High-Shear Processor and Cyclone Separation for Aluminum–Polyolefin Recycling
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Solution Overview
Problem
Existing methods struggle to efficiently separate aluminum and polyolefins from composite materials in waste treatment, leading to high chemical consumption and difficulty in achieving acceptable purity, with foaming issues hindering processing.
Innovation Solution
A processor with a cyclone system, including a decentralized tangential inlet and central outlet, and a hydrocyclone design with a convexly curved outlet, combined with high shear forces and controlled liquid flow, facilitates the separation of aluminum and polyolefins using a multi-stage process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional washing processes with extensive chemicals are used to separate aluminum and olefins, then separation can be achieved, but chemical consumption increases and operational costs rise
Solution Approach 1:
The patent replaces chemical washing processes with a mechanical separation system consisting of a processor with high shear forces and a cyclone separator. The processor mechanically breaks down composite materials and separates components based on size and density, eliminating the need for extensive chemical usage while achieving effective separation of aluminum and polyolefins.
Solution Approach 2:
The patent employs a cyclone separator that uses centrifugal force generated by rotating airflow to separate particles based on density and size. This pneumatic separation mechanism replaces chemical washing, reducing chemical consumption while maintaining separation effectiveness for different material components.
2Productivity
If high shear forces are applied to separate materials in the processor, then separation efficiency improves, but energy consumption increases
Solution Approach 1:
The patent divides the separation process into two distinct stages: (1) mechanical breakdown and initial separation in the processor using high shear forces, and (2) further separation and classification in the cyclone separator. This segmentation allows each stage to be optimized independently, reducing overall energy consumption while maintaining high separation efficiency.
Solution Approach 2:
Instead of using only high-energy mechanical processing to achieve separation, the patent inverts the approach by first applying mechanical forces for breakdown and then using the cyclone separator which operates with lower energy input to complete the separation based on density and size differences, thereby reducing total energy consumption.
3Manufacturing precision
If washing liquid is used to facilitate separation, then separation effectiveness improves, but foaming occurs which hinders processing
Solution Approach 1:
The patent replaces wet washing processes that generate foam with a primarily mechanical separation system. The processor and cyclone separator achieve separation through mechanical forces and centrifugal action without requiring extensive washing liquids, thereby eliminating foaming problems while maintaining separation effectiveness.
Solution Approach 2:
The patent extracts and removes the washing liquid component from the separation process, relying instead on mechanical breakdown and centrifugal separation. This extraction of the problematic element (washing liquid that causes foaming) allows the separation process to proceed without foaming interference while maintaining effectiveness.
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
The system achieves efficient separation of aluminum and polyolefins with minimal chemical use, reducing operational costs and improving purity, while minimizing foaming and energy consumption.
Implementation Method 1
the mixture is mixed in a processing area of a processor under high shear forces
Implementation Method 2
A cyclone not belonging to the invention has a head section with a decentralized, preferably tangential inlet and a central outlet
Implementation Method 3
a hydrocyclone design with a convexly curved outlet, combined with high shear forces and controlled liquid flow, facilitates the separation of aluminum and polyolefins
Implementation Method 4
it has a screen or perforated plate that separates an upper flow from an underflow
Data Source
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AI summary
The invention relates to a method for treating composite materials of aluminum and plastics, in which the composite materials are mixed in a working area of a processor under high shear forces with a spiral in order to remove the aluminum layer from the plastic layer and to suspend it. The particles which are separated by a screen from the working area are treated in a hydrocyclone in order to separate aluminum from the liquid, wherein fibers present in the underflow are fed back with the liquid to the processor.