High Consistency Dispersing for Recycled Textile Fiberization
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Solution Overview
Problem
Current methods for processing recycled textile materials require high energy and long dwell times to fully fiberize the material, often leaving some pieces unfiberized due to low consistency pulping.
Innovation Solution
A system and method that includes a dispersing section with dispergators or HC-refiners to tear recycled textile materials into fibers or fiber flocks at high consistency (15-90%), followed by a refining section with refiners to further process at low or high consistency, optimizing energy consumption and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If low consistency pulping is used to process recycled textile material, then the processing can be done with simpler equipment, but the energy consumption increases and long dwell times are required
Solution Approach 1:
The processing system is divided into two distinct sections: a dispersing section that operates at high consistency (15-90%) to perform initial tearing and fiberization, and a refining section that operates at low consistency (3-6%) for final refinement. This segmentation allows each section to be optimized for its specific function, reducing overall energy consumption while maintaining processing effectiveness.
Solution Approach 2:
The dispersing section performs preliminary dispersing and tearing of textile pieces into fibers and fiber flocks at high consistency before the material enters the refining section. This preliminary action reduces the workload and energy requirements of the subsequent refining process, as the material is already partially fiberized when it enters the low consistency refining stage.
2Device complexity
If low consistency pulping is used, then equipment simplicity is maintained, but unfiberized pieces remain after processing
Solution Approach 1:
The system segments the fiberization process into two stages: first, the dispersing section tears textile pieces into fibers and fiber flocks at high consistency; second, the refining section refines these fibers at low consistency to achieve complete fiberization. This two-stage approach ensures complete fiberization while keeping individual equipment sections relatively simple.
Solution Approach 2:
The dispersing section performs preliminary tearing and dispersing of textile material into fibers and fiber flocks before the refining section processes the material. This preliminary action ensures that the material is sufficiently prepared for complete fiberization in the refining stage, eliminating unfiberized pieces while maintaining equipment simplicity.
3Use of energy by moving object
If high consistency dispersing is used, then energy consumption is reduced, but the equipment complexity increases
Solution Approach 1:
The system segments the processing into a dispersing section with specific high consistency requirements (15-90%) and a refining section with low consistency requirements (3-6%). Each section is designed with appropriate equipment for its specific consistency range, allowing optimized energy consumption in the dispersing section while maintaining overall system manageability through functional segmentation.
Solution Approach 2:
The system changes the consistency parameter between the two processing stages: the dispersing section operates at high consistency (15-90%) to reduce energy consumption and improve dispersing efficiency, while the refining section operates at low consistency (3-6%) for final fiber refinement. This parameter change optimizes energy usage while the functional segmentation keeps equipment complexity manageable.
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 minimizes energy usage and effectively converts textile pieces into fibers or small flocks with specific energy consumption ranging from 30-500 kWh/t, enabling efficient further processing and reducing residual unfiberized material.
Implementation Method 1
the dispersing section is configured to perform a dispersing stage to tear pieces of recycled textile into fibers and/or fiber flocks
Implementation Method 2
the refining section comprising at least one refiner and configured to perform a refining stage to refine in low consistency of 3-6 % the fibers and/or the fiber flocks
Data Source
Figure 1~2
Figure 3A~4
AI summary
The invention relates to a system of processing recycled textile material comprising synthetic fibers and non-synthetic fibers, which system (10) comprises feeding means (11) and a dispersing section (12). The dispersing section (12) is configured to perform a dispersing stage to tear pieces of recycled textile into fibers and/or fiber flocks in high consistency of 15-90%, more advantageously 20-60%, most advantageously 25-45% and the dispersing section (12) comprises at least one dispergator (121) or at least one HC-refiner with fillings formed of bars with bar width of 1,5 mm - 20 mm and grooves with groove depth of 1 mm - 50 mm and groove width of 1 mm - 20 mm. The invention also relates to a method of processing recycled textile fibers, in which method recycled textile material comprising synthetic fibers and non-synthetic fibers, in particular cotton fibers, is processed, which method is performed in a system (10) comprising feeding means (11) and a dispersing section (12), which method comprises a feeding stage, in which pieces of the recycled textile material is fed and/or shredded by the feeding means (11), and a dispersing stage, in which the pieces of the recycled material are torn to fibers and/or fiber flocks of the recycled textile material in the dispersing section (12). The dispersing stage to tear pieces of recycled textile into fibers and/or fiber flocks is performed in high consistency of 15-90%, more advantageously 20-60%, most advantageously 25-45% by at least one dispergator (121) or at least one HC-refiner with fillings formed of bars with bar width of 1,5 mm - 20 mm and grooves with groove depth of 1 mm - 50 mm and groove width of 1 mm - 20 mm.