Waste Plaster Recycling System with Rolling Mill Finalization
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Solution Overview
Problem
Existing mechanical methods for recycling waste plaster struggle to achieve high productivity and purity levels for recovered gypsum, resulting in significant waste and increased costs.
Innovation Solution
A system comprising a waste preparation unit with magnetic sorting, a grinding and sorting unit with flip-flop screens, and a finalization unit with rolling mills and sorting devices, which efficiently separates gypsum from other materials, achieving high purity and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical grinding and sorting methods are used to separate gypsum from waste plaster, then the separation process is simpler and less costly than chemical methods, but the productivity and purity of recovered gypsum are insufficient
Solution Approach 1:
The system segments the waste plaster processing into distinct stages: preliminary sorting, grinding, classification by multiple screens with different mesh sizes, and magnetic separation. Each stage handles specific size ranges and material types, allowing the system to process mixed waste plaster effectively while maintaining high productivity and purity levels.
Solution Approach 2:
Different screening stages use locally optimized mesh sizes tailored to specific separation needs. The first screen uses a coarser mesh for initial separation, while subsequent screens use progressively finer meshes to achieve the target purity level, allowing each local stage to be optimized for its specific function.
2Manufacturing precision
If sorting is performed at smaller dimensions to achieve high gypsum purity, then the purity rate increases, but the productivity decreases and rejects increase
Solution Approach 1:
The sorting process is divided into multiple sequential screening stages, each handling a specific size range. This segmentation allows the system to achieve high purity through progressive refinement without bottlenecking at any single stage, maintaining overall productivity while reaching the desired purity level.
Solution Approach 2:
The system adds the dimension of time by implementing sequential multi-stage screening rather than attempting single-pass separation. This temporal dimension allows material to be progressively refined through multiple passes at different screen sizes, achieving high purity without sacrificing the throughput capacity of individual stages.
3Manufacturing precision
If waste plaster is ground to separate gypsum from paper and cardboard, then separation is possible, but adherent plaster makes detachment difficult and causes clogging
Solution Approach 1:
The system separates the grinding and classification functions into distinct stages. Material is ground to a coarse extent first, then progressively classified through multiple screening stages. This segmentation prevents fine plaster particles from clogging screens while still achieving effective separation, as each stage handles appropriate particle size ranges.
Solution Approach 2:
The system uses dynamic classification where material flow and screen selection adapt to the progressive breakdown of adherent plaster. As plaster detaches from paper and cardboard through grinding, the multi-stage screening dynamically separates freed gypsum particles from remaining composite material, preventing clogging by handling material at appropriate size stages.
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 a recycling rate of up to 99% and a gypsum purity rate of 60%, enabling effective replacement of natural gypsum, while reducing recycling costs and environmental impact.
Implementation Method 1
at least one magnetic sorting device making it possible to at least partially separate metal elements from the rest of the waste
Data Source
AI summary
The invention relates to a system (1) for recycling waste plaster originating from the general public and intended to recover a fraction, referred to as final fraction, comprising elements of particle size smaller than or equal to a determined threshold size, the system (1) comprising: • at least one waste preparation unit (2); • at least one unit (3) for crushing and sorting the waste from the preparation unit (2); • at least one recovery unit (5) recovering at least part of the fine fraction from the crushing and sorting unit (3); the system (1) being characterized in that it further comprises at least one finalization unit (4) receiving at least part of the coarse fraction from the crushing and sorting unit (3), the finalization unit (4) comprising at least one rolling mill having a roll separation less than or equal to the threshold dimension.