Wet pulping system and method for producing cellulosic insulation with low ash content

Abstract

Apparatus and method for recovering organic cellulosic fibers from landfill materials (such as post consumer, municipal and industrial waste materials). The apparatus and method selectively introduces waste materials containing organic cellulosic fibers into a size reduction machine. The pre-cleaned waste materials are conveyed to a tank, drum, or tunnel type fiber recovery apparatus. The waste materials are subjected to mechanical and fluid fiberization for a selected period of time to produce useful products, such as cellulosic insulation with a total ash content equal to or less than 10%, as well animal and fowl bedding products that is substantially devoid of moisture content, among other products.

1 . A process for recovering organic cellulosic fibers from landfill materials such as post consumer, municipal and industrial waste materials comprising:
 a. selectively introducing waste materials containing organic cellulosic fibers into a size reduction machine without prior fluid pre-conditioning of said waste materials;   b. conveying such waste material from said size reduction machine to a tank, drum or tunnel type fiber recovery apparatus; and   c. subjecting such waste material for a selected period of time to simultaneous mechanical and fluid fiberization in said fiber recovery apparatus.   
     
     
         2 . The process of  claim 1  further comprising:
 d. introducing a pulping fluid containing chemicals to enhance the fiber separation process; 
 e. selectively treating the recovered fibers with rapidly penetrating flame retardants, insecticidal chemicals and decay inhibitors; 
 f. selectively dyeing the separated fibers to selected colors; and, 
 g. providing solids separation reagents to selectively remove contaminants in the pulping fluids. 
 
     
     
         3 . The process of  claim 2  where the pulping fluid is selectively heated to a temperature range between about 50° F. to about 200° F., and wherein said simultaneous mechanical and fluid fiberization is carried out at a temperature between about 50° F. and about 200° F. 
     
     
         4 . The process of  claim 1  further comprising:
 h. cleaning the recovered fibers through screening and hydro-cleaning devices to remove plastics and tramp metal; 
 i. conveying the removed plastics and tramp metals to a waste disposal system consisting of a receiving tank and a sludge press; and 
 j. extracting a high percentage of the pulping fluid for further processing including for reuse as a pulping medium. 
 
     
     
         5 . The process of  claim 1  further comprising:
 k. subjecting the recovered fibers to a mechanical disk refiner to control fiber length, fiber bundle separation and fiber surface properties. 
 
     
     
         6 . The process of  claim 1  further comprising:
 l. removing contaminants consisting of fillers, fines, coatings and other extraneous materials through the use of one or more clarifiers with select solids separation reagents and polymers. 
 
     
     
         7 . The process of  claim 1  further comprising:
 m. extracting pulping fluids and water from the recovered fibers to formulate a cellulosic fiber wet lap of about 40% to about 60% pulp solids content; 
 n. fluffing the cellulosic fiber wet lap in a cake fluffer and a disk refiner; 
 o. drying the fluffed fibers in a flash or tunnel dryer; and 
 p. conveying the dried fibers to a packaging or baling system. 
 
     
     
         8 . The process according to  claim 7 , wherein the step of drying comprises:
 drying the fluffed fibers at a temperature from about 150° F. to about 700° F., thereby reducing bacteria content of the recovered fibers, and drying them to a uniform moisture content.   
     
     
         9 . The process according to  claim 8 , wherein the moisture content is between about 10% and about 18%. 
     
     
         10 . The process according to  claim 8 , wherein the dried fibers have a bulk density of between about 2 pounds per cubic foot to about 6 pounds per cubic foot. 
     
     
         11 . The process according to  claim 8 , wherein said drying step produces dried fibers configured for use as animal and fowl bedding and have a higher degree of absorbency than sawdust, straw, wood shaving, or conventional paper-based bedding. 
     
     
         12 . The process according to  claim 11 , wherein the dried fibers are about six times more absorbent than sawdust, straw or wood shavings. 
     
     
         13 . The process according to  claim 11 , wherein the dried fibers are between about 18 percent and 25 percent more absorbent than conventional paper-based bedding. 
     
     
         14 . The process according to  claim 8 , wherein said drying step produces dried fibers are configured for use as animal and fowl bedding and incur between about 40% to about 50% less compaction than conventional paper-based animal and fowl bedding. 
     
     
         15 . The process of  claim 7 , further comprising:
 q. removing inorganic precipitated chemicals and contaminants from the extracted pulping fluids; and   r. recycling the pulping fluids back to the primary tank/drum/tunnel fiber recovery apparatus.   
     
     
         16 . The process of  claim 15  where the removed inorganic precipitated chemicals and selected contaminants are selected from the group consisting of calcium hydroxide, calcium carbonate calcites, aluminum hydroxide, aluminum oxide, magnesium hydroxide, and various other minor hydroxides. 
     
     
         17 . The process according to  claim 1 , wherein the recovered organic cellulosic fibers comprise a final total ash content equal to or less than about 10%. 
     
     
         18 . The process according to  claim 1 , wherein the recovered organic cellulosic fibers comprise a final total ash content of about 8.09%. 
     
     
         19 . The process according to  claim 1 , wherein the recovered organic cellulosic fibers comprise an average fiber length greater than about 0.700 mm. 
     
     
         20 . The process according to  claim 1 , wherein the recovered organic cellulosic fibers comprise an average fiber length of about 0.780 mm.