Hemp separation methods and apparatus

Abstract

The present invention provides improved hemp decortication systems and methods, and include multi stage segmenting, cleaning, and combing methods and apparatus for separating fibrous plant stalk, and particularly for separating hemp bast fiber from hemp hurd.

Claims

1. A system for separating inner and outer fibers from plant stalks comprising: 1) an initial separation apparatus, the initial separation apparatus comprising: a) three rotatable saw cylinders, each of said rotating saw cylinders having an exterior surface and comprising a plurality of blades, with each of the plurality of blades having a plurality of teeth thereon; b) three fiber removal brushes, each of said three brushes located adjacent to a corresponding one of said three saw cylinders operable for separating outer plant stalk fibers from inner plant stalk fibers; c) a first rotatable doffing cylinder adjacent to a first of said three rotatable saw cylinders, the first rotatable doffing cylinder having a first plurality of brushes thereon operable for removing outer fibers of said plant stalks from said first saw cylinder; and d) a second rotatable doffing cylinder adjacent to both a second and a third of said three rotatable saw cylinders, the second rotatable doffing cylinder having a second plurality of brushes thereon operable for removing outer fibers of said plant stalks from said second and third saw cylinders; and 2) a condenser unit, the condenser unit comprising: a) a chamber having an upper inlet operable for receiving outer fibers from said initial separation apparatus, and a lower outlet through which fibers exit; b) a rotatable drum in said chamber, said drum having an outer surface comprising a plurality of openings; c) a suction inside said drum operable to hold the outer fibers against said outer surface of said drum; d) left and right rotatable fluted rollers located below said drum operable to strip the outer fibers from said outer surface of said drum; and e) a first steel plate adjacent to said left rotatable fluted roller and a second steel plate adjacent to said right rotatable fluted roller.

2. The system of claim 1 further comprising a combing apparatus for receiving fibers from said condenser unit, said combing apparatus comprising: a) a rotatable saw drum having teeth on an exterior surface thereon; b) an upper rotatable feed roller and a lower rotatable feed roller, both such rollers provided above said rotatable saw drum for feeding fibers from said condenser unit to said rotatable saw drum; and c) a plurality of grid bars spaced around a portion of the circumference of said rotatable saw drum, each of the plurality of grid bars having a knife blade thereon facing said rotatable saw drum, each such knife blade operable to remove foreign material from the fibers on said rotatable saw drum.

3. The system of claim 2 wherein said lower rotatable feed roller and said rotatable saw drum of said combing apparatus are configured to rotate in a same direction and fibers passing from said lower feed roller make a turn at a toe of a feed bar.

4. The system of claim 1 wherein said plurality of blades have a length of between 1/16 inch and inch, said plurality of teeth have a depth of between 1/16 inch and inch, and the blades are separated from each other by a space of between inch and inch.

5. The system of claim 1 wherein said plurality of blades have a length of inch, said plurality of teeth have a depth of 5/16 inch, and the blades are separated from each other by a space of inch.

6. The system of claim 2 further comprising a feed bar located adjacent to said lower rotatable feed roller, said feed bar further comprising a toe extending below said lower rotatable feed roller.

7. The system of claim 6 wherein a leading edge of the feed bar has a radius of between about 1/16 inch and about inch.

8. The system of claim 6 wherein a leading edge of the feed bar has a radius of about inch.

9. The system of claim 2 wherein said grid bars are spaced apart between about 1/16 inch and about inch.

10. The system of claim 2 wherein said grid bars are spaced apart about inch.

11. A method for separating inner and outer fibers from plant stalks comprising the steps of: a) introducing harvested hemp plant stalks into a top of an initial separation apparatus, the initial separation apparatus comprising: i) three rotatable saw cylinders, each of said rotatable saw cylinders having an exterior surface and comprising a plurality of blades, with each of the plurality of blades having a plurality of teeth thereon, ii) three fiber removal brushes, each said three brushes located adjacent to a corresponding one of said three saw cylinders for separating outer plant stalk fibers from inner plant stalk fibers; iii) a first rotatable doffing cylinder adjacent to a first of said three rotatable saw cylinders, the first rotatable doffing cylinder having a first plurality of brushes thereon for removing outer fibers of said plant stalks from said first saw cylinder; and iv) a second rotatable doffing cylinder adjacent to both a second and a third of said three rotatable saw cylinders, the second rotatable doffing cylinder having a second plurality of brushes thereon for removing outer fibers of said plant stalks from said second and third saw cylinders; b) separating inner and outer fibers of the plant stalks in said initial separation apparatus by: i) passing the stalks between the plurality of teeth of a first of said saw cylinders and underneath a first of said three fiber removal brushes, such that separated outer fibers are removed by the first plurality of brushes on said first doffing cylinder; ii) passing any fibers that drop away from said first saw cylinder between the plurality of teeth of a second of said saw cylinders and underneath a second of said three fiber removal brushes, such that additional outer fibers are removed by the second plurality of brushes on said second doffing cylinder; and iii) passing any fibers that drop away from said second saw cylinder between the plurality of teeth of a third of said saw cylinders and underneath a third of said three fiber removal brushes such that more outer fibers are removed by the second plurality of brushes on said second doffing cylinder; c) sending the outer fibers exiting from the initial separation apparatus into a condenser unit, the condenser unit comprising: i) a chamber having an upper inlet for receiving outer fibers from said initial separation apparatus, and a lower outlet through which fibers exit; ii) a rotatable drum in said chamber, said drum having an outer surface comprising a plurality of openings; iii) a suction inside said drum operable to hold the outer fibers against said outer surface of said drum; iv) left and right rotatable fluted rollers located below said drum operable to strip the outer fibers from said outer surface of said drum; and v) a first steel plate adjacent to said left rotatable fluted roller and a second steel plate adjacent to said right rotatable fluted roller; and d) further separating inner and outer fibers of the plant stalks in said condenser unit by: i) passing the outer fibers exiting from the initial separation apparatus into said chamber such that suction from the drum in said chamber holds said outer fibers against the outer surface of the drum as said drum rotates; ii) stripping said outer fibers from the outer surface of said drum as the drum rotates by said left and right rotatable fluted rollers and said first and second steel plates; and iii) dropping stripped fibers through said lower outlet of said chamber.

12. The method of claim 11 comprising the additional steps of: e) further processing the stripped fibers exiting from the chamber of said condenser by sending said fibers to a combing apparatus, the combing apparatus comprising a rotatable drum having teeth on an exterior surface thereof which temporarily engage the stripped fibers, and a plurality of blades adjacent to a portion of said surface for combing through the fibers on said exterior drum surface, and f) removing foreign material from the fibers on said exterior surface of said drum as it rotates using said plurality of blades.

13. The method of claim 11 comprising the additional steps of: e) sending the outer fibers exiting from the initial separation apparatus to a feeder unit, the feeder unit comprising: i) a pair of upper rollers wherein one of the rollers rotates at least twice as fast as the other roller, ii) a plurality of inclined rotatable spiked cylinders located above a slotted screen, iii) an upper rotatable saw cylinder having a first plurality of grid bars next to the upper rotatable saw cylinder, iv) a lower rotatable saw cylinder having a second plurality of grid bars underneath the lower rotatable saw cylinder, and v) a lower rotatable doffing cylinder; and f) passing said fibers between said pair of upper rollers to spread out the fibers; g) passing the spread-out fibers onto said spiked cylinders such that inner fibers drop through said screen; h) passing fibers from said spiked cylinders onto said upper rotatable saw cylinder, and removing hurd and trash therefrom using said lower doffing cylinder; and i) passing the fibers from said upper rotatable saw cylinder onto said lower rotatable saw cylinder, and further removing hurd and trash therefrom using said lower doffing cylinder.

14. The system of claim 1 further comprising a feeder unit positioned between the initial separation apparatus and the condenser that is configured to feed the outer fibers exiting from the initial separation apparatus to the condenser, the feeder unit comprising a) a pair of upper rollers wherein one of the rollers rotates at least twice as fast as the other roller to spread out fibers, b) a plurality of inclined rotatable spiked cylinders located above a slotted screen for further removal of outer fibers while the inner fibers drop through the screen, c) an upper rotatable saw cylinder having a first plurality of grid bars next to said upper rotatable saw cylinder, d) a lower rotatable saw cylinder having a second plurality of grid bars underneath said lower rotatable saw cylinder, and e) a lower rotatable doffing cylinder for removing outer fibers from said first and second saw cylinders while inner fibers and trash pass through at least one of said first and second plurality of grid bars.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a side schematic view of an embodiment of an initial stalk splitting and separation apparatus (stick machine) of the present invention.

(2) FIG. 2 is a side schematic view of an embodiment of a hurd scrubbing apparatus of the present invention.

(3) FIG. 2A is a close-up view of an auger of an embodiment of the present invention.

(4) FIG. 3 is a side schematic view of an embodiment of a feeder apparatus of the present invention.

(5) FIG. 4 is an exterior side view of the feeder embodiment of FIG. 3 with angled duct.

(6) FIG. 5 is a side schematic view of an embodiment of a condenser and combing apparatus of the present invention.

(7) FIG. 6 is a detailed side schematic view of an embodiment of a combing apparatus of the present invention.

DETAILED DESCRIPTION

(8) Reference will now be made in detail to certain embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in reference to these embodiments, it will be understood that they are not intended to limit the invention. To the contrary, the invention is intended to cover alternatives, modifications, and equivalents that are included within the spirit and scope of the invention, including different combinations of the features identified herein. In the following disclosure, specific details are given to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without all of the specific details provided.

(9) Referring to the drawings, wherein like reference characters designate like or corresponding parts throughout the several views, and referring particularly to FIG. 1 it is seen that a first apparatus of embodiments of the present invention includes an initial stalk splitting and separation apparatus or stick machine 20 used for rough separation of plant fibrous material. Harvested fibrous plant stalks are introduced at the top of the machine 20 an encounter a first rotatable separating saw cylinder 21 having a plurality of teeth on its external surface. In some embodiments, the blades of saw cylinder 21 may have a length or width of between about 1/16 and about , preferably about ; the saw teeth may have a size of between about 1/16 and about , preferably about 5/16 deep; and the saw blades may be separated by a spacer of between about and about , preferably about between saw blades. The fiber that encounters cylinder 21 is pulled underneath a first brush 24 to begin the separation of outer plant stalk fiber (bast fiber) from inner plant stalk fiber (hurd). The shorter inner fiber falls off saw cylinder 21, and the longer outer fiber is clinging to saw cylinder 21 is removed using a rotatable doffer drum 27 with brushes 28.

(10) The inner fiber then drops onto a second rotatable separating saw cylinder 22 also having a plurality of teeth on its external surface. In some embodiments, the blades of saw cylinder 22 may have a length or width of between about 1/16 and about , preferably about ; the saw teeth may have a size of between of between about 1/16 and about , preferably about 5/16 deep; and the saw blades may be separated by a spacer of between about and about , preferably about between saw blades. The fiber that encounters cylinder 22 is pulled underneath a second brush 25 to further the separation of bast fiber from hurd. The shorter hurd falls off saw cylinder 22, and the longer bast fiber clings to saw cylinder 22, and is removed using a second rotatable doffer drum 29 with brushes. The inner fiber then drops onto a third rotatable separating saw cylinder 23 also having a plurality of teeth on its external surface. In some embodiments, the blades of saw cylinder 23 may have a length or width of between about 1/16 and about , preferably about ; the saw teeth may have a size of between about 1/16 and about , preferably about 5/16 deep; and the saw blades may be separated by a spacer of between about and about , preferably about between saw blades. The fiber that encounters cylinder 23 is pulled underneath a third brush 26 to further the separation of bast fiber from hurd. The shorter hurd falls off saw cylinder 23, and the longer bast fiber clings to saw cylinder 22, and is removed using a second rotatable doffer drum 29 with brushes 31.

(11) FIG. 2 illustrates an exemplary embodiment of a scrubber 30 used to process hurd received from an initial process, such as that performed by stick machine 20. The hurd output from the stick machine 20 may be further purified by being sent first to a hammer mill so as to be milled to a desired size (e.g. 10-19 mm). Once the milling process is complete, the output may then be sent to a scrubber apparatus for further processing. The illustrated scrubber 30 includes an input hopper 32 at the bottom, an adjustable inclined chute 35 leading upward from the hopper, and a rotatable auger 37 deployed inside and along the length of the chute. The angle of the chute 35 and the rotational speed of the auger 37 may be adjusted depending on the quantity and density of the material introduced therein to provide efficient processing and to avoid clogging. The bottom surface of the chute has a plurality of openings therein and may be made from mesh or wire screen 39, and the top of the chute may be open. Rotation of auger 37 causes the fibrous plant material deposited into the hopper 32 to be urged upward through chute 35. As the fiber moves upward in chute 35, screen 39 prevents larger plant fibers (bast) from exiting through the bottom of the chute, allowing the smaller fibers (hurd) to drop through. Rotation of the auger 37 also keeps the fiber moving though the chute, and helps prevent clogging of the screen 39. Different sized mesh or openings may be provided in screen 39 to allow separation of different sized plant fibers. For example and without limitation, smaller openings may be provided in screen 39 to allow smaller sized fibers to drop through, whereas larger sized openings may be provided to allow larger sized fibers to drop through. It has been determined that a mesh size of about 1- to 1- openings, that may be diamond shaped may result in approximately 95% of bast fiber to be removed from hurd dropping through the screen 39. The position of the auger 37 in trough 35 may be adjustable up or down, allowing the auger to be brought down as close as inch above screen 39. Longer fibers that are not separated exit from the scrubber 30 at discharge opening 36.

(12) It is to be appreciated that different embodiments of the scrubber 30 may have different dimensions. For example and without limitation, the chute 35 may have a length of between about five and about 15 feet, preferably about 10 feet, and chute 35 may have a diameter of between about 10 and about 20 inches, preferably about 16 inches. In other examples and without limitation, the ends (flights) 33 of auger blades 38 may have tips or edges made of UHMW (ultra-high molecular weight) plastic; in some of these embodiments, the plastic may be between about inch and about 1 inch, preferably about inch. In other examples and without limitation, the legs supporting the chute 35 may be adjustable form a generally horizontal position to an upward angle of as much as sixth degrees, preferably about 45 degrees. In other examples and without limitation, the screen 39 covers as much as the bottom half of the trough 35, half way up side of auger; and the discharge opening 36 at the end may have a size between 10 inches and 20 inches, preferably about 12 to 14 inches. It is to be appreciated that these variables, along with the up/down position and speed of the auger 37 may be adjusted based on such things as the density, moisture level and quantity of fibrous material to be processed.

(13) FIG. 3 illustrates an embodiment of a feeder unit 40 that has been adapted from an existing cotton gin feeder. Fiber that has exited from a stick machine 20 may be fed into the top of the feeder 40 and passes between two adjustable speed feeder rollers 41, 42, which may be fluted. One of the rollers (e.g. 41) is designed to rotate faster than the other (e.g. 42) in order to spread out the fibrous material. In some embodiments, this ratio of speeds may be approximately 3:1, although other ratios such as 3.5:1, 2.5:1, 2:1 and 1.5:1 may also be used to obtain similar results. An electronic control may be used to adjust the speed of the feed rollers. The bast fiber is then passed through four inclined/angled spike cylinders 44 over slotted screens 45. In some embodiments, the screens 45 may have openings sized as large as about 2 by about to as small as about 1 by about , and preferably about 1- by about 3/16. This process allows hurd and trash (dirt, sticks, stems, leaves, etc.) to be cleaned/removed from the fiber and then sent down a slide 46 to a trash conveyor. The fiber exiting from the cylinders 44 travels to two rotatable extractor saw cylinders, upper cylinder 51 and lower cylinder 53. Fiber is removed from both cylinders 51 and 53 using a rotatable doffer drum 52 with brushes. A plurality of grid bars 55 are provided along a side of upper cylinder 51 to help keep the bast fiber close to saw 51, while allowing hurd and trash to exit between the bars 55. In some embodiments, the grid bars may be spaced about 2 inches apart. In some embodiments seven bars 55 may be provided adjacent to upper cylinder 51. Another plurality of grid bars 58 may be provided below and partially around lower cylinder 53 which also keep the fiber close to cylinder 53 for removal by doffer 52, with hurd and trash exiting between bars 58. In some embodiments seven bars 58 may be provided adjacent to lower cylinder 53. Doffing brush cylinder 52 in between the saw cylinders 51, 53 removes fiber from the cylinders (doff them) and onto a stationary apron 56. A bypass valve 49 may be provided, and used when working with fine fiber that does not need to be cleaned by the saw cylinders 51, 53. Valve 49 allows such fiber to be sent directly to the exit apron 56.

(14) In embodiments of the invention, the fiber output from feeder unit 40 may then be directed from apron 56 through a rectangular duct 57 to a condenser 60 and combing apparatus 70. An embodiment of a condenser/comber is illustrated in FIG. 5. The condenser 60 includes a chamber 61 having a centrally mounted rotating drum 63 mounted therein. The exterior surface of the drum 64 includes a plurality of openings, wire mesh or screen, and the center of the drum is attached to air removal devices (not shown). The air removal devices cause the fiber entering the chamber to be sucked against the openings, mesh or screen on the surface 64 of the drum 63 as it rotates. In embodiments of the invention, a pair of fluted rollers 67, 68 are provided below the drum 63 to strip the fiber from the screen surface 64 of the drum as it rotates. In some embodiments, one or more steel plates 69 may be provided to stiffen the flashing against the fluted rollers 67, 68. In embodiments of the invention, plates 69 may be 3 wide and thick.

(15) In embodiments of the invention, the fiber stripped from the drum is then dropped into a combing apparatus 70, as shown in FIGS. 5 and 6. Apparatus 70 may include a large central rotatable saw drum 71 having lint combing teeth 73 on the outer surface thereof which engage the incoming fiber. Two feed rollers 72, 74 are provided above drum 71. A feed bar 75 may be provided adjacent to the input area adjacent to the lower smooth feed roller 74. Feed bar 75 may have a leading edge or toe 78 extending below lower roller 74. Feed bar 75 may have a radius of between about 1/16 and about , preferably about that is spaced so as to be almost touching drum teeth 73. A plurality of grid bars 76 may be spaced around a portion of the circumference of drum 71, each having a knife edge toe or blade 77 that is spaced so as to be almost touching drum teeth 73 for removing trash. In some embodiments, a space of between about 1/16 and about , preferably about may be provided between each grid bar 76 and drum 71. As the fiber on the drum 71 encounters the blades 77, it is combed to remove any remaining foreign material. The fiber is then removed from the drum resulting in elongated fibrous output suitable for many different high-fiber applications. The hurd removed during these processes is usually of high quality making it suitable for use in building materials, paper, paperboard, composites and the like. Hurd output from the stick machine 30, from the feeder 40 and/or from the lint comber 70 may be introduced into a scrubber as shown in FIG. 2 for further purification.

(16) In use, fibrous plants are harvested by severing them from the ground, and then removing leaves and branches from the stalks. The stalks are then fed into an embodiment of a stick machine where the stalks are squeezed between rotating saw cylinders and adjacent blades to begin the separation of outer fiber from inner fiber and trash. The longer, outer fibers adhere to the saw blades and is removed using one or more doffers, and the shorter inner fibers and trash drop through the stick machine. In some embodiments, the inner fibers may then be sent to a hammer mill for processing to a desired size, and then introduced into a scrubber where they are advanced through an upwardly inclined chute using an auger. The lower surface of the chute comprises openings or a screen for further separating the shorter fibers from other fibers and materials. The screen may be sized in order to obtain shorter fibers of a desired length that may then be used for building materials, paperboard and the like.

(17) In other embodiments, the outer fibers that exit from the stick machine are introduced into a feeder through a pair of rollers at the top. One of the rollers travels at a faster speed than the other in order to spread out the fibers as they pass between them. These fibers then encounter a plurality of inclined rotating spiked cylinders above a screen such that passing the fibers between the spiked cylinders and the screen further separates smaller fibers and trash from the longer fibers. The smaller fibers and trash drop through the feeder, and the longer fibers then encounter one or more rotating saw blades with adjacent grid bars for further removal of small fibers and trash. A rotating doffer then removes the longer fibers from the saw blades.

(18) The longer fibers that exit from the feeder then encounter a condenser comprising a rotating drum having a surface comprising a plurality of openings or a screen, and an inner air removal or suction which causes the fibers to adhere to the screen. A pair of fluted rollers at the bottom of the drum remove the fibers and introduce them to a lint comber apparatus. The fibers make a sharp turn at a toe of a feed bar and then encounter a plurality of combing blades which remove fine trash and foreign material from the fiber, making it suitable for use.

(19) It is to be understood that variations, modifications, and permutations of embodiments of the present invention, and uses thereof, may be made without departing from the scope of the invention. It is also to be understood that the present invention is not limited by the specific embodiments, descriptions, or illustrations or combinations of either components or steps disclosed herein, and that different combinations of the features of the illustrated embodiments may be used in other embodiments, all within the scope of the invention. The illustrated embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. Although reference has been made to the accompanying figures, it is to be appreciated that these figures are exemplary and are not meant to limit the scope of the invention. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.