Process for separating synthetic turf product

• US 9,205,460 B2
• Filed: 10/22/2013
• Issued: 12/08/2015
• Est. Priority Date: 10/21/2013
• Status: Active Grant

• Current Assignee: Re-Match Holding A/S
• Original Assignee: Re-Match (UK) Limited
• Inventors: Andersen, Dennis, Riggenmann, Michael
• Primary Examiner(s): Severson, Jeremy R
• Application Number:
  US14/059,800
• Publication Number:
  US 20150108041A1
• Time in Patent Office: 777 Days
• US Class Current: 1/1
• CPC Class Codes: B07B 9/02 Combinations of similar or different apparatus for separating solids from solids using gas currents
• CPC Class Codes: B29B 17/02 Separating plastics from other materials
• CPC Class Codes: B29B 2017/0224 Screens, sieves
• CPC Class Codes: B29B 2017/0234 using gravity, e.g. separating by weight differences in a wind sifter
• CPC Class Codes: B29L 2031/732 Floor coverings piles carpets B29L2031/7652; for vehicles B29L2031/3017
• CPC Class Codes: E01C 13/08 Surfaces simulating grass ; Grass-grown sports grounds grass-like surfaces for skiing E01C13/12
• 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

A process for separating synthetic turf product comprising includes the consecutive steps of: (a) downsizing the synthetic turf product into a downsized turf material; (b) separating the downsized turf material by sieving into at least a first fraction substantially comprising a mixture of backing material and additional components and a second fraction substantially comprising grass fiber components; (c) separating the first fraction by specific gravity to provide a low density fraction and a high density fraction; (d) separating the second fraction by specific gravity and size by providing an airflow directed upwards in a separator configured to cause a swirling motion whereby a lighter fraction is entrained upwards in the air flow and a heavy fraction is allowed to fall downwards; and (e) collecting the low density fraction and the light fraction.

Claims

1. A process for separating a synthetic turf product comprising at least a backing material, a grass fiber component and additional components said process comprising at least the consecutive steps of

(a) downsizing the synthetic turf product into a downsized turf material;

(b) separating the downsized turf material by sieving into at least a first fraction substantially comprising a mixture of the backing material and the additional components and a second fraction substantially comprising grass fiber components;

(c) separating the first fraction obtained in step (b) by specific gravity using air to provide a low density fraction substantially comprising the backing material and a high density fraction substantially comprising the additional components;

(d) separating the second fraction obtained in step (b) by specific gravity and size by providing an airflow directed upwards in a separator configured to cause a swirling motion whereby a lighter fraction is entrained upwards in the air flow and a heavy fraction is allowed to fall downwards;

where the lighter fraction substantially comprises grass fiber components, and the heavy fraction substantially comprises a mixture of the backing material and additional components; and

(e) collecting the low density fraction obtained in step (c) and the light fraction obtained in step (d).

2. The process according to claim 1 where in the sieving of step (b) is performed in a plurality of sets of sieves and/or where the separation by specific gravity of step (c) is performed in a plurality of separating means and where the separation of step (d) is performed in a plurality of sets of separators.

3. The process according to claim 1, wherein the additional component comprises an infill and wherein the first fraction obtained in step (b) before step (c) is subjected to an intermediate sieving step (i) to provide a third fraction substantially comprising the backing material and a fourth fraction substantially comprising the infill, and, wherein the third fraction substantially comprising the backing material is further processed in step (c) and the fraction substantially comprising the infill is recovered.

4. The process according to claim 3, wherein the infill material comprises sand and/or rubber and wherein the fourth fraction is subjected to the further step (f) of separating by specific gravity to provide a low density fraction substantially comprising rubber and a high density fraction substantially comprising sand.

5. The process according to claim 3, wherein in the intermediate separation step (i) is performed in a sieve comprising a plurality of sieves, where at least a first sieve has a mesh size of 3 mm;

and a least a second sieve has a mesh size 0.8 mm;

said separation provides;

a large fraction where the length of the largest dimension of the downsized material is 3 mm or higher, said first fraction substantially comprising grass fiber components;

an intermediate fraction where the length of the largest dimension of the downsized material is in the range of 0.8 to 3 mm and said intermediate fraction essentially comprising the backing material; and

a small fraction where the length of the largest dimension is 0.8 mm or smaller, said small fraction substantially comprising infill.

6. The process according to claim 1 wherein the second fraction obtained in step (b) is further down sized before being separated by air sifting in step (d), in a cutting mill.

7. The process according to claim 6, wherein the further downsized fraction has a length of the largest dimension of no more than approximately 10 mm.

8. The process according to claim 6, wherein the further downsized fraction has a length of the largest dimension of no more than 8 mm.

9. The process according to claim 1, wherein the separation of step (d) is performed in a cyclone separator or a zig-zag air sifter.

10. The process according to claim 9, wherein the wherein the separation is performed in a zig-zag air sifter and the air is provided at a frequency of 18-27 Hz.

11. The process according to claim 9, wherein the separation of step (d) is performed in two steps, wherein the frequency of air of the first step is higher than the frequency in the second step.

12. The process according to claim 9, wherein the separation is performed in a zig-zag air sifter and the air is provided at a frequency of 20-25 Hz.

13. The process according to claim 9, wherein the separation of step (d) is performed in two steps, wherein the frequency of air of the first step is approximately 25 Hz in the first step and approximately 20 Hz in the second step.

14. The process according to claim 1, wherein the synthetic turf product is dried before the downsizing the synthetic turf product.

15. The process according to claim 1, wherein the synthetic turf product is dry or dried.

16. The process according to claim 1, wherein the synthetic turf product is dried after downsizing the synthetic turf product in step (a) and before separating the downsized turf material in step (b).

17. A process for separating a dry or dried synthetic turf product comprising at least a backing material, a grass fiber component, and infill, said process comprising at least the consecutive steps of:

(a) downsizing the synthetic turf product into a downsized turf material;

(b) separating the downsized turf material by sieving into at least a first fraction substantially comprising a mixture of the backing material and the infill and a second fraction substantially comprising grass fiber components;

(i) sieving the first fraction substantially comprising a mixture of the backing material and the infill to provide a third fraction substantially comprising the backing material and a fourth fraction substantially comprising the infill and, wherein the third fraction substantially comprising the backing material is further processed in step (c) and the fourth fraction substantially comprising the infill is recovered;

(c) separating the third fraction obtained in step (i) by specific gravity using air to provide a low density fraction substantially comprising the backing material and a high density fraction substantially comprising the infill;

(d) separating the second fraction obtained in step (b) by specific gravity and size by providing an airflow directed upwards in a separator configured to cause a swirling motion whereby a lighter fraction is entrained upwards in the air flow and a heavy fraction is allowed to fall downwards;

where the lighter fraction substantially comprises grass fiber components, and the heavy fraction substantially comprises a mixture of the backing material and the infill; and

(e) at least collecting the low density fraction obtained in step (c) and the light fraction obtained in step (d).

18. The process according to claim 17, wherein the infill comprises sand and rubber and wherein the fourth fraction is subjected to the further step (f) of separating by specific gravity to provide a low density fraction substantially comprising the rubber and a high density fraction substantially comprising the sand.

19. The process according to claim 17, wherein in the intermediate separation step (i) is performed in a sieve comprising a plurality of sieves;

where at least a first sieve has a mesh size of 3 mm; and

a least a second sieve has a mesh size 0.8 mm;

said separation provides;

a large fraction where the length of the largest dimension of the downsized material is 3 mm or higher, said first fraction substantially comprising grass fiber components;

an intermediate fraction where the length of the largest dimension of the downsized material is in the range of 0.8 to 3 mm and said intermediate fraction essentially comprising backing material; and

a small fraction where the length of the largest dimension is 0.8 mm or smaller, said small fraction substantially comprising the infill.