Method for processing fibrous matter from waste material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for processing fibrous materials from waste are not suitable for multiple types of lignocellulosic fibers, result in low-quality fibers with inconsistent properties, are resource-intensive, and have high environmental impact, limiting scalability and economic viability.
Innovation Solution
A method involving mechanical and chemical treatments, including trimming, pre-treating, washing with pressurized fluid, enzyme treatment, heating, and hydro-extraction, followed by drying and spinning, to produce high-quality fibers suitable for various applications, while reducing water and chemical consumption and enhancing sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional processing methods are used for lignocellulosic fibers, then the processing can be performed with existing infrastructure, but the fiber quality is low and suitable only for paper or non-woven applications, not spinning
Solution Approach 1:
The patent applies multiple parameter changes including chemical treatment (enzyme solution, alkaline solution), physical treatment (steam explosion, high-pressure water jet), and mechanical treatment (carding, combing) to transform low-quality lignocellulosic fibers into high-quality spinnable fibers with improved strength, uniformity, and cleanliness
Solution Approach 2:
The patent creates a composite processing approach by combining multiple treatment methods (chemical, physical, mechanical) in sequence to achieve fiber quality that enables spinning applications, transforming the fiber properties through cumulative effects of different processing techniques
2Adaptability or versatility
If conventional processing methods are used, then the process can be established, but it is not suitable for multiple kinds of lignocellulosic fibers, requiring different production lines for different fiber types
Solution Approach 1:
The patent develops a universal processing method that can handle multiple types of lignocellulosic fibers (cotton stalk, jute, hemp, flax, etc.) using the same production line and equipment sequence, eliminating the need for separate specialized lines for each fiber type through standardized multi-functional processing steps
3Object-affected harmful factors
If conventional processing methods are used, then processing can be performed, but water and chemical consumption is high, and the process is not eco-friendly
Solution Approach 1:
The patent implements water recovery and reuse systems where process water is treated and recycled back into the processing sequence, significantly reducing fresh water consumption. Chemical solutions are also optimized and reused where possible to minimize chemical waste and environmental impact
Solution Approach 2:
The patent replaces conventional high-chemical-intensive processing methods with a balanced approach that uses mechanical treatments (high-pressure water jet, carding, combing) combined with optimized chemical treatments, reducing overall chemical consumption while maintaining fiber quality
4Productivity
If conventional processing methods are used, then processing can be performed, but the process is expensive and highly error-prone due to precision required, and not scalable
Solution Approach 1:
The patent divides the processing into distinct sequential stages (trimming, steaming, chemical treatment, mechanical treatment, drying) that can be independently optimized and controlled, improving process consistency and enabling scalable replication across different production facilities
Solution Approach 2:
The patent applies preliminary treatments (steam explosion, enzyme treatment) before main processing steps to prepare the fibers, making subsequent processing more consistent and reliable. This preliminary preparation reduces variability and improves overall process predictability and scalability
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 method produces fibers with improved tensile strength, consistency, and natural properties, reducing resource consumption and environmental footprint, making it scalable and adaptable for diverse industrial applications.
Implementation Method 1
Washing the obtained fibers with pressurized fluid to obtain a densely packed fiber
Implementation Method 2
Providing a first chemical treatment with an enzyme and water solution
Implementation Method 3
Heating the refilled container at a temperature of 60-140 degree Celsius at 3-11 bar in a mixture of chemical and water to obtain a fiber cake
Implementation Method 4
Providing controlled shock waves to the fiber cake
Implementation Method 5
Hydro-extracting a chemically treated fiber cake
Implementation Method 6
Drying the opened fibers
Data Source
AI summary
A method 100 for processing fibrous matter from a waste material involves obtaining 101 the waste material, trimming 102 the waste material, pre-treating 104, second mechanical treatment 106, washing 108, first chemical treatment 110 with an enzyme and water solution, draining 112 the enzyme and water solution, heating 114 to obtain a fiber cake, providing 116 controlled shockwaves, a second chemical treatment 118, hydro-extracting 120 fiber cake, opening 122 the fiber cake, drying 124, pre-conditioning and softening 126, mechanically treating and segregating 128, softening 129, processing 130 to obtain a sliver and spinning 132 the sliver to obtain a product.