Method and Apparatus for Treating a Starting Material

Abstract

The invention relates to a method and an apparatus for treating a starting material, wherein the starting material (1) that contains at least organic material is mixed and agglomerated in a mixing stage (4) in the presence of heat to form agglomerated mixture material (5), the mixture material is mechanically pressed in a pressing stage (8) where the temperature of the mixture material rises due to the pressing, and a predetermined product (9) is formed in the pressing stage. Further, the invention relates to the use of the method.

Claims

1. A method for treating a starting material, wherein a starting material that contains at least organic material is mixed and agglomerated in a mixing stage in the presence of heat to form agglomerated mixture material, the mixture material is mechanically pressed in a pressing stage, where the temperature of the mixture material rises due to the pressing, and a predetermined product is formed in the pressing stage.

2. The method according to claim 1, wherein the starting material comprises waste material, recycled material, reused material, and/or virgin material.

3. The method according to claim 2, wherein the waste material comprises municipal waste, a fraction separated from municipal waste, construction waste, demolition waste, industrial sidestreams, textile waste, ash waste, plastic waste, paperboard waste, insulation material waste, fiberglass waste, or their combinations.

4. The method according to, claim 1, wherein the starting material is crushed and/or ground before the mixing stage.

5. The method according to claim 1, wherein the mixture material is fed from the mixing stage to an extrusion stage before the pressing stage.

6. The method according to claim 1, wherein the mixture material is fed to the pressing stage in a granular form.

7. The method according to claim 1, wherein also other material is fed to the pressing stage in addition to the mixture material to form a combination product.

8. The method according to claim 1, wherein the mixture material is heated in a heating stage before the pressing stage.

9. An apparatus for treating a starting material, wherein the apparatus comprises at least one mixing stage comprising at least one mixing device selected such that a starting material is mixed and agglomerated in the mixing device to form agglomerated mixture material from the starting material that contains at least organic material, at least one pressing stage for mechanically pressing the mixture material, where the temperature of the mixture material rises due to the pressing and where a predetermined product is formed.

10. The apparatus according to claim 9, wherein the apparatus comprises at least one crushing and/or grinding stage.

11. The apparatus according to claim 9, wherein the apparatus comprises at least one extrusion stage before the pressing stage.

12. The apparatus according to claim 9, wherein the pressing stage comprises at least one press device for mechanically pressing the mixture material.

13. The apparatus according to claim 12, wherein the press device comprises a shape-giving part and a piston for pressing the material against the shape-giving part, and a part generating power and movement for moving the piston.

14. The apparatus according to claim 9, wherein the apparatus comprises a pressure adjusting system for monitoring and adjusting the pressure of the pressing stage.

15. Use of the method according to claim 1, wherein the method is used in applications selected from a group comprising treatment of a starting material into reused products or recycled products, manufacture of composite products, manufacture of combination products, manufacture of layered products, manufacture of an asphalt raw material component, manufacture of a concrete composition component, treatment of industrial sidestreams, manufacture of products from waste material and/or reduction of the amount of waste material and their combinations.

Description

LIST OF FIGURES

[0048] FIG. 1 represents one apparatus according to the invention, and

[0049] FIG. 2 represents another apparatus according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0050] The invention will be described below by way of detailed examples of its embodiments with reference to the accompanying figures.

EXAMPLE 1

[0051] FIG. 1 represents an apparatus that comprises a mixing stage (4) for forming a mixture material (5) from a starting material (1) that contains at least organic material, and a pressing stage (8) for mechanically pressing the mixture material into a product (9) by means of heat.

[0052] The mixing stage (4) comprises a mixing device for forming the mixture material (5). The mixing stage may also comprise an agglomeration device for forming agglomerates. Alternatively the mixing device is selected such that the starting material is mixed and agglomerated in the mixing device. The mixing device may be an agglomeration device known per se, where both mixing and agglomeration takes place. In the agglomeration device the temperature of the material rises under the effect of friction in connection with the mixing. Preferably the mixing takes place in the presence of heat.

[0053] The pressing stage (8) comprises a press device, such as a tool comprising a shape-giving part, such as a mould, and a piston for moving the material and pressing it against the shape-giving part, and an actuator e.g. a hydraulic, pneumatic or electrical cylinder, for moving the piston and providing the pressing. The press device may be a counter extrusion device. Alternatively the press device may be a movable press, a rotary press or other known press device. The apparatus comprises a pressure adjusting system for monitoring and adjusting the pressure of the press device.

[0054] In one embodiment the starting material (1) that contains at least organic material is mixed in the mixing stage (4) to form the mixture material (5). The starting material (1) preferably contains waste material. The mixture material (5) is in the form of agglomerates after the mixing stage. The mixture material agglomerates are conducted or placed to the tool of the press device of the pressing stage (8), where the agglomerates are mechanically pressed. The actuator of the tool moves the piston against the mould, such that the pressure of air in the mixture material starts to increase while the volume decreases, which results in the rise of the temperature of the compressing air. The temperature of the mixture material rises due to the pressing, and the product (9) is formed in the presence of heat. Advantageously the pressure of air inside the cellular cavities of the organic material rises due to the pressing, such that the temperature rises and the components, such as fibres, of the mixture material adhere to each other so as to form a desired product.

EXAMPLE 2

[0055] FIG. 2 represents an apparatus comprising a starting material (1) crushing/grinding stage (2), a mixing stage (4) for forming a mixture material (5) from the starting material that contains at least organic material, an extrusion stage (6), and a pressing stage (8) for mechanically pressing the mixture material into a product (9) by means of heat.

[0056] The apparatus comprises at least one crushing and/or grinding stage (2) for crushing the starting material.

[0057] The mixing stage (4) comprises a mixing device for forming the mixture material (5). Preferably the mixing device is an agglomeration device known per se, where both mixing and agglomeration takes place. In the agglomeration device the temperature of the material rises under the effect of friction in connection with the mixing. Preferably the mixing takes place in the presence of heat.

[0058] The extrusion stage (6) comprises an extrusion device, such as an extruder that is disposed before the pressing stage (8). In the extrusion stage the mixture material (5) is formed into an extrusion intermediate product, such as granules (7) that are conducted to the pressing stage (8).

[0059] The pressing stage (8) comprises a press device, such as a tool comprising a shape-giving part, such as a mould, and a piston for moving the material and pressing it against the shape-giving part, and an actuator e.g. a hydraulic, pneumatic or electrical cylinder, for moving the piston and providing the pressing. The press device may be a counter extrusion device. Alternatively the press device may be a movable press, a rotary press or other known press device. The apparatus comprises a pressure adjusting system for monitoring and adjusting the pressure of the press device.

[0060] In one embodiment the starting material (1) that contains at least organic material is crushed in the crushing and/or grinding stage (2). The starting material (1) preferably contains waste material. Crushed starting material (3) is mixed in the mixing stage (4) to form the mixture material (5). To the mixture material, additives as desired may be added in the mixing stage. The mixture material is in the form of agglomerates after the mixing stage. The mixture material (5) is fed in the form of agglomerates from the mixing stage (4) to the extrusion stage (6), where the mixture material is formed into the intermediate product (7) that may be in the form of granules. In the extrusion stage, additional material as desired or additives (10) may be added to the mixture material. The mixture material in the form of granules (7) is conducted or placed to the tool of the press device of the pressing stage (8), where the agglomerates are mechanically pressed. The actuator of the tool moves the piston against the mould, such that the pressure of air in the mixture material starts to increase while the volume decreases, which results in the rise of the temperature of the compressing air. The temperature of the mixture material rises due to the pressing, and the product (9) is formed in the presence of heat. Advantageously the pressure of air inside the cellular cavities of the organic material rises due to the pressing, such that the temperature rises and the components, such as fibres, of the mixture material adhere to each other so as to form a desired product.

EXAMPLE 3

[0061] In this example the product (9) is formed from the starting material (1) by the apparatus according to FIG. 2 and Example 2, where the extrusion stage (6) is replaced with a mixture material (5) heating stage.

EXAMPLE 4

[0062] In this example the product (9) is formed from the starting material (1) by the apparatus according to FIG. 2 and Example 2, where the extrusion stage (6) is replaced with a mixture material (5) heating stage and where the press device used is a mechanical press device that is provided with additional heating to facilitate the pressing.

EXAMPLE 5

[0063] In this example the product (9) is formed from the starting material (1) by the apparatus according to FIG. 1 and Example 1 or FIG. 2 and Example 2, where there is no extrusion stage (6) and where in the pressing stage, also other material is used in addition to the mixture material to form the product.

[0064] The method and apparatus according to the invention are suited as different embodiments for use in a variety of applications to treat a variety of starting materials. Further, the method and apparatus according to the invention are suited as different embodiments for use in the manufacture of a variety of composite products. Further, the method and apparatus according to the invention are suited as different embodiments for use to treat a variety of waste materials.

[0065] The invention is not limited merely to the above examples, but many variations are possible within the scope of the inventive idea defined by the claims.