Apparatus and method for processing a material flow containing valuable substances

Abstract

The invention relates to an apparatus for processing a material flow containing valuable substances, which in particular comprises fibrous and / or plastic-containing valuable substances, the apparatus comprising the following: a dry sorting unit, which has a reject device in order to sort the material flow containing valuable substances into a reject flow and a material flow; a material processing unit, which has at least one material processing device which is designed to discharge foreign substances and / or contaminants from the material flow; and a control device. The control device is designed to control the reject device of the dry sorting unit depending on the amount of foreign substances and / or contaminants discharged in the material processing device. By taking into account the amount of foreign substances and / or contaminants discharged in the material processing unit when controlling the dry sorting unit, optimized recycling of the valuable substances contained in the material flow can be achieved.

Description

[0001] P606795PC00

[0002] DESCRIPTION

[0003] Title of the invention

[0004] Device and method for processing a material stream containing valuable materials

[0005] Technical field

[0006] The present invention relates to a device and a method for processing a material stream containing valuable materials, wherein the material stream particularly comprises fiber-containing and / or plastic-containing valuable materials. Furthermore, the present invention relates to the use of the material stream processed according to the invention for papermaking or for the production of recycled plastics.

[0007] State of the art

[0008] The material recovery of valuable materials contained in collected waste is contrasted with energy recovery (e.g., through incineration). Energy recovery currently represents the preferred recovery route, as the processing of waste streams required for material recovery is, in most cases, economically unattractive due to regulatory requirements and unclear material yield and quality.

[0009] However, the ongoing efforts to reduce energy consumption and greenhouse gas emissions, and the associated target recycling rates, necessitate increased material recovery of the valuable materials contained in waste streams. In this context, the high recycling quotas required are particularly problematic, as are regulatory requirements (e.g., consumer protection) for the use of materials made from secondary raw materials (e.g., packaging for food or cosmetics). Consequently, there is a need for a device or process for processing material streams containing valuable materials, such as waste streams, that optimally utilizes the valuable materials contained within the stream while simultaneously ensuring compliance with regulatory requirements.

[0010] Technical problem to be solved by the invention

[0011] It is therefore the object of the present invention to provide a device or a method for processing a material stream containing valuable materials, which achieves an optimized use of the material potential of the material stream containing valuable materials, taking into account regulatory requirements.

[0012] Disclosure of the invention

[0013] The problem is solved according to the invention with a device having the features of independent claim 1. A method according to the invention is the subject of claim 11. A use of the processed material stream according to the invention is the subject of claim 13. Further advantageous embodiments are defined in the dependent claims.

[0014] The device according to the invention for processing a material stream containing recyclables, which in particular comprises fiber-containing and / or plastic-containing recyclables, has a dry sorting unit which includes a reject device for sorting the material stream containing recyclables into a reject stream and a usable stream, a material processing unit which includes at least one material processing device configured to remove foreign materials and / or contaminants from the material stream, and a control device. The control device is configured to control the reject device of the dry sorting unit depending on the quantity of foreign materials and / or contaminants removed in the material processing device.By taking into account the amount of foreign materials and / or contaminants that are discharged in a later process step in the material preparation unit when controlling the dry sorting unit, the proportion of the material flow that is sorted out as rejects in the dry sorting unit can be reduced and optimized recycling of the valuable materials contained in the material flow can be achieved.

[0015] The control device can be configured to record the quantity of foreign substances and / or contaminants discharged in the material processing plant.

[0016] By recording the quantity of foreign substances and / or contaminants discharged in the material processing plant, optimized sorting in the dry sorting unit and an improved recycling rate of the valuable materials contained in the material stream can be achieved.

[0017] The material stream containing recyclables may include fibrous recyclables. The material processing unit may include a wet sorting unit and a first separation unit. The wet sorting unit may be configured to defibreize the fibrous recyclables contained in the material stream by adding process water, thereby separating foreign materials and / or contaminants from the fibrous recyclables. The first separation unit may be configured to separate the separated foreign materials from the material stream. The control unit may be configured to measure the quantity of foreign materials and / or contaminants separated in the first separation unit.

[0018] By measuring the quantity of foreign materials and / or contaminants that can be detached and separated from the recyclable materials during the dissolution and fiberization process, a lower reject rate in the dry sorting unit and thus an improved recycling rate can be achieved. The stock preparation unit can further comprise a thickening unit and a second separation unit. The thickening unit can be configured to at least partially remove the process water added for fiberization from the stock stream. The second separation unit can be configured to separate foreign materials and / or contaminants contained in the removed process water from the process water. The control unit can be configured to measure the quantity of foreign materials and / or contaminants separated in the second separation unit.

[0019] By recording the quantity of foreign substances and / or contaminants that are separated during the treatment of the process water, targeted control of the dry sorting can be achieved in order to influence the concentration of foreign substances and / or contaminants in the material stream in such a way that an optimal recycling rate can be ensured despite consideration of regulatory requirements (e.g. compliance with various limit values ​​for certain foreign substances and / or contaminants).

[0020] The second separation device may be designed to separate foreign substances and / or contaminants from the process water by means of mechanical and / or chemical purification stages and in particular by means of flotation, preferably microflotation and / or disc filters and the like.

[0021] The material stream containing recyclables may include plastics. The material processing unit may comprise a shredding unit, a pre-cleaning unit, an intensive cleaning unit, and a processing unit.

[0022] This also results in optimized sorting in the dry sorting unit and an improved recycling rate of the plastic recyclables contained in the material stream, even when processing a material stream containing recyclables. Limit values ​​for the quantities of foreign materials and / or contaminants detected by the control unit can be predefined. The control unit can then regulate the reject unit to ensure that these predefined limits are met but not exceeded.

[0023] This maximizes the amount of recyclable fiber-containing materials in the material flow by taking into account the maximum "reject capacities" of the subsequent material processing during the preceding dry sorting in the dry sorting unit.

[0024] The device may further comprise a first detection unit configured to detect components of the material stream fed to the dry sorting unit. The control unit may be configured to categorize the detected components of the material stream with regard to foreign matter and / or contaminants. The control unit may be configured to control the reject device based on the components of the material stream detected by the first detection unit.

[0025] By capturing the components of the recyclable material stream using the first capture device and categorizing the components with regard to foreign substances and / or contaminants, targeted dry sorting can be carried out in the dry sorting unit with regard to specific foreign substances and / or contaminants.

[0026] Furthermore, by capturing the components of the recyclable material stream with the first capture device, a correlation can be established between the properties of the recyclable material stream fed into the device and the properties of the material stream obtained after processing. Thus, an estimation of the material composition after processing can be made based on the captured components of the fed material stream ("digital twin") and, if necessary, adjusted by appropriately modifying the sorting criteria of the dry sorting unit. The device can also include a second capture device configured to capture components of the material stream after sorting by the reject unit in the dry sorting unit.The control device can be configured to control the reject device based on the components of the material flow detected by the second detection device.

[0027] The provision of the second detection unit allows for monitoring the sorting results of the dry sorting unit and, if necessary, influencing them by adjusting the sorting criteria. Furthermore, by analyzing the components of the material stream after dry sorting, various parameters for subsequent material processing and potential further process steps can be optimized.

[0028] The acquisition device can be, for example, an image acquisition device or a spectral analysis device, in particular a near-infrared scanning device.

[0029] A process for processing a material stream containing valuable materials, in particular fibrous and / or plastic-containing valuable materials, comprises the following steps: dry sorting, wherein in a dry sorting unit the material stream containing valuable materials is sorted by a reject device into a reject stream and a material stream, and material processing, wherein in a material processing unit which has at least one material processing device foreign materials and / or contaminants are removed from the material stream, wherein in dry sorting the reject device is controlled depending on the quantity of foreign materials and / or contaminants removed in the material processing device.

[0030] The process can be carried out in one of the devices described above. A material stream obtained from a material stream containing valuable materials, which in particular includes fiber-containing and / or plastic-containing valuable materials, and processed in one of the devices and / or according to one of the processes described above, can be used for papermaking or for the production of recycled plastics.

[0031] Further advantages of the present invention are evident from the following detailed description of an embodiment and the attached drawings.

[0032] Brief description of the drawings

[0033] Figure 1 is a schematic representation of a first exemplary embodiment of the present invention.

[0034] Figure 2 is a schematic representation of a second exemplary embodiment of the present invention.

[0035] Figure 3 is a schematic representation of a third exemplary embodiment of the present invention.

[0036] Description of exemplary embodiments of the invention

[0037] First embodiment

[0038] A first exemplary embodiment of the present invention is described below with reference to Figure 1.

[0039] In the figures, material flows are illustrated with solid lines, and data or information flows with dashed lines. Figure 1 shows a device for processing a material flow WS containing recyclable materials, which in particular comprises fiber-containing and / or plastic-containing recyclable materials.

[0040] The device comprises a dry sorting unit 100, which includes a reject device 110. By means of the reject device 110, components of the recyclable material stream WS can be separated from the material stream and sorted out into a reject stream AS. This allows the recyclable material stream WS to be sorted into a reject stream AS and a material stream SS. The reject device 110 can, for example, have compressed air nozzles through which components are selectively blown out of the recyclable material stream WS. The dry sorting unit 100 can remove components containing foreign substances FS and / or contaminants K, which are not desired in further processing, from the material stream.

[0041] The device further comprises a stock preparation unit 200 with at least one stock preparation device. Foreign substances FS and / or contaminants K are also discharged in the stock preparation device. This discharge is carried out, for example, by mechanical, thermal, and chemical treatment of the components of the stock stream SS.

[0042] Furthermore, the device includes a control unit 300. The control unit 300 controls the reject unit 110 of the dry sorting unit 100 to sort the recyclable material stream WS into the reject stream AS and the material stream SS.

[0043] As illustrated in Figure 1 by the dashed line between the stock preparation unit 200 and the control unit 300, the reject device 110 is controlled by the control unit 300, taking into account the foreign substances FS and / or contaminants K discharged from the stock preparation unit. The quantity of foreign substances FS and / or contaminants K discharged from the stock preparation unit 200 is detected by the control unit 300. The control of the reject device 110 by the control unit 300 depends on the quantity of foreign substances FS and / or contaminants K discharged from the stock preparation unit 200.

[0044] By taking into account the quantity of foreign materials (FS) and / or contaminants (K) discharged in the material processing unit 200, components of the recyclable material stream containing foreign materials (FS) and / or contaminants (K) can be tolerated to a greater extent during dry sorting and remain in the material stream. This allows for an improved recycling rate and optimized utilization of the material potential of the recyclable material stream.

[0045] The quantities of foreign substances (FS) and / or contaminants (K) that can be discharged within the material processing unit 200 are, however, limited by process engineering. The maximum dischargeable quantities of the respective foreign substances (FS) and / or contaminants (K) are reflected in predefined limit values, which are known, for example, from empirical data in various material processing processes and the technical data of the material processing unit 200 used.

[0046] The control unit 300 controls the reject unit 110 in such a way that the predefined limit values ​​are reached but not exceeded. This means that the limit values ​​are approached from below. If the quantity of a specific foreign substance FS or a specific contaminant discharged in the material preparation unit 200 approaches the respective predefined limit value, the control unit 300 controls the reject unit 110 of the dry sorting unit 100 in such a way that components of the recyclable material stream WS containing foreign substances FS and / or contaminants K are increasingly sorted from the material stream SS into the reject stream AS. In this way, exceeding the predefined limit values ​​can be prevented, and the desired or required composition of the material stream SS for processing can be achieved.

[0047] Second embodiment

[0048] A second exemplary embodiment of the present invention is described below with reference to Figure 2.

[0049] The second embodiment differs from the first embodiment in the design of the material preparation unit 200 and in the provision of a collection device 410. In particular, the second embodiment is designed such that the material stream WS containing recyclable materials comprises fiber-containing recyclable materials, and the processed material stream can be used, for example, for paper production.

[0050] As illustrated in Figure 2, the stock preparation unit 200 comprises a wet sorting device 210 and a first separation device 220 as a stock preparation device.

[0051] In the wet sorting unit 210, the fiber-containing recyclables in the material stream SS are fiberized by the addition of process water PW. This results in the separation of foreign materials FS and / or contaminants K from the fiber-containing recyclables. The wet sorting unit 210 can, for example, be designed as a pulper in which the fiberization takes place and foreign materials FS, such as plastics and metals, are separated from the fibers. For example, foreign materials FS, which are particularly common in composite materials, can be separated and subsequently discharged in this way.

[0052] The foreign materials and / or contaminants separated in the wet sorting unit 210 are separated from the material stream SS by the first separation unit 220. The quantity of foreign materials FS and / or contaminants K separated and discharged in the first separation unit 220 is recorded by the control unit 300 and taken into account accordingly in the control of the reject unit 110 of the dry sorting unit 100.

[0053] Furthermore, the stock preparation unit 200 of the present embodiment comprises a stock preparation device, a thickening device 230 and a second separation device 240.

[0054] In the thickening unit 230, the process water PW added for fiberization is at least partially removed from the material stream SS. In the second separation unit 240, foreign substances FS and / or contaminants K contained in the removed process water PW are separated from the process water PW. The quantity of foreign substances FS and / or contaminants K separated in the second separation unit 240 is recorded by the control unit 300 and taken into account accordingly in the control of the reject unit 110 of the dry sorting unit 100.

[0055] The separation of foreign substances FS and / or contaminants K from the process water PW in the second separation device 240 can be carried out, for example, by means of mechanical and / or chemical cleaning stages and in particular by means of flotation, preferably microflotation, and / or filter devices, preferably disc filters, and the like.

[0056] Furthermore, the device according to the present embodiment comprises a first detection device 410. The first detection device 410 detects components of the material stream WS containing recyclables, which is fed to the dry sorting unit 100. The first detection device 410 can, for example, be configured as an image acquisition device or a spectral analysis device, in particular a near-infrared scanning device.

[0057] The components of the material flow WS detected by the first detection unit 410 are transmitted to the control unit 300 and categorized with regard to foreign substances FS and / or contaminants K. This categorization can be based, for example, on empirical data. Thus, certain components (such as beverage cartons) that can be detected by the first detection unit 410 can be assigned specific foreign substances FS and / or contaminants K that are known to be present in these components.

[0058] This categorization allows a connection to be established between the foreign substances FS and / or contaminants K discharged in the material preparation unit and the components of the valuable material stream WS supplied to the dry sorting unit 100.

[0059] The control unit 300 controls the reject unit 110 based on the components of the material stream detected by the first detection unit 410. This means that if the quantity of a specific foreign substance FS or a specific contaminant K, which is discharged in the material processing unit 200, approaches the predetermined limit value, the control unit 300 can control the reject unit 110, taking into account the components detected by the first detection unit 410, in such a way that, in particular, the components of the recyclable material stream WS that are related to the foreign substance F or contaminant K in question are sorted to a greater extent into the reject stream AS.

[0060] Third embodiment

[0061] A third exemplary embodiment of the present invention is described below with reference to Figure 3.

[0062] The third embodiment differs from the second embodiment in that the device further comprises a second detection device 420.

[0063] The second detection device 420 detects components of the material flow SS after sorting by the reject device 110 in the dry sorting unit 100. Like the first detection device 410, the second detection device 420 can also be configured, for example, as an image detection device or a spectral analysis device, in particular a near-infrared scanning device.

[0064] The second detection unit allows the sorting result of the dry sorting unit to be monitored and, if necessary, influenced by adjusting the sorting criteria of the dry sorting unit. This means that the control unit 300 also controls the reject unit 110 based on the components of the material stream SS detected by the second detection unit 420, in order to further improve the quality of the desired sorting result (i.e., the desired consistency of the material stream SS).

[0065] Another aspect, for example, is that the second collection unit 420, which captures the components of the material stream SS after dry sorting, allows for the optimized adjustment of various parameters for subsequent material processing and possible further process steps. Depending on the type of subsequent material processing, the addition of process water, specific chemicals, the use of thermal energy, etc., can be adjusted and optimized based on the capture of the components of the material stream SS by the second collection unit 420.

[0066] For example, depending on the categorization of the input material (stock stream SS), the intensity of flotation, the dosage, and the composition of flotation chemicals can be varied. Furthermore, the temperature and residence time of a processed fiber (stock stream SS) in a subsequent sanitization unit (e.g., dispersion, heating screw) can be adjusted accordingly. Water exchange with fresh water in a process water treatment plant can also be carried out depending on the foreign matter and contaminant load derived from the categorization and, if necessary, measured. If the processed stock stream is used for papermaking, the dosage of the processed stock stream (fiber stream) into the main stream of a paper machine can be optimized based on the foreign matter and contaminant load derived from the categorization and, if necessary, measured.Further variations of the designs.

[0067] The embodiments described above can be modified or combined as appropriate.

[0068] As described in the second embodiment, the material stream containing recyclable materials (WS) comprises fiber-containing recyclable materials, and the processed material stream can be used, for example, for paper production. However, the present invention is not limited to this.

[0069] For example, the material stream containing recyclable materials (WS) can include plastic-containing recyclable materials, and the processed material stream can be used to produce secondary plastics. For this embodiment, the material processing unit 200 can comprise a comminution unit 210, a pre-cleaning unit 220, an intensive cleaning unit 230, and a processing unit 240.

[0070] In the comminution unit 210, the components of the material stream SS are comminuted, optionally in conjunction with a pre-wash (dry / wet grinding).

[0071] After comminution, the material stream SS undergoes a pre-wash or dry cleaning in the pre-cleaning unit 220.

[0072] Subsequently, in the intensive cleaning unit 230, the material stream SS undergoes intensive washing (hot wash / friction wash) with cleaning agents, density separation, and subsequent rinsing and drying. In the treatment unit 240, the used wash water and cleaning agents are treated.

[0073] Here too, by providing a second collection device, 420 parameters for subsequent material processing can be optimized. For example, depending on the categorization of the input material (material stream SS), the intensity of flotation, dosage, and composition of flotation chemicals can be varied. Water exchange with fresh water in a process water treatment plant can also be carried out depending on the foreign matter and contaminant load derived from the categorization and, if necessary, measured.

[0074] The above description is not exhaustive, and the present invention is not limited to the embodiment(s) mentioned above. Those skilled in the art will recognize that various modifications and combinations of the features contained in the above embodiment(s) are possible within the scope of the present invention. Therefore, the scope of the present invention should be defined by the accompanying claims.

Claims

P606795PC00 PATENT CLAIMS 1. Device for processing a material stream (WS) containing recyclable materials, which in particular comprises fiber-containing and / or plastic-containing recyclable materials, comprising a dry sorting unit (100) having a reject device (110) for sorting the material stream (WS) containing recyclable materials into a reject stream (AS) and a material stream (SS), a material processing unit (200) having at least one material processing device (210, 220, 230, 240) configured to remove foreign materials (FS) and / or contaminants (K) from the material stream (SS), and a control device (300) wherein the control device (300) is configured to control the reject device (110) of the dry sorting unit (100) depending on the quantity of foreign materials (FS) and / or contaminants (K) removed in the material processing unit (200).

2. Device according to claim 1, wherein the control device (300) is configured to detect the quantity of foreign substances (FS) and / or contaminants (K) discharged in the stock preparation device.

3. Device according to claim 1 or 2, wherein the material stream (WS) containing recyclables comprises fiber-containing recyclables, the material processing unit (200) being a material processing device comprising a wet sorting device (210) and a first separation device (220), wherein the wet sorting device (210) is configured to cause the fiber-containing valuable materials contained in the material stream (SS) to be defibrated by adding process water (PW), thereby causing foreign substances (FS) and / or contaminants (K) to be detached from the fiber-containing valuable materials, and the first separation device (220) is set up to separate the detached foreign substances (FS) and / or contaminants (K) from the material stream (SS), wherein the control device (300) is set up to record the quantity of foreign substances (FS) and / or contaminants (K) separated in the first separation device (220).

4. Device according to claim 3, wherein the stock preparation unit (200) further comprises a thickening device (230) and a second separation device (240), wherein the thickening device (230) is configured to at least partially remove the process water (PW) added for fiberization from the stock stream (SS), and the second separation device (240) is configured to separate foreign substances (FS) and / or contaminants (K) contained in the removed process water (PW) from the process water (PW), wherein the control device (300) is configured to detect the quantity of foreign substances (FS) and / or contaminants (K) separated in the second separation device (240).

5. Device according to claim 4, wherein the second separation device (240) is configured to separate foreign substances (FS) and / or contaminants (K) from the process water (PW) by means of mechanical and / or chemical purification stages and in particular by means of flotation, preferably microflotation and / or disc filters and the like.

6. Device (1) according to claim 1 or 2, wherein the material stream (WS) containing recyclables comprises plastic-containing recyclables, and the material processing unit (200) as material processing equipment comprises a comminution device (210), a pre-cleaning device (220), a It has an intensive cleaning facility (230) and a processing facility (240).

7. Device according to one of the preceding claims, wherein Limit values ​​are specified for the quantities of discharged foreign substances (FS) and / or contaminants (K) detected by the control device (300), and the control device (300) controls the reject device (110) in such a way as to meet but not exceed the specified limit values.

8. Device according to one of the preceding claims, wherein the device further comprises a first detection device (410) configured to detect components of the material stream (WS) supplied to the dry sorting unit, and the control device (300) configured to categorize the detected components of the material stream (WS) with respect to foreign matter (FS) and / or contaminants (K), and the control device (300) configured to control the reject device (110) on the basis of the components of the material stream (WS) detected by the first detection device (410).

9. Device according to claim 8, wherein the device further comprises a second detection device (420) configured to detect components of the material stream (SS) after sorting by the reject device (110) in the dry sorting unit (100), and the control device (300) configured to control the reject device (110) on the basis of the components of the material stream (SS) detected by the second detection device (420).

10. Device according to claim 8 or 9, wherein the first and / or second acquisition device (410, 420) is an image acquisition device or a spectral analysis device, in particular a near-infrared scanning device.

11. Method for processing a material stream containing recyclables (WS), which in particular comprises fiber-containing and / or plastic-containing recyclables, comprising a dry sorting unit (100) in which the material stream containing recyclables (WS) is sorted by a reject device (110) into a reject stream (AS) and a material stream (SS), and a material processing unit (SS) in which foreign materials (FS) and / or contaminants (K) are removed from the material stream (SS) in a material processing unit (200) comprising at least one material processing device (210, 220, 230, 240), wherein in the dry sorting the reject device is controlled depending on the quantity of foreign materials (FS) and / or contaminants (K) removed in the material processing device (210, 220, 230, 240).

12. Method according to claim 11, wherein the method is carried out in a device according to one of the preceding claims.

13. Use of a material stream (SS) obtained from a material stream (WS) containing valuable materials, which in particular comprises fiber-containing and / or plastic-containing valuable materials, for papermaking or for the production of secondary plastics, wherein the material stream is processed in the device according to one of the preceding claims and / or according to the method according to one of the preceding claims.

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