U.S. patent application number 15/073945 was filed with the patent office on 2016-07-14 for method of operating a temperature-controlled thermokinetic mixer for regenerating vulcanized rubber.
This patent application is currently assigned to PHOENIX INNOVATION TECHNOLOGY INC.. The applicant listed for this patent is PHOENIX INNOVATION TECHNOLOGY INC.. Invention is credited to Sylvain Martel, Stephen Murphy.
Application Number | 20160200005 15/073945 |
Document ID | / |
Family ID | 50543823 |
Filed Date | 2016-07-14 |
United States Patent
Application |
20160200005 |
Kind Code |
A1 |
Martel; Sylvain ; et
al. |
July 14, 2016 |
METHOD OF OPERATING A TEMPERATURE-CONTROLLED THERMOKINETIC MIXER
FOR REGENERATING VULCANIZED RUBBER
Abstract
A method of operating a temperature-controlled K-mixer for
thermally and kinetically regenerating vulcanized crumb rubber is
provided. The K-mixer includes a chamber and a shaft provided with
a plurality of blades. The method includes the steps of inserting a
mixture of vulcanized crumb rubber and a lubricant in the chamber
of the K-mixer; heating the mixture by rotating the shaft of the
K-mixer until the temperature of the mixture has reached a
devulcanizing or regeneration temperature; cooling the mixture by
reducing the rotational speed of the K-mixer and by circulating a
cooling fluid in the shaft and in channels of the blades.
Inventors: |
Martel; Sylvain;
(Sainte-Therese, CA) ; Murphy; Stephen;
(L'lle-Bizard, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PHOENIX INNOVATION TECHNOLOGY INC. |
Westmount |
|
CA |
|
|
Assignee: |
PHOENIX INNOVATION TECHNOLOGY
INC.
Westmount
CA
|
Family ID: |
50543823 |
Appl. No.: |
15/073945 |
Filed: |
March 18, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14422629 |
Feb 19, 2015 |
9321190 |
|
|
PCT/CA2013/050808 |
Oct 24, 2013 |
|
|
|
15073945 |
|
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|
61717878 |
Oct 24, 2012 |
|
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Current U.S.
Class: |
521/45.5 |
Current CPC
Class: |
C08J 11/06 20130101;
B01F 7/0065 20130101; B01F 7/04 20130101; B29K 2021/00 20130101;
B29B 7/16 20130101; B29B 7/28 20130101; B29B 13/02 20130101; B29B
7/823 20130101; B29B 7/14 20130101; Y02W 30/62 20150501; B01F
2015/061 20130101; B29B 17/00 20130101; B01F 7/00425 20130101; B29B
7/38 20130101; B01F 2015/062 20130101; B01F 15/068 20130101; B01F
15/00337 20130101; B29B 7/283 20130101; B01F 2215/0049 20130101;
B29B 7/726 20130101; B29B 7/125 20130101 |
International
Class: |
B29B 17/00 20060101
B29B017/00; C08J 11/06 20060101 C08J011/06; B29B 7/28 20060101
B29B007/28; B29B 7/82 20060101 B29B007/82; B29B 7/16 20060101
B29B007/16 |
Claims
1. A method of operating a temperature-controlled K-mixer for
thermally and kinetically regenerating vulcanized crumb rubber,
said K-mixer including a chamber and a shaft provided with a
plurality of blades, the method comprising the steps of: inserting
a mixture of vulcanized crumb rubber and a lubricant in the chamber
of the K-mixer; heating the mixture by rotating the shaft of the
K-mixer until the temperature of the mixture has reached a
devulcanizing temperature; cooling the mixture by reducing the
rotational speed of the K-mixer and by circulating a cooling fluid
in the shaft and in channels of the blades; and recovering
regenerated crumb rubber from the chamber.
2. The method of claim 1, wherein the shaft of the K-mixer includes
inner and outer passages in fluid communication with the channels
of the blades, and wherein circulating the cooling fluid comprises
circulating fluid from one of the inner and outer passages, to the
channels in the blades, to the other one of the inner and outer
passages.
3. The method of claim 2, wherein the blades of the shaft are
respectively formed from at least one plate, the channels being
formed at least partially within said at least one plate, and
wherein the cooling fluid is circulated within said at least one
plate forming the blade.
4. The method of claim 1, wherein the flow of the cooling fluid in
the channels of the blades is controlled individually within each
blade.
5. The method of claim 2, wherein the flow of the cooling fluid
circulating in the inner and outer passages is controlled with a
return flow adjustment mechanism.
6. The method of claim 1, comprising measuring the temperature of
the mixture inside the chamber, and wherein the circulation of a
cooling fluid in the shaft and in the blades is regulated based on
the measured temperature of the mixture.
7. The method according to claim 1, wherein the step of cooling the
mixture includes cooling the chamber by circulating water in a
cooling jacket surrounding the mixing chamber.
8. The method according to claim 1, wherein the step of cooling the
mixture includes injecting a cooling agent in the mixing
chamber.
9. The method according to claim 8, wherein the cooling agent is
injected using at least one spray nozzle in the form of a mist or
of a stream.
10. The method according to claim 1, wherein the step of heating
the mixture is performed by increasing the rotational speed of the
shaft to between 1700 and 2000 rpm.
11. The method according to claim 1, wherein the step of heating
the mixture is performed by increasing the rotational speed of the
shaft to between 1750 and 1850 rpm.
12. The method according to claim 10, wherein in the step of
heating the mixture, the devulcanizing temperature is reached
within a time period of 25 to 60 seconds.
13. The method according to claim 10, wherein in the step of
heating the mixture, the devulcanizing temperature is reached
within a time period of 30 to 45 seconds.
14. The method according to claim 10, wherein the step of cooling
the mixture is performed until the temperature of the mixture has
decreased to less than 125.degree. C.
15. The method according to claim 10, wherein the step of cooling
the mixture is performed for less than 45 seconds.
16. The method according to claim 10, wherein the step of cooling
the mixture is performed for less than 35 seconds.
17. The method according to claim 1, wherein the step of cooling
the mixture is performed by reducing the rotational speed of the
shaft to between 400 and 700 rpm.
18. The method according to claim 1, wherein the step of cooling
the mixture is performed by reducing the rotational speed of the
shaft to about 600 rpm.
19. The method according to claim 1, comprising a step of mixing
the vulcanized crumb rubber and the lubricant prior to transferring
the mixture to the chamber.
20. The method according to claim 1, wherein the devulcanizing
temperature is between 210.degree. C. to 225.degree. C.
21. A method of operating a temperature-controlled K-mixer for
thermally and kinetically treating vulcanized crumb rubber, said
K-mixer including a chamber and a shaft provided with a plurality
of blades, the method comprising the steps of: mixing vulcanized
crumb rubber and oil to form a mixture; transferring the mixture to
the chamber of the K-mixer; heating the mixture by rotating the
shaft of the K-mixer between 1700 and 2000 rpm, for a heating time
period of between 25 to 60 seconds, until the temperature of the
mixture has reached a devulcanizing temperature; cooling the
mixture by reducing the rotational speed of the K-mixer to between
400 and 700 rpm, for cooling time period of less than 40 seconds,
by circulating a cooling fluid in the shaft and in channels of the
blades, the blades of the shaft being respectively formed from at
least one plate, the channels being formed at least partially
within said at least one plate, and wherein the cooling fluid is
circulated within said at least one plate forming the blade; and by
injecting a cooling agent in the mixing chamber; and recovering
regenerated crumb rubber from the chamber.
22. The method according to claim 21, wherein in the step of
cooling the mixture, the cooling fluid is oil and chamber is also
cooled with cooling water jackets.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 14/422,629, filed Feb. 9, 2015, which is a national stage
application under 35 U.S.C. 371 of International Patent Application
Serial No. PCT/CA2013/050808, filed Oct. 24, 2013, which claims
priority to U.S. Patent Application No. 61/717,878, filed Oct. 24,
2012, the disclosures of which are incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a thermal kinetic
mixer, or thermokinetic mixer, also named hereinafter K-mixer. More
particularly, the invention relates to a shaft assembly and to a
K-mixer having improved features for controlling the temperature of
the blades of the K-mixer while the K-mixer is operating.
BACKGROUND OF THE INVENTION
[0003] K-mixers are high intensity mixers (see U.S. Pat. No.
4,332,479 to Crocker et al.) that can be used, among other
applications, for mechanical regenerating of rubber (see U.S. Pat.
No. 5,883,140 (Fisher et al.); U.S. Pat. No. 7,342,052 (Fulford et
al.); or Applicant's application WO 2011/113148). K-mixers differ
from agitators and kneading apparatuses in that they can be
operated at higher RPMs (revolutions per minute) and high moments
of force (torque). Their components are thus subjected to high
temperatures, and in rubber regeneration applications, the thermal
inertia of the components prevents operating the K-mixer in a
semi-continuous process environment. A semi-continuous process is
typically a batch process which can be realised without having to
stop or minimally stopping equipment in between batches. In order
to mitigate this problem, a cooling jacket can be provided around
the mixing chamber and/or a coolant can be circulated in the shaft.
While these solutions help to alleviate problems related to
over-heating in the K-mixer, they are still insufficient for some
applications, especially for rubber regeneration.
[0004] Agitators, kneaders, bladed rotors or other sorts of
apparatuses including temperature-controlled systems have been
disclosed in the past, such as in U.S. Pat. No. 4,040,768
(Christian); U.S. Pat. No. 4,856,907 (Moriyama) or U.S. Pat. No.
7,540,651 B2 (Matsumoto et al.). However, none of these US patents
discloses temperature-controlled systems adapted for K-mixers.
[0005] Referring to U.S. Pat. No. 4,856,907 to Moriyama, a kneader
is disclosed. The kneader has a shaft 5 on which external members 7
are fitted. The rotor shaft 5 is provided with heat transfer
passages 13, 14 linked to spaces 9 of the blades 10, which are
integrally formed by the external members 7. As shown in FIG. 2 of
the patent, the passages 13, 14 of the shaft 5 are located on the
central axis of the shaft, meaning that the outer periphery of the
shaft where there are no blades is not thermally-controlled by the
heat transfer liquid. In addition, the space 9 of the blades is
completely hollow, the heat transfer liquid freely circulating in
the space, which does not provide for an efficient flow of fluid
within the blade. In addition, the flow of fluid within the
external members 7 cannot be adjusted.
[0006] Referring to U.S. Pat. No. 7,540,651 to Matsumoto et al., an
agitator is disclosed, especially adapted for agitating fluids,
such as inks and coloring liquids. The agitator includes a rotating
shaft 3 and a flat paddle blade 4. The shaft 3 includes inner and
outer pipes 3a, 3b, and an integrally formed paddle with a passage
12 for a coolant medium. The passage 12 zigzags in the paddle,
which results in the coolant circulating in different directions,
clockwise and counter-clockwise, within the paddle. The
configuration of the passage therefore requires the coolant to be
circulated at high pressure to be able to cool the paddle
efficiently. In addition, the blade 4 is integrally formed with the
shaft, and is not adapted for K-mixers, for which blades must
sometimes be replaced. Furthermore, agitators typically have a
single blade and are subject to low intensity loads with a single
blade integrally formed at the end of the shaft, oriented in the
direction of the shaft. Conversely, K-mixers have typically a
plurality of blades that are perpendicular to the shaft which
rotate at high RPMs and generate high moments of force.
[0007] In view of the above, there is thus a need for an improved
K-mixer that would be able to overcome or at least minimize some of
the above-discussed concerns. It would be desirable for the
improved K-mixer to allow a temperature control of the shaft and of
the independent blade(s), and to improve flow of a heat transfer
fluid within the shaft assembly and the blade assembly so as to
increase heat transfer exchanges. Furthermore, there is also a need
for a K-mixer which would facilitate replacement of the blades when
the hard facing begins to wear down, and additionally would allow
for a custom blade design and replacement. Additionally, a K-mixer
allowing temperature control of each blade individually would prove
beneficial.
SUMMARY OF THE INVENTION
[0008] In accordance with the present invention, there is provided
a temperature-controlled shaft assembly of a K-mixer, preferably
for use in a rubber regenerating process. The K-mixer disclosed
herein is an improvement of the K-mixer disclosed in Applicant's
application WO 2011/113148, the content of which is incorporated
herewith by reference.
[0009] The improvement consists of a temperature-controlled shaft
assembly, embedded inside the shaft and blades of the K-mixer, in
order to efficiently control and modify the temperature of the
shaft and blades while the K-mixer is functioning.
[0010] According to the invention, there is provided a
thermokinetic mixer, or K-mixer, comprising a substantially
cylindrical stationary chamber for containing the material, the
chamber having a chamber inlet for receiving the material and a
chamber outlet for discharging the material. The K-mixer includes a
shaft assembly coaxial with the chamber and having a portion
extending in the stationary chamber. The shaft assembly comprises
an inner hollow shaft defining an inner passage which extends
therein. The shaft assembly also comprises an outer hollow shaft
coaxially surrounding and spaced away from the inner hollow shaft.
The outer hollow shaft forming an outer passage with the inner
hollow shaft, the outer passage extending between the inner and
outer hollow shafts, the inner and outer passages are in fluid
communication with each other. The shaft assembly has a motor end
connectable to a motor for rotating the shaft assembly, and a joint
end connectable to a rotary joint. The joint end has a fluid inlet
and a fluid outlet, each communicating with a respective one of the
inner and outer passages. The shaft assembly includes a plurality
of blades extending from the outer hollow shaft in the stationary
chamber, for mixing the material. Each of the blades is provided
with channels extending therein, a channel inlet communicating with
one of the passages, and a channel outlet communicating with the
other one of the passages. The inner passage channels and the outer
passage form a continuous flow path allowing a pressurized fluid to
circulate within inner and outer hollow shafts and through the
plurality of blades, from the fluid inlet to the fluid outlet, for
controlling a temperature of the shafts and a temperature of the
blades. The channels allow a flow of the fluid in the blades in an
opposite direction of a rotational direction of the shaft
assembly.
[0011] Preferably, each of the blades has a body with a mounting
end operatively mounted to the outer hollow shaft, and an outer end
opposed to the mounting end. At least some of the channels of each
blade extend from the mounting end to the outer end.
[0012] In a preferred embodiment, the channels are shaped and
configured as concentric U-shaped channels.
[0013] Preferably, each of the blades comprises opposed first and
second faces which are substantially parallel to a transverse
cross-section the hollow shafts. Each blade includes a cavity
formed between said lateral faces; and a plurality of sidewalls
extend within the cavity from the first to the second lateral face.
The sidewalls delimit the channels.
[0014] Preferably, each of the blades comprises a mounting
mechanism for removably connecting the blade to the outer hollow
shaft. The mounting mechanism allows replacement of the blade.
[0015] Preferably, the shaft assembly includes pairs of connecting
tubes associated with the respective blades. The connecting tubes
extend radially relative to the hollow shafts. The connecting tubes
connect the channel inlets and the channel outlets to one of the
inner and outer passages, respectively.
[0016] Preferably, each of the blades is provided with a flow
adjustment device sized to individually control the flow of fluid
within each blade. Preferably, the flow adjustment device is a
gasket.
[0017] Preferably, the shaft assembly includes a return flow
adjustment mechanism disposed between the inner and outer passages,
for controlling flow of the fluid between the inner and the outer
passages and an exit flow of the blades.
[0018] Preferably, the cross-sectional area of the inner passage
substantially matches cross-sectional area of the outer
passage.
[0019] The fluid can be a cooling or a heating fluid.
[0020] Preferably, the outer surfaces of the blades are
non-uniform, and some or all can be twisted longitudinally.
[0021] Preferably, the K-mixer can include a temperature sensor for
sensing the temperature of at least one of the blades.
[0022] One of the advantages of the K-mixer disclosed herein is
that the surface temperature of the shaft and blades of the K-mixer
can be controlled (temperature is maintained constant, decreased or
increased) and that the inertial effects caused by the rotational
movement of the shaft are used to assist with the circulation of
the fluid within the blades. Consequently, if the blades are cooled
efficiently, the K-mixer can then be operated in a semi-continuous
process environment with consistent temperatures ensuring reliable
processing parameters and therefore dependable quality of the
regenerated rubber.
[0023] The improvements of the K-mixer and their advantages will be
better understood upon reading the following description made with
reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of a K-mixer.
[0025] FIG. 2 is a cut-away view of a portion of the K-mixer,
showing a shaft assembly, according to an embodiment of the
invention.
[0026] FIG. 3 is a perspective view of the shaft assembly of FIG.
2, according to an embodiment of the invention.
[0027] FIG. 4 is an exploded view of the shaft assembly of FIG.
3.
[0028] FIG. 5 is a transverse cross-section view taken alone lines
V-V on FIG. 3.
[0029] FIG. 6 is a schematic longitudinal cross-sectional view of a
portion of a shaft assembly, according to an embodiment of the
invention.
[0030] FIG. 7 is a front view of a twisted blade, according to an
embodiment. FIG. 7A is a cross section view taken along lines A-A
of FIG. 7, showing the outlines of the seal welding locations
forming the channels inside the blades.
[0031] FIG. 8 is a front view of a blade, according to another
embodiment. FIG. 8A is a cross section view taken along lines A-A
of FIG. 8, showing machined channels made in a single metal plate
blade.
[0032] FIG. 9 is a graph of the average temperature measured on the
8 blades of the shaft, when only the shaft was cooled for 3
different sets of 5 trials (curves "Shaft 5-1", "Shaft 5-2" and
"Shaft 5-3"), and of the average temperature measured from the 8
blades of the shaft (curve "ShaftBlade"), when the shaft and all 8
blades were cooled, as a function of the number of cycles for which
the K-mixer was operated.
[0033] FIG. 10A is a graph of the average of the temperature
measured on each blade of the shaft during 5 trials, when only the
shaft was cooled (upper curve "Shaft") and of the average of the
temperature of each blade, when both the shaft and the blades were
cooled (curve "ShaftBlade"), as a function of the position of the
blade on the shaft.
[0034] FIG. 10B is a side view of the shaft assembly, indicating
the position of each blade on the shaft, as used in the graph of
FIG. 10A.
[0035] FIG. 11A is a graph of including four curves resulting from
a crumb rubber regeneration cycle, with only the shaft of the
K-mixer being cooled, and with a shaft RPM (Revolution Per Minute)
set at 1780 during the heating step. Two of the curves illustrate
the RPM (Y axis on the left side of the graph), one curve
corresponding to the set point RPM, and the other corresponding to
the process value RPM, as a function of time. The two other curves
illustrate the set point and process value temperature of the crumb
rubber being mixed in the mixing chamber (Y-axis on the right-side
of the graph), as a function of time.
[0036] FIG. 11B is a graph of including four curves resulting from
a crumb rubber regeneration cycle, with the shaft and blades of the
K-mixer being cooled, and with a shaft RPM (Revolution per minute)
set at 1780 during the heating step. Two of the curves illustrate
the RPM (Y axis on the left side of the graph), one curve
corresponding to the set point RPM, and the other corresponding to
the process value RPM, as a function of time. The two other curves
illustrate the set point and process value of the temperature of
the crumb rubber being mixed in the mixing chamber (Y-axis on the
right-side of the graph), as a function of time.
[0037] FIG. 11C is a graph of including four curves resulting from
a crumb rubber regeneration cycle, with the shaft and blades the
K-mixer being cooled, and with a shaft RPM (Revolution per minute)
set at 1800 during the heating step. Two of the curves illustrate
the RPM (Y axis on the left side of the graph), one curve
corresponding to the set point RPM, and the other corresponding to
the process value RPM, as a function of time. The two other curves
illustrate the set point and process value of the temperature of
the crumb rubber being mixed in the mixing chamber (Y-axis on the
right-side of the graph), as a function of time.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] In the following description, the same numerical references
refer to similar elements. The embodiments described in the present
description are preferred embodiments only; they are given solely
for exemplification purposes.
[0039] Referring to FIG. 1, a K-mixer (10), or K-mixer, is shown.
This K-mixer (10) is temperature-controlled, and is for thermally
and kinetically treating a material, such as a particulate or
granular material. "Treating" the material includes beating, mixing
or agitating and shearing without being limited to such actions.
The K-mixer (10) described herein below is especially adapted for
regenerating crumb rubber. The material can include a single
component, or a mix of various components. In the case of rubber
regeneration, the material includes oil and crumb rubber from
recycled rubber.
[0040] The K-mixer (10) includes a hopper (12), through which the
material is fed to the mixer (10). By "hopper", it is meant a
component which allows directing or guiding the material into the
mixer (10). A substantially cylindrical stationary chamber (14),
also referred to as a "mixing" chamber, allows to contain the
material. The chamber (14) has a chamber inlet (16) communicating
with the hopper (12), and a chamber outlet (18) for discharging the
material. A shaft assembly extends inside the chamber (not shown in
the figure), and will be described in more detail with reference to
FIGS. 2 to 6. The motor 34 allows rotating the shaft assembly
(shown in FIG. 2). The mixer (10) also preferably includes a
cooling system (19). The cooling system can include a plurality of
injection nozzles, which can be located on the motor side and/or on
the screw feed/rotation joint side of the mixing chamber. The
mixing chamber is preferably substantially airtight, and a ram
valve (21) can be used for the vacuum of the mixing chamber.
[0041] FIG. 2 illustrates how the shaft assembly (20) is disposed
in the K-mixer (10). The shaft assembly (20) is coaxial relative to
the chamber (14) and has a portion extending in the chamber (14).
The shaft assembly (20) includes a feed screw (30) operatively
connected to an outer hollow shaft (26). The feed screw (30) is
located in line with the hopper (12), and is for displacing the
material toward the chamber (14). The portion of the shaft assembly
(20) in the chamber (14) includes a plurality of blades (44)
extending from the outer hollow shaft (26) in the stationary
chamber (14), for treating the material. The blades (44) can also
be referred to as "paddles". They allow mixing, shearing, beating
and/or propelling the material within the chamber, for heating or
cooling the material, when the shaft assembly (20) is rotating at
high speed (up to 2000 rpm) or slower speeds to assist cooling.
[0042] The shaft assembly has a rotary joint end (36) connectable
to an inner shaft. By "rotary joint" it is meant a joint which
allows the rotation of the shaft assembly (20) relative to a fixed
structure. In this particular embodiment, the rotary joint (38)
also allows a fluid from a fluid source (74) to be circulated in
and out of the shaft assembly (20). The fluid used is a heat
transfer fluid, such as water, chemically treated water or
vegetable oil. Of course, other types of heat transfer fluid can be
used.
[0043] While in the present embodiment the hopper (12) and the feed
screw (30) are located away from the motor, other embodiments of
the K-mixer (10) can be considered, in which the hopper and feed
screw (30) are located close to the motor, and the chamber (14) is
located away from it. Preferably, and as shown in enlarged FIG. 2A,
the inner surface of the chamber (14) is non-uniform, to create
friction and shearing forces between the inner non-uniform surface
(23) of the chamber (14) and the material being treated. The
non-uniform surface can be obtained by applying hardfacing on the
inner sidewall of the mixing chamber (14). Preferably, the lateral
faces of the blades 44 are also provided with hard facing (23).
[0044] Referring to FIGS. 3 and 4, a preferred embodiment of the
shaft assembly (20) can be viewed in full, from the rotary joint
end (36) to the motor end (32). The shaft assembly (20) includes
the outer hollow shaft (26), and also an inner hollow shaft (22)
(shown in FIG. 4). In this embodiment, each blade (44) has a
substantially rectangular flat body (54), with a mounting end (56)
operatively mounted to the outer hollow shaft (26), and an outer
end (58) opposed to the mounting end (56). Of course, other
geometries can be considered for the blades. The blades can be
provided with a non-uniform surface, by applying hard facing for
example, to increase friction and shearing between the blades and
the material. The blades (44) have opposed first and second faces
(60, 62), and they extend radially relative to the outer hollow
shaft (26).
[0045] As best shown in FIG. 4, the blades (44) are removably
attached to the outer hollow shaft (26), which allows replacing a
blade, for example when its hard facing begins to wear. The
modularity of the blades also allows changing the configuration of
the blades on the shaft without having to change the entire shaft
assembly. The blades (44) therefore include a mounting mechanism
allowing to removably attaching the blade to the hollow shaft
(26).
[0046] As best shown in FIG. 3, at least some of the blades are
substantially parallel to a transverse cross-section the outer
hollow shaft (26), such as the three leftmost blades (44i, 44ii,
44iii) located on the upper side of the shaft (26). Some of the
blades can also extend at an angle relative to a radial direction
from the outer hollow shaft (26), such as the rightmost blade
(44iv) located on the upper side of the shaft (26), and the
leftmost blade located on the lower side of the shaft (26). The
blades extending at an angle relative to the radial direction of
the shaft (26) are preferably located at the extremities of the
shaft (26), acting as a scraper that guides the material from the
sidewalls of the chamber towards the centre of the chamber. Of
course, in other embodiments of the invention, all blades can be
longitudinally twisted.
[0047] Referring to FIGS. 5 and 6, the continuous flow path (52)
which allows a pressurized fluid to circulate within inner and
outer hollow shafts (22, 26) and through the plurality of blades
(44) will be described. The inner hollow shaft (22) defines an
inner passage (24) which extends axially therein. The outer hollow
shaft (26) coaxially surrounds the shaft (22) and is spaced away
from it. The joint end (36) (shown in FIG. 6) has a fluid inlet
(40) and a fluid outlet (42), each communicating with one of the
inner and outer passages (24, 28). It can also be considered to
provide the inner tube with insulation around it to resist heating
by the return tube. Of course, the feed and return can be reversed,
ie the feed of coolant can flow in the outer passage 28, and the
return of coolant can flow in the inner passage 24.
[0048] As best shown in FIG. 5, the outer hollow shaft (26) forms
an outer passage (28) with the inner hollow shaft (22), this outer
passage (28) extending between the inner and outer hollow shafts
(22, 26). The inner and outer passages (24, 28) are in fluid
communication with each other, preferably near the motor end.
Preferably, although not necessarily, the cross-sectional area of
the inner passage (24) substantially matches cross-sectional area
of the outer passage (28). By approximately matching the feed and
return cross-sectional areas the input (feed) pressure is roughly
equivalent to the output (return) pressure, allowing circulating
the fluid in a closed loop.
[0049] Still referring to FIG. 5, each blade (44) is provided with
a network of channels provide a flow of fluid throughout the blade.
The channels are configured to allow flow from the front edge to
the back edge of the blade, taking advantage of the rotational
inertia of the shaft assembly. The "front edge" and "back edge"
being relative to the rotational direction of the shaft. Each of
the blades can be provided with substantially concentric channels
(46). By "substantially concentric", it is meant that the channels
have a common center, or that they are coaxial, but it does not
mean that they need to be configured as concentric circles. In the
present embodiment, the channels (46) are disposed side-by-side,
and have U-shape, but of course, other configurations can be
considered. For each blade (44), a channel inlet (48) communicates
with one of the passages (24, 28), and a channel outlet (50)
communicating with the other one of the passages (28, 24). As can
be appreciated, the channels 46 form a network of heating or
cooling passages within the blade.
[0050] Referring now to both FIGS. 5 and 6, the inner passage (24),
the channels (46) and the outer passage (28) form the continuous
flow path (52), allowing a pressurized fluid to circulate within
inner and outer hollow shafts (22, 26) and through the plurality of
blades (44), from the fluid inlet (40) to the fluid outlet (42).
The continuous flow path allows for controlling not only the
temperature of the shafts (22, 26) but also the temperature of the
blades (44). In addition, the concentric configuration of the
channels (46) allow for the fluid to flow in an opposite direction
of a rotational direction of the shaft assembly (20), taking
advantage of the rotational inertia generated by the shaft when the
mixer is in use. The flow of the fluid that enters the blade from
the feeding passage can be adjusted either at the channel inlet
(48) or within the blade (44). The feed pressure applied to the
fluid (ex: 12 psi) and inertial effects of the blade rotation will
assist with the circulation of the fluid from the input channel(s)
to the output channel(s).
[0051] As best shown in FIG. 5, the blades are provided with flow
adjustment devices, such as neoprene gaskets (51), provided between
the paddle-shaped plate (54) and the connecting tubes (68,70),
which are preferably made of metal. The gaskets (51) not only allow
sealing the connection between the blade's body (54) and the tubes
(68, 70), they also allow controlling or adjusting the flow of
fluid in the blade. This can be achieved by selecting the proper
opening size (diameter) of the gasket. The size of the gasket
opening can be selected to increase or decrease the flow of fluid
in the blade relative to the other blades. For example, if during
operation of the K-mixer, one of the blades is running hotter than
neighboring blades, the diameter of the gasket's opening for this
blade can be increased, which will in turn increase the flow of
fluid in the blade, allowing to lower its temperature. The opening
size of the gaskets (15) can also be sized to control the flow of
fluid within the blades (44), with different inlet and outlet
sizes; for example with the inlet being greater than the outlet. Of
course, there can be more than one inlet or outlet per blade.
[0052] With the present invention, the bent portions of the
channels (46), and their configuration which forces the fluid to
move in a direction opposite to the rotation of the shaft, allows
taking advantage of the inertial effects, and advantageously
improve heat transfer between the fluid and the material treated in
the mixer. In other words, the channels are designed to
<<remove>> as much heat as possible from the inertial
mass of the metal. >> The proposed design of channels
generally guides the flow of fluid in the blades from the front
side to the back side of the blade, the "front side" and "back
side" of the blade being determined by the rotational direction of
the assembly.
[0053] As shown in FIG. 5, at least one of the channels (46) of
each blade (44) extends from the mounting end (56) to the outer end
(58), providing heat transfer channels throughout an extended area
of the blade (44). The cavity (64) in the blade (44), formed
between its opposed faces, includes sidewalls (66) which delimits
the channels (46). Some of the sidewalls have an I-shape, and some
have an L-shape. The sidewalls together provide the channels (44)
with a substantially inverted U-shape. As can be appreciated, the
channels (46) are sized and shaped to promote continuous fluid flow
within the blades, which in turn improves heat transfer and allow
controlling the temperature of the blades. In the context of rubber
regeneration, controlling of the blade temperatures for initial and
repeated cycles ensures process consistency and the regenerated
rubber (RR) product quality. Injection of the coolant, typically
water, and reduction of revolution per minute of (RPM) the shaft is
also used to cool the regenerated rubber.
[0054] Each blade 44 has a pair of connecting tubes (68, 70)
extending radially relative to the hollow shafts (22, 26). The
connecting tubes (68, 70) are connected to respective gaskets (51)
which in turn are connected to the channel inlet (48) and the
channel outlet (50). The connecting tubes (68, 70) are also
connected to the inner and outer passages (24, 28), respectively.
The inner and outer hollow shafts (22, 26) (feed shaft and return)
are equipped with perforations to accommodate connecting tubes of
the blades. The connected tubes 68, 70 are preferably threaded in
the hollow shafts (22,26) but of course other types of connections
can be considered.
[0055] In the present case, and as best shown in FIG. 6, the fluid
inlet (40) is connected to the inner passage (24) and the fluid
outlet (42) is connected to the outer passage (28). The fluid is
thus fed from the fluid inlet (40), then through the inner passage
(24) first, passing through the return flow adjustment (72) (which
is optional). The fluid then passes in each of the blades 44, and
returns to the outlet (42) through the outer passage (28). For each
blade (44), the channel inlet (48) communicates with the inner
passage (24) and the channel outlet (50) communicates with the
outer passage (28). Of course, in other embodiments, it can be
considered to have the fluid first flow in the outer passage (28),
and return to the outlet from the inner passage. In this case, the
channel inlet (48) of the blades would communicate with the outer
passage (28) and the channel outlet (50) would be linked to the
inner passage (24).
[0056] Still referring to FIG. 6, the return flow adjustment
mechanism (72) is optional and can be disposed between the inner
and outer passages (24, 28), for controlling the flow of fluid
between the inner and the outer passages (24, 28). At the joint end
(36) the fluid inlet (40) and the fluid outlet (42) each
communicates with a respective one of the inner and outer passages
(24, 28).
[0057] The K-mixer described therein is especially adapted for the
regeneration of crumb rubber, which requires in some applications
heating the crumbs at a temperature up to about 225 degrees
Celsius, in about 50 seconds, and then cooling it to about 120
degrees Celsius, in about 40 seconds. Preferably, the crumbs must
not be heated over 230 to 250 degrees Celsius. In order to be able
to operate the K-mixer semi-continuously, which means without
interruption (or very little delay ex: 2 to 10 sec) from one batch
to the other, the blades and the devulcanized rubber must be cooled
rapidly once the devulcanization has occurred, and thus the fluid
used is a cooling fluid. The continuous flow path extending in both
the shafts and blades of the shaft assembly (20) allows not only to
control/limit the temperature increase in the chamber when the
devulcanization is reached, but also to decrease the time required
to cool down the regenerated crumb rubber, which in turn improves
the production yields of the regeneration process. Of course, the
temperature of the mixing chamber is also controlled by water
jackets surrounding it. Preferably, the RPM of the shaft assembly
is controlled based upon the cooled state of the blades. Cooling is
preferably only circulated in the shaft and blades when maximum
temperature is reached and the water is injected into the chamber,
after which the cooling phase begins. By "continuous" flow path, it
is meant that the passages in the hollow shafts and the channels in
the blades are in fluid communication. The flow of fluid in the
path can run continuously, or flow intermittently, according to the
specific requirements of the process. Of course, for other
applications, it can be considered to use a heating fluid instead
of a cooling fluid. The fluid can be heated or cooled using
external or internal devices, such as for instance an electric coil
or a chiller.
[0058] In order to adapt the flow of fluid in the shafts and in the
blades in function of the need of the K-mixer application, a
temperature sensor, preferably an infrared (IR) sensor, such as the
LuminSense.TM. can be located on the bottom of the chamber, at
approximately 0.010'' below the inner surface, to measure crumb
rubber temperature and possibly the blade temperatures.
Additionally, an IR temperature sensor such as sensor 76 identified
in FIG. 1, can be used to sense the temperature of at least one and
preferably of all the blades. Another option for measuring the
temperature of each blade is by using a hand held IR thermometer at
the start and end of a cycle.
[0059] As best shown in FIGS. 7 and 7A, the blades (44) can have a
shape which is twisted longitudinally, for improving the propelling
of the material. In this particular case the blade has a
rectangular shape, but other shapes can be considered. Also, still
with the goal of increasing friction and shear between the blades
and the material, the outer surfaces (60, 62) of the blades can be
non-uniform, by applying a hard facing (23). In this example the
channels (46) are machined in symmetric pieces of metal. The top
piece has additional channels cut through the entire thickness. The
flat pieces are then "seal" welded together.
[0060] Referring now to FIGS. 8 and 8A, another possible embodiment
of a blade is shown. In this case the channels are machined in a
solid metallic plate. Welded plugs are provided on the side of the
blade to close off the channels on the side of the blade, allowing
the fluid to circulate from the front to the back edge. As can be
appreciated, this variant of the blade is provided with several
inputs and outputs.
Experimental Results
[0061] Trials were conducted in order to demonstrate the advantages
and benefits of using the improved shaft assembly described above,
in which both the shaft and the blades are cooled, compared to a
shaft assembly in which only the shaft is cooled. The trials were
conducted in the context of regenerating vulcanized crumb rubber.
All trials were performed with a LumaSense Photrix.TM. Infra Red
(IR) temperature sensor operating over the span of 65.degree. C. to
950.degree. C. (model number ML-GAPX-LO-M3-MP2-05) to measure the
regenerated rubber (RR) temperature. Blade and shaft temperatures
were measured with an infra-red hand held thermometer (either at
the start or at the end of a cycle).
Shaft Vs. Shaft/Blade Cooling
[0062] In a first trial, only the shaft of the K-mixer was cooled
during the regeneration cycle of the crumb rubber. In other words,
a coolant was circulated solely in the inner and outer hollow
shafts of the K-mixer during the cooling phase of the processing.
The temperatures for each of the eight (8) blades over 5
consecutive trials were recorded at the end of each cycle followed
by a 15 minute cool down period three times to obtain data for 15
trials.
[0063] In a second trial, the shaft and all eight blades were
cooled, with a continuous flow of coolant circulating in the blades
and in the inner and outer hollow shafts during the cooling period
which coincides with the injection of the water into the chamber
the instant the max temperature set point of the crumb rubber has
been achieved. The respective temperatures of the eight blades were
recorded, for 15 consecutive trials.
[0064] Table 1 summarized the temperature control achieved when the
shaft only was cooled compared to when both the shaft and the
blades were cooled. Introducing cooling to the blades significantly
(.alpha.=0.05) reduced the blade temperature by 38.degree. C. (or
29.5%) from 129.degree. C. to 91.degree. C. assuring that the
system can be operated semi-continuously with consistent process
performance and therefore product quality.
TABLE-US-00001 TABLE 1 Average temperatures of 8 blades over 15
trials. Temp. Avg Type of Cooling (.degree. C.) Shaft only 129
Shaft and blades 91 Difference (.degree. C.) 38 (%) 29.5%
[0065] Referring to FIG. 9, this graph shows the recorded average
of the respective temperatures of the eight blades over 15
consecutive trials with cooling applied to the shaft only (top
three curves Shaft 5-1, 5-2 and 5-3) and with cooling applied to
the shaft and the blades. When running the shaft cooling only
trials, a pause was required of 15 minutes otherwise blade
temperatures continued to increase. The discontinuities between the
three top curves correspond to the pauses. The average of the
temperatures measured on the eight blades when only the shaft was
cooled was 129.degree. C. while it was 91.degree. C. when the shaft
and blades were cooled (38.degree. C. or 29.5% cooler).
Blade Temperature by Position
[0066] In this experiment, five trials were conducted for which the
temperature of each of the eight blades was recorded, by position,
with the shaft only being cooled, and with the shaft and blades
being cooled. The recorded temperatures for each blade were
averaged and the results are listed in the table below.
TABLE-US-00002 TABLE 2 Average temperatures of the 8 blade
positions over 5 trials. Cooling Blade Shaft ShaftBlade (Position)
(.degree. C.) (.degree. C.) 1 135.6 90.8 2 125.4 88.6 3 127.4 87.8
4 134.8 92.2 5 128.2 92.2 6 128.6 96.4 7 121.6 94.4 8 151.8 95.8
Avg 131.7 92.3 SD 9.3 3.2 COV 0.071 0.034 COV % 7.1% 3.4% Diff %
52%
[0067] Referring to FIG. 10A, the curves correspond to the recorded
average temperature for each of the eight blades over 5 trials with
cooling applied to the shaft only and to the shaft and blades.
Shaft cooling only average was 132.degree. C. (.sigma.=9.3) while
the shaft and blade had an average of 92.degree. C. (.sigma.=3.2)
which was significantly reduced (.alpha.=0.05) by 40.degree. C. (or
30%) cooler. Furthermore, when both the shaft and the blades were
cooled, the variation between the blades was appreciably reduced
with standard deviations that decreased from 9.3 to 3.2.degree. C.
while the corresponding coefficient of variation (COV=.sigma./x)
decreased from 0.071 to 0.034 (reduced by 0.037 or 52%). This
consistency in temperature allows for proper system control and
improved product quality since blade temperatures were
significantly reduced on average and the variation in temperature
between blades were noticeably reduced. FIG. 10B indicates the
position of each blade.
[0068] As can be appreciated, the added blade cooling significantly
reduced the temperature for each blade on average (see Table 2).
Furthermore, the variation between blades was appreciably
reduced.
RPM and Temperature Vs. Time Curves for Shaft Only and Shaft and
Blade Cooling
[0069] Referring now to FIGS. 11A to 11C, the graphs provide a
comparison of the rubber regenerated process, 1) using a shaft
assembly for which only the shafts are cooled (FIG. 11A), and 2)
using a shaft assembly for which the shafts and the blades are
cooled (FIGS. 11B and 11C). RPM SP corresponds to the RPM Set Point
(target RPM) of the shaft while RPM PV refers to the actual RPM
Process Value (actual RPM obtained). Similarly, the RR SP refers to
the desired Regenerated Rubber Set Point temperature of the crumb
rubber being mixed, while RR PV is the Regenerated Rubber Process
Value (actual measured temperature).
[0070] The table below summarizes the key values presented in the
graphs:
TABLE-US-00003 TABLE 3 key values for graphs 11A to 11C. RPM SP RR
SP Start Max Cool Max Exit Heat Cool Total Cooling Trial (C.) (C.)
(C.) (C.) (C.) (s) (%) (s) (%) (s) Shaft 1435-001 A 1,000 1,780 600
216 121.8 50 56% 40 44% 90 Shaft/Blades 1473-001 B 1,000 1,780 600
217 121.8 61 66% 31 34% 92 Shaft/Baldes 1565-003 C 1,000 1,800 600
223 117.8 46 60% 31 40% 77
[0071] As can be appreciated, the shaft and blade cooling allows
for consistent and reduced processing temperature profiles which
improves productivity while maintaining Regenerated Rubber (RR)
product quality.
[0072] Typical RPM and Temperature vs. time curves for a shaft only
cooling conditions are presented in FIG. 11A. The processing time
is approximately 90 s with about 56% (or 50 s) of the time
responsible for heating (the rise portion of the curve) and
approximately 44% (or 40 s) of the time associated with the cooling
of the RR (downward slope of the curve).
[0073] Referring to FIG. 11B, maintaining operating parameters with
the shaft and the blades being cooled increased the heating portion
of the curve from 50 to 61 s (or 66% of total cycle time) while the
cooling portion of the curve decreased to 31 s (or 34% of total
cycle time) for a final cycle time total of 92 s, which was
slightly longer than the trial in FIG. 11A. Clearly the cooling of
the blades has had the effect of noticeably reducing the cooling
phase of the curve and furthermore the heating portion of the curve
can be reduced by increasing the RPM's since the blades are
cooler.
[0074] In FIG. 11C, the RPM's were increased from 1,780 to 1,800
reducing the total cycle time from 90 s in FIG. 11A to 77 s
(reduced by 13 s or 14.4%). The heating portion of the curve
decreased from 50 s to 46 s (4 s) while the duration of the cooling
portion of the curve decreased from 40 s to 31 s (9 s). The
reduction in cycle time was achieved in spite of a higher set point
temperature and lower exit temperature which increases processing
time.
[0075] The curve in FIG. 11C is representative of the process
configuration currently being implemented. Total cycle times can be
compressed further. For example, increasing the RPM's will decrease
the heating time portion of the cycle. Furthermore, increasing the
RPM's and reducing the coolant temperature with a suitable chiller
will reduce the overall cycle time as well.
[0076] As can be appreciated, the cooling time required to decrease
the temperature from about 220.degree. C. to about 120.degree. C.
is reduced from 40 seconds to about 30 seconds.
[0077] The results presented in the graph of FIGS. 11A to 11C were
obtained using the following method. Vulcanized crumb rubber and a
lubricant, preferably oil, were introduced in a first mixer, the
lubricant being at room temperature. The crumb rubber and the
lubricant were mixed at room temperature, for a predetermined
period of time, to form a substantially homogenous mixture. This
mixture was then transferred into a K-mixer, as described
above.
[0078] The RPM of the shaft assembly was raised to increase the
temperature of the mixture during a first period of time until a
devulcanizing temperature is reached. The devulcanizing temperature
can be for example 225.degree. C. and is reached within a time
period of 25 and 60 seconds, and is preferably about 40-45 seconds.
The RPM of the shaft assembly is raised between 1700 and 2000, and
preferably to about 1750-1850 rpm. The temperature was then reduced
to a lower temperature during a second period of time. For example,
the crumb rubber can be cooled from about 225 to about 120 degrees
in about 40 seconds, when only the shaft was cooled, and preferably
about 30 seconds, which was possible when the shaft and blades were
cooled.
[0079] During the cooling period, the set point RPM of the shaft
was reduced between 400 and 700 rpm, and preferably to about 600
rpm. The mixing chamber was preferably cooled with a cooling jacket
surrounding the mixing chamber, and with a spray nozzle injecting a
stream or mist of cooling agent, preferably water, in the mixing
chamber. Finally, the motor was stopped and the regenerated crumb
rubber was recovered from the mixing chamber.
[0080] The scope of the invention should not be limited by the
preferred embodiments set forth in the examples, but should be
given the broadest interpretation consistent with the description
as a whole.
* * * * *