WO2024013508A1

WO2024013508A1 - An apparatus for recycling paper and cardboard materials

Info

Publication number: WO2024013508A1
Application number: PCT/GB2023/051845
Authority: WO
Inventors: Jerry CATHCART
Original assignee: Point of Origin Waste Solutions Limited
Priority date: 2022-07-15
Filing date: 2023-07-13
Publication date: 2024-01-18
Also published as: EP4555143A1; GB202210459D0

Abstract

An apparatus for recycling paper and cardboard materials comprising cellulosic fibres, the apparatus comprising a hopper for receiving waste paper and/or cardboard material, the hopper including a hopper inlet and a hopper outlet; a shredder having an inlet in communication with the hopper outlet, one or more shredding elements, and a shredded product outlet; a cellulosic fibre separation station having an inlet in communication with the shredded product outlet, one or more high pressure fluid nozzles, and a fibre pulp outlet; and a moulding station having an inlet in communication with the fibre pulp outlet, a high pressure mould, and a moulded product outlet.

Description

An Apparatus for Recycling Paper and Cardboard Materials

The present invention relates to an apparatus for recycling paper and cardboard materials.

According to a first aspect of the invention, there is provided an apparatus for recycling paper and cardboard materials comprising cellulosic fibres, the apparatus comprising a hopper for receiving waste paper and/or cardboard material, the hopper including a hopper inlet and a hopper outlet; a shredder having an inlet in communication with the hopper outlet, one or more shredding elements, and a shredded product outlet; a cellulosic fibre separation station having an inlet in communication with the shredded product outlet, one or more high pressure fluid nozzles, and a fibre pulp outlet; and a moulding station having an inlet in communication with the fibre pulp outlet, a high pressure mould, and a moulded product outlet.

Accordingly, the invention relates primarily to the recycling of cellulosic fibres, regardless of their source.

The cellulosic fibres are separated during the process to form a cellulosic fibre pulp, which is then moulded into a product. The moulded product may then be used as a source of clean cellulosic fibres for subsequent processing.

It should be appreciated that the term "in communication with" means that the first component is in direct communication with the second component, or it is in indirect communication with the second component. Thus, one or more intermediate components may be disposed between the first and second components. Accordingly, the second component may be in communication with the first component, optionally via one or more intermediate components.

In an embodiment of the invention, the hopper includes a water inlet, wherein the paper and/or cardboard materials are mixed with water in the hopper prior to moving downstream to the shredder. In this way, the water can start to clean and separate the cellulosic fibres at the start of the process and the output from the shredder is a cellulosic fibre pulp. Suitably, the water is heated. For example, the temperature of the water in the hopper may be 50°C or greater, such as 55°C or greater or 60°C or greater. The heated water suitably increases the rate at which the cellulosic fibres are cleaned and separated. As noted above, the shredder includes a shredded product outlet. This may include an active transport element, such as a motorised transport element. For example, the motorised transport element may include one or more augers which rotate about a respective rotational axis and actively transport the shredded cellulosic fibres (optionally in the form of a fibre pulp) from the shredder to the cellulosic fibre separation station. The action of the or each active transport element may further separate the cellulosic fibres.

Although some separation of the cellulosic fibres occurs in the hopper and shredder, the main separation of the fibres occurs in the separation station. The fluid from the high pressure fluid nozzles forces the fibres apart, in addition to providing a cleaning action. Suitably, the high pressure fluid nozzles release a liquid. Thus, the high pressure fluid may be a high pressure liquid.

The high pressure fluid suitably has a pressure of at least lOOpsi. Accordingly, the or each high pressure fluid nozzle may be connected to a fluid system which pressurises the fluid to a pressure of at least lOOpsi. For example, the pressure of the high pressure fluid may be at least 250 psi, at least 500psi, at least 750psi, at least lOOOpsi, at least 1500psi, at least 2000psi, or at least 2500psi. The skilled person will appreciate that the greater the pressure of the pressurised fluid, the greater the separation of the cellulosic fibres. However, the greater the fluid pressure, the more energy is required to pressurise the fluid and the high pressure fluid system will need to accommodate the higher pressures.

The high pressure nozzles may include more than one fluid outlet port. Additionally or alternatively, the nozzles may rotate about a rotational axis. Such an arrangement suitably generates variable streams of high pressure fluid.

In an embodiment of the invention, the cellulosic fibre separation station includes a chamber having a first end and a second end; the high pressure fluid nozzles are located at the first end of the chamber; and the fibre pulp outlet is arranged at the second end of the chamber; wherein the separated cellulosic fibres are urged towards the fibre pulp outlet by the high pressure fluid nozzles.

In such embodiments, the chamber may be an elongate chamber. Suitably, the chamber defines a longitudinal axis and the longitudinal axis may be arranged to be substantially vertical. In embodiments in which the chamber has a vertical longitudinal axis, the first end may be at the bottom of the chamber and the second end may be at the top of the chamber. In such embodiments, the cellulosic fibres are driven upwards against gravity by the high pressure fluid from the or each nozzle. This increases the chaotic flow of the cellulosic fibres, which in turn increases the separation of the fibres.

Optionally, the apparatus includes two or more separation stations as defined herein. The stations may used alternately or they may be used simultaneously.

The cellulosic fibre output from the separation station(s), which is suitably in the form of a pulp suspended in an aqueous carrier liquid, is transported to the moulding station, where it is placed into a mould. The moulding station or the mould itself may be heated. In such an arrangement, the cellulosic fibre output (e.g., fibre pulp) is heated, for example to a temperature of 60°C or higher, to a temperature of 70°C or higher, or to a temperature of 80°C or higher. This helps to dry the cellulosic fibres to a moisture content that is desirable for moulding.

In an embodiment of the invention, the mould suitably includes a liquid drain, whereby excess liquid within the pulp may be forced out of the mould during the moulding process.

The moulding station may include more than one mould. For example, the moulding station may include a first mould which produces a pallet-shaped moulded product, and a second mould which produces a moulded sheet. The cellulosic fibre output from the separation station may be directed to either the first mould or the second mould. Thus, according to the invention, a moulded pallet may first be formed from the cellulosic fibres, followed by two or more moulded sheets, which may be stacked on the moulded pallet-shaped product.

It will be appreciated that the moulding station may include a moulded product receiver and a transport component which transports the moulded products to the moulded product receiver. For example, the moulding station may first mould a pallet-shaped moulded product, which may then be transported to the moulded product receiver. The moulding station may then mould sequentially a plurality of moulded sheets, wherein each sheet is transported to the moulded product receiver, where it is located on the pallet-shaped moulded product.

The transport component may include a vacuum suction element which transports the moulded products from the moulds to the moulded product receiver. For example, the mould may be a two- part mould comprising a first (bottom) mould part and a second (top) mould part. The top mould part may include a vacuum suction apparatus, whereby after moulding, the top mould part is raised upwards away from the bottom mould part. The vacuum suction apparatus maintains the moulded product in engagement with the top mould part via suction applied to the moulded product. The top mould may be carried by a conveyer, whereby the top mould part may be conveyed to the moulded product received, whereupon the vacuum is removed and the moulded product is released from the top mould part.

Suitably, the mould comprises a first mould part, a second mould part and a vacuum source, wherein when the first mould part engages the second mould part, a vacuum chamber is defined between the first and second mould parts; and the vacuum source generates a vacuum within the vacuum chamber. The vacuum source may be in fluid communication with the second (top) mould part. In this way, the vacuum source may generate the vacuum within the vacuum chamber during moulding and it may also provide a suction for transporting the moulded products from the mould to the moulded product receiver.

The skilled person will appreciate that the pulp may be transported to the mould as an aqueous suspension, for example 4 to 10% by volume of cellulosic fibres and a water-based carrier liquid. The mould may be filled to a pre-determined level with the pulp, during which time, excess water is allowed to drain via the liquid drain. The liquid drain may then be closed and the vacuum chamber is exposed to the vacuum source, which generates a vacuum within the vacuum chamber.

The skilled person will appreciate that reference to "a vacuum" refers to a significant reduction in pressure within the vacuum chamber and is not intended to mean that a perfect vacuum is obtained within the vacuum chamber.

The vacuum within the vacuum chamber may be used to generate the pressure applied to the pulp within the mould to generate the moulded product. For example, using a mould which is heated to about 200°C and a pulp which is heated to about 90oC, it is possible to generate a pressure within the mould of about 20 tonnes using a suitable vacuum source. This has the effect of compressing the pulp at a depth of about 50mm to a moulded product having a depth of about 5mm. In addition, the heat and pressure flash-dries the product by removing up to 95% of the water content from the pulp. The drying is achieved by the heat generated when compressing the product as a result of Boyles Law. The moulded products may need to be dried further following the moulding process. In order to aid the drying process, the first and/or second mould parts may provide an array of pimples or projections on one or both surfaces of the moulded sheet. Such projections or protrusions space adjacent moulded sheets and permit an airflow between them. Thus, the projections/protrusions act as spacers and define air channels between adjacent sheets. The spacing between adjacent sheets may be from 0.5 to 5mm. The provision of an air gap between adjacent sheets aids the drying process and also minimises mould growth on the moulded products.

It will be appreciated that the projections/protrusions may have a hardened surface as a result of the moulding process. This hardened surface permits transportation of the moulded products with a decreased risk of damage to them.

Suitably, the apparatus further includes a contaminant separator disposed between the cellulosic fibre separation station and the moulding station. In other words, the moulding station may in communication with the cellulosic fibre separation station via the contaminant separator. The contaminant separator may include a water tank, wherein metal contaminants sink to the bottom of the tank. In order to assist with the separation of metal contaminants, a floor of the water tank may be sloped floor which directs the metal contaminants to a contaminant outlet under the influence of gravity. Optionally, the sloped floor may be a vibrating floor, which further assists with the transportation of the metal contaminants to the contaminant outlet.

The contaminant separator may also separate out relatively lightweight contaminants, such as smaller cellulosic fibres and plastics materials. This may be achieved by providing the separator with an air mat disposed above the floor. The air mat may contain a number of parallel pipes, wherein each pipe includes a plurality of airholes that result in a plurality of air bubbles (often referred to as an "air curtain") within the tank. These air bubbles drive the relatively light-weight contaminants to the surface of the water, where they may be removed by a skimmer.

An intermediate floor may be provided in the contaminant separator, wherein the intermediate floor is disposed between the sloping floor and the air mat. The intermediate floor may comprise a mesh membrane through which the metallic contaminants may pass. It may also include a cellulosic fibre outlet port. For example, the cellulosic fibre outlet port may comprise a pump and associated conduit. Thus, in certain embodiments of the invention, the relatively light-weight contaminants may be urged to the top of the tank by the air curtain, where they are suitably removed by the skimmer; the relatively heavy metallic contaminants fall to the bottom of the tank, where they pass through the air mat and the intermediate floor and are removed via the metal contaminant outlet; and the desired cellulosic fibres pass through the air mat and are collected on the intermediate floor, where they are removed from the contaminant separator via the cellulosic fibre outlet port. The cellulosic fibres are suitably transported from the cellulosic fibre outlet port to the moulding station, for example via a pump and associated conduit.

The light-weight contaminants may be transported from the skimmer to a filter tank. In the filter tank, the light-weight contaminants are filtered from the water. In such embodiments, the filtered water may then be recycled within the apparatus.

It will be appreciated that the light-weight contaminants include a relatively high percentage of smaller cellulosic fibres, which have a relatively high calorific content. Accordingly, the filtered lightweight contaminants may be compressed in the filter tank to form pellets. These pellets may then be used as a fuel source for a burner or similar generator which is able to generate heated air and/or electrical power from the lightweight contaminant pellets. The heated air and/or electrical power may be used in the various parts of the apparatus, thereby making the apparatus self-sufficient in its energy requirements.

In a further embodiment of the invention, the apparatus further includes a drying station, wherein the drying station is located downstream of the moulding station and includes one or more air jets which direct a flow of air over the moulded products. The drying station may include one or more heating elements or heat exchangers which heat the air jets.

As noted above, the apparatus may be relatively self-sufficient in terms of its energy requirements. Accordingly, the apparatus may be contained in a container, such that the apparatus may be moved from place to place within the container (i.e. the apparatus may be a mobile apparatus). Optionally, the apparatus need not be removed from the container. Thus, for example, the waste paper/cardboard to be recycled may be placed in the hopper at one end of the container and the moulded cellulosic products may be removed from the opposite end of the container.

The invention may be defined in one aspect according to the following definitions: 1.1 An apparatus for recycling paper and cardboard materials comprising cellulosic fibres, the apparatus comprising a hopper for receiving waste paper and/or cardboard material, the hopper including a hopper inlet and a hopper outlet; a shredder having an inlet in communication with the hopper outlet, one or more shredding elements, and a shredded product outlet; a cellulosic fibre separation station having an inlet in communication with the shredded product outlet, one or more high pressure fluid nozzles, and a fibre pulp outlet; and a moulding station having an inlet in communication with the fibre pulp outlet, a high pressure mould, and a moulded product outlet; wherein the cellulosic fibre separation station includes a vertical chamber having a bottom end and a top end; the high pressure fluid nozzles are located at the bottom end of the chamber; and the fibre pulp outlet is arranged at the top end of the chamber; wherein the separated cellulosic fibres are urged towards the fibre pulp outlet by the high pressure fluid nozzles.

1.2 An apparatus according to definition 1.1, wherein the hopper includes a water inlet, wherein the paper and/or cardboard materials are mixed with water in the hopper.

1.3 An apparatus according to definition 1.2, wherein the water is heated to a temperature above 50°C.

1.4 An apparatus according to any of definitions 1.1 to 1.3, wherein the shredded product outlet includes a shredded product transport element.

1.5 An apparatus according to definition 1.4, wherein the shredded product transport element includes one or more augers.

1.6 An apparatus according to any of definitions 1.1 to 1.5, wherein the high pressure fluid is high pressure water.

1.7 An apparatus according to any of definitions 1.1 to 1.6, wherein the moulding station includes a heater and/or heat exchanger that heats the fibre pulp to a temperature in excess of 60°C 1.8 An apparatus according to any of definitions 1.1 to 1.7, wherein the moulding station further includes a liquid drain.

1.9 An apparatus according to any of definitions 1.1 to 1.8, wherein the moulding station includes a first mould which produces a pallet-shaped moulded product, and a second mould which produces a moulded sheet.

1.10 An apparatus according to definition 1.9, wherein the moulding station includes a transport component which stacks two or more moulded sheets on a pallet-shaped moulded product.

1.11 An apparatus according to definition 1.9 or definition 1.10, wherein the second mould provides an array of pimples or projections on at least one surface of the moulded sheet.

1.12 An apparatus according to any of definitions 1.7 to 1.11, wherein the or each mould comprises a first mould element, a second mould element and a vacuum source, wherein when the first mould element engages the second mould element, a vacuum chamber is defined; and the vacuum source generates a vacuum within the vacuum chamber.

1.13 An apparatus according to any of definitions 1.1 to 1.12, wherein the apparatus further includes a contaminant-separation station disposed between the cellulosic fibre separation station and the moulding station, wherein the contaminant-separation station comprises a tank that is filled with water and metal contaminants sink to the bottom of the tank.

1.14 An apparatus according to definition 1.13, wherein the tank includes a sloped floor which directs the metal contaminants to a contaminant outlet under the influence of gravity.

1.15 An apparatus according to definition 1.14, wherein the floor is a vibrating floor. 1.16 An apparatus according to any of definitions 1.13 to 1.15, wherein the tank includes an air curtain disposed above the bottom of the tank, wherein the air curtain generates bubbles in the water and the air bubbles carry non-metallic contaminants to the top of the tank, where they are removed from the tank by a skimmer.

1.17 An apparatus according to any of definitions 1.1 to 1.16, wherein the apparatus further includes a drying station, wherein the drying station is located downstream of the moulding station and includes one or more air jets which direct a flow of air over the moulded products.

1.18 An apparatus according to definition 1.17, wherein the drying station further includes one or more heating elements and/or heat exchangers which heat the air jets.

In a further aspect, the invention may be defined as follows:

2.1 An apparatus for recycling paper and cardboard materials comprising cellulosic fibres, the apparatus comprising a hopper for receiving waste paper and/or cardboard material, the hopper including a hopper inlet and a hopper outlet; a shredder having an inlet in communication with the hopper outlet, one or more shredding elements, and a shredded product outlet; a cellulosic fibre separation station having an inlet in communication with the shredded product outlet, one or more high pressure fluid nozzles, and a fibre pulp outlet; and a moulding station having an inlet in communication with the fibre pulp outlet, a high pressure mould, and a moulded product outlet; wherein the mould comprises a first mould element, a second mould element and a vacuum source, wherein when the first mould element engages the second mould element, a vacuum chamber is defined; and the vacuum source generates a vacuum within the vacuum chamber.

2.2 An apparatus according to definition 2.1, wherein the hopper includes a water inlet, wherein the paper and/or cardboard materials are mixed with water in the hopper.

2.3 An apparatus according to definition 2.2, wherein the water is heated to a temperature above 50°C. 2.4 An apparatus according to any of definitions 2.1 to 2.3, wherein the shredded product outlet includes a shredded product transport element.

2.5 An apparatus according to definition 2.4, wherein the shredded product transport element includes one or more augers.

2.6 An apparatus according to any of definitions 2.1 to 2.5, wherein the high pressure fluid is high pressure water.

2.7 An apparatus according to definition 2.6, wherein the cellulosic fibre separation station includes a chamber having a first end and a second end; the high pressure fluid nozzles are located at the first end of the chamber; and the fibre pulp outlet is arranged at the second end of the chamber; wherein the separated cellulosic fibres are urged towards the fibre pulp outlet by the high pressure fluid nozzles.

2.8 An apparatus according to definition 2.7, wherein the chamber is arranged vertically with the first end being located at the bottom of the chamber and the second end being located at the top of the chamber.

2.9 An apparatus according to any of definitions 2.1 to 2.8, wherein the moulding station includes a heater and/or heat exchanger that heats the fibre pulp to a temperature in excess of 60°C

2.10 An apparatus according to any of definitions 2.1 to 2.9, wherein the moulding station further includes a liquid drain.

2.11 An apparatus according to any of definitions 2.1 to 2.10, wherein the moulding station includes a first mould which produces a pallet-shaped moulded product, and a second mould which produces a moulded sheet. 2.12 An apparatus according to definition 2.11, wherein the moulding station includes a transport component which stacks two or more moulded sheets on a pallet-shaped moulded product.

2.13 An apparatus according to definition 2.11 or definition 2.12, wherein the second mould provides an array of pimples or projections on at least one surface of the moulded sheet.

2.14 An apparatus according to any of definitions 2.1 to 2.13, wherein the apparatus further includes a contaminant-separation station disposed between the cellulosic fibre separation station and the moulding station, wherein the contaminant-separation station comprises a tank that is filled with water and metal contaminants sink to the bottom of the tank.

2.15 An apparatus according to definition 2.14, wherein the tank includes a sloped floor which directs the metal contaminants to a contaminant outlet under the influence of gravity.

2.16 An apparatus according to definition 2.15, wherein the floor is a vibrating floor.

2.17 An apparatus according to any of definitions 2.14 to 2.16, wherein the tank includes an air curtain disposed above the bottom of the tank, wherein the air curtain generates bubbles in the water and the air bubbles carry non-metallic contaminants to the top of the tank, where they are removed from the tank by a skimmer.

2.18 An apparatus according to any of definitions 2.1 to 2.17, wherein the apparatus further includes a drying station, wherein the drying station is located downstream of the moulding station and includes one or more air jets which direct a flow of air over the moulded products.

2.19 An apparatus according to definition 2.18, wherein the drying station further includes one or more heating elements and/or heat exchangers which heat the air jets. In a further aspect, the invention may be defined as follows:

3.1 An apparatus for recycling paper and cardboard materials comprising cellulosic fibres, the apparatus comprising a hopper for receiving waste paper and/or cardboard material, the hopper including a hopper inlet and a hopper outlet; a shredder having an inlet in communication with the hopper outlet, one or more shredding elements, and a shredded product outlet; a cellulosic fibre separation station having an inlet in communication with the shredded product outlet, one or more high pressure fluid nozzles, and a fibre pulp outlet; and a moulding station having an inlet in communication with the fibre pulp outlet, a high pressure mould, and a moulded product outlet; wherein the apparatus further includes a contaminant-separation station disposed between the cellulosic fibre separation station and the moulding station, wherein the contaminant-separation station comprises a tank that is filled with water and metal contaminants sink to the bottom of the tank.

3.2 An apparatus according to definition 3.1, wherein the hopper includes a water inlet, wherein the paper and/or cardboard materials are mixed with water in the hopper.

3.3 An apparatus according to definition 3.2, wherein the water is heated to a temperature above 50°C.

3.4 An apparatus according to any of definitions 3.1 to 3.3, wherein the shredded product outlet includes a shredded product transport element.

3.5 An apparatus according to definition 3.4, wherein the shredded product transport element includes one or more augers.

3.6 An apparatus according to any of definitions 3.1 to 3.5, wherein the high pressure fluid is high pressure water.

3.7 An apparatus according to definition 3.6, wherein the cellulosic fibre separation station includes a chamber having a first end and a second end; the high pressure fluid nozzles are located at the first end of the chamber; and the fibre pulp outlet is arranged at the second end of the chamber; wherein the separated cellulosic fibres are urged towards the fibre pulp outlet by the high pressure fluid nozzles. 3.8 An apparatus according to definition 3.7, wherein the chamber is arranged vertically with the first end being located at the bottom of the chamber and the second end being located at the top of the chamber.

3.9 An apparatus according to any of definitions 3.1 to 3.8, wherein the moulding station includes a heater and/or heat exchanger that heats the fibre pulp to a temperature in excess of 60°C

3.10 An apparatus according to any of definitions 3.1 to 3.9, wherein the moulding station further includes a liquid drain.

3.11 An apparatus according to any of definitions 3.1 to 3.10, wherein the moulding station includes a first mould which produces a pallet-shaped moulded product, and a second mould which produces a moulded sheet.

3.12 An apparatus according to definition 3.11, wherein the moulding station includes a transport component which stacks two or more moulded sheets on a pallet-shaped moulded product.

3.13 An apparatus according to definition 3.11 or definition 3.12, wherein the second mould provides an array of pimples or projections on at least one surface of the moulded sheet.

3.14 An apparatus according to any of definitions 3.9 to 3.13, wherein the mould comprises a first mould element, a second mould element and a vacuum source, wherein when the first mould element engages the second mould element, a vacuum chamber is defined; and the vacuum source generates a vacuum within the vacuum chamber.

3.15 An apparatus according to any of definitions 3.1 to 3.14, wherein the tank includes a sloped floor which directs the metal contaminants to a contaminant outlet under the influence of gravity. 3.16 An apparatus according to definition 3.15, wherein the floor is a vibrating floor.

3.17 An apparatus according to any of definitions 3.1 to 3.16, wherein the tank includes an air curtain disposed above the bottom of the tank, wherein the air curtain generates bubbles in the water and the air bubbles carry non-metallic contaminants to the top of the tank, where they are removed from the tank by a skimmer.

3.18 An apparatus according to any of definitions 3.1 to 3.17, wherein the apparatus further includes a drying station, wherein the drying station is located downstream of the moulding station and includes one or more air jets which direct a flow of air over the moulded products.

3.19 An apparatus according to definition 3.18, wherein the drying station further includes one or more heating elements and/or heat exchangers which heat the air jets.

In a further aspect, the invention may be defined as follows:

4.1 An apparatus for recycling paper and cardboard materials comprising cellulosic fibres, the apparatus comprising a hopper for receiving waste paper and/or cardboard material, the hopper including a hopper inlet and a hopper outlet; a shredder having an inlet in communication with the hopper outlet, one or more shredding elements, and a shredded product outlet; a cellulosic fibre separation station having an inlet in communication with the shredded product outlet, one or more high pressure fluid nozzles, and a fibre pulp outlet; and a moulding station having an inlet in communication with the fibre pulp outlet, a high pressure mould, and a moulded product outlet; wherein the moulding station includes a first mould which produces a pallet-shaped moulded product, and a second mould which produces a moulded sheet.

4.2 An apparatus according to definition 4.1, wherein the hopper includes a water inlet, wherein the paper and/or cardboard materials are mixed with water in the hopper. 4.3 An apparatus according to definition 4.2, wherein the water is heated to a temperature above 50°C.

4.4 An apparatus according to any of definitions 4.1 to 4.3, wherein the shredded product outlet includes a shredded product transport element.

4.5 An apparatus according to definition 4.4, wherein the shredded product transport element includes one or more augers.

4.6 An apparatus according to any of definitions 4.1 to 4.5, wherein the high pressure fluid is high pressure water.

4.7 An apparatus according to definition 4.6, wherein the cellulosic fibre separation station includes a chamber having a first end and a second end; the high pressure fluid nozzles are located at the first end of the chamber; and the fibre pulp outlet is arranged at the second end of the chamber; wherein the separated cellulosic fibres are urged towards the fibre pulp outlet by the high pressure fluid nozzles.

4.8 An apparatus according to definition 4.7, wherein the chamber is arranged vertically with the first end being located at the bottom of the chamber and the second end being located at the top of the chamber.

4.9 An apparatus according to any of definitions 4.1 to 4.8, wherein the moulding station includes a heater and/or heat exchanger that heats the fibre pulp to a temperature in excess of 60°C

4.10 An apparatus according to any of definitions 4.1 to 4.9, wherein the moulding station further includes a liquid drain.

4.11 An apparatus according to any of definitions 4.1 to 4.10, wherein the moulding station includes a transport component which stacks two or more moulded sheets on a pallet-shaped moulded product. 4.12 An apparatus according to any of definitions 4.1 to 4.11, wherein the second mould provides an array of pimples or projections on at least one surface of the moulded sheet.

4.13 An apparatus according to any of definitions 4.1 to 4.12, wherein each mould comprises a first mould element, a second mould element and a vacuum source, wherein when the first mould element engages the second mould element, a vacuum chamber is defined; and the vacuum source generates a vacuum within the vacuum chamber.

4.14 An apparatus according to any of definitions 4.1 to 4.13, wherein the apparatus further includes a contaminant-separation station disposed between the cellulosic fibre separation station and the moulding station, wherein the contaminant-separation station comprises a tank that is filled with water and metal contaminants sink to the bottom of the tank.

4.15 An apparatus according to definition 4.14, wherein the tank includes a sloped floor which directs the metal contaminants to a contaminant outlet under the influence of gravity.

4.16 An apparatus according to definition 4.15, wherein the floor is a vibrating floor.

4.17 An apparatus according to any of definitions 4.14 to 4.16, wherein the tank includes an air curtain disposed above the bottom of the tank, wherein the air curtain generates bubbles in the water and the air bubbles carry non-metallic contaminants to the top of the tank, where they are removed from the tank by a skimmer.

4.18 An apparatus according to any of definitions 4.1 to 4.17, wherein the apparatus further includes a drying station, wherein the drying station is located downstream of the moulding station and includes one or more air jets which direct a flow of air over the moulded products.

4.19 An apparatus according to definition 4.18, wherein the drying station further includes one or more heating elements and/or heat exchangers which heat the air jets. The skilled person will appreciate that the features described and defined in connection with the aspects of the invention and the embodiments thereof may be combined in any combination, regardless of whether the specific combination is expressly mentioned herein. Thus, all such combinations are considered to be made available to the skilled person.

An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a perspective view of an apparatus for recycling paper and cardboard materials according to the first aspect of the invention;

Figure 2 is a sectional view through a hopper which forms the first stage of the apparatus shown in Figure 1;

Figures 3 and 3a show a separation station and a high pressure nozzle which forms part of the separation station;

Figure 4 shows a contaminant separation station which forms part of the apparatus shown in Figure 1;

Figure 5 shows water filter stations which form part of the apparatus shown in Figure 1;

Figures 6a and 6b show a pair of moulds which form part of the apparatus shown in Figure 1; and

Figure 7 shows a drying station which forms part of the apparatus shown in Figure 1.

For the avoidance of doubt, the skilled person will appreciate that in this specification, the terms "up", "down", "front", "rear", "upper", "lower", "width", etc. refer to the orientation of the components as found in the example when installed for normal use as shown in the Figures.

Figure 1 shows a multi-stage apparatus 2 for recycling paper and cardboard materials comprising cellulosic fibres.

A first stage 4 consists of a waste material hopper 20, a shredder component 24, and a pulp transport component 26a, 26b. It will be appreciated that the term "pulp" used herein refers to a suspension of shredded cellulosic fibres in an aqueous carrier. The second stage 6 consists of a separations station within which the shredded fibres are separated.

The separation is effected by a high pressure rotating nozzle 40 (shown in Figure 3a).

The third stage 8 is a contaminant material separation stage, in which contaminants, such as staples, adhesive tape and/or lightweight paper materials (e.g., from labels and such like) are separated from the pulp.

The fourth stage 10, 12 is a water filtering station in which the water that acts as a carrier for the pulp is filter so that it can be recycled back to the first and second stations.

The fifth stage 14 is a moulding station in which the pulp is moulded into a product and transported to a moulded product receiver.

Finally, the sixth stage 16 is a drying station in which the moulded products are dried prior to storage and/or transportation.

Figure 2 shows the first stage 4 in more detail. Waste cardboard material is disposed within the hopper 20 via an open mouth 20a. The cardboard material is mixed within the hopper 20 with warm water (about 50°C) which enters the hopper 20 via the water inlet pipe 22.

The cardboard material sinks to the bottom of the hopper 20 where it is shredded by the rotating teeth of the shredder 24. The shredded cardboard material mixes with the water within the hopper 20 to form a pulp material consisting of shredded cardboard suspended with the water.

The pulp material falls through the bottom of the shredder 24 and into one of two separate transport channels 26a, 26b. The pulp is transported along the respective transport channel 26a, 26b via an auger 28. At the end of the transport channels 26a, 26b, the pulp enters one of the two separation stations 30a, 30b.

Figures 3 and 3a show the separation stations 30a, 30b in more detail. The separation stations 30a, 30b consist of vertical cylinders which have open inlet ports 34 at the bottom thereof. Located above the inlet ports 34 are high pressure rotating nozzles 40, which are commercially available in connection with drain cleaning apparatus. A nozzle assembly 36 is shown in more detail in Figure 3a The nozzles 40 emit high pressure water at about 3000psi, which separates the shredded cardboard material into separate cellulosic fibres without significantly damaging the fibres. As shown in Figure 3a, each of the nozzles 40 is fed by high pressure water via an inlet 38. The high pressure inlets 38 are coupled to a high pressure water supply via pipes 32, which in turn are connected to a water pump (not shown) which provides a supply of water at the pre-determined pressure.

A lower conical body 42 directs the pulp into the water jets generated by the nozzles 40. An upper conical body 44 fulfils a similar function for the pulp which descends within the cylinders under the action of gravity.

The action of the water jets generated by the nozzles 40 forces the pulp containing the separated cellulosic fibres upwards a respective contaminant separation station inlet ports 50.

The contaminant separation station 8 is shown in more detail in Figure 4. The contaminant separation station comprises a tank 46 into which the pulp is fed via the inlet ports 50. The pulp is urged to sink to the bottom of the tank under the action of gravity. However, a counter-current is provided by an air curtain that is generated by a grid-like arrangement of perforated pipes 52, which emit air bubbles that rise to the top of the tank 46 through the pulp.

The heavier cellulosic fibres eventually fall through the grid-like arrangement of perforated pipes 52 and are collected on a mesh plate 54. The collected cellulosic fibres are transported from the mesh plate 54 via an exit conduit 56 and a pump 58.

The heavier contaminant particles, such as staples and such like, also fall through the grid-like arrangement of perforated pipes, but the metallic contaminants also fall through the mesh plate 54. Beneath the mesh plate 54 is a vibrating sloped plate 60 that collects the metallic and other small, relatively heavy contaminants. The sloping vibrating plate 60 urges the contaminant particles disposed thereon towards a waste collecting conduit 62, via which they are removed from the apparatus.

Lightweight contaminant materials, such as paper and polymeric tapes are urged to the top of the tank 46 by the air curtain. These relatively lightweight contaminants are skimmed from the top of the water within the tank 46 by a flow of water that enters a skimmer outlet conduit 64. The suspended cellulosic fibres within the conduit 56 are directed to the moulding station shown in more detail in Figures 6a and 6b.

The water flow which contains the lightweight contaminant matter is directed to the water filter stations shown in Figure 5. The water filter stations consist of a first filter station 10 and a second filter station 12.

The first water filter station includes a first filter tank 70 within which is located a rotary drum filter 70a. The rotary drum filter 70a is a relatively coarse filter. The contaminant material filtered from the water flow by the rotary drum filter 70 is urged into a screw compressor 72 within which it is formed into pellets. The pellets exit the compressor 72 via an outlet port 74 and are collected. The waste pellets are used as a fuel source for a burner which is used to heat the water for the apparatus 2.

A portion of the filtered water from the first filter station 10 is directed into the second filter station 12. The remainder of the filtered water from the first water filter station 10 is recycled back to the hopper 20, where it is mixed with fresh cardboard waste.

The water that is directed into the second filter station passes through two finer rotary drum filters 76a, 76b via a conduit network 76. The water that has been filtered through the second filter station 12 is then stored within a storage tank 78. The water within the storage tank 78 is recycled to the high pressure nozzles 40 via one or more water pumps.

Figure 6a and 6b show the moulding station in more detail.

The apparatus includes two separate moulds, which are formed by respective bottom mould parts 94, 96 and a common top mould part 80. The common top mould part 80 includes a frame 80a that comprises engagement lugs 82. The engagement lugs 82 are slidably coupled to a pair of opposed rails whereby the frame 80a is capable of linear displacement between the first and second bottom mould parts 94, 96 and a moulded product receiving platform 110.

The frame 80a carries four hydraulic actuators 84 which in turn are coupled to a mould plate 86. On the downwardly facing side of the mould plate 86 is a perforated Teflon mould 100 and around the periphery of the mould plate 86 is a first seal 102 and a second seal 104. Connected to the mould plate 86 is a pulp inlet conduit 88 which is in fluid communication with the pulp exit conduit 56 from the contaminant separation station 8 via a pulp heater which heats the pulp to about 90°C prior to the pulp being pumped into the mould. The mould plate also carries a vacuum conduit 90 and a water drain conduit 92.

In use, the top mould part 80 is located directly above the second bottom mould part 94. The hydraulic actuators 84 urge the mould plate 86 downwards until the first seal 102 engages the side of the second bottom mould part 94. At this stage, a moulding chamber is defined between the mould plate 86 and the bottom mould part 94. The heated pulp is then pumped into the mould chamber via the conduit 88, with excess water being permitted to drain from the mould chamber via the water drain conduit 92. When the moulding chamber contains the desired volume of pulp, the water drain conduit is closed and the hydraulic actuators 84 exert a force on the mould plate 86 of about 2000kg. As the mould plate 86 is urged downwards by the hydraulic actuators 84, the second seal 104 engages the side of the bottom mould part 94a. When the second seal 104 engages the bottom mould part 94, a vacuum is applied to the mould chamber via the vacuum conduit 90. The combined effects of the vacuum and the hydraulic actuators 84 compresses the pulp into the desired moulded product and raises the temperature within the mould chamber such that a moisture content of about 5% remains.

After moulding, the mould plate is urged upwards via the hydraulic actuators 84 and the vacuum applied via the vacuum conduit 90 is reduced. The reduced vacuum is sufficient to retain the moulded product in contact with the mould plate 86. The top mould part 80 is then displaced linearly to the moulded product receiving station 98. The vacuum is then removed and the moulded product is released from the mould plate 86.

The moulding process is the same for the first bottom mould part 96.

It will be appreciated that the first bottom mould part 96 produces a moulded product in the form of a pallet 98, in which the moulded product includes downwardly projecting feet, whereas the second bottom mould part 94 produces a moulded product in the form of a sheet.

Both the perforated Teflon mould surface 100 of the mould plate 86 and the upwardly facing mould surface of the bottom mould parts 94, 96 define circular perforations. These impart circular projections on the surfaces of the moulded products. These circular projections have the effect of providing air channels between adjacent moulded products and providing a strengthened surface of the moulded products.

Figure 7 shows the drying station 16. The drying station comprises a vertical shaft within which is disposed a sprung platform 110. The sprung platform 110 is biased in an upwards direction and the increasing weight of moulded products being loaded onto the platform urges it slowly downwards, against the biasing force of the springs, within the shaft until is reaches a pre-determined position in the shaft, at which point, the platform 110 is tilted towards a sloping floor 114 and the moulded products disposed on the platform 110 are urged into the sloping floor 114 under the action of gravity.

The pallet-shaped moulded product 98, which is moulded from the first bottom mould part 96, is first placed on the sprung platform 110. Thereafter, a number of moulded sheet products are stacked on top of the pallet-shaped moulded product 98.

The sloping floor 114 is located within a drying tunnel 116 which carries heated pipes 112 along its length. The heated pipes maintains a dry, heated environment within the drying tunnel 116. At the opposite end of the tunnel 116 is a door (not shown), which may be opened to remove a dried stack of moulded products from the tunnel 116.

The skilled person will appreciate that both the pallet -shaped moulded product 98 and the moulded sheet products may be used as a source of cellulosic fibres.

Claims

1 An apparatus for recycling paper and cardboard materials comprising cellulosic fibres, the apparatus comprising a hopper for receiving waste paper and/or cardboard material, the hopper including a hopper inlet and a hopper outlet; a shredder having an inlet in communication with the hopper outlet, one or more shredding elements, and a shredded product outlet; a cellulosic fibre separation station having an inlet in communication with the shredded product outlet, one or more high pressure fluid nozzles, and a fibre pulp outlet; and a moulding station having an inlet in communication with the fibre pulp outlet, a high pressure mould, and a moulded product outlet.

2 An apparatus according to Claim 1, wherein the hopper includes a water inlet, wherein the paper and/or cardboard materials are mixed with water in the hopper.

3 An apparatus according to Claim 2, wherein the water is heated to a temperature above 50°C.

4 An apparatus according to any of Claims 1 to 3, wherein the shredded product outlet includes a shredded product transport element.

5 An apparatus according to Claim 4, wherein the shredded product transport element includes one or more augers.

6 An apparatus according to any of Claims 1 to 5, wherein the high pressure fluid is high pressure water.

7 An apparatus according to Claim 6, wherein the cellulosic fibre separation station includes a chamber having a first end and a second end; the high pressure fluid nozzles are located at the first end of the chamber; and the fibre pulp outlet is arranged at the second end of the chamber; wherein the separated cellulosic fibres are urged towards the fibre pulp outlet by the high pressure fluid nozzles. 8 An apparatus according to Claim 7, wherein the chamber is arranged vertically with the first end being located at the bottom of the chamber and the second end being located at the top of the chamber.

9 An apparatus according to any of Claims 1 to 8, wherein the moulding station includes a heater and/or heat exchanger that heats the fibre pulp to a temperature in excess of 60°C

10 An apparatus according to any of Claims 1 to 9, wherein the moulding station further includes a liquid drain.

11 An apparatus according to any of Claims 1 to 10, wherein the moulding station includes a first mould which produces a pallet-shaped moulded product, and a second mould which produces a moulded sheet.

12 An apparatus according to Claim 11, wherein the moulding station includes a transport component which stacks two or more moulded sheets on a pallet-shaped moulded product.

13 An apparatus according to Claim 11 or Claim 12, wherein the second mould provides an array of pimples or projections on at least one surface of the moulded sheet.

14 An apparatus according to any of Claims 9 to 13, wherein the mould comprises a first mould element, a second mould element and a vacuum source, wherein when the first mould element engages the second mould element, a vacuum chamber is defined; and the vacuum source generates a vacuum within the vacuum chamber.

15 An apparatus according to any of Claims 1 to 14, wherein the apparatus further includes a contaminant-separation station disposed between the cellulosic fibre separation station and the moulding station, wherein the contaminant-separation station comprises a tank that is filled with water and metal contaminants sink to the bottom of the tank.

16 An apparatus according to Claim 15, wherein the tank includes a sloped floor which directs the metal contaminants to a contaminant outlet under the influence of gravity. An apparatus according to Claim 16, wherein the floor is a vibrating floor. An apparatus according to any of Claims 15 to 17, wherein the tank includes an air curtain disposed above the bottom of the tank, wherein the air curtain generates bubbles in the water and the air bubbles carry non-metallic contaminants to the top of the tank, where they are removed from the tank by a skimmer. An apparatus according to any of Claims 1 to 18, wherein the apparatus further includes a drying station, wherein the drying station is located downstream of the moulding station and includes one or more air jets which direct a flow of air over the moulded products. An apparatus according to Claim 19, wherein the drying station further includes one or more heating elements and/or heat exchangers which heat the air jets.