Wet pulping system and method for producing cellulosic insulation with low ash content
First Claim
1. A method for producing cellulosic fibers from mixed trash 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 a 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 the 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°
F. and about 700°
F.;
q. drying the cellulosic fibers in a dryer to further reduce the moisture content to about 10% to about 18%; and
s. packaging or baling the dried cellulosic fibers.
4 Assignments
0 Petitions
Accused Products
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.
33 Citations
4 Claims
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1. A method for producing cellulosic fibers from mixed trash comprising:
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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 a 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 the 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°
F. and about 700°
F.;q. drying the cellulosic fibers in a dryer to further reduce the moisture content to about 10% to about 18%; and s. packaging or baling the dried cellulosic fibers. - View Dependent Claims (2, 3, 4)
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Specification