U.S. patent application number 12/839655 was filed with the patent office on 2011-01-20 for wet pulping system and method for producing cellulosic insulation with low ash content.
This patent application is currently assigned to Fiberight LLC. Invention is credited to Milton L. Gerber, Steven A. Gerber, Eric M. Oganesoff, Craig Stuart-Paul.
Application Number | 20110011544 12/839655 |
Document ID | / |
Family ID | 43464453 |
Filed Date | 2011-01-20 |
United States Patent
Application |
20110011544 |
Kind Code |
A1 |
Gerber; Steven A. ; et
al. |
January 20, 2011 |
WET PULPING SYSTEM AND METHOD FOR PRODUCING CELLULOSIC INSULATION
WITH LOW ASH CONTENT
Abstract
Apparatus and method for recovering organic cellulosic fibers
from landfill materials (such as post consumer, municipal and
industrial waste materials). The apparatus and method selectively
introduces waste materials containing organic cellulosic fibers
into a size reduction machine. The pre-cleaned waste materials are
conveyed to a tank, drum, or tunnel type fiber recovery apparatus.
The waste materials are subjected to mechanical and fluid
fiberization for a selected period of time to produce useful
products, such as cellulosic insulation with a total ash content
equal to or less than 10%, as well animal and fowl bedding products
that is substantially devoid of moisture content, among other
products.
Inventors: |
Gerber; Steven A.; (South
Hill, VA) ; Oganesoff; Eric M.; (Potomac, MD)
; Gerber; Milton L.; (Cedarville, MI) ;
Stuart-Paul; Craig; (Catonsville, MD) |
Correspondence
Address: |
WHITEFORD, TAYLOR & PRESTON, LLP;ATTN: GREGORY M STONE
SEVEN SAINT PAUL STREET
BALTIMORE
MD
21202-1626
US
|
Assignee: |
Fiberight LLC
Catonsville
MD
|
Family ID: |
43464453 |
Appl. No.: |
12/839655 |
Filed: |
July 20, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11610977 |
Dec 14, 2006 |
7758719 |
|
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12839655 |
|
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60750788 |
Dec 16, 2005 |
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Current U.S.
Class: |
162/4 |
Current CPC
Class: |
A01K 1/0155 20130101;
Y02W 30/64 20150501; D21C 5/02 20130101; A01K 1/0152 20130101; Y02W
30/648 20150501; D21B 1/026 20130101 |
Class at
Publication: |
162/4 |
International
Class: |
D21B 1/32 20060101
D21B001/32 |
Claims
1. A process for recovering organic cellulosic fibers from landfill
materials such as post consumer, municipal and industrial waste
materials comprising: a. selectively introducing waste materials
containing organic cellulosic fibers into a size reduction machine
without prior fluid pre-conditioning of said waste materials; b.
conveying such waste material from said size reduction machine to a
tank, drum or tunnel type fiber recovery apparatus; and c.
subjecting such waste material for a selected period of time to
simultaneous mechanical and fluid fiberization in said fiber
recovery apparatus.
2. The process of claim 1 further comprising: d. introducing a
pulping fluid containing chemicals to enhance the fiber separation
process; e. selectively treating the recovered fibers with rapidly
penetrating flame retardants, insecticidal chemicals and decay
inhibitors; f. selectively dyeing the separated fibers to selected
colors; and, g. providing solids separation reagents to selectively
remove contaminants in the pulping fluids.
3. The process of claim 2 where the pulping fluid is selectively
heated to a temperature range between about 50.degree. F. to about
200.degree. F., and wherein said simultaneous mechanical and fluid
fiberization is carried out at a temperature between about
50.degree. F. and about 200.degree. F.
4. The process of claim 1 further comprising: h. cleaning the
recovered fibers through screening and hydro-cleaning devices to
remove plastics and tramp metal; i. conveying the removed plastics
and tramp metals to a waste disposal system consisting of a
receiving tank and a sludge press; and j. extracting a high
percentage of the pulping fluid for further processing including
for reuse as a pulping medium.
5. The process of claim 1 further comprising: k. subjecting the
recovered fibers to a mechanical disk refiner to control fiber
length, fiber bundle separation and fiber surface properties.
6. The process of claim 1 further comprising: l. removing
contaminants consisting of fillers, fines, coatings and other
extraneous materials through the use of one or more clarifiers with
select solids separation reagents and polymers.
7. The process of claim 1 further comprising: m. extracting pulping
fluids and water from the recovered fibers to formulate a
cellulosic fiber wet lap of about 40% to about 60% pulp solids
content; n. fluffing the cellulosic fiber wet lap in a cake fluffer
and a disk refiner; o. drying the fluffed fibers in a flash or
tunnel dryer; and p. conveying the dried fibers to a packaging or
baling system.
8. The process according to claim 7, wherein the step of drying
comprises: drying the fluffed fibers at a temperature from about
150.degree. F. to about 700.degree. F., thereby reducing bacteria
content of the recovered fibers, and drying them to a uniform
moisture content.
9. The process according to claim 8, wherein the moisture content
is between about 10% and about 18%.
10. The process according to claim 8, wherein the dried fibers have
a bulk density of between about 2 pounds per cubic foot to about 6
pounds per cubic foot.
11. The process according to claim 8, wherein said drying step
produces dried fibers configured for use as animal and fowl bedding
and have a higher degree of absorbency than sawdust, straw, wood
shaving, or conventional paper-based bedding.
12. The process according to claim 11, wherein the dried fibers are
about six times more absorbent than sawdust, straw or wood
shavings.
13. The process according to claim 11, wherein the dried fibers are
between about 18 percent and 25 percent more absorbent than
conventional paper-based bedding.
14. The process according to claim 8, wherein said drying step
produces dried fibers are configured for use as animal and fowl
bedding and incur between about 40% to about 50% less compaction
than conventional paper-based animal and fowl bedding.
15. The process of claim 7, further comprising: q. removing
inorganic precipitated chemicals and contaminants from the
extracted pulping fluids; and r. recycling the pulping fluids back
to the primary tank/drum/tunnel fiber recovery apparatus.
16. The process of claim 15 where the removed inorganic
precipitated chemicals and selected contaminants are selected from
the group consisting of calcium hydroxide, calcium carbonate
calcites, aluminum hydroxide, aluminum oxide, magnesium hydroxide,
and various other minor hydroxides.
17. The process according to claim 1, wherein the recovered organic
cellulosic fibers comprise a final total ash content equal to or
less than about 10%.
18. The process according to claim 1, wherein the recovered organic
cellulosic fibers comprise a final total ash content of about
8.09%.
19. The process according to claim 1, wherein the recovered organic
cellulosic fibers comprise an average fiber length greater than
about 0.700 mm.
20. The process according to claim 1, wherein the recovered organic
cellulosic fibers comprise an average fiber length of about 0.780
mm.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of, and claims
priority to, co-pending U.S. patent application Ser. No.
11/610,977, filed Dec. 14, 2006, and now U.S. Pat. No. 7,758,719,
which application claims the benefit of U.S. Provisional
Application No. 60/750,788, filed on Dec. 16, 2005, the
specifications of each of which are incorporated herein in their
entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to systems and methods for
recovering cellulosic fiber from waste products such as landfill
materials, e.g., post-consumer, municipal, and industrial waste
materials, and to systems and methods for removing and recovering
adverse inorganic chemicals and materials from such products in
order to produce cellulosic thermal insulation with certain
performance and ash content characteristics, as well as to produce
material used in fowl and animal bedding with certain desirable
characteristics and filler materials for various organic and
inorganic compositions.
[0004] 2. Related Art
[0005] A widely used insulating material for homes and other
buildings is commonly manufactured by fiberizing waste (primarily
clean recycled newsprint; commonly referred to as "old newsprint"
or "ONP") that has few contaminates (such as plastic, string, metal
foil and glass), in suitable equipment (such as a hammer mill or a
disc refiner), while adding dry fire retardant chemicals (such as
boric acid and ammonium sulfate).
[0006] Cellulose insulation has been produced using a variety of
manufacturing equipment for approximately 80 years. Methodology has
only varied slightly over the years using a combination of paper
shredders, hammer-mills with sizing screens and disc refiners to
produce a market acceptable product.
[0007] The quality of cellulose insulation is defined technically
as compliance with the industry standard ASTM C739. Products are
labeled with testing results; normally from a third party testing
facility, and certain components are tested regularly by
manufacturers for quality assurance. The attributes traditionally
tested in-house by manufacturers include two fire resistance tests;
radiant panel and smoldering combustion, pH to confirm fire
retardant chemical formulation and settled density.
[0008] Customers assume compliance with ASTM C739; however consider
a quality product as one that provides the coverage per package
that is advertised (product density and package weight), product
texture or particle size, amount of contaminants and dust
level.
[0009] Product coverage dictates the economic impact to the
customer of using the product. The product density is an important
indicator of a product's eventual coverage. A product's density is
impacted by the fiber quality of the ONP, the condition of wear
surfaces in the disc refiner and chemical content. Particle size is
dictated by the condition of wear surfaces in the disc refiner and
the gap settings within the refiner. Contaminants are a factor of
the quality of the ONP and minimal process separation devices. Dust
levels are dictated by the quality of ONP, wear surface condition
in the disc refiner, chemical content and level of inorganic
components from the ONP source.
[0010] In recent years it has become more difficult to obtain clean
waste newsprint at acceptable prices in order to manufacture
cellulosic insulation using the common dry manufacturing process
mentioned above (which process is currently utilized by the entire
U.S. cellulosic insulation market). There are numerous less
expensive cellulosic fiber sources available today that all have
non-desirable compositions or are mixed with non-desirable
materials that cannot be used to manufacture cellulosic insulation
utilizing the traditional dry production process to produce
cellulosic insulation that meets Federal Specification requirements
(including those by the U.S. Consumer Product Safety Commission and
Federal Specifications such as ASTM C739-91, ASTM C739-03, ASTM
E970, ASTM C518, ASTM C1148, ASTM D778 and HH-I-515D). In addition,
the cost of clean dry waste newsprint has risen to levels that make
it difficult to economically and competitively manufacture
acceptable cellulosic insulation. This is due to the increase in
demand for clean recycled newsprint, primarily from Asia.
[0011] Modern conventional processes require the use of #8 or #9
old newspapers (ONP) that are considered a high grade of recycled
fiber. The entire process requires the use of dry ONP that has
minimal contaminants (plastic, metal waste, etc). ONP is metered
through a primary shredder, through a secondary hammer-mill and
then a disc refiner to create the finished product. Fire retardant
chemicals are metered through a pulverizer and added to the process
normally before the disc refiner.
[0012] The most significant challenge facing conventional processes
is the quality and composition of ONP. Papermaking technology has
advanced to using recycled ONP as the primary source of fiber
rather than virgin sources (trees). The addition of various fillers
(primarily calcium carbonate; CaCO.sub.3) has caused difficulty for
cellulose insulation manufacturers to maintain good (lower)
densities and a low-dust level product. The measurement of a
product's thermal performance (R-value) is hindered by high
densities and high levels of inorganic particles. Additionally, the
advent of single-stream recycling programs has significantly
reduced the availability of high quality ONP, one that is virtually
free of contaminants and is dry.
[0013] Attempts to utilize a wet process to separate cellulosic
fibers from contaminates found with or adhering to the cellulosic
fibers have been made in the past. The common approach has been to
utilize a standard hydro-pulping device to separate the cellulosic
fibers from the contaminates, utilizing a harsh mechanical process
that also degrades the fibers and leaves the contaminates in very
small pieces that are difficult or impossible to remove. This
method has not proven to be successful commercially to produce a
cellulose based fiber insulation.
[0014] There are many types of waste materials that contain
cellulosic fibers that cannot be recycled in conventional processes
and are sent to landfills because the fibers are either (i)
laminated and contain layers of plastic or metal foil (such as milk
cartons and industrial scrap from aluminum roll boxes), and/or (ii)
mixed with plastics, metal and/or glass to such a degree that it
cannot be used. In addition, current papermaking research is
directed to increasing the calcium carbonate loading, from
approximately 5 to 7%, to a much higher 15 to 20% loading by
reacting in situ calcium carbonate not only on the surface of the
fibers but also in the hollow spaces within the fibers.
[0015] Paper manufacturers continue to increase the use of calcium
carbonate as a major component in their papermaking processes to
facilitate the use of greater amounts of shorter recycled fibers
and thereby retain the desired sheet strength and other desirable
physical properties. It should be noted that typical waste paper
recycling processes, by design, retain these fillers as a necessary
component to retain the physical properties of recycled paper
stock. However, it is desirable to remove these fillers in order to
produce acceptable products for uses other than the recycling of
waste paper back into reconstituted (recycled) paper stock. Current
levels of calcium carbonate and other fillers along with the
increasing use of short fibers (fines) in the recycled waste paper
stream is presenting a major problem for dry process cellulosic
insulation manufacturers today. Products increasingly have a higher
nuisance dust content, have higher bulk densities, and lower heat
loss resistance values.
[0016] In order for a quality cellulosic thermal insulation to be
manufactured with today's recoverable waste paper and fiber
sources, the greater portion of the calcium carbonate's and other
fillers should be removed, for example, by dissolving the calcium
carbonate from within and on the fiber surfaces, and then
precipitate and remove this contaminant and other fillers. The
manufacture of quality cellulosic thermal insulation will become
increasingly more difficult using the processes and technologies
that are available today.
[0017] There have been several attempts to produce cellulosic
insulation from waste fibers using systems that utilize a
combination of wet and dry process steps. For example, U.S. Pat.
No. 6,155,020, to Deem, issued Dec. 5, 2000, discloses a method for
producing insulation out of recycled carpet utilizing a dry
shredding process to separate the useful fibers from the carpet
backing and other non-used materials.
[0018] U.S. Pat. No. 5,714,040, to Poy et al., issued Feb. 3, 1998,
discloses a method for recovering fiber from printed newspaper by
loading the waste paper and water into a continuous batch fiber
recovery apparatus. All are agitated within the apparatus to form a
pulp fiber slurry while introducing de-inking and agglomerating
compositions to causes ink particles associated with the printed
newspaper to separate. These ink particles are then removed from
the pulp using separation techniques.
[0019] U.S. Pat. No. 5,272,852, to Fortin et al., issued Dec. 28,
1993, discloses a process where an insulating pulp is formed from
debarked trees, primarily black spruce, using a
chemi-thermo-mechanical pulping process to make a fluffed form or
to form a compressed sheet that is later defiberized utilizing a
portable insulating pulp applicator. The resulting product has a
fire retardant additive in the range of 10%-25% by weight.
[0020] U.S. Pat. No. 5,084,307, to Nishimoto et al., issued Jan.
28, 1992, discloses a flame retardant vegetable fiber material and
a process for the production of this material. Vegetable fiber is
immersed into two inorganic solutions to fill the inherent gaps of
the fiber to create an insoluble and incombustible inorganic
compound that can be used as a fire retardant material such as
asbestos or rock wool. The inorganic solutions utilized include
first, magnesium chloride, barium chloride, calcium carbonate,
aluminum chloride, aluminum borate and aluminum sulfate and second,
ammonium sulfate, ammonium pyrophosphate, ammonium magnesia and
boric acid soda.
[0021] U.S. Pat. No. 4,454,992, to Draganov, issued Jun. 19, 1984,
discloses a combination wet/dry system that utilizes an aqueous
solution of non-hydroscopic fire retardants to produce cellulosic
insulation. The process described uses a predominately dry process
to grind shredded newsprint and add fire retardant chemicals in a
wet form with elevated temperature to utilize a low amount of fire
retardant chemicals to meet commercial fire retardancy
requirements.
[0022] There also have been attempts to produce non-insulation
products from waste fibers that focus on separating the fibers from
non-fibrous materials. For example, U.S. Pat. No. 4,737,238, to de
Ruvo, et al., issued Apr. 12, 1988, discloses a process for
treating waste paper containing aluminum and having high lignin
content by de-lignifying and pulping the waste paper for reuse in
papermaking.
[0023] U.S. Pat. No. 4,760,717, to Ponzielli, issued Aug. 2, 1998,
discloses a process that uses a hydro-pulping like apparatus to
separate plastic film from cellulosic fibers goods. This process
acts like a blender to shred the materials during processing.
[0024] U.S. Pat. No. 6,238,516, to Watson et al., issued May 29,
2001, discloses a system and process whereby pulping machines are
utilized to recycle plastic and cellulosic fibers from disposed
diapers. The process utilizes a similar fiber recovery apparatus to
separate the plastic from the cellulosic fibers, then clean the
plastic and cellulosic fibers from all waste material for further
use.
[0025] Despite these known approaches, and the increasing need for
quality waste products, no commercial process has been developed to
produce cellulosic insulation out of waste paper materials that are
contaminated with a high degree of calcium carbonate, fines, and
other non-organic materials (such as plastics, foils, glass, metal
and other non-organic content), and materials that are contained
in, commingled with, or laminated to the cellulosic fibers or waste
fibers. These waste materials are currently sent to a landfill and
landfills are becoming increasingly scarce and difficult to
build.
[0026] In regard to animal and fowl bedding materials, conventional
paper-based bedding frequently contains contaminants that are a
result of poor quality old newspapers. Since the animals frequently
ingest the bedding, some of these contaminants can cause illness
and therefore growth issues with the animals. Mold and bacteria are
a significant problem with conventional wood shavings or sawdust.
These also are supplied with widely varying levels of moisture.
[0027] Conventional paper-based bedding has previously been
supplied either as chips of paper or as fiber. These tend to not be
as absorbent and compact tightly minimizing the thermal advantages.
Customers will endeavor to reconstitute or fluff up their bedding
to allow it to dry and gain additional life from the bedding.
Conventional paper-based bedding is produced in a dry process using
various shredders and hammer-mills, thus making the addition of
additives that adequately adhere to the fibers difficult or
inefficient.
[0028] Conventional paper-based bedding is produced using ONP and
other common recycled paper based products. Conventional processes
do not have the capability of managing and therefore reducing the
inorganic components of the raw material. Inorganic particles add
to the dust level of the finished product, add no absorption
qualities and aid in the compaction issues inherent with
paper-based bedding.
[0029] There are several purposes for providing animal and fowl
bedding: animal and fowl bedding absorbs excess moisture from the
droppings and drinkers and promotes drying by increasing the
surface area of the house floor; animal and fowl bedding dilutes
fecal material, thus reducing contact between birds and manure; and
in the poultry industry, animal and fowl bedding insulates chicks
from the cooling effects of the ground and provides a protective
cushion between the birds and the floor.
[0030] An effective bedding material must be absorbent,
lightweight, inexpensive and non-toxic. Ideal materials will have
high moisture absorption and release qualities to minimize litter
caking. In addition, a bedding material must be compatible as a
fertilizer or soil amendment or for incineration after it has
served its purpose in the poultry house.
[0031] Excess moisture in the litter increases the incidence of
breast blisters, skin burns, scabby areas, bruising, condemnations
and downgrades. The wetter the litter, the more likely it will
promote the proliferation of pathogenic bacteria and molds. Wet
litter is also the primary cause of ammonia emissions, one of the
most serious performance and environmental factors affecting
broiler production today. Controlling litter moisture is the most
important step in avoiding ammonia problems.
[0032] Conventional animal and fowl bedding products have
significant disadvantages, as Table I indicates:
TABLE-US-00001 TABLE I Advantages and Disadvantages of Various
Animal and Fowl Bedding Materials Pine shavings Preferred litter
material but becoming limited and sawdust in supply and expensive
in areas. Hardwood shavings Often high in moisture and susceptible
to and sawdust dangerous mold growth if stored improperly prior to
use. Pine or Used successfully but may cause increased hardwood
chips incidence of breast blisters if allowed to become too wet.
Pine or Similar to chips or shavings in moisture hardwood bark
absorption capacity. Medium-sized particles preferred. Rice hulls A
good litter material where available at a competitive price. Young
chicks may be prone to litter eating (not a serious problem).
Peanut hulls An inexpensive litter material in peanut- producing
areas. Tends to cake and crust but can be managed. Susceptible to
mold growth and increased incidence of aspergillosis. Some problems
with pesticides have been noted in the past. Sand Field trials show
comparable performance to pine shavings. Long-term reuse potential
with de-caking. More difficult to maintain suitable floor
temperatures during cold weather brooding. Need ample time and
ventilation prior to brooding to assure dryness. Crushed corn cobs
Limited availability. May be associated with increased breast
blisters. Chopped straw, Considerable tendency toward caking. Mold
hay or corn stover growth can also be a disadvantage. Processed
paper Various forms of processed paper have proven to be good
litter material in research and commercial situations. Tendency to
cake with increased particle size. Top dressing paper base with
shavings may minimize this problem.
[0033] Despite these known animal and fowl bedding products, and
the increasing need for a high quality, inexpensive and widely
available product, limited commercial products or processes have
been developed to meet the needs of private and commercial animal
owners for animal and fowl bedding. These needs include: (a) a
higher degree of absorbency than sawdust, straw or wood shavings;
(b) a higher degree of absorbency than conventional paper-based
bedding; (c) a consistently manufactured product; (d) a uniform
particle size and composition; (e) a product that maintains its
uniform particle size and composition without severe compaction;
(f) improved thermal qualities; and (g) relatively quick
decomposition following disposal. Furthermore, consumer and
commercial users of animal and fowl bedding would greatly
appreciate animal and fowl bedding that is virtually free from
contamination, can be custom manufactured to include performance
enhancers, is delivered with consistent moisture content levels,
that can be purchased in packages that are relatively clean and
easy to store, and which can be used for biomass power generation
in a manner that is safe for the environment.
SUMMARY OF THE INVENTION
[0034] In one aspect of the present invention, a cellulosic thermal
insulation composition is provided with selective inorganic
contents resulting in a selective final product ash content. In
another aspect of the present invention, a composition is provided
that is produced in a wet pulping process using non-traditional raw
materials (such as beater dye, materials recycling facility (MRF)
residual, fibers laminated with plastic and/or metal foil, pulp
sludge, wet cellulosic fibers, industrial waste, mixed waste,
post-consumer mixed recyclables, mixed office waste, post-consumer
industrial fiber waste, and other commercial waste).
[0035] In another aspect of the present invention, a system and a
method are provided for manufacturing commercially saleable
cellulosic insulation from non-traditional raw materials (such as
beater dye, MRF residual, fibers laminated with plastic and/or
metal foil, pulp sludge, wet cellulosic fibers, industrial waste,
mixed waste, post-consumer mixed recyclables, mixed office waste,
post-consumer industrial fiber waste, and other commercial waste)
without utilizing a process to substantially pre-separate and
dispose of any contaminates.
[0036] In a further aspect of the present invention, a system and
method are provided to process raw materials containing cellulosic
fibers with high levels of inorganic chemicals such that the amount
of inorganic materials contained in the processed material falls
below a specific ash content that provides for a commercially
saleable cellulosic insulation.
[0037] In a further aspect of the present invention, a method is
provided for processing previously un-processable materials in a
conventional hydro pulper (such materials as beater dye, MRF
residual, fibers laminated with plastic and/or metal foil, pulp
sludge, wet cellulosic fibers, industrial waste, mixed waste,
post-consumer mixed recyclables, mixed office waste, post-consumer
industrial fiber waste, and other commercial waste that are
currently being sent to a landfill for disposal).
[0038] Still another aspect of the present invention is to provide
a method for processing previously un-processable materials (such
as beater dye, MRF residual, fibers laminated with plastic and/or
metal foil, pulp sludge, wet cellulosic fibers, industrial waste,
mixed waste, post-consumer mixed recyclables, mixed office waste,
post-consumer industrial fiber waste and other commercial waste
that are currently being sent to a landfill for disposal) whereby
the fiber recovery process releases fines, clays, calcium
carbonate, and other non-organic material into a pulping fluid,
which is then referred to as dirty water. The pulping fluid is
preferably further processed through one or more clarifiers with
select solids separation reagents to selectively remove excess
fines, clays, calcium carbonate, and other inorganic materials that
are detrimental to producing cellulosic insulation with a total ash
content equal to or less than 10%, that meets the commercial
product requirements listed herein.
[0039] Still another aspect of the present invention is to recover
commercially viable compounds (such as aluminum hydroxide,
magnesium hydroxide, and calcium carbonate) in order to reduce the
overall cost of the fiber recovery process.
[0040] Preferably, a method according to one embodiment of the
present invention processes commingled materials (such as beater
dye, MRF residual, fibers laminated with plastic and/or metal foil,
pulp sludge, wet cellulosic fibers, industrial waste, mixed waste,
post-consumer mixed recyclables, mixed office waste, post-consumer
industrial fiber waste, and other commercial waste). These
materials are first deposited into a fiber recovery apparatus such
as a tunnel washer or a hydro-pulper, where the commingled
materials are washed in a pulping fluid that includes water, fire
retardant chemicals, dyes, insecticides, biocides, surfactants,
decay inhibitors, and polymers. The disposed materials are
preferably agitated in the first two zones of the fiber recovery
apparatus, so as to separate the cellulosic fibers from the
non-cellulosic material (which includes plastic, metal foil, and
fillers such as calcium carbonate and clay, and other
contaminates). Preferably, the cellulosic material and large
containments are then transferred to a third fiber recovery
apparatus where the cellulosic fibers are filtered out and away
from the non-cellulosic fibers with the process liquor, for further
processing. Preferably, the non-cellulosic materials are then
scooped out of the end of the third zone of the fiber recovery
apparatus and disposed of. The dirtied pulping fluid is further
processed through one or more clarifiers with select solids
separation reagents and polymers to selectively remove fines,
clays, calcium carbonate and other non-organic material, and then
returned to the pulping fluid that is preferably in a closed loop
system. The cellulosic fibers are preferably further processed
through a series of presses to remove excess water and pulping
fluid, disc refiner(s) to fluff the fibers, a dryer(s), and a
packaging machine.
[0041] Another aspect of the present invention is to provide a
cellulosic thermal insulation which is formed from the materials
through the preferred wet pulping process described herein, with a
inorganic or total ash content equal to or less than 10% including
the fire retardant chemicals.
[0042] Accordingly, the above described disadvantages are overcome
and a number of advantages are realized by a first aspect of the
present invention which relates to a process for recovering organic
cellulosic fibers from landfill materials such as post consumer,
municipal and industrial waste materials comprising: a. selectively
introducing waste materials containing organic cellulosic fibers
into a size reduction machine; b. conveying such pre-cleaned waste
material to a tank, drum or tunnel type fiber recovery apparatus;
and c. subjecting such waste material for a selected period of time
to mechanical and fluid fiberization. The method of first aspect of
the present invention further comprises: d. introducing a pulping
fluid containing chemicals to enhance the fiber separation process;
e. selectively treating the recovered fibers with rapidly
penetrating flame retardants, insecticidal properties and decay
inhibitors; f. selectively dyeing the separated fibers to selected
colors; and, g. providing solids separation reagents to selectively
remove contaminants in the pulping fluids. In the first aspect of
the present invention, the pulping fluid is selectively heated to a
temperature range between about 50.degree. F. to about 200.degree.
F.
[0043] The method of first aspect of the present invention further
comprises: h. cleaning the recovered fibers through screening and
hydro-cleaning devices to remove plastics and tramp metal; i.
conveying the removed plastics and tramp metals to a waste disposal
system consisting of a receiving tank and a sludge press; j.
extracting a high percentage of the pulping fluid for further
processing; k. subjecting the recovered fibers to a mechanical disk
refiner to control fiber length, fiber bundle separation and fiber
surface properties; l. removing contaminants consisting of fillers,
fines, coatings and other extraneous materials through the use of
one or more clarifiers with select solids separation reagents and
polymers; m. extracting pulping fluids and water from the recovered
fibers to formulate a cellulosic fiber wet lap of about 40% to
about 60% pulp solids content; n. fluffing the cellulosic fiber wet
lap in a cake fluffer and a disk refiner; and o. drying the fluffed
fibers in a flash or tunnel dryer; and p. conveying the dried
fibers to a packaging or baling system.
[0044] According to the first aspect of the present invention, the
step of drying comprises: drying the fluffed fibers at a
temperature from about 150.degree. F. to about 700.degree. F.,
thereby reducing bacteria content of the recovered fibers, and
drying them to a uniform moisture content, and wherein the uniform
moisture content is between about 10% and about 18%. According to
the first aspect of the present invention, the dried fibers have a
bulk density of between about 2 pounds per cubic foot to about 6
pounds per cubic foot, and the dried fibers are used for animal and
fowl bedding and have a higher degree of absorbency than sawdust,
straw, wood shaving, or conventional paper-based bedding, and
further wherein the dried fibers used for animal and fowl bedding
are about six times more absorbent than sawdust, straw or wood
shavings. Still further according to the first aspect of the
present invention, the dried fibers used for animal and fowl
bedding are between about 18% to about 25% more absorbent than
conventional paper-based bedding, and incur between about 40% to
about 50% less compaction than conventional paper-based animal and
fowl bedding.
[0045] According to the first aspect of the present invention, the
process further comprises: q. removing inorganic precipitated
chemicals and contaminants from the extracted pulping fluids; and
r. recycling the pulping fluids back to the primary
tank/drum/tunnel fiber recovery apparatus. According to the first
aspect of the present invention, the removed inorganic precipitated
chemicals and selected contaminants comprise calcium hydroxide,
calcium carbonate calcites, aluminum hydroxide, aluminum oxide,
magnesium hydroxide and/or various other minor hydroxides. Still
further according to the first aspect of the present invention, the
recovered organic cellulosic fibers comprise a final total ash
content equal to or less than about 10%. According to the first
aspect of the present invention, the recovered organic cellulosic
fibers comprise a final total ash content of about 8.09%, and
wherein the recovered organic cellulosic fibers comprise an average
fiber length greater than about 0.700 mm. According to the first
aspect of the present invention, the recovered organic cellulosic
fibers comprise an average fiber length of about 0.780 mm.
[0046] A second aspect of the present invention is provided that
relates to a cellulosic insulating fiber product that is used for
thermal insulation in applications ranging from about -50.degree.
F. to about +170.degree. F., wherein the composition of the fiber
product has a bulk density of about 1.0 pounds per cubic foot, to
about 1.6 pounds per cubic foot, the composition of the fiber
product is substantially free of dust particles, and wherein the
composition of the fiber product has a final total ash content
equal to or less than about 10%.
[0047] According to the second aspect of the present invention, the
final total ash content is less than about 9%. According to the
second aspect of the present invention, the final total ash content
is about 8.09%, and wherein the fiber product is selectively dyed
to provide brand identification. According to the second aspect of
the present invention, the fiber product is used as acoustical
insulation, packaging materials, industrial thickeners or fillers
to be combined with other products, hydro-mulch and other related
uses.
[0048] According to a third aspect of the present invention, a
cellulosic animal and fowl bedding fiber product is provided that
is used for the absorption of excess moisture, fecal matter and
thermal insulation in animal applications, wherein the composition
of the cellulosic animal and fowl bedding fiber product has a bulk
density of about 2.0 pounds per cubic foot to about 6.0 pounds per
cubic foot, the composition of the cellulosic animal and fowl
bedding fiber product is substantially free of dust particles, and
wherein the composition of the cellulosic animal and fowl bedding
fiber product has a final total ash content equal to or less than
about 10%. According to the third aspect of the present invention,
the ash content is less than about 9%. According to the third
aspect of the present invention, the ash content is about 8.09%,
and the fiber product is selectively dyed to provide brand
identification.
[0049] According to the third aspect of the present invention, the
fiber product has a higher absorbency than wood shavings, sawdust
or straw and conventional paper-based litter, and the fiber product
reduces foot sores in poultry products in comparison to wood based
bedding. Still further according to the third aspect of the present
invention, fiber product is used for animal and fowl bedding and
incurs between about 40% to about 50% less compaction than
conventional paper-based animal and fowl bedding.
[0050] According to a fourth aspect of the present invention, a
system for recovering organic cellulosic fibers from landfill
materials such as post consumer, municipal and industrial waste
materials is provided comprising: a. means for selectively
introducing waste materials containing organic cellulosic fibers
into a size reduction machine; b. means for conveying such
pre-cleaned waste material to a tank, drum or tunnel type fiber
recovery apparatus; and c. means for subjecting such waste material
for a selected period of time to mechanical and fluid fiberization.
The system according to the fourth aspect of the present invention
further comprises: d. means for introducing a pulping fluid
containing chemicals to enhance the fiber separation process; e.
means for selectively treating the recovered fibers with rapidly
penetrating flame retardants, insecticidal properties and decay
inhibitors; f. means for selectively dyeing the separated fibers to
selected colors; and, g. means for providing solids separation
reagents to selectively remove contaminants in the pulping fluids.
According to the fourth aspect of the present invention, the
pulping fluid is selectively heated to a temperature range between
about 50.degree. F. to about 200.degree. F., and the system further
comprises: h. means for cleaning the recovered fibers through
screening and hydro-cleaning devices to remove plastics and tramp
metal; i. means for conveying the removed plastics and tramp metals
to a waste disposal system consisting of a receiving tank and a
sludge press; and j. means for extracting a high percentage of the
pulping fluid for further processing.
[0051] According to the fourth aspect of the present invention, the
system still further comprises k. means for subjecting the
recovered fibers to a mechanical disk refiner to control fiber
length, fiber bundle separation and fiber surface properties; l.
means for removing contaminants consisting of fillers, fines,
coatings and other extraneous materials through the use of one or
more clarifiers with select solids separation reagents and
polymers; m. means for extracting pulping fluids and water from the
recovered fibers to formulate a cellulosic fiber wet lap of about
40% to about 60% pulp solids content; n. means for fluffing the
cellulosic fiber wet lap in a cake fluffer and a disk refiner; o.
means for drying the fluffed fibers in a flash and/or tunnel dryer;
and p. means for conveying the dried fibers to a packaging or
baling system. According to the fourth aspect of the present
invention, the means for drying comprises: drying the fluffed
fibers at a temperature above about 150.degree. F. to about
700.degree. F., thereby reducing bacteria in the fluffed recovered
fibers.
[0052] According to the fourth aspect of the present invention, the
means for drying comprises: drying the fluffed fibers at a
temperature above about 300.degree. F., thereby reducing bacteria
in the fluffed recovered fibers, and drying them to a uniform
moisture content, and wherein the moisture content is between about
10% and about 18%.
[0053] According to the fourth aspect of the present invention, the
system further comprises q. means for removing inorganic
precipitated chemicals and contaminants from the extracted pulping
fluids; and r. means for recycling the pulping fluids back to the
primary tank/drum/tunnel fiber recovery apparatus. According to the
fourth aspect of the present invention, the removed inorganic
precipitated chemicals and selected contaminants comprise calcium
hydroxide, calcium carbonate calcites, aluminum hydroxide, aluminum
oxide, magnesium hydroxide and/or various other minor hydroxides,
and wherein the recovered organic cellulosic fibers comprise a
final total ash content equal to or less than about 10%.
[0054] According to the fourth aspect of the present invention, the
recovered organic cellulosic fibers comprise an average fiber
length greater than about 0.700 mm. According to the fourth aspect
of the present invention, the recovered organic cellulosic fibers
comprise an average fiber length greater than about 0.780 mm.
[0055] According to a fifth aspect of the present invention, a
method for recovering cellulosic fibers from mixed trash is
provided comprising: a. loading waste containing cellulosic fibers
and other non-organic materials into a sorting apparatus to produce
a combination of short and long fiber feedstock; b. blending the
sorted trash to maintain ratio of about 50% to about 90% short
fiber feedstock and about 10% to about 50% long fiber feedstock; c.
shredding the blended sorted fiber feedstock; d. weighing the
shredded fiber feedstock into load sizes of about 100 to about 300
lbs; e. pulping the weighed fiber feedstock into cellulosic fibers
and a first through fourth group of select waste materials with
pulping fluids in a fiber extractor recovery apparatus thereby
impregnating the cellulosic fibers with the pulping fluids: f.
draining the cellulosic fibers from the extractor fiber recovery
apparatus into a hydro-cleaner; g. de-watering the impregnated
cellulosic fibers in the hydro-cleaner to reduce the amount of
pulping fluid in the impregnated cellulosic fibers, and extracting
a portion of the second group of select waste materials; h.
depositing the extracted portion of second group of select waste
materials into a landfill; i. fluffing the de-watered cellulosic
fibers in a first disk refiner; j. thickening the fluffed
cellulosic fibers in a thickener and extracting pulping fluid for
re-use in the fiber extractor recovery apparatus; k. storing the
thickened cellulosic fibers in a stock chest apparatus; l.
extracting pulping fluid from the thickened cellulosic fibers in a
pulping fluid extractor; m. impregnating additional chemicals
comprising fire retardant chemicals, dyes, insecticides, and/or
biocides, such that the final cellulosic fiber product comprises a
flame retardant loading of about 6%; n. extracting excess pulping
fluid from the thickened cellulosic fibers in a pulp press thereby
producing partially dried thickened cellulosic fibers; o. fluffing
the partially dried thickened cellulosic fibers in a fluffer
apparatus that reduces a density of the cellulosic fibers from a
first range of about 6 to about 10 lbs per cubic foot to a second
density range from about 2 to about 6 lbs per cubic foot, with a
post fluffing moisture content of about 40% to about 60%; p.
additionally fluffing the cellulosic fibers in a second disk
refiner at a temperature between about 150.degree. F. and about
700.degree. F.; q. drying the cellulosic fibers in a dryer to
further reduce the moisture content to about 10% to about 18%; and
s. packaging and/or baling the dried cellulosic fibers.
[0056] According to the fifth aspect of the present invention, the
step of pulping comprises: i. rotating and agitating the shredded
fiber feedstock in a plurality of fiber recovery apparatuses into
cellulosic fibers and first through fourth groups of select waste
materials, each of the fiber recovery apparatuses containing
pulping fluid, wherein the pulping fluid comprises a combination of
water, fire retardant chemicals, biocides, dyes, insecticides and
surfactants; ii. impregnating the cellulosic fibers and the first
through fourth select waste materials with fire resistant
chemicals, dyes, chemical insecticides, and/or biocides; iii.
separating the impregnated cellulosic fibers from the first group
of select waste materials that are not utilized or desired in
separator fiber recovery apparatuses; iv. extracting the first
group of select waste materials dissolved within the pulping fluid
from the cellulosic fibers in a dirty water tank, DAF contaminant
separator, waste tank, sludge press and then depositing the first
group of select waste materials into a landfill; v. separating the
impregnated cellulosic fibers from the second group of select waste
materials in an extractor fiber recovery apparatus; and vi.
extracting the second group of select waste materials from the
impregnated cellulosic fibers.
[0057] According to the fifth aspect of the present invention, the
method further comprises t. transferring pulping fluid extracted
from the pulping fluid extractor and pulp press to a dirty water
storage chest to extract additional inorganic compounds such as
calcium carbonate, aluminum and magnesium hydroxide; u. adding one
or more acids to the water and pulping fluid stored in the dirty
water storage chest to lower the pH of the pulping fluid to a range
of about 4.0 to about 5.0; v. mixing the pulping fluids in a first
precipitator with one or more alkaline agents to increase the pH of
the pulping fluid to a range of about 4.5 to about 6.0 to cause
precipitation of aluminum and magnesium hydroxide byproducts; w.
centrifuging the mixture of pulping fluids and precipitated
aluminum and magnesium hydroxide byproducts in a first centrifuge
to separate and discard the aluminum and magnesium hydroxide
byproducts; x. adding carbon dioxide to the first centrifuged
pulping fluids; y. mixing the pulping fluids in a second
precipitator with one or more additional alkaline agents to
increase the pH of the carbonated pulping fluids to a range of
about 11.5 to about 12.8 or to a pH point wherein calcium carbonate
precipitates from the carbonated pulping fluids; z. centrifuging
the mixture of carbonated pulping fluids and precipitated calcium
carbonate byproducts in a second centrifuge to separate and discard
the calcium carbonate byproducts, thereby producing treated white
water for use in the recovery process; and aa. storing the treated
white water in storage tanks for use in the recover process and
apparatus.
[0058] According to the fifth aspect of the present invention, step
of additionally fluffing the cellulosic fibers in a second disk
refiner is omitted, and the step of drying includes drying the
cellulosic fibers at a temperature between about 250.degree. F. and
350.degree. F., thereby producing animal and fowl bedding
product.
[0059] According to a sixth aspect of the present invention, a
system for recovering organic cellulosic fibers from landfill
materials is provided comprising: a. a stock preparation apparatus
configured to prepare a suitable combination of short fiber and
long fiber feedstock for use in the cellulosic fiber recovery
system from landfill materials and further configured to mix the
short fiber and long fiber feedstock with a pulping fluid thereby
initially separating the short fibers and long fibers from first
through fourth groups of select waste materials, and to further
process the first group of select waste materials; b. a stock
extraction apparatus configured to further mix the separated short
and long fiber feedstock with the pulping fluid, and to extract a
second group of select waste materials thereby producing a
thickened slurry of cellulosic fibers from the combination of short
and long fiber feedstock that is substantially free from the second
group of select waste materials; and c. a pulp drying and packaging
apparatus configured to extract pulping fluid from the thickened
slurry of cellulosic fibers, and which is further configured to
separate third and fourth groups of select waste materials from the
pulping fluid and to fluff, dry, and bale the thickened slurry of
cellulosic fibers as recovered organic cellulosic fibers with a
moisture content of about 10% to about 18%.
[0060] According to the sixth aspect of the present invention, the
first group of select waste materials comprises fillers, coatings,
fines, clays, among other non-organic materials, the second group
of select waste materials comprises plastics, metals, glass, among
others, and the third group of select waste materials comprises
calcium carbonate, among others. According to the sixth aspect of
the present invention, the fourth group of select waste materials
comprises aluminum and magnesium hydroxides, among others, and
wherein the stock preparation apparatus comprises: a. a trash
sorting apparatus configured to sort gross trash into a first group
of trash comprising cellulosic fibers, and a second group of trash
that is substantially free of cellulosic fibers; b. a fiber
blending apparatus configured to selectively and mechanically blend
the first group of trash comprising cellulosic fibers such that a
ratio of about 50% to about 90% of short cellulosic fibers and
about 10% to about 90% long cellulosic fibers is maintained in the
recovery system; c. a shredder apparatus configured to continuously
shred the selectively maintained short and long cellulosic fibers
into smaller pieces; d. a weigh feeder configured to continuously
measure the shredded short and long cellulosic fibers into
substantially equivalent loads of about 100 lbs to about 300 lbs
per load; e. one or more drums/tunnel pulpers configured to
substantially continuously mix pulping fluids with the shredded
short and long cellulosic fibers such that separation of short and
long cellulosic fibers from first through fourth groups of select
waste materials occurs, and treatment of the short and long
cellulosic fibers with the pulping fluid occurs; and f. a chemical
dissolver configured to produce the pulping fluids from a
combination of water, and rapidly penetrating surfactants, dyes,
insecticides, biocides, and/or flame retardants.
[0061] According to the sixth aspect of the present invention, the
short cellulosic fiber comprises fibers of a first length from
about 0.5 mm to about 0.7 mm, and the long cellulosic fiber
comprises fibers of a second length from about 0.7 mm to about 0.9
mm.
[0062] According to the sixth aspect of the present invention, the
one or more drums/tunnels are further configured to rotate at
substantially equal intervals, and then reverse rotation for a
second interval, in the case there are more than one drum/tunnel,
in order to transfer the mixture of pulping fluids and shredded
short and long cellulosic fibers from a first to a subsequent
drum/tunnel, and from the subsequent drum/tunnel to additional
subsequent drum/tunnels should there be such additional subsequent
drum/tunnels; and wherein the one or more drum/tunnels are further
configured to transfer the mixture of pulping fluids, shredded
short and long cellulosic fibers into an additional processing
stage during the reverse rotation interval.
[0063] According to the sixth aspect of the present invention, the
fire retardants comprise those fire retardants that when absorbed
by the short and long cellulosic fibers meet federal requirements
STM C-739, C-1149, C-1497, and CPSC 16 C.F.R. .sctn..sctn.208,
1404.
[0064] According to the sixth aspect of the present invention, the
stock extraction apparatus comprises: i. one or more additional
drums/tunnel pulpers configured to further substantially
continuously mix pulping fluids with the shredded short and long
cellulosic fibers such that separation of short and long cellulosic
fibers further occurs from a first and second group of select waste
material, and continuous treatment of the short and long cellulosic
fibers with the pulping fluid occurs producing a cellulosic fiber
slurry, and further wherein the second group of select waste
materials is removed from the one or more additional drums/tunnel
pulpers, and further wherein the cellulosic fiber slurry is also
transferred out of the one or more additional drums/tunnel pulpers;
ii. an extractor configured to hold the transferred cellulosic
fiber slurry; iii. a hydrocleaner configured to extract still
additional second group of select waste materials from the
cellulosic fiber slurry; iv. a disk refiner configured to fluff the
cellulosic fiber slurry; v. a thickener configured to remove water
and/or additional liquids from the fluffed cellulosic fiber slurry
such that the percentage of cellulosic fibers with the fluffed
cellulosic fiber slurry increases from a first range of about 1.5%
to about 2% to a second range of about 3.0% to about 4.5%; and vi.
a plurality of white water holding tanks configured to hold the
water and other liquids removed by the thickener.
[0065] According to the sixth aspect of the present invention, the
pulp drying and packaging apparatus comprises: i. a pulping fluid
extractor configured to extract additional pulping fluid from the
thickened cellulosic fiber slurry; ii. an additional chemical
dissolver tank to produce an optional fire retardant spray
comprising fire retardant chemicals, dyes, insecticides and/or
biocides, wherein the optional fire retardant spray can be applied
to the thickened fiber cellulosic slurry; iii. a pulp press
configured to extract additional water and/or other liquids such
that the thickened fiber cellulosic slurry is about 40% to about
60% solids, thereby producing cellulosic fiber wet lap; iv. a
fluffer configured to fluff the cellulosic fiber wet lap into a
fluffed cellulosic fiber wet lap; v. a disk refiner configured to
additionally fluff the fluffed cellulosic fiber wet lap; vi. a
flash/tunnel dryer configured to dry the fluffed cellulosic fiber
wet lap at a temperature between about 150.degree. F. and about
700.degree. F., thereby reducing a moisture content to a range of
about 10% to about 18%; and vii. a packaging or bailing apparatus
configured to packagee or bail the substantially dry fluffed
cellulosic fiber wet lap.
[0066] According to the sixth aspect of the present invention, the
system further comprises a water treatment apparatus configured to
recover pulping fluid at various points in the recovery process,
separate the third and fourth group of select waste materials from
the pulping fluid thereby creating treated white water which can
then be returned to the recover system for continuous recovery of
organic cellulosic fibers from landfill materials.
[0067] According to the sixth aspect of the present invention, the
water treatment apparatus comprises: a. an acid supply tank
configured to store a supply of one or more acids, comprising
sulfuric acid, phosphoric acid, acidic acid, among others; b. a
dirty water storage tank configured to receive pulping fluids
removed from the fluffed cellulosic fiber slurry by the thickener
and further configured to add one or more of the acids stored in
the acid supply tank such that a pH level of the pulping fluids is
reduced to a range of about 4.0 to about 5.0 so as to dissolve one
or more organic compounds comprising calcium carbonate, aluminum
hydroxide, magnesium hydroxide, among others; c. a first alkaline
agent holding tank configured to store one or more agents
comprising sodium tetraborate, sodium borates, calcium borates,
ammonium hydroxide, anhydrous ammonia, lime, and/or soda ash, among
others; d. a first precipitator configured to the receive water
and/or additional liquids from the dirty water storage tank, and
further configured to add one or more of the agents stored in the
first alkaline agent storage tank such that a pH level of the
received pulping fluids is increased to a range of about 4.5 to
about 6.0 so as to cause precipitation of aluminum and magnesium
hydroxide byproducts; e. a first centrifuge configured to received
the pulping fluids from the first precipitator, and further
configured to centrifuge the first precipitated pulping fluids to
separate and collect the aluminum and magnesium hydroxide
byproducts; f. a carbonator configured to receive the pulping
fluids from the first centrifuge, and further configured to add
carbon dioxide to the pulping fluids; g. a second alkaline agent
holding tank configured to store one or more agents comprising
sodium tetraborate, sodium borates, calcium borates, ammonium
hydroxide, anhydrous ammonia, lime, and/or soda ash, among others;
h. a second precipitator configured to receive the pulping fluids
from the carbonator, and further configured to add one or more of
the agents stored in the second alkaline agent storage tank such
that a pH level of the received pulping fluids is increased to a
range of about 11.5 to about 12.0, or to such pH level so as to
cause precipitation of calcium carbonate; i. a second centrifuge
configured to received the pulping fluids from the second
precipitator, and further configured to centrifuge the second
precipitated pulping fluids to separate and collect the calcium
carbonate; and j. a treated white water storage tank configured to
store and transfer the treated white water now substantially free
of calcium carbonate, and aluminum and magnesium hydroxide
byproducts and which has a pH level in the range of about 11.5 to
about 12.0. According to the sixth aspect of the present invention,
the flash/tunnel dryer is configured to dry the fluffed cellulosic
fiber wet lap at a temperature between about 250.degree. F. and
about 350.degree. F.
BRIEF DESCRIPTION OF THE DRAWINGS
[0068] The advantageous structure and/or methods according to the
present invention will be more easily understood from the following
detailed description of the preferred embodiments and the appended
drawings, as follows.
[0069] FIG. 1 is a schematic diagram of the structure and method of
the stock preparation zone, the stock extraction zone, and the
process heat element according to a preferred embodiment of the
present invention.
[0070] FIG. 2 is a schematic diagram of the structure and method of
the water treatment zone and the pulp drying and packaging zone
according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY
EMBODIMENTS
Introduction
[0071] A notable aspect of the present invention has been the
discovery that the increasing quantities of inorganic compounds
found in the various solid and fiber-containing household and
industrial waste materials adversely affect the physical properties
of cellulosic thermal insulation. The physical properties that
primarily affect thermal insulation in a substantially negative way
are bulk density, thermal resistance, and nuisance dust content.
All three of these properties are important in manufacturing an
effective thermal insulation product.
[0072] Thermal resistance, or R-value, measures cellulose
insulation's effectiveness. High quality insulation products are
more effective because of their high R-values. Creating air spaces
around the fibers, the natural fiber wall of the cells, and the air
cells that naturally exist within the fibers themselves, maximize
R-value in cellulose insulation. R-value degrades with the addition
of inorganic particles, including fire retardant chemicals that
tend to be conductors of thermal energy rather than insulators.
Therefore, minimizing the amount of inorganic particles within
cellulose insulation will increase its thermal performance.
Inorganic particles are collectively referred to as "ash".
[0073] There is a direct correlation between inorganic levels in
the finished product and the product's density and dust level.
R-value is a function of a product's design density as well. As
cellulose insulation density increases, the R-value decreases. The
optimal density for cellulose insulation that maximizes the R-value
is a range between about 1.3 and about 1.7 pounds per cubic foot.
Inorganic particles that are not removed increase a product's
density, effecting R-value (making it lower) and hence the coverage
of the finished product.
[0074] An attribute of quality that is normally not tested by
manufacturers, but which is a significant issue for customers
(installers), is the level of dust that the product emits while
installing it. High dust levels during installation is extremely
uncomfortable for the installer, makes it difficult for them to see
their application and creates challenges for living environments
within a home. A high dust level indicates high levels of inorganic
components that free themselves during the installation of the
product.
[0075] Cellulosic insulation manufactured according to the
exemplary embodiments of the present invention described herein
contain significantly reduces levels of ash than other
manufacturer's cellulosic insulation product. Various competitor's
ash content are, an average, about 15.59%, whereas the ash content
of the cellulosic insulation manufactured according to the
preferred embodiments of the present invention is about 8.09%, a
decrease of about 100%.
TABLE-US-00002 TABLE II Comparison of Ash Levels of Insulation
Products Manufactured According to an Embodiment of the Present
Invention, and Other Materials Material Avg. % Ash Cellulosic Fiber
Insulation Manufactured According 8.09 to an Embodiment of the
Present Invention Competitor Insulation 15.59 Sludge 16.67 Foil
Laminates 14.17 White Fiber 7.85
[0076] As can be seen from Table II, which shows the ash content of
several different materials, cellulosic fiber insulation products
manufactured using the system and method according to the different
embodiments of the present invention achieve significantly lower
ash contents. The cellulosic fiber insulation product manufactured
according to an embodiment of the present invention has an ash
content on average of about 8.09%. A competitor's fiber insulation
product has an ash content on average of about 15.59%. The ash
content of sludge, which is the waste material created by the
system and method according to an embodiment of the present
invention that is sent to the landfill (see FIG. 1, output of
sludge press 21, and landfill 23), has an ash content on average of
about 16.67%. Thus a significant amount of ash is removed during
the manufacturing process. The ash content of foil laminates, which
are raw materials going into the system (see feedstock 1 in FIG. 1)
is, on average, about 14.17%. This shows that a significant amount
of ash is removed from the raw waste materials during the process
according to an embodiment of the present invention. Finally, only
when very select raw materials are tested, in this case white
fiber, is the ash content lower at about 7.85% on average. In the
aforementioned test analysis, golf ball boxes were used as a source
of white fiber. Even when starting with low-ash content raw
materials (such as golf ball boxes), because addition of the fire
retardant chemicals adds ash, reduction of total ash content
remains an important feature of the method and system according to
an embodiment of the present invention.
[0077] Managing the ash content in the pulping process is a
significant issue that affects product quality and usability
(density and dust). As the ash content values discussed above
indicate, the reduction achieved by competitors' products is
minimal since most of the fillers (ash) is contained within the
insulation pieces and holds the fibers together. Therefore,
minimizing the ash content of the fiber insulating product is very
important, otherwise an extremely dusty product with high density
levels will be produced.
[0078] Thus, as noted above, the ash content of the products
produced using the systems and methods described herein is
significant. The various raw materials processed by the system
(e.g., post consumer, municipal and industrial waster materials)
can have residual ash content as high as 50%, and unless the ash is
significantly reduced, there is a negative impact on further
processing, such as chemical addition, drying capability, speed of
drying, temperature requirements, fiber size reduction, product
density and packaging. The process described herein further reduces
the ash to a level at or below 10% in order to improve various
chemical additions, decrease drying temperature and time and
improve fiber sixe reduction and consistency of the finished
products.
[0079] Further, another attribute that determines the effectiveness
of the cellulosic insulation product is fiber length, and thus
overall density of the product. Longer fibers will improve (lower)
a product's density and by maintaining fiber structure, fewer
fractured or short fibers are evident that could become part of the
dust level in the finished product. As Table III below indicates,
the system and method of pulping fibers according to the preferred
embodiments of the present invention produce, on average, longer
fibers than competitors' products as a result, in part, through the
pulping of the cellulosic fibers through the disk refiner among
other steps and apparatus of the present invention. Competitors
generally use dry processing, and as a result, their average fiber
lengths are, an average, about 0.521 mm. The system and method for
pulping fibers according to the preferred embodiments of the
present invention produces fibers on average of about 0.781 mm, an
increase, on average, of about 14% in length.
TABLE-US-00003 TABLE III Comparison of Fiber Length and Width of
Insulation Products Manufactured According to an Embodiment of the
Present Invention, and Other Materials Average Length (ii) Material
(mm) Cellulosic Fiber Insulation Product 0.781 Manufactured
According to an Embodiment of the Present Invention Competitor
Insulation 0.685 Sludge 0.666 Foil Laminates 0.689 White Fiber
0.849
[0080] Table III illustrates the results of testing of average
lengths of fibers of the cellulosic fiber insulation product as
manufactured according to an embodiment of the present invention
versus other materials as discussed and shown in Table II. The
increase in length of the product as manufactured according to an
embodiment of the present invention versus that of the competitor
results in an optimization of the density of the cellulosic fiber
insulation product. Again, as with Table II, it is only when a
material is handpicked to have optimal length properties (the white
fiber material, i.e., golf ball boxes) does the length
characteristics exceed that of the product as manufactured
according to an embodiment of the present invention that is made
from an assortment of waste materials.
[0081] It has been further discovered that these inorganic
compounds cannot be removed from the waste feedstock using
conventional dry process fiberization equipment due to the
inorganic compounds being an integral and impregnated part of the
fiber structure. Such compounds are removed by dissolving these
compounds and then precipitating them from the liquid pulping
fluids. The present invention uses a wet pulping process utilizing
a fiber recovery apparatus to recover cellulosic fibers from
landfill materials, and to manufacture a composition of cellulosic
insulation with low ash content with specific performance and
composition characteristics. For example, the cellulosic insulation
composition according to the present invention may comprise
cellulosic fibers impregnated with liquid flame retardants, dyes,
insecticides, decay inhibitors, and/or biocides. Note that fiber
pulp is the end result of the process machine. The present
invention does not propose to pulp the fiber, but rather pulp the
feedstock.
[0082] As a brief overview, dry or wet waste containing cellulosic
fibers and other non-organic materials (such as plastics, metal,
clay, and calcium carbonate) is preferably loaded into a fiber
recovery apparatus and, while being agitated, is washed in water,
surfactants, decay inhibitors, and polymers, and then is
impregnated with fire retardant chemicals, dyes, insecticides,
and/or biocides. During pulping, the cellulosic fibers become
separated from select materials that are not utilized or desired in
the final product. The cellulosic fibers are drained out of the
fiber recovery apparatus with the pulping fluid described herein,
leaving the select non-cellulosic materials (i) in the fiber
recovery apparatus for disposal or (ii) in the pulping fluid, where
additional inorganic materials are precipitated and recovered out
of the pulping fluid. The cellulosic fibers are then transferred
into a series of process steps including a dewatering press to
reduce the amount of water in the cellulosic fibers, then fluffed,
dried, and packaged.
[0083] For the purpose of this discussion, and as shown in the
drawings, process liquor (or pulping fluid as it hereinafter will
be referred to) is defined as a combination of water, fire
retardant chemicals, biocides, insecticides, dyes, and surfactants.
Pulping fluid is the fluid that aids in pulping and flocculation of
the commingled waste according to an embodiment of the present
invention. As discussed herein, the pulping fluid includes chemical
additives that enhance the fiber separation process. Importantly,
waste solubilized organics are non-desirable for the processes
described herein, and therefore are flushed out as part of such
processes.
[0084] Because the system and process described herein is designed
to operate continuously, in order to increase efficiency and hence
its economic performance, the fluids used throughout the system
will be continuously changing in terms of chemical composition and
contaminants, as those of ordinary skill in the art can appreciate.
However, in order to facilitate an understanding of the system and
method of the embodiments of the present invention, the liquids
that are utilized within can be defined as follows: For the purpose
of this discussion, and as shown in the drawings, pulping fluid 47
is defined as a combination of water, fire retardant chemicals,
biocides, insecticides, dyes, and surfactants. Process liquor, or
pulping fluid 47, is the fluid that aids in pulping and
flocculation of the commingled waste according to an embodiment of
the present invention. Pulping fluid 47 is the state of the fluid
at the point of start up, when all the storage tanks and cells are
filled with the fluid to aid in de-pulping and flocculation.
Pulping fluid 47 is the fluid leaves chemical dissolver tank 25 as
shown in FIG. 1. Pulping fluid 47, as described in greater detail
below, is periodically withdrawn from the system at various points,
and can be cleaned and/or refined to become treated white water 51
that is in a state that approximates that of the original pulping
fluid 47. As such, pulping fluid 47 can have different levels and
types of contaminants at different points in the system and process
according to the embodiments of the present invention.
[0085] Pulping fluid 47 is inserted into Zone 1 of apparatus 6 from
chemical dissolver tank 25. Pulping fluid 47 is mixture of water,
surfactants, insecticides, biocides, dyes and fire retardant
chemicals. As soon as pulping fluid 47 starts mixing with the
landfill waste it becomes dirty. Dirty water 48 is extracted from
Zone 2 of apparatus 7. Dirty water 48 is the most contaminated
fluid within the system. The liquid that is carried into Zone 3 of
apparatus 8 is cleaner than dirty water 48 and is called white
water 49. White water 49 is substantially free of solids (fillers,
contaminants and coatings; which is what makes dirty water
dirty).
[0086] A portion of dirty water 49 is returned to fiber recovery
apparatuses 6, 7 and 8, untreated, and not cleaned at all. Most of
dirty water 48, however, is sent to dirty water tank 22. Dirty
water 48 is then sent to DAF containment separator 15; its output
is untreated white water 50 (meaning it is cleaner (no solids) than
dirty water 48, but contains calcium carbonate, and aluminum and
magnesium hydroxides). Untreated white water 50 is stored (tanks
16, 17 and 18) and is added to dirty water 48 that is taken from
Zone 2.
[0087] White water 49 is extracted from thickener 12, and is
immediately recycled back to Zone 3, after being combined with
untreated white water 50 and treated white water 51. Some of white
water 49--or pulping fluid with containments (CaCO.sub.3 aluminum
and magnesium hydroxide by products) is retained by the fibers. In
pulping fluid extractor 27, untreated white water 50 is extracted
from the fibers. While untreated white water 50 contains calcium
carbonates, and aluminum and magnesium hydroxides, it can be
immediately re-used, because it has the chemicals needed by the
system (fire retardants, surfactants, biocides, insecticides, dyes,
among others), and is substantially free of solid contaminants. The
balance of untreated white water 50 is sent to the water treatment
zone (See FIG. 2) to remove the calcium carbonate and aluminum and
magnesium hydroxides, the process of which is described in greater
detail below.
[0088] Once the calcium carbonates and aluminum and magnesium
hydroxides are removed from untreated white water 50, the cleaned
liquid is referred to as treated alkaline white water 51.
Therefore, in terms of "cleanliness" the following is a list of the
fluids used in the system and method according to an embodiment of
the present invention from cleanliest to dirtiest: pulping fluid
47; treated alkaline white water 51; white water 49; untreated
white water 50; and dirty water 48.
[0089] Of course, as those of ordinary skill in the art of the
present invention can appreciate, there is no set chemical/solid
composition that completely defines the differences between pulping
fluid 47, dirty water 48, white water 49, untreated white water 50,
or treated white water 51, and as such the definitions are not
intended and should not be construed to limit the scope of the
exemplary embodiments of the present invention, but are merely
intended to be used as an aid for the reader to understand the
processes and systems described herein.
[0090] As noted above, the residual pulping fluid is thus subjected
to stages of separation and cleaning in order to condition the
pulping fluid for reuse as a pulping medium. Importantly, the
specific inorganic precipitated chemicals withdrawn from the fiber
waste stream in order to recycle the pulping fluids back to the
fiber recovery apparatus, if not removed, would continue to build
up and eventually impede the effectiveness of future pulped fiber
purity.
[0091] The system and method of the present invention involves the
use of disposed products that contain cellulosic fibers (such as
beater dye, MRF residual, fibers laminated with plastic and/or
metal foil, pulp sludge, wet cellulosic fibers, industrial waste,
mixed waste, post-consumer mixed recyclables, mixed office waste,
post-consumer industrial fiber waste, and other commercial waste)
to preferably manufacture cellulosic insulation with certain
characteristics (including a total ash content equal to or less
than about 10%). These disposed products are currently sent to a
landfill because they are typically unsuitable to be processed into
other commodities or products, and typically have an ash content of
over about 15%.
[0092] The system and method described herein are able to produce
cellulosic fibers while using a mixed variety of raw waste paper
materials as the feed stock, thus significantly improving upon the
ability of other methods that seek to process paper stock limited
to, for example, old newspapers. Fibers recovered from such mixed
trash can be of varied physical characteristics and composition,
particularly as compared to those generated from a single source
such as old newspaper. As described herein, processing of such
mixed trash requires a unique process capability, additives, and
drying technology in order to produce a reasonably consistent
product. Different fibers can have different absorbency rates and
capability and, therefore, have differing drying characteristics as
well as differing capability to accept additives, such as dyes,
insecticidal compositions, flame retardants, and decay
inhibitors.
[0093] Advantageously, the method disclosed in the application does
not require pre-conditioning of any of the landfill materials in
order to accomplish biomass separation. Thus, size reduction of
such materials is performed prior to the fibers being introduced to
the pulping fluid, and are therefore not solubilized and are at 80%
to 90% solids. By so avoiding pre-conditioning of the landfill
waste materials, the structural integrity of the cellulosic fibers
in those materials is maintained. Rather, prior to the addition of
any water, pulping fluid or pulping activity, the raw, mixed trash
is subjected to a dry sorting process, a dry blending process in
which the sorted trash is blended to provide a particularly
desirable ratio of short to long cellulose fibers, and dry
mechanical shredding to alter the particle size of the materials
while maintaining desirable fiber length, and thereafter pulping
the fibers with pulping fluid having chemical additives that are
able to cover and impregnate the cellulosic fibers.
The Structure and Process of the Preferred Embodiments
[0094] In FIGS. 1 and 2, there is shown a schematic view of the
structure and process in accordance with the preferred embodiment.
The system includes a manual trash-sorting station 2, a fiber
blending chamber (blending chamber) 3, a shredder 4, a weigh feeder
5, multiple zone fiber recovery apparatuses 6, 7, and 8, a
hydro-cleaner 10, a disk refiner 11, a dissolved air flotation
(DAF) contaminant separator or water clarifier (water clarifier)
15, a pulp slurry thickener 12, pulping fluid extractor (otherwise
known as pulp dewatering presses) 27 and pulp press 28, a pulp
fluffer 29, a disk refiner 30, a flash/tunnel dryer (dryer) 31, and
a packaging or baling (packaging) system 32, among other
components.
[0095] Various waste materials 1 containing cellulosic fibers are
sorted of gross trash (out throws) in the manual trash-sorting
station 2, then they are selectively and mechanically blended in a
chamber 3 by maintaining a preferred ratio of about 50% to about
90% short fiber feedstock and about 10% to about 50% long fiber
feedstock, and then conveyed to a shredder 4 as manufactured by
Saturn (model #Z2A) where the material is reduced in size.
According to an exemplary embodiment of the present invention,
short fibers are those fibers whose average length ranges from
about 0.5 mm to about 0.7 mm, and long fibers are those fibers
whose average length ranges from about 0.7 mm to about 0.9 mm. An
example of cellulosic fibers that can be input to the system
according to an embodiment of the present invention that are short
fibers is the Foil laminates material described above, with an
average length of about 0.689 mm. An example of cellulosic fibers
that can be input to the system according to an embodiment of the
present invention that are long fibers is the white fiber material
described above, with an average length of about 0.849 mm. The
material continues to a weigh feeder 5 as manufactured by Ronan
(model X96S) to measure load sizes of about 100 lbs to about 300
lbs, depending on the size of the fiber recovery apparatuses 6, 7
and 8, and on automatic un-pulped material feedback from points
later in the system.
[0096] One type of fiber recovery apparatus 6, 7, and 8 is a model
#76039P4F Continuous Batch Tunnel Washer manufactured by Pellerin
Milnor Corporation of Kenner, La., U.S.A. that is typically used
for the washing of textile goods (such as clothes) and has
perforated drums rotatable within multiple end-to-end compartments,
or chambers, as described herein. Continual processing of the waste
through the system provides an efficient means for separating the
cellulosic fibers from various contaminants. Additionally, a
continuous batch system results in an equilibrium of the chemical
and other conditions within the apparatus to be established as the
waste is processed due to the continuous recirculation of the
pulping fluids. Other pulping systems (such as drum, tank or tunnel
type pulping machines) may be used as fiber recovery apparatus 6, 7
or 8, that provide various levels of fiber separation from
undesirable contaminates. Of course, the fiber recovery apparatus
may comprise a single apparatus 6, two apparatuses, three
apparatuses (as shown in FIG. 1), or more sections, as desired. The
first and second zones of apparatus 6 and apparatus 7 in the fiber
recovery apparatus are substantially similar to each other. One or
more of these apparatuses may include steam injection. Preferably,
the process heat and steam are provided by a 143 Hp boiler, fed
with natural gas and capable of generating 50 Therms/hr. 47, as
manufactured by Williams Davis Boiler, Inc.
[0097] In more detail, approximately equal volumes or loads of
waste material (from about 100 lbs to about 300 lbs) are loaded
into the first chamber of the first zone of the fiber recovery
apparatus 6 (preferably comprising nine cells). As each load of
waste is transferred from the first chamber (or cell) into the
second chamber (or cell) of the first apparatus 6, a new load of
waste replaces it so that a steady stream of waste is continuously
processed in the system. This waste continues through the remaining
chambers (or cells) of the fiber recovery apparatuses 6, 7, and
8.
[0098] The multiple chambers (or cells) in each of apparatus 6, 7
and 8 are rotated for predetermined, essentially equal intervals
e.g., about 20 minutes. At the end of each interval, a
predetermined sequence of reverse rotation is initiated so as to
transfer the batch in the chamber to a succeeding chamber. At the
same time, the batch in the last chamber of apparatus 6 is
transferred to the first chamber of apparatus 7 and the last
chamber of apparatus 7 transfers the batch into the first chamber
of apparatus 8. The fiber recovery apparatuses 6, 7 and 8 uses a
continuous flow of pulping fluid 47 that includes water, fire
retardant chemicals, dyes, insecticides, biocides and surfactants
that flows through the fiber recovery apparatus. The composition of
pulping fluid 47 may consist of the following ingredients depending
on the type of finished product that is being manufactured:
TABLE-US-00004 TABLE IV Pulping Fluid Composition PERCENTAGE RANGE
(all ranges from about a first percentage INGREDIENTS to about a
second percentage) Water 80.0 to 95.0% w/v Flame Retardant's 0.5 to
20.0% w/v Surfactants 0.001 to 2.0% w/v Boron Insecticides 0.12 to
3.0% w/v Biocides 0.001 to 2.0% w/v Dyes 0.05 to 2.0% w/v The flame
retardants comprise about 40% to about 60% ammonium sulfate
(NH.sub.4) 2SO.sub.4 and from about 40% to about 60% boric acid
H.sub.3BO.sub.3. Alternatively, a product can also be used that
includes no ammonium sulfate as a fire retardant and 100% boric
acid.
[0099] Pulping fluid 47 is preferably maintained at a temperature
of at least 120.degree. F. to insure that the chemicals added to
pulping fluid 47 remain in solution, and to increase the pulping
activity within the chambers. According to an alternative
embodiment of the present invention, pulping fluid 47 can work
properly at temperatures that range from about 50.degree. F., to
about 200.degree. F. Preferably, pulping fluid 47 is kept at a
level that covers approximately 1/3 of each chamber within the
fiber recovery apparatus. Agitation due to the rotation of the
chambers promotes separation of the cellulosic fibers from any
contaminants so as to form a cellulosic fiber slurry.
[0100] The first two fiber recovery apparatuses 6 and 7 are
referred to as the separation zones. Preferably, the apparatus 6
referred to as zone 1 and apparatus 7 referred to as zone 2
includes nine cells each, and the apparatus 8 includes six cells
referred to as zone 3. Pulping fluid 47 utilized in the separation
zones 1 and 2 is preferably circulated in a closed loop that
includes a series of one or more untreated white water 50 holding
tanks 16, 17 and 18 (one or more of which may include steam
injection). Pulping fluid 47 used in the fiber recovery apparatus
6, 7 and 8 and white water 49 pressed from the cellulosic fibers in
the pulp dewatering presses 27, as manufactured by Fields &
Boyd Wedge Belt Press (model #XLWT-80) and 28, as manufactured by
Rietz (60 inch V-Press) includes various inorganic chemicals such
as clays, calcites, talc, fluorspar, feldspar and other
contaminates such as metals, glass, minerals and plastics that are
released from the waste during the pulping process. White water 49
is processed thorough one or more hydro-cleaners 10, as
manufactured by Black-Clawson (HD Cleaner). Dirty water 48 is
processed through water clarifiers 15, as manufactured by Beloit
((DAF Clarifier), to which are added selected promoter and
collector reagents and polymers comprising of crude or refined
fatty acids, petroleum sulfonates, sulfonated fatty acids, fatty
amines and amine salts at dosages of about 0.1 to about 2.0 pounds
per ton of waste materials processed to selectively remove fine
contaminants 19 (such as clay, other inorganic material, and ultra
fine organic fibers) from dirty water 48 that is then pumped to
storage tank 20, and a sludge press 21 as manufactured by Andritz
(Andritz 0.3 Meter Press), for disposal to a landfill 23. The rate
of removal of the above described contaminants at water clarifier
15 is based on the density and fines content of the final product
(after packaging 32) that is measured using conventional methods
such as ASTM C-739 for determining the settled density of
cellulosic insulation and TAPPI T-413 for determining the ash
content of paper pulp.
[0101] Pulping fluid 47 additionally preferably comprises water
containing fire retardant (FR) chemicals 24, dyes, insecticides,
biocides, surfactants and decay inhibitors [as listed in Table III]
that are added in solution utilizing a chemical dissolver or
chemical add feeder apparatus 25 preferably fed with steam and
make-up water. The fire retardant chemicals and other chemicals are
preferably absorbed by the cellulosic fibers to provide a finished
product that, after packaging system 32, meets federal requirements
ASTM C-739, C-1149, C-1497, CPSC 16 CFR209 and 1404 for product
performance with a total ash content equal to or less than 10%, and
preferably an average, with an ash content of about 8.09%.
[0102] The solid waste material moves through the washing chambers
in the extraction zone 3, fiber recovery apparatus 8 where the
plastics, glass metal foil and other contaminates are separated
from the cellulosic fibers.
[0103] From the last chamber in zone 2, fiber recovery apparatus 7,
the waste material is transferred to the first chamber in zone 3,
fiber recovery apparatus 8, that is referred to as the extraction
zone. The cellulosic fiber slurry that has been transferred into
the first and succeeding chambers of zone 3 of the fiber recovery
apparatus 8 are washed within zone 3, apparatus 8, and the
separated cellulosic fibers are permitted to pass through
perforations in the drums of the chambers of zone 3 fiber recovery
apparatus 8 in a (preferably) 1%-2% cellulose fiber slurry for
further processing. The remaining material (comprising larger
inorganic contaminants that remain in the extraction zone 3, fiber
recovery apparatus 8) are transferred out of the last chamber for
disposal to a landfill 23. Dirty water 48 at 120.degree. F. is
preferably output from fiber recovery apparatus 7 to a dirty water
tank 22, where it may be processed with or separately from
untreated white water 50 stored in tanks 16, 17, and 18.
[0104] The cellulosic fiber slurry that has been filtered through
the perforations in the chambers of zone three, apparatus 8, of the
fiber recovery apparatus is transferred into an extract tank (stock
tank) 9 for further processing. The cellulosic slurry is
transferred from the stock tank 9, through the hydro-cleaner 10,
which de-waters ("de-waters" being used generally to describe the
process of removing all liquids (not just water) present in the
cellulosic slurry) the cellulosic slurry, as manufactured by
Black-Clawson (HD Cleaner), to a disk refiner 11, as manufactured
by Ring-R (model 48-S), which fluffs (or de-lumps) the fiber
bundles following the de-watering that occurs in hydro-cleaner 10.
The de-lumped fiber cellulosic slurry is then transferred to a
slurry thickener 12, as manufactured by Black Clawson (48.times.144
Thickener), where the percentage of cellulosic fibers within the
slurry is increased from a first range of about 1.5% to about 2.0%
to a second range of about 3.0% to about 4.5% for further
processing. The thickened cellulosic fiber slurry is then
transferred into a stock chest (or stock tank) 14 that holds the
cellulosic slurry prior to feeding the pulp drying and packaging
process (to be described below). The thickened cellulosic fiber
slurry is transferred from the stock tank 14 to a pulping fluid
extractor 27, as manufactured by Fields and Boyds (Wedge Belt Press
XLWT-80) (FIG. 2), and to a water press 28, as manufactured by
Rietz (V-Press), where liquid--in this case, untreated white water
50--is pressed out of the slurry so that the remaining material
coming out of the pulping fluid extractor and the pulp press is
about 40% to about 60% solids. This remaining material is referred
to herein as "cellulosic fiber wet lap".
[0105] An optional FR spray station (second chemical add station)
26 can be provided after the pulping fluid extractor 27, for
example, by spraying the cellulosic fiber wet lap with additional
chemicals that include liquid flame retardants, dyes, insecticides
and/or biocides that have been dissolved in water (see above, Table
III: Pulping Fluid Composition). The amount of chemical sprayed on
the cellulosic fiber wet lap is based on final product quality and
various product performance requirements. The final cellulosic
insulation 33 of the preferred embodiment has a flame retardant
chemical loading of approximately 6% that is well below the current
industry standard using a predominately dry process of 10% to
20%.
[0106] The cellulosic fiber wet lap is conveyed from the optional
chemical spray station 26 to a pulp press 28, as manufactured by
Rietz (V-Press), and then to a fluffer 29, as manufactured by
Sprout-Bauer (refiner #DM-36), that fluffs the cellulosic fiber wet
lap from a first density range of about 6 to about 10 lbs per cubic
foot to a second density range of about 2 to about 4 lbs per cubic
foot with a moisture content of about 40% to about 60%.
[0107] The fluffed cellulosic fiber wet lap is then conveyed to a
disk refiner 30, as manufactured by Ring-R (attrition mill model
48-S). Disk refiner 30 aids in fluffing (i.e., de-lumping) the
fiber bundles following the de-watering processes and thus improves
the efficiency of the drying process that follows the disk refiner
30. The method described herein first fluffs the fibers to, in
turn, break up the wet lap, and maintains a fibrous surface with a
preferred density of 2-6 p.c.f. This process is used to size the
individual fibers to the desired length of approximately 0.700 mm.
The preferred density of 2-6 p.c.f. is significantly lower than
nodules produced from other known methods. Notably, producing a
significantly less dense product is a significant factor in
minimizing the raw material, manufacturing and energy costs of
production. While obtaining such a lower density is a result of the
unique pulping methods, dewatering methods, fluffing methods,
drying methods, and packaging methods described herein with regard
to particular aspects of the invention, an important factor in
contributing to such lower density is maintenance of a drying
temperature for fluffed fibers in a second disc refiner of between
150 to 700.degree. F., which temperature range is also important to
reduce bacteria content and to dry the fibers to a uniform dryness.
As the system and method described herein process feed stock
comprised of a wide variety of waste materials from various waste
sources, the feed stock and any resulting fibers are more
susceptible to bacteriological growth, and the maintenance of
proper drying temperatures is important to combat such
bacteriological growth. Moreover, such drying temperature is an
important aspect of the processes described herein to enable
further processing and acceptable product in the marketplace.
[0108] The fluffed cellulosic fiber wet lap is then to a
conventional industrial dryer 31, as manufactured by Wolverine
Proctor & Swartz (model K17305), where the dryer reduces the
moisture content of the cellulosic fibers to a range of about 10%
to about 18%. Dryer 31 dries the fluffed cellulosic wet lap at a
temperature between about 150.degree. F. and about 700.degree. F.,
and the output is processed cellulosic insulation 33. The processed
cellulosic insulation 33 is then conveyed into a traditional
packaging/baling apparatus 32.
[0109] According to an alternative embodiment of the present
invention, a second flash/tunnel dryer 31a can be inserted prior to
disk refiner 30, or, subsequent to existing flash/tunnel dryer 31.
In the former case, the first dryer can be a tunnel dryer, followed
by disk refiner 30, followed by flash dryer 31. In the latter case,
the two dryers can both be the same, either flash or tunnel, or can
be different (flash and tunnel). Placing the disk refiner between
the two dryers refines the cellulosic fiber product at a moisture
content between about 20% to about 25%, rather than about 50%.
[0110] Untreated white water 50 extracted from pulping fluid
extractor 27 and pulp press 28 is preferably transferred to
untreated white water storage chest 35 to remove additional
inorganic compounds such as calcium carbonate 46, and aluminum and
magnesium hydroxide 45, among others, that can be commercially sold
to reduce the overall cost of the process described herein. An acid
34 such as sulfuric acid, phosphoric acid, or acidic acid, among
others, is preferably added to untreated white water 50 in storage
chest 35 to lower the pH of untreated white water 50 to a range of
about 4.0 to about 5.0 so as to dissolve the inorganic compounds
listed above.
[0111] The solution is then transferred to a precipitator 37, as
manufactured by US Filter (models 001 through 012 depending on
production capacity required). Alkaline agents 36 such as sodium
tetraborate, sodium borates, calcium borates, ammonium hydroxide,
anhydrous ammonia, lime, and/or soda ash, among others, are then
added to the solution in the precipitator 37 to increase the pH to
a range of about 4.5 to about 6.0 so as to cause precipitation of
aluminum and magnesium hydroxide byproducts 45 that are then
recovered with a batch or continuous flow filter/centrifuge 38 as
manufactured by Western States Machine Company. The remaining
solution is then transferred to a carbonator 40, as manufactured by
Niro Inc., where carbon dioxide 39 is added to the solution, and
the solution is then transferred to a precipitator 42, as
Manufactured by US Filter, where additional alkaline agents 41 such
as sodium tetraborate, sodium borates, calcium borates, ammonium
hydroxide, anhydrous ammonia, and lime, among others, are added to
increase the pH to a range of about 1.5 to about 12.8, or to a
point where suitable quantities of calcium carbonate 46 will
precipitate out of the solution. The solution is then pumped
through a filter/centrifuge 43, as manufactured by the Western
States Machine Company, for removal of the calcium carbonate 46.
The remaining solution, hereinafter referred to as treated white
water 51, is then transferred into treated white water storage
chest 44 and re-circulated to the fiber recovery apparatus. As FIG.
2 illustrates, treated white water 51 is combined with untreated
white water 50 and both are sent to white water storage chest
13.
Animal and Fowl Bedding Products
[0112] As discussed above, the system and method discussed above
can also be used for the manufacture of animal and fowl bedding,
with only slight modifications in the system and method according
to the embodiments of the present invention. The manufacturing
process described above is modified to exclude disc refiner 30 (see
FIG. 2) in order to maintain adequate fiber bundles that yield a
finished bulk density animal and fowl bedding product with a range
in density from about 2 lbs per cubic foot to about 6 lbs per cubic
foot. The animal and fowl bedding product is also dried to a
uniform moisture level of about 10% to about 18%, similarly to that
as described above in regard to the manufacture of cellulosic fiber
insulation products. Mold and bacteria, which are a significant
problem with conventional wood shavings or sawdust, are
significantly reduced when animal and fowl bedding manufactured
according to the embodiments of the present invention. Animal and
fowl bedding products manufactured according to the embodiments of
the present invention have consistent--and low--levels of
moisture.
[0113] Another substantial advantage of the animal and fowl bedding
product produced by the system and method according to an
embodiment of the present invention is that such animal and fowl
bedding product is substantially free of contaminants. While the
animal and fowl bedding products manufactured according to the
embodiments of the present invention can be made substantially free
of containments, certain desirable agents that originate in the raw
materials can be left in the animal and fowl bedding product.
Furthermore, according to an embodiment of the present invention,
the animal and fowl bedding product can be applied easier than
prior art bedding products. For example, animal and fowl bedding
product manufactured according the system and method of the present
invention can be applied to desired locations by a pneumatic
spreading device, which is very easy and efficient to use versus
mechanical or manual spreading of prior art shavings, sawdust or
pellets.
[0114] Animal and fowl bedding produced according to the
embodiments of the present invention processes waste material
containing cellulosic fibers of mixed length, and creates fiber
bundles that have a higher level of memory retention than
competitors' animal and fowl bedding products, thus improving
moisture holding capability, thickness for thermal benefit and
reconstitution. As a result, consumers, whether private or
commercial/industrial, will successfully endeavor to reconstitute
or fluff up their bedding to allow it to dry and gain additional
life from the animal and fowl bedding product. Animal and fowl
bedding product manufactured according to a preferred embodiment of
the present invention incurs between about 40% to about 50% less
compaction compared to conventional paper-based animal and fowl
bedding products.
[0115] Furthermore, because of the flexibility of the manufacturing
process described above according to several embodiments of the
present invention, a nearly limitless amount of additives can be
inserted to the fibers in such a way that the additives become part
of the fiber composition and therefore are not susceptible to
separation.
[0116] Further still, manufacturing animal and fowl bedding product
according to the embodiments of the present invention removes high
levels of inorganic components therefore providing a paper-based
product that has higher absorption qualities per pound of product,
holds its structure better and therefore provides a higher level of
thermal barrier. Compared with conventional paper-based animal and
fowl bedding, the animal and fowl bedding product manufactured
according to an embodiment of the present invention, demonstrates
between about 15% to about 20% higher absorption level. The animal
and fowl bedding product manufactured according to exemplary
embodiments of the present invention has improved moisture
absorption capabilities because of the higher ash content as
compared to known animal and fowl bedding products.
[0117] According to a preferred embodiment of the present
invention, animal and fowl bedding product manufactured according
to the processes and system described herein, with the modification
of subjection of the product to a step that includes applying heat
(or drying) at a temperature between about 250.degree. F. and about
350.degree. F., provides a product that substantially reduces the
ability for mold and bacteria to grow on the animal and fowl
bedding. According to a preferred embodiment of the present
invention, the fibers are dried at a temperature above about
300.degree. F. Other advantages of animal and fowl bedding
manufactured according to the processes and system described herein
includes: substantially higher absorbency than wood shavings,
sawdust or straw (e.g., in the order of about 4 to about 6 times
greater absorbency); substantially higher absorbency than
conventional paper-based bedding (e.g., in the order of about 18%
to about 25% greater absorbency); a uniform and consistently
manufactured product; and an animal and fowl bedding product
wherein the particle size and its composition improves longevity in
the product. Further still, other advantages include reductions in
the amount of foot sores and other ailments linked to wood based
bedding; improved thermal qualities; faster decomposition when
properly disposed of; and an animal and fowl bedding product that
is substantially free from contamination, and one that can be
custom manufactured to include performance enhancers (for example,
scents, colors, among others). In addition, animal and fowl bedding
product manufactured according to the processes and system
described herein comes packaged for clean and dry storage and is
acceptable for decomposition in fields or for biomass power
generation.
CONCLUSION
[0118] Thus, what has been described is an efficient system and
process by which previously unrecoverable waste products are turned
into useful fiber products, such as cellulosic insulation, and
animal and fowl bedding, among other products such as industrial
fibers where fibers are used as thickeners, absorption agents or
fillers and hydro-mulch, with a total ash content equal to or less
than 10%.
[0119] The individual components shown in outline or designated by
blocks in the attached Drawings are all well-known in the waste
recycling arts, and their specific construction and operation are
not critical to the operation or best mode for carrying out the
invention.
[0120] While the present invention has been described with respect
to what is presently considered to be the preferred embodiments, it
is to be understood that the invention is not limited to the
disclosed embodiments. To the contrary, the invention is intended
to cover various modifications and equivalent arrangements included
within the spirit and scope of the appended claims. The scope of
the following claims is to be accorded the broadest interpretation
so as to encompass all such modifications and equivalent structures
and functions.
[0121] Any U.S. and foreign patent document discussed above is
hereby incorporated by reference into the detailed Description of
the Presently Preferred Exemplary Embodiments.
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