Mechanized separation of mixed solid waste and recovery of recyclable products

• US 8,398,006 B2
• Filed: 08/30/2011
• Issued: 03/19/2013
• Est. Priority Date: 11/24/2010
• Status: Active Grant

• Current Assignee: Upland Road IP Holdco LLC
• Original Assignee: Organic Energy Corporation
• Inventors: Gitschel, George
• Primary Examiner(s): Rosenbaum, Mark
• Application Number:
  US13/221,637
• Publication Number:
  US 20120048974A1
• Time in Patent Office: 567 Days
• Field of Search: 209/31, 209/930, 241/24.13, 241/19, 241/20, 241/DIG.38, 241/24.14, 241/24.15, 241/24.18, 241/24.19, 241/24.22
• US Class Current: 241/19
• CPC Class Codes: B02C 23/14 with more than one separator
• CPC Class Codes: B03B 9/06 specially adapted for refuse
• CPC Class Codes: B03C 1/18 with magnets moving during operation
• CPC Class Codes: B03C 1/247 obtained by a rotating magnetic drum
• CPC Class Codes: B03C 1/30 Combinations with other devices, not otherwise provided for
• CPC Class Codes: B03C 2201/18 Magnetic separation whereby the particles are suspended in a liquid
• CPC Class Codes: B07B 11/04 Control arrangements
• CPC Class Codes: B07B 11/06 Feeding or discharging arrangements
• CPC Class Codes: B07B 15/00 Combinations of apparatus for separating solids from solids by dry methods applicable to bulk material, e.g. loose articles fit to be handled like bulk material using wet methods B03B7/00; using gas currents B07B9/00
• CPC Class Codes: B07B 4/02 while the mixtures fall
• CPC Class Codes: B07B 9/00 Combinations of apparatus for screening or sifting or for separating solids from solids using gas currents; General arrangement of plant, e.g. flow sheets
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02W 10/37 using solar energy
• CPC Class Codes: Y02W 30/20 Waste processing or separation
• CPC Class Codes: Y02W 30/52 Mechanical processing of waste for the recovery of materials, e.g. crushing, shredding, separation or disassembly
• CPC Class Codes: Y02W 30/62 Plastics recycling; Rubber recycling

Abstract

The method and systems efficiently extract recyclable materials from a mixed solid waste stream. The methods and systems use sizing, density and dimensional separation to produce intermediate waste streams that are enriched in particular recyclable materials. The recyclable materials can then be efficiently sorted from the individual intermediate streams using mechanized sorting equipment.

Claims

1. A method for recovering recyclable materials from mixed solid waste stream, comprising:

providing a mixed waste stream comprising at least two recyclable materials selected from the group consisting of paper, plastic, and non-ferrous metal, the recyclable materials including 2-dimensional and 3-dimensional materials;

shredding the mixed waste stream in a shredder to produce a shredded mixed waste having 2-dimensional and 3-dimensional recyclable materials;

fractionating the shredded mixed waste stream by size in a size separator to produce a plurality of sized waste streams, wherein an over sized waste stream includes plastic and paper;

fractionating at least a portion of the sized waste streams by density to produce a light fraction and a heavy fraction, the light fraction enriched in the at least two recyclable materials;

sorting the light fraction using one or more

sorting apparatuses to produce at least two separate recyclable products selected from the group consisting of a paper product, a plastic product, and a non-ferrous product; and

recovering the at least two recyclable materials as individual recyclable products.

2. A method as in claim 1, wherein the mixed waste stream includes at least 20% by weight of low value material selected from the group consisting of wet organics, green waste, food waste, grit, fines less than 1 inch, asphalt, concrete, textiles, and wood, rubber, film plastic, PVC, foil, rock, used consumer products, low value glass, composite materials, and combinations of these.

3. A method as in claim 1, wherein the mixed waste stream includes at least 35% by weight of low value material selected from the group consisting of wet organics, green waste, food waste, grit, fines less than 1 inch, asphalt, concrete, textiles, and wood, rubber, film plastic, PVC, foil, rock, used consumer products, low value glass, composite materials, and combinations of these.

4. A method as in claim 1, wherein a first intermediate waste stream is enriched in plastics, the sorting including separating 3-dimensional plastic from 2-dimensional plastics and recovering a 3-dimensional recyclable plastic product.

5. A method as in claim 1, wherein the first intermediate waste stream includes paper, the method further comprising sorting 2-dimensional plastic from paper to yield a paper product and a 2-dimensional plastic product.

6. A method as in claim 5, wherein the 2-dimensional plastic is sorted from the paper using one or more optical sorters.

7. A method as in claim 1, wherein a second intermediate waste stream is enriched in non-ferrous metals, the sorting of the second intermediate waste stream including separating non-ferrous metals from other materials using an eddy current separator and recovering a non-ferrous product.

8. A method as in claim 1, wherein the mixed waste stream includes from 1.0%-5% by weight of metals selected from the group consisting of ferrous metal, non-ferrous metal, stainless steel, and combinations thereof.

9. A method as in claim 1, wherein the mixed waste stream includes from 15%-60% by weight dry organics selected from mixed paper and plastic.

10. A method as in claim 1, wherein the mixed waste stream is a municipal solid waste.

11. A method as in claim 1, wherein the mixed waste stream is fractionated by size to produce an over sized stream with a bottom cut of at least 2 inches.

12. A method as in claim 1, wherein the mixed waste stream is fractionated by size into at least two sized waste streams wherein the over fraction has a d90 in a range from 2 inches to 12 inches.

13. A method for recovering recyclable materials from mixed solid waste stream, comprising:

providing a mixed waste stream comprising a plurality of recyclable materials including paper, plastic, and metal;

shredding the mixed waste stream in a shredder to produce a shredded mixed waste having 2-dimensional and 3-dimensional recyclable materials;

fractionating the shredded mixed waste stream by size to produce a plurality of sized waste streams wherein an over sized waste stream includes paper and plastic;

fractionating at least a portion of the sized waste streams by density to produce a plurality of intermediate waste streams individually enriched in one or more of the recyclable materials;

individually sorting the plurality of intermediate waste streams using one or more sorting apparatuses to produce a recyclable paper product, a recyclable plastic product, and a recyclable metal product;

recovering the recyclable paper product, the recyclable plastic product, and the recyclable metal product.

14. A method as in claim 13, wherein the shredding produces a mixed waste with a top cut in a range from 6-14 inches.

15. A method as in claim 13, wherein a first intermediate waste stream is enriched in plastics, the sorting including separating 3-dimensional plastic from 2-dimensional plastics and recovering a 3-dimensional recyclable plastic product.

16. A method as in claim 13, wherein a second intermediate waste stream is enriched in non-ferrous metals, the sorting of the second intermediate waste stream including separating non-ferrous metals from other materials using an eddy current separator and recovering a non-ferrous product.

17. A method as in claim 13, wherein the mixed waste includes copper and brass and sorting the metals includes separating brass to produce a recyclable brass product.

18. A method as in claim 13, wherein the mixed waste stream includes 0.1%-15% by weight of metals selected from the group consisting of ferrous metal, non-ferrous metal, stainless steel, and combinations thereof.

19. A method as in claim 13, wherein the mixed waste stream includes from 5%-60% by weight dry organics selected from mixed paper and plastic.

20. A method for recovering recyclable materials from mixed solid waste stream, comprising:

providing a mixed waste stream comprising a plurality of recyclable materials including paper, plastic, and metal;

shredding the mixed waste stream in a shredder to produce a shredded mixed waste having 2-dimensional and 3-dimensional recyclable materials;

fractionating the shredded mixed waste stream by size to produce a plurality of sized waste streams;

fractionating at least a portion of the sized waste streams by density to produce a first intermediate waste stream enriched in the recyclable materials including recyclable paper and recyclable plastic;

sorting the first intermediate waste streams using an eddy current separator to obtain a recyclable non-ferrous metal product;

fractionating the first intermediate stream using a 2D-3D separator to produce a second intermediate stream enriched in 3-dimensional plastic and an third intermediate stream enriched in film plastic and paper;

sorting the second intermediate stream to produce a high density polyethylene product and/or a recyclable polyethylene terephthalate product; and

sorting the third intermediate stream to produce a paper product.