implementations of the first aspect.

[0063] It is within an embodiment of the third aspect that prior to the step of combining the granular material to be sorted with the liquid in the layering or sorting chamber, the material to be treated or sorted is granulated into granules of a size within a defined range of ratio between a minimum particle size and a maximum particle size.

[0064] The term "particulate matter" may be understood to be a solid material in the form of individual grains, particles, granules, flakes, pellets, etc. The lower limit of the grain size in a granular material may be 1 μm.

[0065] The term "type of material" may be understood to mean various types of material, which may be various types of polymers, such as, but not limited to, ABS, PC, POM, PET, PVC, and different types and / or combinations thereof.

[0066] The term "different density" refers to a density of at least 0.0001, preferably 0.001, and more preferably 0.01 g / cm 3 This may be understood to be a different density.

[0067] The term "defined range of ratio between minimum and maximum particle size" can be understood as defining the range of ratio between the minimum and maximum particle size exhibited by the grains of the granular material, i.e., the size difference between the smallest and largest grains of the granular material to be sorted.

[0068] Granulation of the material to be screened can be achieved by granulating the material to be screened in a granulator, such as a polymer granulator.

[0069] At least 40%, 50%, 60%, 70%, 80%, 90% or 95% of the granulation to be screened may be within a defined range of the ratio between the smallest particle size and the largest particle size.

[0070] Granulating the material to be sorted into granules of a size within a defined range of ratio between the minimum and maximum particle size can have the effect of improving the stratification of the granules to be sorted, since the effect of size differences between the granules to be sorted is reduced. The selectable size ratio between the minimum and maximum particle size of different materials can have the effect of optimizing the stratification process to ensure optimal efficiency.

[0071] The granular material to be separated can be granulated to a particle size that depends on the ratio of the volume of the granular material to the volume of the liquid in the layering or separating chamber. This can have the effect of improving the settling of the granular material particles in each layer in the liquid according to the density of the particles. Additionally or alternatively, the material to be separated can be washed before and / or after granulation.

[0072] The term "grain" may also be expressed as "particle." The term "particle size" may also be expressed as "particle diameter," and may be understood to be the diameter of an individual grain or particle.

[0073] The term "stratification" may be understood as separating and layering particles of powder or granules of different densities according to their respective densities in a sorting chamber. The term "stratification process" may be understood as a process of stratifying particles of powder or granules of different densities according to their respective densities, i.e., including a process of performing a predetermined sorting operation.

[0074] Additionally or alternatively, the polymeric material to be sorted or the granulated polymeric material to be sorted may be pelletized. The term "pelletization" may be understood as the process of compressing or molding material into the shape of a pellet. The term "pellet" may be understood as a small, rounded, compressed mass of material. Additionally or alternatively, the material to be sorted may be pelletized such that the grains of the material to be sorted are substantially the same shape. This may have the effect of further improving the layering process, as the effect of the grain shape of the material to be sorted is reduced.

[0075] Additionally or alternatively, substances may be added to the liquid in the stratification or sorting chamber to reduce the surface tension of the liquid, which may have the effect of improving the stratification process of the particulate matter to be sorted.

[0076] Additionally or alternatively, the liquid in the stratification or sorting chamber may have a density selected based on the densities of the different types of materials to be sorted. The density of the liquid may be selected so that it is the average of the different densities of the materials to be sorted. Additionally or alternatively, the density of the liquid may be manipulated by additives and / or magnetic forces. Additionally or alternatively, liquids of different densities may be used. Additionally or alternatively, liquids of different viscosities may be used.

[0077] One or more side walls of the vessel may define a cylindrical, rectangular, square, circular or polygonal layering or sorting chamber.

[0078] Additionally or alternatively, the stratification or sorting chamber may be in fluid communication with a second chamber.

[0079] Providing a movable plate in the layering or separating chamber that substantially seals against one or more side walls of the layering or separating chamber and has an opening smaller than the smallest particle size of the granular material to be separated can have the effect of keeping the granular material to be separated above the movable plate. This can have the effect of more effectively moving the granular material to be separated because substantially all of the granular material can move with the same movement as the movable plate and none of the granular material will bypass the movable plate. This can result in more efficient layering of the granular material to be separated.

[0080] The movable plate can be moved in accordance with a predetermined sorting action within the stratification or sorting chamber. Moving the movable plate in accordance with a predetermined sorting action has the effect of improving the stratification of the granular material to be sorted.

[0081] The parameters of a given sorting operation may be adjusted based on the type of material to be sorted. The parameters of a given sorting operation may be adjusted based on the ratio of the volume of granular material to be sorted to the volume of liquid in the stratification or sorting chamber. This may have the effect of optimizing the stratification process for optimal efficiency based on the type of material to be sorted and / or based on the ratio of the volume of granular material to be sorted to the volume of liquid in the sorting chamber. The parameters of a given sorting operation may also be adjusted during the sorting process, for example, towards the end of a sorting cycle.

[0082] The time of the layering process can be adjusted according to the amount of upstrokes and downstrokes, and the time of the layering process can be adjusted according to the cycle time, i.e., the time from starting the layering to completing the layering process.

[0083] When the granular material to be separated is combined with the liquid in the layering or separating chamber, the granular material to be separated or the liquid may be fed into the layering or separating chamber first. The liquid and the granular material to be separated may also be fed substantially simultaneously.

[0084] In one embodiment of the present invention, the predetermined sorting operation comprises a series of vertical upstrokes and vertical downstrokes through the liquid in the stratification or sorting chamber. The amplitude of the upstrokes and downstrokes may be different. The amplitude of the upstrokes and / or downstrokes may be adjusted over time. The speed of the upstrokes and / or downstrokes may be different. The speed of the upstrokes and / or downstrokes may be adjusted over time. The acceleration of the upstrokes and / or downstrokes may be different. The acceleration of the upstrokes and / or downstrokes may be adjusted over time. Similarly, successive upstrokes may be different from one another. Successive downstrokes may be different from one another. This may improve the stratification process, as the operating parameters of the upstrokes and downstrokes may be selected for optimal efficiency for a given type of material or stratification condition.

[0085] The term "upstrokes and downstrokes may be different" may be understood as upstrokes exhibiting one type of vertical motion and downstrokes exhibiting a different type of vertical motion, i.e., the upstrokes and downstrokes may differ in motion parameters such as amplitude, speed, acceleration, and / or pause at the end or beginning of the stroke. The term "adjusted over time" may be understood as changing over time, for example, changing during the sorting process over time.

[0086] In a development of the latter embodiment, the amplitude of the upstrokes and downstrokes can be adjusted according to the ratio of the volume of the granular material to be separated to the volume of the liquid in the stratification or separation chamber. This can have the effect of improving the stratification process of the granular material to be separated, since different amplitudes of the upstrokes and downstrokes can affect the efficiency of stratification, particularly relative to the volume of the granular material to be separated, and more specifically, the ratio of the volume of the granular material to the volume of the liquid in the separation chamber. Experimental results have shown that the most effective stroke amplitude, in terms of cycle time and particle settling, appears to depend on the volume of granular material relative to the volume of fluid in the stratification or separation chamber. The larger the volume of the granular material to be separated, the higher the solid volume fraction, which can have the effect of reducing the average settling velocity of the particles (hindering settling) and therefore reducing the stratification efficiency.

[0087] Additionally or alternatively, the acceleration of the downstroke can be adjusted according to the ratio of the volume of the granular material to be separated to the volume of the liquid in the stratification or separation chamber. This can have the effect of further improving the efficiency of the stratification process, as it has been found that the acceleration of the downstroke has a significant effect on the stratification process. The ability to adjust the acceleration of the downstroke according to the ratio of the volume of the granular material to be separated to the volume of the liquid in the stratification or separation chamber can have the effect of optimizing the stratification process for optimal efficiency for a given load scenario. Similarly, the acceleration of the upstroke can be adjusted.

[0088] Similarly, the speed of the downstroke may be adjustable according to the ratio of the volume of the granular material to be separated to the volume of the liquid in the stratification or separation chamber. The speed of the upstroke may be adjustable according to the ratio of the volume of the granular material to be separated to the volume of the liquid in the stratification or separation chamber. This may have the effect of further optimizing the stratification process and thus improving the efficiency of the separation method.

[0089] The term "load" may be understood as the volume of granular material to be separated and the volume of liquid in the layering or separating chamber.

[0090] Additionally or alternatively, there is a pause between completing the downward movement or downstroke and starting the upward movement or upstroke. This can have the effect of improving the efficiency of the stratification process. The pause between completing the downstroke and starting the upstroke is associated with improving the settling of the particles of the granular material to be sorted into layers in the liquid according to their density, and therefore improving the stratification process. Experimental results show that the pause between the downstroke and the upstroke is very important for efficient stratification of the granular material. In the latter development, the pause between completing the downstroke and starting the upstroke is at least 0.5 seconds. This can improve the stratification process, as the pause provides time for the particles in the liquid to settle according to their density.

[0091] Additionally or alternatively, there may be a pause between completing the upward movement or upstroke and starting the downward movement or downstroke, which may have the effect of improving the efficiency of the stratification process, as it may improve the settling of the grains of the granular material to be separated in the liquid according to their density.

[0092] The pause between completing the downstroke and beginning the upstroke can be at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, or 150 seconds. Similarly, the pause between completing the upstroke and beginning the downstroke can be at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, or 150 seconds.

[0093] Additionally or alternatively, the defined ratio range is between a 1:1 ratio and a 1:100 ratio between the minimum and maximum particle sizes. This can have the effect of ensuring optimal layering efficiency by keeping the effect of particle size differences on the layering process within limits. The defined ratio range can be between a 1:1 ratio and a 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, 1:12, 1:13, 1:14, 1:15, 1:16, 1:17, 1:18, 1:19, 1:20, 1:30, 1:40, 1:50, 1:60, 1:70, 1:80, 1:90, or 1:100 ratio between the minimum and maximum particle sizes.

[0094] Additionally or alternatively, the sorted particulate fraction is discharged layer by layer from the top to the bottom of the layering or sorting chamber. This may have the effect of simplifying the discharge process, as the layers may be discharged through the same opening and separate discharge openings are not required. This may have the further effect of allowing the discharge order of the discharged layers to be maintained. This may also allow for more efficient handling of the discharged layers in subsequent processes, such as washing, drying, packaging, storage, and / or transportation.

[0095] The term "fraction" may be understood to be a group of grains of a granular material having substantially the same density.

[0096] The layer-by-layer discharge of the sorted granular material may be achieved using an extraction device. The extraction device may be a vacuum device. The vacuum device may discharge the layer from the stratification or sorting chamber by sucking it up and discharging it elsewhere. The extraction device may be a scraping device. The scraping device may discharge the layer of sorted granular material from the stratification or sorting chamber onto or into a new location by scraping it off.

[0097] Additionally or alternatively, transitions between fractions of the sorted granular material having different densities are identified during or after the discharge of the sorted granular material from the layering or sorting channel. The identification of the transitions can be achieved optically. The identification of the transitions can be achieved using mid-infrared (MIR) scanning. The term "transition" can be understood as the point between the later-discharged sorted granular material where one fraction of the sorted granular material ends and the next fraction of the sorted granular material begins. Additionally or alternatively, transition zones or layers where material may not be sufficiently separated can be treated separately and re-sorted. Additionally or alternatively, the order in which the layers of the sorted granular material fractions are discharged from the layering or sorting chamber is maintained in at least one subsequent process. This can have the effect of improving the efficiency of subsequent processes, such as storage and packaging of the discharged granular material fractions, as emphasized above. Additionally or alternatively, the layers of the sorted granular material fractions are packaged according to the order of discharge from the layering or sorting chamber.

[0098] In a fourth aspect, there is provided an apparatus for use in a method according to the third aspect, comprising: a vessel including one or more side walls defining a stratification or sorting chamber; - a movable plate disposed within the layering or sorting chamber, the movable plate substantially sealing against one or more side walls of the layering or sorting chamber and having an opening smaller than the minimum particle size of the granular material to be sorted.

[0099] The one or more side walls may define a cylindrical, circular, rectangular, square, or other polygonal stratification or sorting chamber. The stratification or sorting chamber may further include a base. The base may be disposed below the movable plate and connected to the one or more side walls. The base may be plate-like. The base may include an opening.

[0100] The stratification or sorting chamber may have a volume of at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 200, 250, 300, 400, 500, 600, 700, 800, 900 or 1000 L.

[0101] The movable plate may be sealed against one or more side walls of the stratification or sorting chamber by at least one lip seal.

[0102] The apparatus may further include a drive unit for driving the movable plate. The drive unit may be in the form of a linear drive or a positioning drive. The linear drive and / or positioning drive may include an electric motor and / or a linear guide. The drive unit may be connected to the movable plate via a shaft.

[0103] The device may further include a chamber seal. The chamber seal may be cylindrical. The chamber seal may include an upper housing body and a lower housing body. The upper housing body and the lower housing body may be removably interconnected by bolts, screws, adhesives, threads, and similar interconnection means. To this end, the chamber seal may include one or more threaded holes. The chamber seal may include one or more through holes. The chamber seal may include one or more sealing elements. The one or more sealing elements may be in the form of a wiper seal, a rod seal, an O-ring seal, etc.

[0104] A "wiper seal" may be understood to be a sealing element that maintains sealing contact with the shaft when the shaft is stationary (static, no reciprocating shaft motion) and when it is moving (dynamic, reciprocating shaft motion). A "rod seal" may be understood to be a sealing element that maintains sealing contact in a sliding motion between the chamber seal and the shaft. A rod seal may further include a lubricating film. An "O-ring seal" may be understood to be a ring-shaped mechanical sealing element with a round cross-section.

[0105] A seal element may be housed in the chamber seal. One or more seal elements may be housed in the upper housing body. One or more seal elements may be housed in the lower housing body. The upper housing body may include one or more seal elements, and the lower housing body may include one or more seal elements. The one or more seal elements may be substantially identical. The one or more seal elements may be different from each other. One or more seal elements may be partially made of natural or synthetic rubber, such as BR, NBR, HNBR, EPDM, SiR, etc. One or more seal elements may be made entirely of natural or synthetic rubber, such as BR, NBR, HNBR, EPDM, SiR, etc. The seal element may be partially made of metal, such as steel, stainless steel, aluminum, brass, copper, etc. The seal element may be completely made of metal, such as steel, stainless steel, aluminum, brass, copper, etc. The one or more seal elements may be partially made of polymer, such as PTFE, PE, TPU, TPE, LDPE, HDPE, LLDPE, ULDPE, etc. One or more sealing elements may be made entirely from a polymer such as PTFE, PE, TPU, TPE, LDPE, HDPE, LLDPE, ULDPE, and the like.

[0106] The chamber seal may include one or more flanges. The chamber seal may further include one or more guide elements for guiding the shaft. The one or more guide elements may be in the form of a guide ring, a linear guide such as a linear ball bearing, a friction guide, or the like.

[0107] A "guide ring" may be understood to be a ring-shaped guide element that guides the shaft. The guide ring may prevent contact between the shaft and the chamber seal.

[0108] The chamber seal may include one or more O-rings for sealing between the chamber seal and the stratification or sorting chamber. Additionally or alternatively, the chamber seal may include one or more wiper seals for sealing between the chamber seal and the shaft. Additionally or alternatively, the chamber seal may include a rod seal for sealing between the chamber seal and the shaft. Additionally or alternatively, the chamber seal may include one or more guide elements for guiding the shaft. The one or more guide elements may be in the form of a rod guide ring, and the pair of linear guides may be in the form of linear ball bearings. Additionally or alternatively, the chamber seal may include retaining means for retaining the seal element and / or the guide element within the chamber seal.

[0109] The chamber seal may be located inside the stratification or sorting chamber. The chamber seal may be located outside the stratification or sorting chamber. The chamber seal may be located partially inside and / or outside the stratification or sorting chamber. The upper housing body of the chamber seal may seal against the top of the base of the stratification or sorting chamber. The lower housing body of the chamber seal may seal against the bottom of the base of the stratification or sorting chamber. The upper housing body may be located within the stratification or sorting chamber. The lower housing body may be located outside the stratification or sorting chamber.

[0110] In one embodiment, the chamber seal for sealing between the shaft and the stratification or sorting chamber includes one or more wiper seals, one or more guide rings, one or more rod seals, and one or more linear guides.

[0111] The system or apparatus may further include a control unit for controlling and / or adjusting operating parameters of the moving plate, the control unit being capable of controlling and / or adjusting both the predetermined sorting operation of the moving plate and the operation of the moving plate during the sorting process.

[0112] The above and other objects are achieved by the features of the independent claims. Further implementations are evident from the dependent claims, the description and the drawings. These and other aspects of the invention will be apparent from the embodiments described below. [Brief explanation of the drawings]

[0113] In the following detailed section of the present disclosure, the invention will be described in more detail with reference to exemplary embodiments shown in the drawings.

[0114] [Figure 1] 1 shows a schematic diagram of a processing method according to an exemplary embodiment; [Figure 2] 3 shows a schematic diagram of a processing method according to another exemplary embodiment; [Figures 3a-3d] 1 is a schematic diagram illustrating steps of processing a combination of liquid and particulate material by using a first type of layering or sorting system according to an exemplary embodiment; FIG. [Figures 4a-4d] FIG. 10 is a schematic diagram illustrating steps of processing a combination of liquid and particulate material by using a second type of layering or sorting system according to an exemplary embodiment. [Figures 5a-5d] FIG. 10 is a schematic diagram illustrating steps of processing a combination of liquid and particulate material by using a third type of layering or sorting system according to an exemplary embodiment. [Figures 6a-6e] FIG. 1 is a schematic diagram illustrating the steps of discharging and identifying granular material to be processed by using a stratification or separation system according to an exemplary embodiment; [Figure 7] FIG. 1 is a schematic block diagram illustrating steps for processing granular material according to an exemplary embodiment; [Figure 8] 1 is a schematic diagram of a stratification or sorting system in accordance with an exemplary embodiment; [Figure 9] 9 is a longitudinal cross-sectional view of a chamber seal for use in the stratification or sorting system of FIG. 8 according to a first exemplary embodiment. [Figure 10] 9 is a longitudinal cross-sectional view of a chamber seal for use in the stratification or sorting system of FIG. 8 according to a second exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0115] The particulate matter to be treated or sorted can originate from discarded products or materials from industrial applications. Typically, the material to be treated or sorted originates from waste from industrial manufacturing and contains several different types of material with different densities and particle sizes. In the example described herein, the material to be treated or sorted is polymer waste from the production of polymer-containing products. Such polymer waste is often a mixture of several different types of polymers with various particle sizes and densities. As a result, polymer waste is rarely recycled because melting and recycling mixed polymer waste often results in low-quality polymer products due to the mixture of different polymer types. Consequently, polymer waste is typically incinerated in district heating plants or disposed of in landfills. However, the systems and methods described herein enable polymer waste to be sorted and separated into different polymer components according to their respective densities. This can be achieved by collecting and processing the waste polymer on-site or by transporting the waste polymer to a different dedicated processing system or plant at a different location using the systems and methods described in detail below (as illustrated in Figures 1 and 2).

[0116] In an exemplary embodiment, the polymer waste comprises two polymeric materials having different densities. The method for separating granular material is not limited to granular material containing only two materials having different densities, but may also be used for granular material containing more than two materials having different densities, for example, three, four, five or more materials having different densities.

[0117] FIG. 1 shows a schematic diagram of a processing method according to an exemplary embodiment. The polymeric material to be processed may first be granulated 101 to ensure that the particle sizes of the polymeric material particles are within a specific range of relatively similarly sized particles, i.e., within a defined range of ratios between the smallest and largest particle sizes. This is done to reduce the impact that particle size differences may have on the processing process and, therefore, improve the efficiency of the process. In the first example described here, granulation of the polymeric material may be achieved by feeding the polymeric material into a dry solid material granulator, where the material is granulated and / or shredded into particles within a defined range of ratios between the smallest and largest particle sizes. Granulation may also be achieved by other suitable devices, such as wet or dry shredders or wet granulators. The granulated material may then be fed into a stratification or screening chamber 102 for processing or screening. Once the processing of the granulation is completed within the stratification chamber, the sorted granules may be discharged 103 from the stratification chamber, and the discharged material may then be subjected to a drying process and filled into bags 104.

[0118] FIG. 2 shows a schematic diagram of a processing method according to another exemplary embodiment. Here, the polymeric material to be processed can be subjected to a pretreatment 201 in which the polymeric material is first pelletized, followed by a washing process to remove undesired contaminants. This can be achieved by processing the waste polymer in a turbo washer. Additionally or alternatively, the polymeric material can be pelletized to produce pellets of substantially the same size and shape. In the first example described here, the polymer to be processed is pelletized to a particle size having a substantially 1:1 ratio between the minimum particle size and the maximum particle size. The defined range of ratios can be between a 1:1 ratio and a 1:100 ratio between the minimum particle size and the maximum particle size.

[0119] After granulation and / or pelletization in pre-treatment 201, the granular polymer material to be processed is fed, and then the granulation can be fed to a layering or screening chamber 202 to be processed or screened. Once the processing of the granulation is finished in the layering chamber, the screened granules can be discharged from the layering chamber, and then the discharged material can be subjected to a drying process 203, followed by an identification process 204 to ensure separation of the screened granules, and finally the separated granules can be packed into bags 205.

[0120] 3a-3d are schematic diagrams illustrating steps for processing a combination of a liquid 305 and particulate material 304 by using a first type of stratifier or separator 300 according to an exemplary embodiment. The particulate material 304 includes two or more types of particulate material 304 that are equal to or larger than a minimum particle size and have different densities, with at least two of the two or more types of particulate material 304 having a density greater than that of the liquid 305. In the embodiment illustrated in FIGS. 3a-3d, there are three types of particulate material 304 with different densities, each of which has a density greater than that of the liquid 305. The liquid used is preferably water. Other suitable liquids, including water with density-altering additives, may also be used.

[0121] 3a-3d show a layering machine 300 including a layering or screening chamber 301 for holding a combination of a liquid 305 and particulate material 304, the layering chamber 301 having one or more sidewalls and a bottom. A movable plate 302 is disposed within the layering chamber 301, the movable plate 302 having an outer edge disposed adjacent to one or more sidewalls of the layering chamber 301, with any distance between the outer edge and the one or more sidewalls being smaller than the minimum particle size of the particulate material to be processed. The movable plate 302 is a plate sieve having sieve openings smaller than the minimum particle size of the particulate material to be processed, thereby maintaining the particulate material above or on top of the movable plate. A drive system 303 is provided for moving the movable plate 302 in a vertical upward and downward motion within the layering chamber 301, thereby moving or processing the particulate material 304 in the liquid 305. The drive system 303 is movably inserted into the layering chamber 301 via a liquid-tight connection at the bottom of the layering chamber 301 .

[0122] The three types of granular materials are fed into chamber 301 together with liquid 305, where drive system 303, when activated, moves plate 302 in a vertical upward and downward motion within stratification chamber 301, thereby moving or manipulating granular materials 304 in liquid 305. The amount of liquid 305 within chamber 301 should be sufficient to ensure that granular materials 304 are completely covered by the liquid during these upward and downward movements of plate 302 as they are being moved or manipulated.

[0123] The powder 304 is processed by a series of upward and downward movements in the liquid 305, with a rest period for at least part of the downward movements between the end of the downward movement for the powder 304 to settle in the liquid 305 and the start of a new upward movement of the powder 304 in the liquid 305.

[0124] Figure 3a shows the layering machine 300 in a start or rest position, with the movable plate sieve 302 in a first lower position spaced above the bottom of the chamber 301, with liquid between the bottom and the plate sieve 302, while the particulate material 304 is above the plate sieve 302 in the liquid 305 and below the upper surface of the liquid 305. In Figure 3b, the plate sieve 302 is moved upward by the drive system 303 to a second upper position, thereby pushing the particulate material 304 upward through the liquid 305. In Figure 3c, the plate sieve 302 is moved downward by the drive system 303 to the first lower position, preferably at a speed such that at least a portion of the particulate material 304 floats in the liquid 305 before settling to the top of the plate sieve 302.

[0125] After a series or several upward and downward movements of the plate sieve 302 with a rest or settling period following each or at least some of the downward movements, the granular material 304 begins to settle in a stratified or separated state to the top of the plate sieve 302, as shown in Figure 3d. The granular material 304 having the highest density settles to the lowest position, the granular material 304 having a medium density settles to the intermediate position, and the granular material 304 having the lowest density settles to the upper position.

[0126] By providing sieve openings in the movable plate 302, the movable plate 302 can move up and down in the liquid 305 as it moves the particulate material 304. However, some of the particulate material 304 may be located on top of the movable plate 302 and block the flow of liquid through some of the sieve openings, thereby creating resistance from the liquid 305 as the sieve plate 302 is moved within the chamber 301. Therefore, in the case of the stratifier 300 of Figures 3a-3d, the upward and downward movement of the sieve plate 302 within the liquid 305 can be significantly slowed to allow the liquid 305 to pass through the sieve openings during movement.

[0127] 4a-4d are schematic diagrams illustrating steps of processing a combination of liquid 405 and granular material 404 by using a second type of layering or sorting machine 400 according to an exemplary embodiment. The layering or sorting machine 400 differs from the layering machine 300 of FIGS. 3a-3d in that the machine 400 further comprises a fluid compensation system.

[0128] 4a-4d thus show a layering machine 400 having a layering or screening chamber 401 with side walls for holding a combination of a liquid 405 and particulate material 404. Again, a movable plate 402 is disposed within the layering chamber 401, wherein the movable plate 402 has an outer edge disposed proximate to one or more side walls of the layering chamber 401, with any distance between the outer edge and the one or more side walls being less than the minimum particle size of the particulate material to be processed. The movable plate 402 is a plate sieve having sieve openings smaller than the minimum particle size of the particulate material to be processed, thereby maintaining the particulate material above or on top of the movable plate. A drive system 403 is provided for moving the movable plate 402 in a vertical upward and downward motion within the layering chamber 401, thereby moving or processing the particulate material 404 in the liquid 405.

[0129] The machine 400 also includes a fluid compensation system formed at least in part by an outer chamber 408 having sidewalls and a bottom 406. The stratification chamber 401 is securely positioned within the outer chamber 408, but the bottom of the stratification chamber 401 is at least partially open, allowing fluid communication between the lower portion of the stratification chamber 401 and the outer chamber 408. The movable plate 402 is positioned above the bottom 406 of the outer chamber 408 at a distance and above the bottom or lower portion of the sidewall of the stratification chamber 401, thereby defining a lower chamber portion 407 between an upper surface of the bottom 406 of the outer chamber 408 and a lower surface of the movable plate 402. The lower chamber portion 407 changes volume with upward or downward movement of the movable plate 402 within the stratification chamber 401. The drive system 403 is movably inserted into the stratification chamber 401 via a fluid-tight connection at the bottom 406 of the outer chamber 408.

[0130] Thus, by disposing the stratification chamber 401 and the sieve plate 402 within the outer chamber 408, a fluid compensation system is formed, whereby when the volume of the lower chamber portion 407 increases, liquid 405 can be supplied from the outer chamber 408 to the lower chamber portion 407, and when the volume of the lower chamber portion 407 decreases, liquid can be received from the lower chamber portion 407 by the outer chamber 408.

[0131] When the layering machine 400 is being used to process a combination of liquid 405 and granular material 404, the fluid compensation system allows the sieve plate 402 to move upward and downward at a faster rate than the layering machine 300 of Figures 3a-3d, so that it is no longer necessary to force the liquid 405 through sieve openings to allow the sieve plate 402 to move upward and downward through the liquid 405.

[0132] The processing steps performed by the layering machine 400 of FIGS. 4a-4d are similar to those performed by the layering machine 300 of FIGS. 3a-3d, except that the sieve plate 402 can be moved at a faster speed, thereby improving the efficiency of the layering or screening process. Thus, there are three types of powders 404 with different densities, each of which has a density greater than that of the liquid 405, where the liquid used is water. Other suitable liquids, including water with density-altering additives, can also be used. Also, in the processing process illustrated in FIGS. 4a-4d, the three types of powders are fed into the layering chamber 401 along with the liquid 405, where liquid is provided in both the layering chamber 401 and the outer chamber 408. Here, the drive system 403, when activated, moves the sieve plate 402 in a vertical upward and downward motion within the layering chamber 401, thereby moving or processing the powders 404 in the liquid 405. The amount of liquid 405 in chambers 401 and 408 must be sufficient to ensure that the granular material 404 is completely covered by the liquid during these upward and downward movements of plate 402 when moving or processing the granular material 404.

[0133] 4a shows the layering machine 400 in a start or rest position, with the movable plate sieve 402 in a first lower position spaced above the bottom 406 of the outer chamber 408, with liquid provided in a lower chamber portion 407 between the bottom 406 of the outer chamber 408 and the plate sieve 402, while the particulate material 404 is above the plate sieve 402 in the liquid 405 and below the upper surface of the liquid 405. In this rest position, the upper surface of the liquid 405 reaches the same level in both chambers 401 and 408.

[0134] 4b, the plate sieve 402 is moved upward by the drive system 403 at a relatively high speed to a second upper position, thereby pushing the granular material 404 upward through the liquid 405. During this upward movement, the passage of the liquid 405 through the sieve openings of the plate 402 is partially blocked by the granular material 404, and the liquid 405 is supplied from the outer chamber 408 to the lower chamber portion 407 to stabilize the pressure change within the lower chamber portion 407. Now, just as the upward movement of the sieve plate 402 has finished, the upper surface of the liquid 405 has reached a higher level in the stratification chamber 401, while reaching a lower level in the outer chamber 408.

[0135] 4c, the plate sieve 402 is moved downward by the drive system 403 to a first downward position at a relatively high speed, preferably such that at least a portion of the granular material 404 floats in the liquid 405 and then settles to the top of the plate sieve 402. During this downward movement, liquid 405 is supplied from the lower chamber portion 407 to the outer chamber 408 to stabilize the pressure change within the lower chamber portion 407. Now, just as the downward movement of the sieve plate 402 has finished, the upper surface of the liquid 405 has reached a lower level in the stratification chamber 401, while reaching a higher level in the outer chamber 408.

[0136] After a series or several upward and downward movements of the plate sieve 402 with a rest or settling period following each or at least some of the downward movements, the granular material 404 begins to settle to the top of the plate sieve 402 in a stratified or screened state, as shown in Figure 4d. The granular material 404 having the highest density settles to the lowest position, the granular material 404 having a medium density settles to the middle position, and the granular material 404 having the lowest density settles to the upper position. In Figure 4d, the stratifier 400 is in a rest position, and the upper surface of the liquid 405 reaches the same level in both chambers 401 and 408.

[0137] 5a-5d are schematic diagrams illustrating steps of processing a combination of liquid and particulate material by using a third type of layering or sorting system according to an exemplary embodiment.

[0138] 5a-5d are schematic diagrams illustrating steps for processing a combination of liquid 505 and granular material 504 by using a third type of layering or sorting machine 500 according to an exemplary embodiment. The layering or sorting machine 500 differs from the layering machine 400 of FIGS. 4a-4d in that the machine 500 possesses a fluid compensation system that is slightly different from the fluid compensation system of the layering machine 400.

[0139] 5a-5d thus show a layering machine 500 having a layering or screening chamber 501 with sidewalls and a bottom 506 for holding a combination of a liquid 505 and particulate material 504. Again, a movable plate 502 is disposed within the layering chamber 501, wherein the movable plate 502 has an outer edge disposed proximate to one or more sidewalls of the layering chamber 501, with any distance between the outer edge and the one or more sidewalls being less than the minimum particle size of the particulate material to be processed. The movable plate 502 is a plate sieve having sieve openings smaller than the minimum particle size of the particulate material to be processed, thereby maintaining the particulate material above or on top of the movable plate. A drive system 503 is provided for moving the movable plate 502 in a vertical upward and downward motion within the layering chamber 501, thereby moving or processing the particulate material 504 in the liquid 505. The drive system 503 is movably inserted into the layering chamber 501 via a fluid-tight connection at the bottom 506 of the layering chamber 501 .

[0140] The machine 500 carries a fluid compensation system formed at least in part by one or more outer fluid pipes 508 having open upper and lower end portions fluidly connected to the lower portion of the side wall of the stratification chamber 501 below the lower surface of the sieve plate 502. The movable plate 502 is spaced above the bottom 506 of the chamber 501, thereby defining a lower chamber portion 507 between the upper surface of the bottom 506 of the chamber 501 and the lower surface of the movable plate 502. This lower chamber portion 507 changes volume with upward or downward movement of the movable plate 502 within the stratification chamber 501.

[0141] Therefore, by arranging the stratification chamber 501, the sieve plate 502 and the outer fluid pipe 508, a fluid compensation system is formed, whereby when the volume of the lower chamber portion 507 increases, the liquid 505 can be supplied from the outer fluid pipe 508 to the lower chamber portion 507, and when the volume of the lower chamber portion 507 decreases, the liquid can be received from the lower chamber portion 507 by the outer fluid pipe 508.

[0142] The processing steps performed by the stratifier 500 of FIGS. 5a-5d are similar to those performed by the stratifier 400 of FIGS. 4a-4d. Thus, there are three types of powders 504 with different densities, each of which has a density greater than that of the liquid 505, where the liquid used is water. Other suitable liquids, including water with density-altering additives, can also be used. Also, in the processing process illustrated in FIGS. 5a-5d, the three types of powders are fed into the stratification chamber 501 together with the liquid 505, where the liquid is provided in both the stratification chamber 501 and the outer fluid pipe 508. Here, when the drive system 503 is activated, it moves the sieve plate 502 in a vertical upward and downward motion within the stratification chamber 501, thereby moving or processing the powders 504 in the liquid 505. The amount of liquid 505 in the chamber 501 and fluid pipe 508 must be sufficient to ensure that when the granular material 504 is moved or processed, the granular material 504 is completely covered by the liquid during these upward and downward movements of the plate 502.

[0143] 5a shows the stratifier 500 in a start or rest position, with the movable plate sieve 502 in a first lower position spaced above the bottom 506 of the stratification chamber 508, with the liquid located in the lower chamber 507 between the bottom 506 and the plate sieve 502, while the granular material 504 is above the plate sieve 502 in the liquid 505 and below the upper surface of the liquid 505. In this rest position, the upper surface of the liquid 505 reaches the same level in the chamber 501 and in the fluid pipe 508.

[0144] 5b, the plate sieve 502 is moved upward by the drive system 503 at a relatively high speed to a second upper position, thereby pushing the granular material 504 upward through the liquid 505. During this upward movement, the passage of the liquid 505 through the sieve openings of the plate 502 is partially blocked by the granular material 504, and the liquid 505 is supplied from the outer fluid pipe 508 to the lower chamber portion 507 to stabilize the pressure change in the lower chamber portion 507. Now, just as the upward movement of the sieve plate 502 has finished, the upper surface of the liquid 505 has reached a higher level in the stratification chamber 501, while reaching a lower level in the outer fluid pipe 508.

[0145] 5c, the plate sieve 502 is moved downward by the drive system 503 to a first downward position at a relatively high speed, preferably such that at least a portion of the granular material 504 floats in the liquid 505 and then settles to the top of the plate sieve 502. During this downward movement, liquid 505 is supplied from the lower chamber portion 507 to the outer fluid pipe 508 to stabilize the pressure change within the lower chamber portion 507. Now, just as the downward movement of the sieve plate 502 has finished, the upper surface of the liquid 505 has reached a lower level in the stratification chamber 501, while reaching a higher level in the outer fluid pipe 508.

[0146] After a series or several upward and downward movements of the plate sieve 502 with a rest or settling period following each or at least some of the downward movements, the granular material 504 begins to settle to the top of the plate sieve 502 in a stratified or sorted state, as shown in Figure 5d. The granular material 504 having the highest density settles to the lowest position, the granular material 504 having a medium density settles to the middle position, and the granular material 504 having the lowest density settles to the upper position. In Figure 5d, the stratifier 500 is in a rest position, and the upper surface of the liquid 505 reaches the same level in both the stratification chamber 501 and the fluid pipe 508.

[0147] As described above, when processing a combination of liquid 305, 405, 505 and particulate material 304, 404, 504 to stratify the particulate material into a layer, there is a rest or settling period between the end of the downward movement and the start of a new upward movement of the particulate material 304, 404, 504 in the liquid 305, 405, 505. This rest period may have a minimum length determined according to the ratio of the density of the liquid 305, 405, 505 in the stratification chamber 301, 401, 501 to the density of the particulate material 304, 404, 504 having the highest density. The rest period before i is preferably at least 0.5 seconds.

[0148] During the treatment or layering process, the movement of the movable plate 302, 402, 502 can be controlled to be between a lower or rest position and a predetermined first maximum upper position, which is determined based on the amount of liquid 305, 405, 505 and particulate material 304, 404, 504 in the layering machine 300, 400, 500, thereby ensuring that all of the particulate material 304, 404, 504 is covered by the liquid 305, 405, 505 when the movable plate 302, 402, 502 reaches the first maximum upper position. The distance between the lower position and the first maximum upper position can be determined according to the ratio of the volume of the particulate material 304, 404, 504 to the total volume of the liquid 305, 405, 505 in the layering machine 300, 400, 500.

[0149] It has been found that the acceleration and speed of the upward and downward movements can affect the efficiency of the processing or layering results. Here, the acceleration of the upward and / or downward movements can be determined according to the ratio of the volume of the powder and granular material 304, 404, 504 to the total volume of the liquid 305, 405, 505 in the layering machine 300, 400, 500. Also, the speed of the upward and / or downward movements can be determined according to the ratio of the volume of the powder and granular material 304, 404, 504 to the total volume of the liquid 305, 405, 505 in the layering machine 300, 400, 500.

[0150] Once the granular materials 304, 404, 504 to be sorted have been stratified into a corresponding number of distinct layers according to one of the processes described in connection with Figures 3 to 5, the sorted granular materials 304, 404, 504 need to be discharged from the stratification chamber 301, 401, 501. The discharged material is then subjected to a drying process (see 203 in Figure 2), followed by a classification process (204 in Figure 2) to ensure the sorted granular materials are separated, and finally the separated granular materials can be packed (205 in Figure 2).

[0151] 6a-6e are schematic diagrams illustrating the steps of discharging and identifying three different density granular materials 604a, b, c processed by using a layering or sorting machine 600 system according to an exemplary embodiment.

[0152] 6a-6c show a layering machine 600 including a layering chamber 601 for holding a combination of liquid 605 and particulate material 604a, b, c, the layering chamber 601 having sidewalls and a bottom 606. A movable plate 602 is disposed within the layering chamber 601, the movable plate 602 having an outer edge disposed proximate to one or more sidewalls of the layering chamber 601, with any distance between the outer edge and the one or more sidewalls being smaller than the minimum particle size of the particulate material to be processed. The movable plate 602 is a plate sieve having sieve openings smaller than the minimum particle size of the particulate material to be processed, thereby maintaining the particulate material above or on top of the movable plate. A drive system 603 is provided for moving the movable plate 602 in a vertical upward and downward motion within the layering chamber 601, thereby moving or processing the particulate material 604a, b, c in the liquid 605. The drive system 603 is movably inserted into the layering chamber 601 via a fluid-tight connection at the bottom of the layering chamber 601 .

[0153] The sieve plate 602 and drive system 603 function as part of the discharge system shown in Figure 6a, where the granular materials 604a, b, c have been stratified into three distinct layers 604a, 604b, and 604c. The granular material 604c having the highest density settles to the bottom layer, the granular material 604b having a medium density settles to the middle layer, and the granular material 604a having the lowest density settles to the top layer.

[0154] The first step in the discharge process is to raise the sieve plate 602 by using the drive system 603 to the position shown in Figure 6a, where the sieve plate 602 carrying the particles 604a,b,c is completely above the surface of the liquid 605. The sieve plate 602 may be held in this position for a while to allow the liquid to drip off the particles 604a,b,c.

[0155] The next step in the discharge process is shown in Figure 6b, in which the sieve plate 602 is raised, as indicated by arrow 609, to a level where the upper layer of the granular material 604a is discharged above the side wall of the stratification chamber 601. The granular material 604a, b, c is now discharged layer by layer and the sieve plate 602 is raised accordingly (see Figure 6c). The discharged granular material 604a, b, c can be moved onto a conveyor belt 610 where it can be scanned by a suitable density identification system 611. The density identification system 611 may comprise a mid-infrared (MIR) type device.

[0156] Although not shown here, the discharged granular materials 604a,b,c may be dried after discharge. To this end, the discharged granular materials 604a,b,c may be passed under a drying device as they are moved forward on the conveyor belt 610.

[0157] Figure 6d shows a top view of the first two discharged layers of granular materials 604a and 604b being moved forward on the conveyor belt 610. There is no abrupt transition from the lowest density first granular material 604a to the higher density next granular material 604b, as there is a transition zone where there is a mixture of granular materials of both densities 604ab. Thus, the density identification system 611 can identify or determine which portion of the discharged granular materials 604a,b,c represents only the first granular material 604a, which can then be removed from the conveyor belt 610 and filled or packed into a first container 612 (see Figure 6e). The density identification system 611 can also identify or determine which portion of the discharged granular material represents a mixture of the first granular material and the second granular material 604a and 604b, and this mixture portion 604ab can then be removed from the conveyor belt 610 and sent back to the stratification chamber 601 for re-sorting or re-stratification. Then, after identifying and removing the mixture portion 604ab, the density identification system 611 can identify or determine which portion of the discharged granular material 604a,b,c represents only the second granular material 604b, and this portion can then be removed from the conveyor belt 610 and filled or stuffed into the second container 613.

[0158] This process is repeated for the subsequent transition zone (not shown in Figure 6e) where there is a mixture portion 604bc of medium and highest density granular materials, which is also removed from the conveyor belt 610 and returned to the stratification chamber 601 for re-sorting or re-stratification. Finally, the density identification system 611 can then identify or determine which portion of the discharged granular materials 604a,b,c represents only the third granular material 604c of highest density, which can then be removed from the conveyor belt 610 and filled or stuffed into a third container.

[0159] Once the three different density stratified granular materials 604a, b, c are completely discharged from the stratification chamber 601, a new batch of mixed granular materials 604a, b, c together with the mixture portions 604ab and 604bc can be loaded into the stratification chamber 601 and processed for stratification or sorting, discharging, identifying and packing.

[0160] FIG. 7 is a schematic block diagram illustrating steps for processing granular materials according to an exemplary embodiment. In a first step 701, a system is provided that includes a layering machine having a layering chamber. Two or more types of granular materials having different densities and a liquid to be combined with the granular materials are then provided, where at least two of the different types of granular materials have a density greater than that of the liquid, and the provided granular materials and liquid are filled into the layering chamber (step 702). The layering machine that includes the layering chamber may be selected from one of the machines 300, 400, and 500 described herein (see FIGS. 3, 4, and 5), with the layering machine 400 of FIG. 4 that includes the layering chamber 401 being preferred.

[0161] In step 703, a series of upward and downward stratification movements are performed on the granular material in the liquid. A pause is provided between the end of the downward movement and the start of a new upward movement of the granular material in the liquid, during which the granular material can settle into the liquid. When using the stratifier 400, the upward and downward movements are performed by the plate sieve 402 and the drive system 403. After a series of upward and downward movements of the plate sieve 402 with pauses or settling periods, the granular material begins to settle to the top of the plate sieve 402 in a stratified or screened state. The granular material with the highest density settles to the lowest position, and the granular material with the lowest density settles to the upper position.

[0162] The stratified layers of granular material resulting from step 703 are then discharged layer by layer from the stratification chamber (step 704). As they are discharged from the stratification chamber, the granular material may optionally be subjected to a drying process to remove excess liquid (step 705). The different discharged layers of granular material are then identified (step 706), followed by packaging of the granular material according to density differences (step 707). Discharge, identification and packaging may be performed as described herein in connection with Figures 6a-6e.

[0163] In a first example, the waste polymer material contains only two types of polymers with different densities, and the polymer material is a combination of PC-ABS (polycarbonate-acrylonitrile butadiene styrene) and POM (polymethylene). The density of PC-ABS is 1.26 g / cm 3 and the density of POM is 1.41 g / cm 3 A stratifier 500 of the type illustrated in Figures 5a-5d is used, for which the stratification chamber 501 has a capacity of 200 L or 0.2 m 3 In a first example, 11.25 L each of PC-ABS and POM are fed into the stratification or sorting chamber 501, followed by 150 L of water.

[0164] The stratification process involves moving the movable plate 502 according to a predetermined sorting action within the stratification or sorting chamber 501. The predetermined sorting action involves a series of vertical upstrokes and downstrokes through the liquid 505 within the sorting chamber 501. The vertical upstrokes push the granular material 504 to be sorted upward, causing the grains of material 504 to move relative to the liquid 505. This relative movement assists the natural tendency of the grains of the granular material 504 to move and settle within the liquid 505 according to their respective densities (specific gravities) relative to the liquid 505 and other grains of the granular material 504 to be sorted within the liquid 505. The induced relative movement in the grains of the granular material 504 to be sorted creates movement in an area where the grains in the liquid 505 might normally be substantially static, thereby assisting this natural tendency of the grains to settle according to their specific gravities. Likewise, the downstroke induces movement of the particles of the granular material 504 to be separated in the liquid 505, which further influences the settling of the particles and therefore the efficiency of the stratification process as a whole.

[0165] Experiments have shown that the amplitude of the upstrokes and downstrokes affects the efficiency of the stratification process. The experimental results also indicate that the optimal amplitude of the upstrokes and downstrokes depends, at least in part, on the volume of the granular material 504 to be separated and the volume of the liquid 505 in the stratification or separation chamber 501. More importantly, the optimal amplitude of the upstrokes and downstrokes appears to depend on the ratio of the volume of the granular material 504 to the volume of the liquid 505 in the first separation chamber 501. An explanation for this may be that the larger the ratio of the volume of the granular material 504 to the volume of the liquid 505, the more densely packed the particles of the granular material 504 to be separated become, making it more difficult for individual particles to move and settle because their movement is restricted (prevented from settling) by surrounding particles. In such cases, a larger amplitude of the upstrokes and / or downstrokes may be beneficial to the stratification process, as it results in more movement among the particles, allowing them to move and settle relative to each other according to their density. However, when the volume of the granular material 504 to be separated is small compared to the volume of the liquid 505, a smaller amplitude of the upstrokes and / or downstrokes may be optimal for the stratification process because the granules are not so densely packed and can move more easily than other granules and settle according to their density, thus requiring less stimulation to move and settle in the liquid 505. In this case, a large amplitude of the upstrokes and / or downstrokes may move the granules against their natural settling direction and remix already settled granules of different densities, adversely affecting the stratification process. Therefore, being able to adjust the amplitude of the upstrokes and / or downstrokes according to the ratio of the volume of the granular material 504 to the volume of the liquid 505 in the stratification or separation chamber 501 may be very advantageous for achieving optimal efficiency of the stratification process. In the first example described herein, the amplitude of the upstrokes and downstrokes is 60 mm.

[0166] It should be noted that while the amplitudes of the upstrokes and downstrokes in the examples described herein are equal, this is not required and the amplitude of the upstrokes may be different from the amplitude of the downstrokes. Furthermore, since the amplitude of the upstrokes and / or downstrokes may be selected for optimal layering efficiency, depending, for example, on the degree to which the granular material 504 to be sorted is layered, subsequent upstrokes and / or downstrokes may have different amplitudes than the preceding upstrokes and / or downstrokes to further improve the efficiency of the layering process.

[0167] Experiments have also shown that the speed and acceleration of the downstroke are particularly important, as they can have a significant effect on the settling of particles of the particulate material 504 to be screened. This is most likely a result of the effect the speed and acceleration of the downstroke have on the wake that results and follows the movable plate 502, as well as on vortices that may form around the movable plate 502 as it moves downward through the liquid 505. Both the wake and vortices can cause particles to swirl and thus adversely affect the natural settling of the particles. Therefore, being able to adjust the acceleration and speed of the downstroke of the movable plate 502 is important for being able to optimize the stratification process for optimal efficiency. Similarly, the speed and acceleration of the upstroke can be adjusted. In the first example described herein, the upstroke and downstroke speeds are 60 mm / s, and the upstroke acceleration is 800 mm / s. 2 and the acceleration of the downstroke is 650mm / s 2 is.

[0168] Additionally, the time between completing the downstroke and starting the upstroke (pause) has been shown to have a significant impact on the efficiency of the stratification process. This is believed to be because the pause allows time for the grains, particularly those in the upper half of the stratification or screening chamber 501, to move downward and settle according to their specific gravity, thereby improving the efficiency of the stratification process. Therefore, it plays an important role in the stratification of the powder material 504 to be screened. Similarly, it may be advantageous to be able to adjust the pause between completing the upstroke and starting the downstroke. In the first example described herein, there is a one-second pause between completing the downstroke and starting the upstroke, and a one-second pause between completing the upstroke and starting the downstroke.

[0169] All of the above parameters may be adjusted and / or set as part of a given sorting operation. However, these parameters may not be fixed during the stratification process, but may be set to vary as the stratification process progresses, for example, according to the elapsed time or elapsed cycle of the stratification process. In this way, the stratification process may be further optimized according to the state of the stratification.

[0170] The duration of the layering process can be set and adjusted according to the elapsed time or elapsed cycle of a given sorting operation. In the first example described herein, the duration of the layering process is 600 seconds.

[0171] Once the stratification process is complete, the granular material to be sorted 504 will have been separated into two layers of granular material to be sorted 504 corresponding to two different types of material with different densities, in this case PC-ABS and POM, respectively. The two layers of sorted granular material 504 are then discharged from the stratification or sorting chamber 501 according to the process described in relation to Figures 6a-6e.

[0172] In a second example, the waste polymer material includes two polymer materials having different densities, where the polymers have a density of 1.21 g / cm 3 and 30% thermoplastic polyurethane (TPU) with a density of 1.12 g / cm 3 The polymer is combined with 70% polystyrene (PS) with a density of 1000 MPa. The polymer is granulated to sizes ranging from 2 mm to 30 mm, with shapes ranging from thin flakes to spheres. The total amount of polymer material processed is 150 kg. A stratifier 400 of the type illustrated in Figures 4a-4d was used, for which the stratification chamber 401 had an inner diameter of 1000 mm and a height of 750 mm, measured from the bottom 406. The movable plate 402 had a diameter of 999 mm, holding sieve openings of 1.5 mm diameter. 150 kg of polymer material was loaded into the stratification chamber, and 650 L of water was loaded into the stratification chamber 401 and outer chamber 408.

[0173] The second example includes two different treatment processes, which were implemented with different rest or pause periods between the end of the downward movement of the movable plate 402 and the start of the upward movement of the movable plate 402, and with different amplitudes of movement of the movable plate 402.

[0174] The first processing process of the second example is divided into two parts, and the movement data of the movable plate 402 in the first part is as follows: Total processing time or process time for Part 1: 500 seconds Movement amplitude: 110mm Upstroke or upward movement speed: 20mm / s Downstroke or downward movement speed: 20mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 8 seconds

[0175] For the second part of the first treatment process of the second example, the movement data of the movable plate 402 is as follows: Total processing time or process time for part 2: 700 seconds Movement amplitude: 60mm Upstroke or upward movement speed: 20mm / s Downstroke or downward movement speed: 20mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 6 seconds

[0176] Therefore, the total processing time for the first treatment process was (500 + 700) seconds, which is equal to 1200 seconds. Here, the amplitude of the movement varied from 110 mm to 60 mm from part 1 to part 2, and the pause period varied from 8 seconds to 6 seconds from part 1 to part 2.

[0177] After the first and second parts of the first sorting or treatment process of the second example were completed, the amount of polystyrene (PS) having a lower density and the amount of thermoplastic polyurethane (TPU) having a higher density were calculated for the top layer of material and the bottom layer of material in the stratification or sorting chamber. The results of the first treatment process showed more than 98.5% polystyrene (PS) in the top layer and more than 98.5% thermoplastic polyurethane (TPU) in the bottom layer. These results are considered successful.

[0178] For the second treatment process of the second example, the movement data of the movable plate 402 is as follows: Total processing time: 1200 seconds Movement amplitude: 60mm Upstroke or upward movement speed: 20mm / s Downstroke or downward movement speed: 20mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 2 seconds

[0179] The results for the second treatment process in the second example showed a top layer of 80% polystyrene (PS) and a bottom layer of 82% thermoplastic polyurethane (TPU). This result was considered insufficient, indicating that the 2 second pause period was too short to allow the heavier particles to completely settle to the bottom of the stratification or sorting chamber.

[0180] In a third example, the waste polymeric material includes three polymeric materials having different densities, where the polymeric materials have a density of 1.41 g / cm 3 50% polyoxymethylene (POM) with a density of 1.08 g / cm 3 and 25% acrylonitrile butadiene styrene (ABS) with a density of 1.13 g / cm 3 The polymer is a combination of 25% polycarbonate / acrylonitrile butadiene styrene (PC / ABS) with a density of 1000 MPa. The polymer is granulated to sizes ranging from 2 mm to 30 mm with shapes ranging from thin flakes to tubes. The total amount of polymer material processed is 150 kg. The layering machine 400 used in the second example is also used in the third example.

[0181] The third example also includes two different processing processes, with different rest or pause periods between the end of the downward movement of the movable plate 402 and the start of the upward movement of the movable plate 402, different amplitudes of the movement of the movable plate 402, and different speeds of the downward movement of the movable plate 402.

[0182] The first processing process of the third example is also divided into two parts, and the movement data of the movable plate 402 in the first part is as follows: Total processing time or process time for Part 1: 500 seconds Movement amplitude: 120mm Upstroke or upward movement speed: 20mm / s Downstroke or downward movement speed: 40mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 6 seconds

[0183] For the second part of the first treatment process of the third example, the movement data of the movable plate 402 is as follows: Total processing time or process time for part 2: 700 seconds Movement amplitude: 70mm Upstroke or upward movement speed: 20mm / s Downstroke or downward movement speed: 40mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 5 seconds

[0184] Therefore, the total processing time for the first treatment process was (500 + 700) seconds, which is equal to 1200 seconds. Here, the amplitude of the movement changed from 120 mm to 70 mm from the first to the second part, and the pause period changed from 6 seconds to 5 seconds from the first to the second part.

[0185] After the first and second parts of the first sorting or treatment process of the third example were completed, the amounts of lower density acrylonitrile butadiene styrene (ABS), medium density polycarbonate / acrylonitrile butadiene styrene (PC / ABS), and higher density polyoxymethylene (POM) were calculated for the top layer of material, the middle layer of material, and the bottom layer of material in the stratification or sorting chamber. The results of the first treatment process showed more than 98.5% acrylonitrile butadiene styrene (ABS) in the top layer, more than 95.5% polycarbonate / acrylonitrile butadiene styrene (PC / ABS) in the middle layer, and more than 98.5% polyoxymethylene (POM) in the bottom layer. These results are considered successful.

[0186] It has been found that by dividing the entire treatment process into two parts with different amplitudes of movement of the movable plate 402, improved results can be obtained in terms of the final sorted product.

[0187] For the second treatment process of the third example, the movement data of the movable plate 402 is as follows: Total processing time: 1200 seconds Movement amplitude: 80mm Upstroke or upward movement speed: 20mm / s Downstroke or downward movement speed: 20mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 6 seconds

[0188] The results for the second process in Example 3 showed a top layer of 77% acrylonitrile butadiene styrene (ABS), a middle layer of 70% polycarbonate / acrylonitrile butadiene styrene (PC / ABS), and a bottom layer of 82% polyoxymethylene (POM). This result was considered insufficient, showing a dwell period of 6 seconds, which is longer than the 5 seconds used for the second process in Example 3, but this is not enough to compensate for the reduction in downstroke speed, from 40 mm / s to 20 mm / s. The heaviest material in Example 3, POM, has a density of 1.41 g / cm. 3 whereas the density of the heaviest material in the second example, TPU, is 1.21 g / cm 3 It can be seen that, which may indicate that for heavier materials, the downstroke velocity should be faster compared to lighter materials.

[0189] In a fourth example, the waste polymer material includes three polymer materials having different densities, where the polymers have a density of 0.93 g / cm3, which is lower than the density of water used as a liquid in the process. 3 and 20% polyethylene (PE) with a density of 1.38 g / cm 3 and 70% polyethylene terephthalate (PET) with a density of 1.52 g / cm 3 The PE and PET polymers are granulated to sizes ranging from 2 mm to 30 mm, with shapes ranging from thin flakes to tubes. The rubber pieces have a solid cylindrical shape with a diameter of 5 mm and lengths ranging from 1 mm to 20 mm. The total amount of polymer material processed is 150 kg. The stratifier 400 used in the second and third examples is also used in the fourth example. 150 kg of polymer material was charged into the stratification chamber, and 650 L of water was charged into the stratification chamber 401 and outer chamber 408.

[0190] The fourth example involves one treatment process divided into two parts. Because polyethylene (PE) has a lower density than water, PE floats to the top in water, while polyethylene terephthalate (PET) and rubber fall into the water. Therefore, in the first part of the sorting or treatment process, the mixture of PE, PET, and rubber needs to be shaken slightly in the water to ensure that all the PE floats to the top layer and the rubber falls to the bottom. Therefore, a larger amplitude and a longer pause period are required in the first part of the process. The movement data of the movable plate 402 in the first part are as follows: Total processing time or process time for part 1: 1000 seconds Movement amplitude: 120mm Upstroke or upward movement speed: 30mm / s Downstroke or downward movement speed: 40mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 5 seconds

[0191] For the second part of the fourth example process, the movement data of the movable plate 402 is as follows: Total processing time or process time for part 2: 1000 seconds Movement amplitude: 55mm Upstroke or upward movement speed: 30mm / s Downstroke or downward movement speed: 40mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 1 second

[0192] Therefore, the total processing time of the treatment process was (1000 + 1000) seconds, which is equal to 2000 seconds. Here, the amplitude of the movement varied from 120 mm to 55 mm from part 1 to part 2, and the pause period varied from 5 seconds to 1 second from part 1 to part 2.

[0193] After the first and second parts of the sorting or treatment process of the fourth example were completed, the amount of polyethylene (PE) having a lower density, the amount of polyethylene terephthalate (PET) having a medium density, and the amount of rubber having a higher density were calculated for the top layer of material, the middle layer of material, and the bottom layer of material in the stratification or sorting chamber. The final results of the treatment process showed more than 99% polyethylene (PE) in the top layer, more than 98.5% polyethylene terephthalate (PET) in the middle layer, and more than 90% rubber in the bottom layer. These results are considered successful.

[0194] In a fifth example, the waste polymeric material includes three polymeric materials having different densities, where the polymeric materials have a density of 1.04 g / cm 3 and 35% acrylonitrile butadiene styrene (ABS) with a density of 1.2 / cm 3 35% polycarbonate (PC) with a density of 1.4 g / cm 3 The polymer is combined with 30% polyoxymethylene (POM) with a density of 1000 MPa. The polymer is granulated to sizes ranging from 2 mm to 30 mm, with shapes ranging from thin flakes to tubes. The total amount of polymer material processed is 150 kg. The stratifier 400 used in Examples 2, 3, and 4 is also used in Example 5. 150 kg of polymer material was loaded into the stratification chamber, and 650 L of water was loaded into the stratification chamber 401 and outer chamber 408.

[0195] A fifth example includes a treatment process divided into three parts, each of which holds three series of upward and downward movements of granular polymer in a liquid, with different rest or pause periods between the end of the downward movement of the movable plate 402 and the start of the upward movement of the movable plate 402, different amplitudes of the movement of the movable plate 402, and different speeds of the downward movement of the movable plate 402.

[0196] For the fifth example, the movement data of the movable plate 402 for the first part or first series of movements is as follows: Total processing time or process time for Part 1: 600 seconds Movement amplitude: 110mm Upstroke or upward movement speed: 20mm / s Downstroke or downward movement speed: 20mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 8 seconds

[0197] For the second part or second series of movements of the fifth example treatment process, the movement data of the movable plate 402 is as follows: Total processing time or process time for part 2: 600 seconds Movement amplitude: 90mm Upstroke or upward movement speed: 20mm / s Downstroke or downward movement speed: 30mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 6 seconds

[0198] For the third part or third series of movements of the fifth example treatment process, the movement data of the movable plate 402 is as follows: Total processing time or process time for part 2: 1000 seconds Movement amplitude: 60mm Upstroke or upward movement speed: 40mm / s Downstroke or downward movement speed: 40mm / s Upstroke or upward movement acceleration: 1500mm / s 2 Downstroke or downward movement acceleration: 1500mm / s 2 Pause period between downward and upward movements: 3 seconds

[0199] Therefore, the total process time for the fifth example treatment process was (600 + 600 + 1000) seconds, which was equal to 2200 seconds. Here, the amplitude of the movement varied and decreased from 110 mm to 90 mm and 60 mm, respectively, from Part 1 to Part 2 and Part 3, and the pause period varied and decreased from 8 seconds to 6 seconds and 3 seconds, respectively, from Part 1 to Part 2 and Part 3. Also, the speed of the downward movement of the movable plate 402 varied by increasing from 20 mm / s to 30 mm / s and 40 mm / s, respectively, from Part 1 to Part 2 and Part 3.

[0200] After the first, second, and third parts of the sorting or treatment process of the fifth example were completed, the amount of acrylonitrile butadiene styrene (ABS) having a lower density, the amount of polycarbonate (PC) having a medium density, and the amount of polyoxymethylene (POM) having a higher density were calculated for the top layer of material, the middle layer of material, and the bottom layer of material in the stratification or sorting chamber. The results of the treatment process showed more than 99.5% acrylonitrile butadiene styrene (ABS) in the top layer, more than 99.5% polycarbonate (PC) in the middle layer, and more than 99.5% polyoxymethylene (POM) in the bottom layer. These results are considered successful.

[0201] 8 is a schematic diagram of a layering machine or apparatus or a sorting machine or apparatus according to an exemplary embodiment. The layering machine of FIG. 8 is rectangular in shape defined by side walls 801 and has a width of 0.2 m 3 The stratification or separation chamber 800 holds a stratification or separation chamber 800 having a volume of 1000. A movable plate 802 is disposed inside the stratification or separation chamber 800, and any distance between the outer edge of the plate 802 and the sidewall 801 is smaller than the minimum particle size of the powder or granular material to be processed. A drive shaft 805 is connected to the movable plate 802 through an opening in the base 812 of the stratification or separation chamber 800 and sealed by a chamber seal 900 (see FIG. 9 ). The chamber seal 900 is disposed in the opening in the base 812 and seals against both the stratification or separation chamber 800 and the shaft 805, preventing liquid from escaping from the stratification or separation chamber 800. The shaft 805 is connected to a linear drive unit 807 via a shaft connector 811, which allows the movable plate 802 to move and allows control and adjustment of its operation. Although not shown here, a control unit with a display may be provided to improve control and ease of operation of the stratification or separation machine.

[0202] The bottom of the stratifier apparatus includes four adjustable legs 808 that allow the machine to be adjusted to ensure it is level. The side of the machine includes a loading platform 810 with steps 809 that allow the user to inspect and / or fill the stratification or sorting chamber 800.

[0203] Once the stratification or sorting chamber 800 is filled with the powder and liquid to be sorted and the stratification process is initiated, the linear drive unit 807 drives the shaft 805, which then drives the movable plate 802, according to a predetermined sorting operation. The movable plate 802 is a plate sieve that includes openings smaller than the minimum particle size of the powder and liquid to be sorted, thus allowing only the liquid to pass through. As a result, during the upstroke, the movable plate 802 moves the powder and liquid to be sorted upward, moving the grains of the material to be sorted relative to the liquid and other grains of the material to be sorted. During the downstroke, the movable plate 802 creates a downward movement in the grains of the powder and liquid to be sorted, thereby moving the grains relative to the liquid and other grains of the material to be sorted. This movement and relative motion of the grains of the material to be sorted allows the grains to settle according to their respective densities, thus resulting in stratification and sorting of the grains according to density.

[0204] FIG. 9 is a longitudinal cross-sectional view of a chamber seal 900 for use in the stratification or sorting system machine or apparatus of FIG. 8 according to a first exemplary embodiment. The chamber seal 900 in this embodiment is made of two parts in the form of an upper housing body 900a and a lower housing body 900b. The upper housing body 900a includes a wiper seal 901 that seals against the shaft 805 when installed, preventing contaminants from the stratification or sorting chamber 800 from entering the chamber seal 900 between the shaft 805 and the chamber seal 900. The upper housing body 900a includes a pair of O-rings 903 disposed in corresponding grooves to seal against the base 812 of the stratification or sorting chamber 800 and prevent leakage of liquids and the like between the chamber seal 900 and the stratification or sorting chamber 800. A series of threaded holes 906 that align with through holes 907 in the lower housing body 900b are provided to secure the upper housing body 900a. The lower housing body 900b includes an O-ring 903 at its top for sealing against the bottom of the base 812 of the stratification or sorting chamber 800. A wiper seal 901 is positioned below this to seal against the shaft 805 and further prevent contaminants from entering the lower housing body 900b. Below this is a rod seal 902, which seals between the shaft 805 and the lower housing body 900b. A guide ring 904 is positioned below the rod seal 902 and above a linear ball bearing (not shown) to help guide the shaft 805. The linear ball bearing also helps guide the shaft 805, improving the efficiency of shaft operation. A retaining element 905 in the form of a retaining ring is positioned at the bottom of the lower housing body 905, i.e., below the linear ball bearing (not shown), to secure the assembly within the lower housing body 900b.

[0205] In this embodiment, the chamber seal 900 is secured to the stratification or sorting chamber 800 by aligning the upper housing body 900a with the top of the opening in the base 812, then aligning the lower housing body 900b with the bottom of the opening in the base 812, thereby aligning the threaded holes 906 and through holes 907 in the upper and lower housing bodies 900a and 900b, respectively, and then passing bolts through each through hole 907 and securing them to the corresponding threaded holes 906.

[0206] Figure 10 is a longitudinal cross-sectional view of a chamber seal 1000 for use in the stratification or sortation machine or apparatus of Figure 8 according to a second exemplary embodiment. The chamber seal 1000 comprises only one housing body 1000a, which comprises an O-ring 1003 for sealing against the top of the base 812 of the stratification or sortation chamber 800. Like the chamber seal 900, the chamber seal 1000 comprises a wiper seal 1001, a rod seal 1002, a guide ring 1004, a linear ball bearing (not shown), and a retaining element 1005 in the form of a retaining ring at the bottom of the housing body 1000a, all of which perform the same functions as previously described for the chamber seal 900.

[0207] In this embodiment, the chamber seal 1000 is secured to the stratification or sorting chamber 800 by sliding the housing body 1000a from the top through the opening in the base 812 so that the flange 1010 abuts the top of the base 812 and the threaded holes 1006 align with corresponding holes extending through the base 812, and then fastening bolts through the corresponding holes in the base 812 and into the threaded holes 1006.

[0208] The invention has been described in conjunction with various embodiments herein. However, other variations of the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.

Claims

1. 1. A system for processing a combination of a liquid and particulate material, wherein the particulate material includes two or more types of particulate material that are equal to or larger than a minimum particle size and have different densities, at least two of the two or more types of particulate material having a density greater than the density of the liquid, the system comprising: a stratification or separation chamber for holding said combination of liquid and particulate material, said stratification or separation chamber having one or more side walls; a movable plate disposed within the stratifying or separating chamber, the movable plate having an outer edge disposed close to the one or more side walls of the stratifying or separating chamber, any distance between the outer edge and the one or more side walls being smaller than the minimum particle size of the powder or granular material to be processed, and the movable plate being a plate sieve having sieve openings smaller than the minimum particle size of the powder or granular material to be processed, thereby maintaining the powder or granular material above or on the movable plate; and a drive system for moving the movable plate in a vertical upward and downward motion within the layering or screening chamber, thereby moving or manipulating the granular material in the liquid.

2. the movable plate is disposed above a bottom below the sidewall of the layering or sorting chamber at a distance, thereby defining a lower chamber portion between an upper surface of the bottom and a lower surface of the movable plate, the lower chamber portion changing in volume with upward or downward movement of the movable plate within the layering or sorting chamber; 10. The system of claim 1, wherein the stratifier further comprises a fluid compensation system fluidly connected to the lower chamber portion and configured to deliver liquid to and receive liquid from the lower chamber portion, whereby liquid can be supplied to the lower chamber portion when the volume of the lower chamber portion increases and liquid can be received from the lower chamber portion when the volume of the lower chamber portion decreases.

3. A system for processing a combination of a liquid and powder or granular material, wherein the powder or granular material includes two or more types of powder or granular material that are equal to or larger than a minimum particle size and have different densities, at least two of the two or more types of powder or granular material having a density greater than the density of the liquid, and the system includes: a stratification or separation chamber for holding said combination of liquid and particulate material, said stratification or separation chamber having one or more side walls; a movable plate disposed within the stratifying or separating chamber, the movable plate having an outer edge disposed close to the one or more side walls of the stratifying or separating chamber, any distance between the outer edge and the one or more side walls being smaller than the minimum particle size of the powder or granular material to be processed, the movable plate being a plate sieve having sieve openings smaller than the minimum particle size of the powder or granular material to be processed, thereby maintaining the powder or granular material above or on the movable plate, the movable plate being disposed at a distance above a bottom below the side walls of the stratifying or separating chamber, thereby defining a lower chamber portion between an upper surface of the bottom and a lower surface of the movable plate; a drive system for moving the movable plate in a vertical upward and downward motion within the layering or sorting chamber, thereby varying the volume of the lower chamber portion; a fluid compensation system fluidly connected to the lower chamber portion and configured to deliver and receive liquid to and from the lower chamber portion, whereby liquid can be supplied to the lower chamber portion when the volume of the lower chamber portion increases, and liquid can be received from the lower chamber portion when the volume of the lower chamber portion decreases; The system includes a stratifier.

4. The system of any one of claims 1 to 3, wherein the upper portion or top of the stratification or sorting chamber is configured to allow free entry of air.

5. 5. The system of claim 1, wherein the drive system is configured to move the movable plate through a stratification or sorting operation comprising a series of vertical upstrokes and vertical downstrokes through the liquid in the stratification or sorting chamber.

6. 6. The system of claim 1, wherein the drive system is configured to pause the movement of the movable plate between completing its downward movement or downstroke and initiating its upward movement or upstroke.

7. 7. The system of claim 6, wherein the drive system is configured to maintain a pause of at least 0.5 seconds between completing a downward movement or downstroke of the movable plate and initiating an upward movement or upstroke.

8. 8. The system of claim 6 or 7, wherein the drive system is configurable to adjust the length of the pause between completing a downward movement or downstroke of the movable plate and commencing an upward movement or upstroke.

9. the drive system may be configured to adjust the acceleration of the upward movement of the movable plate; and / or The system of any one of claims 1 to 8, wherein the drive system is configurable to adjust the speed of the upward movement of the movable plate.

10. the drive system may be configured to adjust the acceleration of the downward movement of the movable plate; and / or The system of any one of claims 1 to 9, wherein the drive system is configurable to adjust the speed of the downward movement of the movable plate.

11. 11. The system of claim 1, wherein the drive system is configurable to adjust the amplitude of the movement of the movable plate according to a ratio of a volume of the granular material to be separated to a volume of the liquid in the stratification or separation chamber.

12. The system of any one of claims 1 to 11, wherein the drive system is configured to control the amplitude of the movement of the movable plate between a lower or rest position and a first maximum upper position.

13. 13. The system of claim 12, wherein the first maximum upper position is determined based on the amount of liquid and particulate material in the stratification chamber, thereby ensuring that all of the particulate material is covered by the liquid when the movable plate reaches the first maximum upper position.

14. The system of any one of claims 1 to 13, wherein the drive system is reconfigurable to control the amplitude of the movement of the movable plate.

15. The system according to any one of claims 1 to 14, wherein the at least two types of granular materials having a density greater than the density of the liquid have particle sizes within a defined range of ratio between a minimum particle size and a maximum particle size.

16. 16. The system of claim 15, wherein the defined range of ratios is between the minimum particle size and the maximum particle size in a ratio of 1:1 to 1:

100.

17. 17. The system of any one of claims 1 to 16, wherein the drive system is configurable to lift the movable plate upwardly to a discharge height, at which height at least some or all of the particulate material is lifted above the surface of the liquid in the stratification chamber.

18. The system of any one of claims 1 to 17, further comprising a discharge system for discharging the particulate material from the liquid in the stratification chamber.

19. 19. The system of claims 17 and 18, wherein the discharge system is configured to discharge a top layer of the granular material lifted above the surface of the liquid in the stratification chamber.

20. 20. The system of claim 19, wherein the discharge system is configured to repeatedly discharge the top layer of the particulate material.

21. The system according to any one of claims 1 to 20, wherein the system further comprises a density discrimination system for discriminating between granular materials of different densities.

22. 22. The system of claim 21, wherein the density discrimination system is configured to discern variations in density between fractions of particulate material exiting the discharge system.

23. The system of any one of claims 1 to 22, wherein the powder comprises a polymer powder.

24. 1. A method for treating a combination of a liquid and particulate material, wherein the particulate material comprises two or more types of particulate material having different densities, the method comprising: Providing a system according to any one of claims 1 to 23; supplying two or more types of powders and granules having different densities and a liquid to be used in the combination, wherein at least two of the two or more types of powders and granules have a density greater than the density of the liquid; combining a supply of granular material and a supply of liquid in the stratification or separation chamber of the system; causing a series of upward and downward movements of the granular material in the liquid, wherein for at least some of the downward movements there is a pause between the end of the downward movement to allow the granular material to settle in the liquid and the initiation of a new upward movement of the granular material in the liquid.

25. 25. The method of claim 24, wherein the dwell period has a minimum length determined according to the ratio of the density of the liquid in the stratification chamber to the density of the granular material having the highest density.

26. 26. The method of claim 24 or 25, wherein the pause period before commencing a new upward movement of the granular material in the liquid is at least 0.5 seconds.

27. the series of upward and downward movements of the particulate matter in the liquid is divided into at least first and second series of upward and downward movements; for at least a portion of the downward movement of both the first and second series of movements, there is a pause between the end of the downward movement for settling of the granular material in the liquid and the start of a new upward movement of the granular material in the liquid; the rest period differs from the first series of movements to the second series of movements; and / or 27. The method of any one of claims 24 to 26, wherein the first series of movements has an amplitude of the upward movement that differs from an amplitude of the upward movement of the second series of movements.

28. 28. The method of claim 27, wherein the first series of movements is performed before the second series of movements, and the rest period of the first series of movements is longer than the rest period of the second series of movements.

29. 29. The method of claim 27 or 28, wherein the first series of movements is performed before the second series of movements, and the amplitude of the upward movement of the first series of movements is greater than the amplitude of the upward movement of the second series of movements.

30. 30. The method of any one of claims 27 to 29, wherein the first series of movements is performed before the second series of movements, and the total time for treating the combination of the liquid and particulate material with the first series of movements is less than or equal to the total time for treating the combination of the liquid and particulate material with the second series of movements.

31. A method described in any one of claims 24 to 30, wherein at least two types of powder or granular material have a minimum particle size or larger.

32. 32. The method of claim 31 , wherein the at least two types of granular materials provided having a density greater than the density of the liquid have particle sizes within a defined range of ratio between the minimum particle size and the maximum particle size.

33. a movable plate is provided and positioned within the stratification or separation chamber, the movable plate having an outer edge positioned in close proximity to the one or more side walls of the stratification or separation chamber, any distance between the outer edge and the one or more side walls being less than the minimum particle size of the particulate material to be processed, the movable plate being configured to maintain the particulate material above or on top of the movable plate; 33. The method of claim 31 or 32, further comprising moving the movable plate in a vertical upward and downward motion within the stratification or separation chamber, thereby effecting the series of upward and downward movements of the particulate matter in the liquid.

34. 34. The method of claim 33, wherein the movable plate is a plate sieve having sieve openings smaller than the minimum particle size of the granular material to be processed, thereby allowing the movable plate to move up and down in the liquid while maintaining the granular material above or on top of the movable plate.

35. the movable plate is disposed above a bottom below the sidewall of the stratification or sorting chamber at a distance, thereby defining a lower chamber portion between an upper surface of the bottom and a lower surface of the movable plate, the lower chamber portion changing in volume with upward or downward movement of the movable plate within the stratification chamber; 35. The method of claim 33 or 34, wherein a fluid compensation system is provided that is fluidly connected to the lower chamber portion and configured to deliver liquid to and receive liquid from the lower chamber portion, whereby liquid can be supplied to the lower chamber portion when the volume of the lower chamber portion increases due to the upward movement of the movable plate, and liquid can be received from the lower chamber portion when the volume of the lower chamber portion decreases due to the downward movement of the movable plate.

36. the movement of the movable plate is controlled to be between a lower or rest position and a predetermined first maximum upper position; 36. The method according to any one of claims 33 to 35, wherein the first maximum upper position is determined based on an amount of liquid and granular material in the stratification chamber, thereby ensuring that the granular material is all covered by the liquid when the movable plate reaches the first maximum upper position.

37. 37. The method of claim 36, wherein the distance between the lower position and the first maximum upper position is determined according to the ratio of the volume of the granular material to the volume of the liquid in the stratification chamber.

38. 33. The method of claim 32, wherein the defined range of ratios is a ratio of 1:1 to 1:100 between the smallest particle size and the largest particle size.

39. 39. The method of any one of claims 24 to 38, wherein the method further comprises a discharge process in which at least some or all of the treated granular material is separated from the liquid.

40. 40. The method of claim 39, wherein the granular material is raised upwardly to a height at which at least some or all of the granular material is raised above the surface of the liquid in the stratification chamber.

41. 34. The method of claim 33, wherein the movable plate is moved upward to a discharge height to separate the particulate material from the liquid, at which height all of the particulate material is raised above the surface of the liquid in the stratification chamber.

42. 41. The method of claim 40, wherein the draining process includes removing from the stratification chamber a top layer of the particulate material that has been lifted above the surface of the liquid.

43. 43. The method of claim 42, wherein the discharge process includes repeatedly removing a top layer of the granular material from the stratification chamber.

44. 44. The method according to any one of claims 39 to 43, wherein the method further comprises a density discrimination process for discriminating between granular materials of different densities.

45. 45. The method of claim 44, wherein the density process comprises identifying variations in density between fractions of particulate material removed from the stratification chamber during the discharge process.

46. The method of any one of claims 24 to 45, wherein the granules comprise polymer granules.

47. 47. The method of any one of claims 24 to 46, wherein a surfactant is added to or is part of the liquid provided for use in the combination.

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