Process and system for manufacturing composite material

Abstract

The invention provides a process for controlling the parameters of a filler material for use in a composite material. The process comprises monitoring a parameter of a filler material, and monitoring a parameter of a mixture of the filler material and a binder. The parameter of the filler material is controlled based on the monitored parameter of the mixture and / or the parameter of the mixture is controlled based on the monitored parameter of the filler material.

Description

PROCESS AND SYSTEM FOR MANUFACTURING COMPOSITE MATERIALTECHNICAL FIELD

[0001] The present invention relates to the field of composite materials and in particular a process and system for using bulk waste materials as fillers in the production of composite materials. The invention is particularly suited for converting inconsistent bulk waste materials, which may contain hazardous, volatile, or contaminated substances and would otherwise be difficult to treat or dispose of, into composite materials that have industrial or structural application.BACKGROUND OF THE INVENTION

[0002] Red mud, also known as bauxite residue, is the primary byproduct of the Bayer bauxite process used in the production of aluminium from bauxite ore. It is primarily composed of various oxide compounds, including iron oxides, which give red mud its distinct red colour, as well as other components, including silica, unleached residual aluminium compounds, titanium oxide, and other mineral impurities.

[0003] Red mud poses environmental challenges due to its highly alkaline nature, making it corrosive, and the presence of toxic heavy metals. Improper disposal can lead to soil and water contamination, threatening ecosystems and human health.

[0004] The alumina industry produces roughly 1.5 tonnes of red mud for every tonne of alumina produced, contributing to an estimated global stockpile of 4 billion tonnes that continues to rapidly expand. The sheer volume of red mud generated annually, exceeding 150 million tonnes, intensifies the difficulty in identifying sufficient storage and disposal methods.

[0005] Regarded as a toxic industrial waste, red mud currently has no scalable methods for its neutralization, repurposing, or utilisation in large-scale applications. Consequently, it is commonly stored as a slurry in retention ponds, often created within former bauxite mines, disused quarries, or constructed using dams and levee.

[0006] Waste materials such as end-of-life-vehicle (ELV) residual materials (floc) derived from scrapping and recycling motor vehicles, present challenges for properdisposal and recycling. Similarly, soft plastics are another source of waste materials that are difficult to dispose of or recycle effectively, and like ELV wastes the co-mingled nature and their inconsistent compositions have prevented scalable effective solutions being developed to process and recycle these materials. Additionally, both ELV and soft plastics wastes can typically be contaminated with organic and / or volatile materials - as in the case with ELV wastes, and contaminations of soft plastic wastes with food materials and scraps. Also, the soft flimsy characteristics of soft plastic wastes can interfere with mechanical recycling machinery. Consequently, the common practice has been to divert these materials to landfill.

[0007] Cured thermosetting plastics or polymers, also called thermosets, are generally considered unrecyclable. Thermosets are made up of a polymeric material that irreversibly cross-link together during a curing process. Because of this cross-linking, cured thermosets are no longer affected by heat and cannot be remelted or remoulded, or broken down easily. Given the lack of scalable solutions to properly recycle these materials, thermoset waste generally ends up in landfills.

[0008] Accordingly, a need exists for a way to convert and stabilise Red Mud, ELV, and other wastes such as soft plastics and floc to environmentally safe materials that contain or encapsulate the hazardous constituents of these waste materials to prevent these constituents contaminating the surrounding environment.

[0009] A need also exists for a way to convert and stabilise other inconsistent bulk waste materials, which may contain hazardous, volatile, or contaminated substances, in a manner that contains or encapsulates the hazardous constituents and prevents them from leeching into the surrounding environment. These materials often pose challenges due to their unpredictable nature and the difficulty in standardising treatment or disposal. Examples of other such inconsistent bulk waste materials include mining waste or tailings which can comprise hazardous compounds inorganic mined materials, minesite overburden and minerals processing wastes, plastic wastes, waste aggregates from road and pavement repair and construction, and demolition materials such as ground concrete wastes.

[0010] A need also exists for a way to recycle thermosets. There also exists a need to utilise the streams of waste and by-products produced in polymer moulding and manufacturing processes, such as resin casting / moulding.

[0011] Throughout the description and claims of this specification, the word “comprise” and variations of that word, such as “comprising” and “comprises” are not intended to exclude other additives, steps or integers.SUMMARY OF THE INVENTION

[0012] In one aspect, the invention relates to a process for controlling the parameters of a filler material for use in a composite material, the process comprising monitoring a parameter of a filler material and monitoring a parameter of a mixture of the filler material and a binder, wherein the parameter of the filler material is controlled based on the monitored parameter of the mixture and / or wherein the parameter of the mixture is controlled based on the monitored parameter of the filler material.

[0013] According to embodiments, the parameters of the filler material are dynamically controlled based on the monitored parameters of the mixture, e.g. controlled in real time or as part of a constant feedback loop.

[0014] In embodiments, the filler material includes Red Mud, ELV, and other wastes such as soft plastics and floc. In embodiments, the filler material includes thermosetting polymers or plastics preferably including resin material. In embodiments, the filler includes resin material, glass fibres, grounds or beads, hollow spheres, minerals, calcium carbonate, alumina, sand, flyash and / or bottom ash

[0015] In embodiments, monitoring the parameter of the filler material includes monitoring a moisture content parameter.

[0016] In embodiments, the moisture content parameter includes a weight% moisture content.

[0017] In embodiments, control of the moisture content parameter includes dewatering or drying the material to a predetermined or dynamically determined moisture content.

[0018] In embodiments, monitoring the parameter of the filler material includes monitoring a particle size parameter.

[0019] In embodiments, the particle size parameter includes any one or more of mean, maximum, or minimum particle size.

[0020] In embodiments, control of the particle size parameter includes altering the particle size of the filler material to a predetermined or a dynamically determined particle size, preferably by milling the filler material.

[0021] In embodiments, monitoring the parameter of the filler material includes monitoring a composition of the filler material.

[0022] In embodiments, monitoring the composition parameter includes any one or more of metal content, and particle size distribution.

[0023] In embodiments, monitoring the parameter of the filler material includes monitoring a temperature of the filler material.

[0024] In embodiments, monitoring the parameter of the filler material includes monitoring a flowrate of the filler material.

[0025] In embodiments, monitoring a parameter of the mixture includes monitoring any one or more of a distribution of particles of the filler material and / or the binder, a dispersion of the filler material and / or the binder in the mixture, a composition of the mixture, homogeneity, viscosity, and temperature.

[0026] In embodiments, control of the parameter of the mixture includes controlling any one or more of a distribution of particles of the filler material and / or the binder, a dispersion of the filler material and the binder in the mixture, a composition of the mixture, homogeneity, viscosity, and temperature.

[0027] In embodiments control of the parameter of the mixture includes altering an amount of the filler material and / or the binder in the mixture.

[0028] In embodiments, control of the parameter of the mixture further includes altering an amount of an activator in the mixture.

[0029] In embodiments, control of the parameter of the mixture further includes altering a feed rate of the filler material, the binder, and / or the activator to a blending or mixing apparatus.

[0030] In another aspect, the invention relates to a composite material comprising a filler material, a binder, and a hardener.

[0031] In embodiments, the filler material includes Red Mud, ELV, and other wastes such as soft plastics and floc. In embodiments, the filler material includes thermosetting polymers or plastics preferably including resin material. In embodiments, the filler includes resin material, glass fibres, grounds or beads, hollow spheres, minerals, calcium carbonate, alumina, sand, flyash and / or bottom ash

[0032] In a further aspect, the invention relates to a composite material comprising a mixture of a filler material and a binder provided by the process according to the aspect of the invention described above, or any one of the embodiments thereof, and a hardener.

[0033] In another aspect, the invention relates to a system for controlling the parameters of a filler material for use in a composite material, the system comprising a drying apparatus for dewatering or drying the filler material, a milling apparatus for altering a particle size of the filler material, and a blending apparatus for blending or mixing the filler material with a binder.

[0034] In embodiments, the system further includes a control system comprising interrelated series of sensors and activator units.

[0035] In embodiments, the system further comprises a conveyance system for moving the filler material, the binder, and the mixture of the filler and the binder.

[0036] In embodiments, the system further comprises an automated sampling system for drawing a sample and presenting to an analyser.BRIEF DESCRIPTION OF THE FIGURES

[0037] The present invention will now be described in more detail with reference to preferred embodiments illustrated in the accompanying figures, wherein:

[0038] Figure 1 is a flowchart illustrating a process of using bulk waste materials as filler materials in producing composite materials including obtaining bulk waste materials from mineral processing operations, dewatering the bulk waste to obtain the solids, and converting the solids to composite material.

[0039] Figure 2 illustrates a schematic representation of a system and a process in accordance with other embodiments of the invention including providing a feed of filler material and binder from a repository / hopper to a blending apparatus for blending, adding an activator to the filler material and binder and blending the filler material, binder, and activator. The figure also illustrates the system comprising a controller wherein the blending apparatus is configured with analysers that provide data to the controller.

[0040] Figure 3 is a flowchart illustrating a process for manufacturing a composite material in accordance with an embodiment of the invention including using red mud as the filler material, storing red mud in repositories prior to conditioning, conditioning the filler by altering the particle size in a milling apparatus, storing the conditioned filler material in an intermediate repository after milling and before blending, blending the filler material and the binder in a blending apparatus, storing the mixture of the filler material and binder, and delivering the blended product to third party formulators for various end-user applications.

[0041] Figure 4 illustrates a sampling system with a sample preparation unit for filtering out solids from liquid phase samples before presenting to an analyser.

[0042] Figure 5 illustrates a manifold analyser with multiple sensors for sample analysis.

[0043] Figure 6 illustrates a system for manufacturing composite material comprising a filler and a binder, wherein the filler is bulk waste material.

[0044] Figure 7 illustrates a control system.

[0045] Figure 8 illustrates a resin casting / moulding process and sources of waste to be converted as filler material.DETAILED DESCRIPTION

[0046] The invention relates to a process and a system for ensuring that a bulk waste material is conditioned to a filler material suitable for use in producing a composite material.

[0047] In one aspect, the invention relates to a process for controlling the parameters of a filler material for use in a composite material, the process comprising monitoring a parameter of a filler material and monitoring a parameter of a mixture of the filler material and a binder, wherein the parameter of the filler material is controlled based on the monitored parameter of the mixture and / or wherein the parameter of the mixture is controlled based on the monitored parameter of the filler material.

[0048] Preferably, the process uses red mud and / or soft plastics as the filler material.

[0049] In embodiments, the process uses thermosetting polymers or plastics such as polyurethane, silicone, fibreglass, bakelite, duroplast and resin such as polyester resin, silicone resin, epoxy resin, and melamine resin, or materials that may contain the aforementioned materials or combinations thereof, as the filler material.

[0050] In embodiments, the process uses other by-products or wastes from polymer moulding or manufacturing process, glass fibres, grounds or beads, hollow spheres, minerals, calcium carbonate, alumina, sand, flyash and / or bottom ash or materials thatmay contain the aforementioned materials or combinations thereof, as the filler material.

[0051] In other embodiments, the process uses other inconsistent bulk waste materials as the filler material, such as mining waste or tailings which can comprise hazardous compounds, and inorganic mined materials, minesite overburden and minerals processing wastes, plastic wastes, waste aggregates from road and pavement repair and construction, and demolition materials such as ground concrete wastes.

[0052] For example and with reference to Figure 1 , bulk waste materials can be obtained from mineral processing operations. Such bulk waste materials are conditioned to a filler material by extracting solids by dewatering. The solids are then used as the filler material in producing a composite material.Parameters of the Filler MaterialMoisture Content

[0053] In embodiments, monitoring the parameter of the filler material includes monitoring a moisture content parameter.

[0054] In embodiments, the moisture content parameter includes a weight% moisture content.

[0055] In embodiments, control of the moisture content parameter includes dewatering or drying the material to a predetermined or dynamically determined moisture content.

[0056] Monitoring and control of the moisture content parameter of the filler material conditions the filler material to have a moisture content suitable for use in producing composite materials. The control of the moisture content parameter can include dewatering or drying the filler material to a predetermined moisture content. Additionally, control of the moisture content parameter can include dewatering or drying the filler material to a dynamically determined moisture content (e.g. controlled in real time or as part of a constant feedback loop)

[0057] Preferably, monitoring of the moisture content is performed continuously by drawing samples of the filler material at designated intervals and presenting to a moisture analyser for determining the moisture content.

[0058] The monitoring of the moisture content can be configured with an automated sampling system that draws a sample representative of a batch of filler material or a stream of filler material being monitored. The automated sampling system draws samples at designated intervals and presents the sample to a moisture analyser. The moisture analyser can be an X-ray or photonic spectral imager.

[0059] Preferably, the process uses red mud as the filler material and the moisture content of the filler material is controlled at 45-50% moisture content.Particle Size

[0060] In embodiments, monitoring the parameter of the filler material includes monitoring a particle size parameter.

[0061] In embodiments, the particle size parameter includes any one or more of mean, maximum, or minimum particle size.

[0062] In embodiments, control of the particle size parameter includes altering the particle size of the filler material to a predetermined or a dynamically determined particle size, preferably by milling or grinding the filler material.

[0063] Monitoring and control of the particle size parameter of the filler material conditions the filler material to have a particle size suitable for use in producing composite materials. The control of the particle size parameter can include milling or grinding the filler material to a predetermined particle size. Additionally, control of the particle size parameter can include milling or grinding the filler material to a dynamically determined particle size (e.g. controlled in real time or as part of a constant feedback loop)

[0064] Preferably, monitoring of the particle size is performed continuously by drawing samples of the filler material at designated intervals and presenting to a particle size analyser for determining the particle size.

[0065] The monitoring of the particle size can be configured with an automated sampling system that draws samples representative of a batch of filler material or a stream of filler material being monitored. The automated sampling system draws samples at designated intervals and presents the sample to a particle size analyser. The particle size analyser can be a 3D artificial intelligence camera technology, or similar technologies for determining particle size, such as those used in mining and mill operations.Other parameters of the Filler Material

[0066] In embodiments, monitoring the parameter of the filler material includes monitoring a filler material composition parameter.

[0067] In embodiments, the filler material composition parameter includes any one or more of metal content, and particle size distribution.

[0068] In embodiments, monitoring the parameter of the filler material includes monitoring a temperature of the filler material.

[0069] In embodiments, monitoring the parameter of the filler material includes monitoring a flowrate of the filler material.

[0070] Suitably, the monitoring of the filler material composition can be configured with an automated sampling system that draws samples representative of a batch of filler material or a stream of filler material being monitored. The automated sampling system draws samples at designated intervals and presents the sample to a composition analyser. For example, the filler material can be monitored using an X-ray fluorescence system that provides a broad spectrum analysis of metals and associated compounds in the filler material.Parameters of the Mixture

[0071] In embodiments, monitoring a parameter of the mixture includes monitoring any one or more of a distribution of particles of the filler material and / or the binder, a dispersion of the filler material and / or the binder in the mixture, a composition of the mixture, homogeneity, viscosity, temperature, flow rate, and moisture content.

[0072] In embodiments, control of the parameter of the mixture includes controlling any one or more of a distribution of particles of the filler material and / or the binder, a dispersion of the filler material and the binder in the mixture, a composition of the mixture, homogeneity, viscosity, temperature, flow rate, and moisture content.

[0073] In embodiments control of the parameter of the mixture includes altering an amount of the filler material and / or the binder in the mixture.

[0074] In embodiments, control of the parameter of the mixture further includes altering an amount of an activator in the mixture.

[0075] In embodiments, control of the parameter of the mixture further includes altering a feed rate of the filler material, the binder, and / or the activator to a blending or mixing apparatus.

[0076] The mixture of the filler material and the binder is obtained by blending the conditioned filler material and the binder in predetermined or dynamically determined ratio. Blending can be carried out in a blending or mixing apparatus configured with an auger or vortex for mixing.

[0077] Monitoring of the parameters of the mixture can be configured with an automated sampling system that draws samples at designated intervals and presents the sample to analysers.

[0078] For example and with reference to Figure 2, blending of the filler material and the binder material includes feeds of filler and binder that deliver the materials from a filler repository and a binder repository to a blending apparatus. An activator can also be added during blending. The blending apparatus is configured with analysers for monitoring the mixture during blending. Samples are drawn from a feed coming froma filler and a binder repository, and from the blending apparatus. Samples are presented to the analysers, which then provide data to a control system. The control system can adjust feed rates and / or amounts of filler, binder, and / or activators.

[0079] Preferably, the mixture comprises 85% filler, 10% binder, and 5% activator.

[0080] After blending, the mixture of the filler material and the binder are stored in a repository, such as silo, hopper, or bin to ensure weather factors do not alter the parameters of the mixture.

[0081] For example and with reference to Figure 3, red mud is used as a filler material for producing a composite material. Red mud is prepared as the filler material in a process including storing red mud from holding ponds to a repository, delivering red mud from the repository to a milling apparatus, milling the red mud to predetermined or dynamically determined particle size, storing the conditioned filler material in an intermediate repository after milling and before blending, blending the filler material and the binder, storing the mixture of the filler material and the binder in a repository, and delivering the mixture to third party formulators for various end user applications.Composite Material

[0082] In another aspect, the invention relates to a composite material comprising a filler material, a binder, and a hardener.

[0083] In a further aspect, the invention relates to a composite material comprising a mixture of a filler material and a binder provided by the process of claim 1 and a hardener.System for Producing Composite Material

[0084] In a further aspect, the invention relates to a system for controlling the parameters of a filler material for use in a composite material, the system comprising a drying apparatus for dewatering or drying the filler material, a milling apparatus for altering a particle size of the filler material, and a blending apparatus for blending or mixing the filler material with a binder.Dewatering Apparatus

[0085] The system preferably includes a drying apparatus for dewatering or drying the filler material to a predetermined moisture content.

[0086] The dewatering apparatus can comprise an automated sampling system that draws samples at designated intervals and presents the sample to analysers. The dewatering apparatus can also be configured with a moisture analyser for monitoring a moisture content of the filler. For example, the sampling system draws samples at designated intervals and presents the sample to a moisture analyser, such as an X- ray or photonic spectral imager.Milling Apparatus

[0087] The system preferably includes a milling apparatus for milling the or grinding the filler material to a predetermined or dynamically determined particle size.

[0088] In embodiments, the milling apparatus includes analysers such as a 3D artificial intelligence camera technology or similar technologies for determining particle size, for monitoring the particle size of the filler material.

[0089] The milling apparatus can further comprise an automated sampling system that draws samples at designated intervals and presents the sample to analysers.

[0090] Suitably, the milling apparatus can be configured with a material composition analyser. For example, the automated sampling system draws samples representative of the batch of filler, or the stream of filler material being monitored at designated intervals and presents the sample to an X-ray Fluorescence systems to provide a broad spectrum fast analysis of metals and associated compounds in the filler material.

[0091] The milling apparatus can also be configured with a moisture analyser, such as X-ray or photonic spectral imager.Blending apparatus

[0092] The system preferably includes a blending apparatus for blending the filler, the binder, and / or the activator.

[0093] The filler, binder, and activator are delivered into the blending apparatus from the repositories via the conveyance systems. The materials flow from the repositories through the rotary valve positioned at the bottom of the repository. The rotary valve can be driven by a motor gearbox with a variable speed drive for controlling the flow rate of the materials.

[0094] The blending apparatus is configured to include feeds of filler, binder, and / or activator that delivers the materials to the blending apparatus.

[0095] The blending apparatus is configured with an auger or a vortex for blending the filler, binder, and / or activator.

[0096] The blending apparatus can be configured with an automated sampling system that draws samples at designated intervals and presents the sample to analysers for moisture content and material composition monitoring. The moisture analyser can be X-ray or photonic spectral imager and the material composition analyser can be X-ray Fluorescence system.

[0097] After the blending step, the blended filler and binder material are stored in product repositories such as silos, hoppers, bins, silos, etc. to ensure weather factors do not jeopardise filler / binder properties via uncontrolled moisture ingress.Storage

[0098] In embodiments, the system is configured to have repositories for the storage of the filler, binder, and blended filler and binder at each stage in the production process. Storage units can include silos, bins, and / or hoppers.

[0099] The repositories comprise storage for the binder, storage for the bulk waste materials to be used as filler, intermediate storage for the filler between dewateringand milling, intermediate storage for the filler between milling and blending, and storage for the blended filler and binder.

[0100] The repositories include a rotary valve placed at the bottom of the repository to allow the flow of materials. The rotary valve can be driven by a motor gearbox with a variable speed drive for controlling the flow rate of the materials.

[0101] The repositories can further include load cells and / or ultrasonic detectors for monitoring product weight and volume inside the repository. Weight and volume measurements can be used to determine production rates and flow rates at each stage in the production process.Conveyance System

[0102] In embodiments, the system further comprises a conveyance system for moving the filler material, the binder, and the mixture of the filler and the binder.

[0103] The conveyance systems can include load cells and ultrasonic detectors to measure weight and volume of materials. Weight and volume measurements on the conveyance systems allow monitoring of the flow of materials within the system.Sampling System

[0104] In embodiments, the system preferably further comprises an automated sampling system for drawing a sample and presenting to an analyser. The sampling system allows continuous monitoring by drawing samples at designated intervals and presenting the sample to analysers.

[0105] For example and with reference to Figure 4, the sampling system can include a sample preparation unit that filters out suspended solids from the liquid sample before presenting to an analyser. This type of sample preparation unit is intended for those streams where there are solids, greases, oils, etc., that must be removed from the sample in order to provide proper functioning of the analyser. Example of such analysers are those using selective-ion electrodes. The sampling system can include an automated sampler located at a designated depth within the liquid sample. The automated sampler is connected via a sample line to a sample chamber including acassette filter. When sampling, the sampler draws in a sample to a sample chamber, wherein the sample is forced through the filter to a sample collection trough, where the prepared sample is then presented to the analyser for analysis.Analysers

[0106] In embodiments, the system preferably includes analysers for monitoring characteristics of the filler, binder, and blended filler during the process.

[0107] Analysers include X-ray or photonic spectral imagers for monitoring moisture content, X-ray fluorescence systems for analysis of metals and associated compounds, density analysers for measuring specific density, load cells and ultrasonic detectors for measuring weight and volume, temperature analyser, and flow rate analyser.

[0108] Referring to Figure 5, the system can also include a manifold analyser comprising multiple sensors positioned in a manifold to provide real-time data on a range of contaminants that can be analysed using electrodes for specific elements and compounds in solution. The manifold analyser allows the samples to pass by a host of selective sensors. Suitably, the manifold analyser can be configured with a sampling system with a sample preparation unit that filters out suspended solids from the liquid sample before presenting to the manifold analyser. The manifold analyser can further comprise an inline cleaning system using ultrasonic generators buried within the manifold wall to provide a high frequency vibration - typically more than 40Hz - to clean electrodes of contaminants during a cleaning cycle when the end valves would close for cleaning. Wash solution would be drained, and a calibration solution applied to reset calibration on all probes.Control System

[0109] In embodiments, the system preferably includes a control system comprising interrelated series of sensors and activator units. The control system controls all aspects of the system including the apparatus, repositories, analysers, conveyance systems, and sampling system.

[0110] The control system is connected to the analysers and uses the parameters measure by the analysers to control the parameters of the filler material and the mixture of the filler material and the binder. For example, moisture content is continuously monitored, and the moisture content data provided to the control system. If the moisture content is not within a predetermined range, the batch will be diverted and returned to the conditioning process for reprocessing. Similarly, moisture content and material composition can be monitored continuously during blending. The analysers provide data to the control system and in turn, the control system can adjust feed rate of the filler material, binder, and activator during the blending in the blending apparatus.Example 1

[0111] Figure 6 illustrates a process and a system for using a bulk waste material as a filler material in producing a composite material. Bulk waste materials, such as red mud, are delivered from holding ponds to a processing repository (bulk filler holding area). To start the process, the filler material is delivered via a conveyance system to a conditioning apparatus for preparation of the filler material. The conditioning apparatus can be a dewatering apparatus for drying the filler material and / or milling apparatus for milling the filler material. The filler material is conditioned to a predetermined or dynamically determined moisture content and / or particle size, before being delivered to an intermediate repository via the conveyance system. The conveyance system is configured with analysers for monitoring moisture content and / or particle size. The moisture content and / or particle size measurement are sent to a control system which controls all aspects of the system including the apparatus, repositories, analysers, and conveyance systems. If a batch of filler material is not within set parameters (i.e. moisture content, particle size), then the control system will divert the batch back for reconditioning.

[0112] The conditioned filler material and binder are delivered to the blending apparatus from the repositories via the conveyance system configured with analysers for measuring moisture content, particle size, and / or flow rate. The filler material and the binder are blended in the blending apparatus then delivered to silos for storage via the conveyance system. Similarly, the conveyance system is configured with an analyser for material composition analysis. If the batch does not meet the set materialcomposition, then it will be diverted back for reprocessing. Additionally, the conveyance system from the blending apparatus to the silos are equipped with a cooling system to maintain product integrity during transfer from the blending apparatus to storage.

[0113] The silos for storage of the blended filler and binder are configured with analysers for measuring weight, height, and temperature within each silo. The silos are also jacketed and water cooled to maintain product integrity. Data collected by the analysers in the silos are used to calculate production rate and are also used to ensure and verify product quality before delivery to end users. If the batch does not meet the set product characteristics as analysed by the analysers, then it will be diverted back for reprocessing.

[0114] Referring to Figure 7, the process is controlled by a control system that controls all aspects of the system including the apparatus, repositories, analysers, conveyance systems, and sampling systems.

[0115] The status of the bulk filler is monitored coming into the repository and its makeup reported to the control system for verification and validation.

[0116] The status of the bulk filler during delivery to the holding area is reported to the control system for verification and validation.

[0117] The bulk filler is monitored for any changes in make-up whilst being held in the holding area prior to conversion. Its condition is reported to the control system for verification and validation.

[0118] The status of the filler is monitored during the preparation for conversion and its condition is reported to the control system for verification and validation.

[0119] The prepared filler is monitored whilst being held in the prepared filler repository and its condition is reported to the control system for verification and validation.

[0120] By noting the data reported in the previous steps of the process, the control system is able to take into account the condition of the filler and modify the binder (“A Binder”) accordingly to achieve optimum cross linking properties within a given tolerance.

[0121] The blended material, “Filler & A Binder” are monitored for conformity and its status reported to the control system.

[0122] The status of binder “A Binder” is monitored for conformity and its status reported to the control system.

[0123] The status of binder “B Binder” is monitored for conformity and its status reported to the control system.

[0124] The status of “B” binder in the “B” binder holding area is monitored and reported to the control system.

[0125] Material “Filler & A Binder” and “B Binder” are homologated and dispatched from the system. All records are kept within the system for Quality Assurance.Example 2

[0126] Elements of waste or by-product from a resin casting / moulding process or other polymer moulding and manufacturing processes, are collected, converted into a comingled filler (“Master Batch”), and subsequently up-cycled by way of being used as a filler. This is possible, because the process of the present invention does not require the filler materials to be separated pre-use. The process can take the so called “dirty” Master Batch (i.e. co-mingled) and use it directly and effectively without the need for costly and potentially high risk segregation, separation and sorting processes.

[0127] Figure 8 illustrates a typical resin casting / moulding process divided into the following sub-processes:

[0128] All inbound packaging is shredded, chopped and / or ground, and used as bulk filler in embodiments of the present invention.

[0129] Tooling typically used in resin casting / moulding processes are light in construction (compared to an injection moulding tool, for example) often called rapid or soft tooling, and often comprised of composite type materials. These tools can, at the end of life, be shredded, chopped and / or ground and used as bulk filler in the process of the present invention. If the tools are derived from a master pattern or machined, all of the scrap materials generated as a by-product of the toolmaking process (i.e. swarf, scrap blocks and offcuts, scrap masters, inserts, clamps ancillaries etc.) can also be shredded, chopped and / or ground, and used as bulk filler in the process of the present invention.

[0130] Resin casting / moulding processes are typically associated with low yields and higher scrap or waste levels (i.e. waste or poor fills, bad mouldings, over moulding, flash, non-compliant mouldings, sprews, runners and risers etc.), compared to other polymer moulding processes, resulting in cured waste that needs to be disposed of (typically landfill for example). This waste can be shredded, chopped and / or ground, and used as bulk filler in embodiments of the present invention.

[0131] Other products for use as bulk filler material in embodiments of the present invention are made from resin casting / moulding processes in End of Product Life applications, where the entire moulding is returned to the resin casting / moulding producer for up-cycling and it is shredded, chopped and / or ground, and used as bulk filler in embodiments of the present invention. End of Product Life applications and 100% up-cycling of product made from resin casting / moulding processes were not previously possible because of the singular nature of the materials used and no identification of an up-stream use and application to take the product End of Life and up-cycle it in any manner. This is especially the case with mouldings containing inserts and other “foreign” objects (i.e. co-mingled materials in a single moulding) that would need to be removed or separated prior to up-cycling.

[0132] Typically considered to be the least environmentally friendly sub-process of the resin casting / moulding process, and often generating significant and multi waste streams. In most cases, these waste streams are disposed of externally to the production and up-cycling process. It is however possible to collect all spent paint(including overspray and other dusts), fillers, cleaning tools and products and general residue such as masking tape etc. and shred, chopped and / or ground, and used as bulk filler in embodiments of the present invention.

[0133] Mouldings are typically sent to the customer wrapped and packaged. There is residue from this process and also spent packaging at the customer end of the system. All of this co-mingled packaging can be collected and returned to the moulder where it can be shredded, chopped and / or ground, and used as bulk filler in embodiments of the present invention.

Claims

CLAIMS1. A process for controlling the parameters of a filler material for use in a composite material, the process comprising: monitoring a parameter of a filler material; and monitoring a parameter of a mixture of the filler material and a binder; wherein the parameter of the filler material is controlled based on the monitored parameter of the mixture; and / or wherein the parameter of the mixture is controlled based on the monitored parameter of the filler material.

2. The process of claim 1, wherein monitoring the parameter of the filler material includes monitoring a moisture content parameter.

3. The process of claim 2, wherein the moisture content parameter includes a weight% moisture content.

4. The process of claim 2, wherein control of the moisture content parameter includes dewatering or drying the material to a predetermined or dynamically determined moisture content.

5. The process of claim 1, wherein monitoring the parameter of the filler material includes monitoring a particle size parameter.

6. The process of claim 5, wherein the particle size parameter includes any one or more of mean, maximum, or minimum particle size.

7. The process of claim 5, wherein control of the particle size parameter includes altering the particle size of the filler material to a predetermined or a dynamically determined particle size, preferably by milling the filler material.

8. The process of claim 1, wherein monitoring the parameter of the filler material includes monitoring a composition of the filler material.

9. The process of claim 8, wherein monitoring the composition parameter includes any one or more of metal content, and particle size distribution.

10. The process of claim 1, wherein monitoring the parameter of the filler material includes monitoring a temperature of the filler material.

11. The process of claim 1 , wherein monitoring the parameter of the filler material includes monitoring a flowrate of the filler material.

12. The process of claim 1 , wherein monitoring a parameter of the mixture includes monitoring any one or more of a distribution of particles of the filler material and / or the binder, a dispersion of the filler material and / or the binder in the mixture, a composition of the mixture, homogeneity, viscosity, temperature, flow rate, and moisture content.

13. The process of claim 12, wherein control of the parameter of the mixture includes controlling any one or more of a distribution of particles of the filler material and / or the binder, a dispersion of the filler material and the binder in the mixture, a composition of the mixture, homogeneity, viscosity, temperature, flow rate, and moisture content.

14. The process of claim 12, wherein control of the parameter of the mixture includes altering an amount of the filler material and / or the binder in the mixture.

15. The process of claim 12, wherein control of the parameter of the mixture further includes altering an amount of an activator in the mixture.

16. The process of claim 12, wherein control of the parameter of the mixture further includes altering a feed rate of the filler material, the binder, and / or the activator to a blending or mixing apparatus.

17. A composite material comprising: a filler material; a binder; and a hardener.

18. A composite material comprising: a mixture of a filler material and a binder provided by the process of claim 1 ; and a hardener.

19. A system for controlling the parameters of a filler material for use in a composite material, the system comprising: a drying apparatus for dewatering or drying the filler material; a milling apparatus for altering a particle size of the filler material; and a blending apparatus for blending or mixing the filler material with a binder.

20. The system of claim 19, further including a control system comprising interrelated series of sensors and activator units.

21. The system of claim 19, further comprising a conveyance system for moving the filler material, the binder, and the mixture of the filler and the binder.

22. The system of claim 19, further comprising an automated sampling system for drawing a sample and presenting to an analyser.

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