Methods and systems for separating and recovering recyclables using a comminution device

• US 9,713,812 B1
• Filed: 09/12/2012
• Issued: 07/25/2017
• Est. Priority Date: 09/12/2011
• 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:
  US13/612,037
• Time in Patent Office: 1,777 Days
• Field of Search: 241 19, 241 20, 241 2413, 241 2414, 241 2418, 241 2419, 241 38, 241 79, 241 791, 241 30
• CPC Class Codes: B02C 23/14 with more than one separator
• CPC Class Codes: B03B 9/06 specially adapted for refuse
• CPC Class Codes: B07B 13/003 Separation of articles by differences in their geometrical form or by difference in their physical properties, e.g. elasticity, compressibility, hardness
• 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: Y02W 30/52 Mechanical processing of waste for the recovery of materials, e.g. crushing, shredding, separation or disassembly

Abstract

Methods and systems for mining or recovering high value recyclable materials from waste streams with high percentages of recyclable materials. Examples of waste streams that can be advantageously processed using the methods and systems herein include dry commercial solid waste, dry industrial solid waste, and/or source separated curbside collected and processed single stream waste. The methods utilize a shredder to improve the efficiency and recovery rate of recyclables. Some methods also include upgrading an existing waste processing facility to include a shredder.

Claims

1. A method for sorting recyclable materials, comprising:

providing a recyclable mixed solid waste stream that includes a plurality of mixed recyclable materials, wherein the source of the recyclable mixed solid waste stream is a dry commercial solid waste stream, a dry industrial solid waste stream, and/or a source separated residential recyclable material stream;

comminuting the recyclable mixed solid waste;

fractionating the comminuted recyclable mixed solid waste stream by size and density to produce a plurality of intermediate waste streams, wherein at least one of the mixed solid waste streams includes 3-dimensional plastic and 2-dimensional plastic or paper;

individually sorting the plurality of intermediate waste streams using one or more sorting apparatuses to produce at least two recyclable products, wherein the sorting includes separating 3-dimensional plastic from the 2-dimensional plastic or paper;

and recovering the at least two recyclable products, at least one of the recovered recyclable products being selected from the group consisting of paper and wood.

2. A method as in claim 1, wherein the comminuting is carried out using a shredder with a shredder opening in a range from 8-20 inches.

3. A method as in claim 1, wherein the recyclable mixed solid waste stream is provided with less than 40% wet organics.

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 two dimensional plastics and recovering a 3-dimensional recyclable plastic product.

5. A method as in claim 4, 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 plastic film 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 other non-ferrous metal recovery technologies and recovering a non-ferrous product.

8. A method as in claim 1, wherein the recyclable mixed solid waste stream includes 0.1%-10% 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 recyclable mixed solid 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.

10. A method as in claim 1, wherein the recyclable mixed solid waste stream includes from 10%-90% by weight dry organics selected from mixed paper and plastic.

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

12. A method as in claim 1, wherein the, wherein the plurality of intermediate waste streams have a bottom cut size greater than 2 inches.

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

14. A method as in claim 1, wherein the recyclable mixed solid 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.

15. A method for upgrading a solid waste recycling facility, comprising:

providing a recycling facility that includes an established waste processing line including a plurality of size separating apparatuses that fractionate waste by size and a plurality of sorting apparatuses that sort recyclable materials into recyclable products, wherein the established waste processing line is configured to and has been operated to recover recyclable products from a dry commercial solid waste stream, a dry industry solid waste stream, and/or a source separated residential or commercial recyclable material stream;

upgrading the established waste processing line to newly include a shredder or grinder upstream from the plurality of sorting apparatuses thereby yielding an upgraded waste processing line, wherein the upgraded waste processing line includes a 2D-3D sorter for separating 3-dimensional plastic from 2-dimensional plastic or paper; and

processing a recyclable mixed solid waste stream on the upgraded waste processing line, wherein the recyclable mixed solid waste stream includes a dry commercial solid waste stream, a dry industry solid waste stream, and/or a source separated recyclable solid waste stream, the processing including shredding and/or grinding the recyclable mixed solid waste stream and using at least one of the sorting apparatuses to recover a recyclable product selected from the group consisting of paper and wood.

16. A method as in claim 15, further comprising upgrading the waste processing line to newly include a density separator downstream from the shredder or grinder and upstream from the plurality of sorting apparatuses.

17. A method as in claim 15, wherein the shredder is positioned in the upgraded waste processing line upstream from all the size separation apparatuses.

18. A method as in claim 15, further comprising upgrading the waste processing line to newly include a plurality of optical sorters configured to separate film plastic from paper.

19. A method as in claim 15, wherein the comminuting is carried out using a shredder with a shredder opening in a range from 8-20 inches.

20. A method as in claim 15, wherein the established waste processing line is configured to and has been operated to recover recyclable products from waste streams with less than 25% wet organics.