Cutting Compressor Gas Injection for Plastic Recycling Moisture Removal
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Solution Overview
Problem
Existing plastic recycling processes face issues with high residual moisture, large density fluctuations, and problematic substances that lead to reduced extruder performance, non-uniform melting, and increased energy requirements, which can result in lower productivity and material quality.
Innovation Solution
A process and apparatus that introduce a gas capable of absorbing and entraining problematic substances, such as air or an inert gas, into the cutting compressor below the material level, allowing for effective removal of volatile substances and moisture by creating a forced flow through the material, particularly between the mixing tools, and using perforations in the carrier disk to facilitate the escape of volatile substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If material is processed in a single-zone compressor without gas introduction, then device complexity is reduced, but problematic substances and moisture cannot be effectively removed, leading to reduced product quality and increased energy consumption in the extruder
Solution Approach 1:
The processing system is divided into two independent zones: a first zone for comminution and drying, and a second zone for pressing and plasticization. This segmentation allows each zone to be optimized for its specific function, with the first zone removing problematic substances and moisture before material enters the extruder, thereby improving material quality uniformity without excessive complexity
Solution Approach 2:
A gas introduction device is introduced as an intermediary component in the first zone to facilitate the removal of volatile substances and moisture. This mediator enables effective separation of problematic substances from the material without requiring complex modification of the extruder itself
2Reliability
If high processing temperatures are used to ensure sufficient plasticization, then material processing reliability is improved, but energy consumption increases and thermal damage to material occurs
Solution Approach 1:
The first zone performs preliminary drying and heating of the material before it enters the extruder. By removing moisture and volatile substances in advance, the material requires less energy for plasticization in the extruder, reducing peak temperatures and overall energy consumption while maintaining reliable plasticization
Solution Approach 2:
The process changes the temperature profile from a single high-temperature stage to a two-stage profile: moderate heating in the first zone for drying, followed by controlled heating in the second zone for plasticization. This parameter change reduces thermal damage and energy consumption while ensuring sufficient plasticization
3Ease of operation
If material with high residual moisture is processed without pre-drying, then ease of operation is improved, but extruder performance deteriorates and productivity decreases
Solution Approach 1:
The system segments the processing into a first zone dedicated to drying and comminution, and a second zone for extrusion. This allows high-moisture material to be effectively dried in the first zone before entering the extruder, maintaining high productivity without complicating operation, as the drying function is integrated into the feeding mechanism
4Device complexity
If carrier disk operates without perforations, then device complexity is reduced, but volatile substances accumulate under the disk, contaminating the extruded material
Solution Approach 1:
The carrier disk is designed with perforations that create a porous structure, allowing volatile substances and moisture to escape from the space under the disk. This simple structural modification effectively prevents contamination of the extruded material without significantly increasing device complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a more uniform material temperature and quality, reduced energy consumption, and increased productivity by up to 15% while minimizing the inclusion of volatile substances in the extruded material, leading to improved processing conditions and higher granulate quality.
Implementation Method 1
introduce a gas capable of absorbing and/or entraining the problematic substances, especially air or an inert gas, into the interior of the cutting compressor from below
Implementation Method 2
introduce a gas capable of absorbing and/or entraining the problematic substances
Implementation Method 3
A forced flow is formed thereby and the gas flows through at least a partial region of the material
Implementation Method 4
removal of volatile substances given off from the processed material occurs in the space under the upper carrier disk
Data Source
AI summary
The invention relates to a process and an apparatus for the treatment of a material in the form of fragments or particles which is moved and/or rotated, mixed, heated and, if appropriate, comminuted by at least one mixing element (12, 21) in a receiver or cutter-compactor (1), where, in the course of the process, undesired substances which impair the treatment of and/or further operations on the material are removed from the material by introducing a gas, in particular air or an inert gas, in a region below the level of the material located in the receiver (1) during its operation, or below the level of material of the mixing vortex which forms within the receiver (1), where the gas is forced to flow through at least a subregion of the material, and where the gas then saturated with, or with an increased concentration of, undesired substances is discharged from the receiver (1) in a region above the level of the material located in the receiver (1) during its operation or above the level of the material of the mixing vortex.