Horizontal Recycled Material Pulper System for Gravity Separation
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Solution Overview
Problem
Existing recycling processes for materials like paper and bio waste are inefficient due to the need for extensive space and time-consuming impurity removal, especially when using vertically positioned pulpers and conveyors, which disrupts the continuous processing and reduces overall capacity.
Innovation Solution
A horizontal processing system with partitioned vessels allows for gravity-driven separation of impurities, eliminating the need for pumps and enabling a continuous, easy-to-control process that is shallow and cost-effective, with all stages connected sequentially to facilitate quick flushing during malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vertical pulpers and conveyors are used for impurity removal, then separation effectiveness is improved, but space requirements and processing time increase significantly
Solution Approach 1:
The patent transitions from vertical arrangement of pulpers and conveyors to a horizontal arrangement where pulpers are positioned side-by-side in the same horizontal plane. This dimensional change eliminates the need for vertical stacking and long vertical conveyors, significantly reducing the vertical space footprint while maintaining the sequential processing capability for effective impurity removal.
Solution Approach 2:
The patent combines multiple pulpers and processing stages into a single horizontal plane, merging what were previously separate vertical units into an integrated horizontal system. This consolidation reduces the overall space requirements by eliminating the need for multiple levels and complex vertical conveyor connections between separate pulpers.
2Manufacturing precision
If vertical pulpers with long conveyors are used, then impurity removal capability is improved, but the duration of material removal process increases
Solution Approach 1:
By arranging pulpers horizontally in the same plane rather than vertically stacked, the patent enables gravity-driven horizontal flow of material between pulpers. This eliminates the need for long vertical conveyors and complex material transfer mechanisms, significantly reducing the time required for material to pass through each processing stage while maintaining effective impurity removal capability.
Solution Approach 2:
The horizontal arrangement with gravity-driven flow between pulpers creates a continuous material stream that moves sequentially through each processing stage without interruption. This eliminates idle time associated with vertical conveyor loading/unloading and enables continuous operation, reducing the overall duration of the material removal process.
3Manufacturing precision
If sequential processing with vertical pulpers is used, then processing thoroughness is improved, but overall productivity decreases
Solution Approach 1:
The horizontal arrangement of multiple pulpers in parallel allows material to flow continuously through each stage in sequence without the bottlenecks inherent in vertical stacking. This maintains the thoroughness of sequential processing while enabling simultaneous operation of multiple pulpers, thereby increasing overall system capacity and productivity.
Solution Approach 2:
The patent divides the processing system into multiple independent horizontal pulper units that can operate in parallel. Each pulper performs a specific stage of impurity removal, and the horizontal arrangement allows these segmented units to process material simultaneously, increasing overall throughput while maintaining processing thoroughness.
4Ease of operation
If complex conveyor systems are used for material transfer, then material handling capability is improved, but device complexity increases
Solution Approach 1:
By positioning all pulpers in the same horizontal plane, the patent enables gravity-driven material flow between stages without requiring complex vertical conveyors, elevators, or multi-level transfer mechanisms. This simplifies the conveyor system to basic horizontal conveyors or even gravity flow channels, dramatically reducing system complexity while maintaining effective material handling capability.
Solution Approach 2:
The horizontal arrangement allows material to move between pulpers using gravity alone, eliminating the need for powered vertical conveyors and complex transfer mechanisms. The system uses its own weight and the horizontal slope to drive material flow, reducing mechanical complexity and eliminating the need for additional motors and controls on conveyor systems.
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 configuration significantly reduces space requirements, enhances processing capacity, and allows for fast and effective impurity removal, improving the overall efficiency of recycling processes by maintaining continuous operation even during interruptions.
Implementation Method 1
Particles of recycled material that are heavier than water will settle at the bottom of the vessel, as will the material containing impurities or material that is difficult to pump between process stages. The material settling at the bottom may be transferred to the next process stage with the help of gravity.
Implementation Method 2
Particles of recycled material that are heavier than water will settle at the bottom of the vessel
Data Source
Figure 1
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Figure 4~5
AI summary
An apparatus and a method for processing recycled material, comprising a first pulper (3) having an inlet (2) for receiving recycled material (1), a water inlet (26) for producing a mixture of water and particles of recycled material, a first rotor unit (R1) configured to slush recycled material and a first screen plate (18) connected to a first outlet (20) configured to extract a first portion of recycled material from the first pulper (3); a last pulper (8) having a reject washer configured to remove coarse rejected recycled material from the last pulper (8); and an upper channel (4) from the first pulper (3) to the last pulper (8), wherein the mixture of water and particles of recycled material is configured to flow over from the first pulper (3) to the last pulper (8). The apparatus comprises a bottom of the last pulper (8) being lower than or at the same level as the first pulper (3); a lower channel (40) at the bottom of the first pulper (3) extending to the last pulper (8); and a gate (45) at the lower channel (40), configured to cause, when open, the mixture of water and particles of recycled material to flush to the last pulper (8).