Thermoplastic Baling Strap with Surface Undulations for RDF Incineration
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Solution Overview
Problem
The disposal of refuse-derived fuel (RDF) bales in incinerators is inefficient due to the need to break open bales wrapped with metal straps, leading to uncontrollable burn rates and increased CO2 emissions, as the metal straps must be cut and handled separately, causing logistical and environmental issues.
Innovation Solution
A thermoplastic baling strap with surface undulations that allows for secure knotting and gripping, enabling bales to be fed directly into incinerators without unwrapping, made from materials like polypropylene or polyethylene terephthalate, and manufactured using extrusion processes with impression rollers to create the undulating surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal wire straps are used to compress and hold RDF bales together, then the bales can be compressed under high force (around 100 tonnes) and transported efficiently without coming apart, but the metal wire must be cut and handled separately before incineration, causing increased CO2 emissions, additional labor, and reduced controllability of the burn rate
Solution Approach 1:
The harmful metal wire straps are extracted and replaced with a thermoplastic strap that can be incinerated with the RDF bale, eliminating the need for separate cutting and handling operations that generate CO2 emissions and require additional labor
Solution Approach 2:
The material parameter of the strap is changed from metal to thermoplastic, fundamentally altering its end-of-life behavior from requiring mechanical cutting to being incineratable, thus resolving the contradiction between strong compression and reduced harmful factors
2Stability of the object's composition
If metal wire straps are used to secure RDF bales, then the bales maintain structural integrity during transport and storage, but the wire must be cut to recover the steel wire for recycling, which causes the bales to unfold and expand over a large area, requiring bulldozers or mechanical handling equipment that increases operational complexity
Solution Approach 1:
The metal wire strap is replaced with a thermoplastic strap that can be incinerated with the bale, eliminating the need for separate unwrapping operations and mechanical handling equipment like bulldozers
Solution Approach 2:
The thermoplastic strap is designed as a disposable element that is incinerated with the RDF bale, eliminating the need for wire recovery and recycling operations, thus simplifying the handling process and reducing equipment requirements
3Productivity
If metal wire straps are used to bind RDF bales, then the bales can be efficiently transported without coming apart, but the wire straps prevent direct feeding of complete bales into incinerators, requiring bales to be broken open which makes it difficult to control the burn rate and power production
Solution Approach 1:
The strap material is changed from metal to thermoplastic, enabling the entire bale including the strap to be fed directly into the incinerator without breaking open, thus maintaining transport efficiency while enabling direct bale feeding and better burn rate control
Solution Approach 2:
The thermoplastic strap is designed to be compatible with the RDF bale material, allowing both to be incinerated together as a unified system, eliminating the need to separate the binding element from the fuel material
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 solution allows for automated handling and controlled burn rates, reduces labor and environmental impact by eliminating the need to break open bales, maintains moisture stability, and simplifies handling processes, while also eliminating the need for metal strap collection.
Implementation Method 1
a heating chamber for heating said thermoplastic cable
Implementation Method 2
an extrusion die for extruding said thermoplastic cable into an extruded strip
Implementation Method 3
a set of one or more impression rollers for applying a set of undulations to an outer surface of said extruded strip
Data Source
AI summary
A thermoplastic baling strip comprises an elongate band of thermoplastic material said elongate band having sufficient flexibility to be formed into a knot; the elongate band having an outer surface formed with a set of surface undulations extending along its main length. The plurality of surface undulations operate in use to grip a surface to which said strip surface contacts. The use of undulations extending along the length of the strip enable the strip to be reliably tied in a knot, without releasing or coming undone when transported. Complete bales can be fed into an incinerator without the need to remove the baling strip, which burns on incineration.