System and method for continuous processing of recyclable material

• US 9,457,354 B2
• Filed: 06/13/2013
• Issued: 10/04/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: BMIC LLC
• Original Assignee: Building Materials Investment Corporation (Standard Industries, Inc.)
• Inventors: Svec, James A., Tibah, Denis Muki, Stephens, Keith Edward
• Primary Examiner(s): SOOHOO, TONY GLEN
• Application Number:
  US13/916,713
• Publication Number:
  US 20140263779A1
• Time in Patent Office: 1,209 Days
• Field of Search: 366/7, 366/16
• US Class Current: 1/1
• CPC Class Codes: B02C 19/0056 specially adapted for specific materials not otherwise provided for
• CPC Class Codes: B09B 3/00 Destroying solid waste or transforming solid waste into something useful or harmless
• CPC Class Codes: B29L 2031/108 Roofs
• CPC Class Codes: C08L 95/00 Compositions of bituminous materials, e.g. asphalt, tar, pitch
• CPC Class Codes: E01C 19/10 Apparatus or plants for premixing or precoating aggregate or fillers with non-hydraulic binders, e.g. with bitumen, with resins, i.e. producing mixtures or coating aggregates otherwise than by penetrating or surface dressing; Apparatus for premixing non-hydraulic mixtures prior to placing or for reconditioning salvaged non-hydraulic compositions E01C19/08, E01C19/21, E01C21/00, E01C23/065 take precedence

Abstract

A continuous system for making shingles from recyclable material is provided comprising a milling device to receive recyclable material and process the recyclable material into particulate and a transfer device to receive and transfer the particulate from the milling device. An apparatus receives the particulate from the transfer device and weighs the particulate. A continuous processor receives the particulate and reacts and/or mixes the particulate with at least one admixture to form a homogenous mixture. A filler mixer receives the homogenous mixture and incorporates the homogenous mixture with shingle material to form core product and a control panel controls input of the homogenous mixture into the filler mixer.

Claims

1. A method of continuous processing of recyclable material, comprising:

measuring and outputting an amount of recyclable material with an apparatus to a continuous processor;

supplying at least one admixture by a supply device to the continuous processor;

at least one of continuously reacting and continuously mixing the recyclable material with the at least one admixture in the continuous processor to form a homogenous mixture having a predetermined temperature ranging from approximately 250°

F. to approximately 450°

F.;

outputting the homogenous mixture at the predetermined temperature to a holding tank or directly to a filler mixer;

controlling an amount of the homogenous mixture input from the holding tank or continuous processor into the filler mixer;

outputting shingle material from a source into the filler mixer; and

forming a recycled core product by incorporating up to approximately 30% of the homogenous mixture at the predetermined temperature with the shingle material in the filler mixer, wherein the filler mixer is independently operable from the continuous processor to enable the filler mixer to selectively form at least one of the recycled core product or an unrecycled core product.

2. The method according to claim 1, wherein the at least one of continuously reacting and continuously mixing the recyclable material with the at least one admixture in the continuous processor to form the homogenous mixture includes a predetermined residence time, wherein the predetermined residence time is a function of a capacity of the continuous processor and operation of a mixing system of the continuous processor.

3. The method according to claim 1, further comprising varying a rate and volume of the homogenous mixture input into the filler mixer.

4. The method according to claim 2, wherein the predetermined residence time comprises up to and including about 20 minutes.

5. The method according to claim 1, further comprising outputting an amount of recyclable material with the apparatus to a holding device.

6. The method according to claim 2, wherein the mixing includes mixing the recyclable material with the at least one admixture with a paddle system, a screw system, and a shaft support system.

7. The method according to claim 1, wherein the continuously mixing transfers energy into the homogenous mixture and heats the recyclable material and the at least one admixture.

8. The method according to claim 1, wherein the continuous processor comprises a mechanical heat transfer of from approximately 12,000 BTUs to approximately 75,000 BTUs.

9. The method according to claim 1, further comprising controlling a rate and volume of the recyclable material output to the continuous processor with the apparatus.

10. The method according to claim 1, wherein the continuous processor forms the homogenous mixture at a rate ranging from approximately 1,000 lbs/hour to approximately 20,000 lbs/hour.

11. The method according to claim 1, wherein the continuous processor further comprises at least one oil jacket, and the method further comprises at least one of heating and cooling the homogenous mixture with the oil jacket of the continuous processor.

12. The method according to claim 1, further comprising continuously receiving the homogenous mixture from the continuous processor with the filler mixer.

13. The method according to claim 1, further comprising controlling an input of the homogenous mixture into the filler mixture with a control panel.

14. The method according to claim 13, further comprising controlling the continuous processor with a main control panel.

15. The method according to claim 14, wherein the controlling an input comprises varying a weight percentage of the homogenous mixture based on a signal from the main control panel.

16. The method according to claim 1, further comprising forming the homogenous mixture with a specific gravity ranging from approximately 1 to approximately 3.5.

17. The method according to claim 1, wherein the amount of recyclable material output into the continuous processor forms from approximately 5 weight percent to approximately 70 weight percent of the homogenous mixture.

18. The method according to claim 1, further comprising

providing the recyclable material to a milling device;

grinding the recyclable material into particulate form with the milling device; and

transferring the particulate form of the recyclable material to the apparatus.

19. The method according to claim 18, further comprising providing a recyclable material comprising recycled asphalt shingles.

20. The method according to claim 18, further comprising transferring the particulate form to a separation system and separating the particulate form based on a particle size.

21. The method according to claim 18, wherein the transferring the particulate form to the apparatus comprises:

receiving the particulate form with a transfer system comprising a hopper;

storing an influx of the particulate form within the transfer system; and

outputting the particulate form with a bin activator feeder.

22. The method according to claim 21, further comprising controlling the transfer system and the bin activator feeder with a control panel.