Method and apparatus for treating filler-containing material, such as recycled fibers

Abstract

Recycled fiber pulp from a vortex cleaning plant (e.g. connected to the short circulation of a paper machine) effects the recovery and return of fillers in the recycled fiber pulp discharged from the vortex cleaning plant, in an efficient and economical manner. The loss of filler in the recycled fiber pulp discharged from the vortex cleaning plant is decreased by treating a concentrated fraction of the rejects from the vortex cleaning plant with a mixer/disperser for dispersing the filler in the recycled fiber pulp, and returning as much usable filler as possible back to the process.

I claim:  
     
       1. A method of treating filler-containing material utilizing a vortex cleaning plant having a plurality of steps including a last step, and utilizing a first fractionation stage and a last fractionation stage distinct from the vortex cleaning plant, said method comprising the steps of: 
       (a) passing filler-containing material to the vortex cleaning plant including the last step thereof in which the material is divided into a first, finer, fraction and a second, coarser, fraction;  
       (b) passing the second fraction to the first fractionation stage to divide the second fraction into a third, fine, fraction, and a fourth, coarse, fraction;  
       (c) returning the third fraction to the vortex cleaning plant;  
       (d) dispersing the fourth fraction to produce dispersed material;  
       (e) passing the dispersed material to the last fractionation stage;  
       (f) in the last fractionation stage, dividing the dispersed material into a fifth, fine fraction and a sixth fraction; and  
       (g) returning the fifth fraction to the vortex cleaning plant, or to be treated again in steps (b) or (e).  
     
     
       2. A method as recited in  claim 1  wherein steps (a) through (g) are practiced utilizing recycled fiber pulp as the filler-containing material. 
     
     
       3. A method as recited in  claim 2  comprising the further steps, between steps (d) and (e), of: (h) dividing the recycled fiber material into a sixth fine fraction, and a seventh coarser fraction; (i) returning the sixth fraction to steps (a) or (b); and (j) dispersing the seventh fraction and using the dispersed seventh fraction in step (e). 
     
     
       4. A method as recited in  claim 3  wherein step (i) is practiced by returning the sixth fraction to step (b). 
     
     
       5. A method as recited in  claim 2  comprising the further step (h) of returning the sixth fraction to be dispersed in step (d). 
     
     
       6. A method as recited in  claim 2  wherein step (d) is practiced by passing the fraction being dispersed into several consecutive dispersion stages without any fractionation stage therebetween. 
     
     
       7. A method as recited in  claim 2  comprising the further step (h), between steps (d) and (e), of diluting the dispersed fraction. 
     
     
       8. A method as recited in  claim 2  wherein steps (a) and (b) are practiced so that the fourth fraction has a consistency of greater than 30% prior to the practice of step (d), and step (d) is practiced at a consistency of greater than 30%. 
     
     
       9. A method of treating recycled fiber pulp containing filler comprising the steps of: 
       (a) passing the recycled pulp containing filler to a vortex cleaning plant having a plurality of steps including first and last steps;  
       (b) in the last step of the vortex cleaning plant dividing the pulp into a first finer fraction, and a second, coarser fraction;  
       (c) returning the first fraction to the vortex cleaning plant;  
       (d) screening the second fraction in a first screening stage to separate the recycled fiber pulp into a third fraction containing shives and other wood-based material, and a fourth fraction containing filler material;  
       (e) passing the fourth fraction to a second screening stage in which the fourth fraction is divided into a fifth, fine material, fraction and a sixth, coarse material, fraction; and  
       (f) dispersing the sixth fraction in a dispersion stage.  
     
     
       10. A method as recited in  claim 9  comprising the further step (g) of leading the dispersed sixth fraction from step (f) back to the second screening stage in step (e). 
     
     
       11. A method as recited in  claim 9  comprising the further step (g) of leading the dispersed sixth fraction from step (f) back to the first screening stage in step (d). 
     
     
       12. A method as recited in  claim 9  comprising the further step (g), after step (f), of fractionating the dispersed fraction from step (f) into a seventh fine fraction, and an eighth coarse fraction; (h) returning the seventh fraction to the vortex cleaning plant or to step (d); and (i) dispersing the eighth fraction. 
     
     
       13. A method as recited in  claim 9  wherein steps (a) through (e) are practiced so as produce the sixth fraction at a consistency of greater than 30%, step (f) being practiced at a consistency of greater than 30%. 
     
     
       14. Apparatus for treating filler-containing material comprising: 
       a vortex cleaning plant including a first treatment stage and a last treatment stage, said last treatment stage comprising a fractionation stage producing a reject material including filler-containing material;  
       further treatment apparatus connected to said vortex cleaning plant for treating the reject material therefrom, said treatment apparatus comprising at least one dispersing device for breaking the filler-containing material into smaller particles; a pump and a first fractionation device between said at least one dispersing device and said vortex cleaning plant; and a pump and a second fractionation device on the opposite side of said at least one dispersing device from said first fractionation device; and  
       means for returning filler material broken into smaller particles to said vortex cleaning plant.  
     
     
       15. Apparatus as recited in  claim 14  wherein said further treatment apparatus further comprises a first fractionation device connected between said vortex cleaning plant and said at least one dispersing device. 
     
     
       16. Apparatus as recited in  claim 15  wherein said further treatment apparatus comprises a second fractionating device disposed on the opposite side of said at least one mixing/dispersing device from said first fractionation device. 
     
     
       17. Apparatus as recited in  claim 15  wherein said first fractionation device comprises a vortex separator. 
     
     
       18. Apparatus as recited in  claim 14  wherein said at least one dispersing device comprises a first mixing/dispersing device, and further comprising a second dispersing device connected on the opposite side of said second fractionation device from said first dispersing device, and further comprising a pump and a third fractionation device connected on the opposite side of the second dispersing device from said second fractionation device. 
     
     
       19. Apparatus as recited in  claim 14  wherein said second fractionation device contains a reject conduit, and wherein said reject conduit is connected to said dispersing device. 
     
     
       20. Apparatus as recited in  claim 14  wherein said at least one dispersing device has at least two stages. 
     
     
       21. Apparatus as recited in  claim 14  wherein said at least one dispersing device comprises a plate grinder, cone grinder, or mill grinder. 
     
     
       22. Apparatus as recited in  claim 14  wherein said vortex cleaning plant is connected to the short circulation of a paper machine. 
     
     
       23. Apparatus for treating filler-containing material comprising: 
       a vortex cleaning plant including a first treatment stage and a last treatment stage, said last treatment stage comprising a fractionation stage producing a reject material; and  
       further treatment apparatus connected to said vortex cleaning plant for treating the reject material therefrom, said treatment apparatus comprising at least one mixing/dispersing device, said further treatment apparatus comprising a first fractionation device connected between said vortex cleaning plant and said at least one mixing/dispersing device, and a second fractionating device disposed on the opposite side of said at least one mixing/dispersing device from said first fractionation device.  
     
     
       24. Apparatus as recited in  claim 23  wherein said second fractionation device comprises a vortex separator. 
     
     
       25. Apparatus as recited in  claim 23  wherein said second fractionation device comprises a curved screen or a pressure screen, having a perforated or slotted screen plate. 
     
     
       26. Apparatus for treating filler-containing material comprising: 
       a vortex cleaning plant including a first treatment stage and a last treatment stage, said last treatment stage comprising a fractionation stage producing a reject material including filler-containing material;  
       further treatment apparatus connected to said vortex cleaning plant for treating the reject material therefrom, said treatment apparatus comprising first and second dispersing devices for breaking the filler-containing material into smaller particles; a pump and a first fractionation device connected between said vortex cleaning plant and said first and second dispersing devices; and a pump and a second fractionation device connected on the opposite side of said first and second dispersing devices from said first fractionation apparatus; and  
       means for returning filler material broken into smaller particles to said vortex cleaning plant.  
     
     
       27. A method of treating filler- containing material in a production process utilizing a vortex cleaning plant, the vortex cleaning plant having a plurality of steps including a predetermined step, and utilizing a first fractionation stage, a mixing/dispersion stage, and a second fractionation stage operatively associated with the vortex cleaning plant, said method comprising the steps of    
       ( a )  passing filler - containing material to the vortex cleaning plant including the predetermined step thereof in which predetermined step the material is divided into a first, finer, fraction and a second, coarser filler rich fraction containing filler material;    
       ( b )  passing the second filler rich fraction to the first fractionation stage to divide the second fraction into a third, fine, fraction, and a fourth, coarse filler rich fraction;    
       ( c )  returning the third, fine, fraction to an earlier point in the production process;    
       ( d )  dispersing the fourth coarse filler rich fraction in the mixing/dispersion stage to produce dispersed filler rich material;    
       ( e )  passing the dispersed filler rich material from the mixing/dispersion stage to the second fractionation stage;    
       ( f )  in the second fractionation stage, dividing the dispersed filler rich material into a fifth, fine fraction and a sixth coarse fraction; and    
       ( g )  returning the fifth fine fraction to an earlier point in the production process.   
     
     
       28. A method as recited in  claim 27  wherein ( g )  is practiced by returning the fifth fraction to be treated again in step  ( b ). 
     
     
       29. A method as recited in  claim 27  wherein steps ( a )  through  ( g )  are practiced utilizing recycled fiber pulp as the filler - containing material.   
     
     
       30. A method as recited in  claim 27  wherein steps ( a )  and  ( b )  are practiced so that the fourth fraction has a consistency of greater than  30   %  prior to the practice of step  ( d ) , and step  ( d )  is practiced at a consistency of greater than  30   %. 
     
     
       31. A method of treating filler- containing material in a production process utilizing a vortex cleaning plant, the vortex cleaning plant having a plurality of steps including a predetermined step, and utilizing a mixing/dispersing stage and a fractionation stage which are operatively associated with the vortex cleaning plant, said method comprising the steps of:    
       ( a )  passing filler - containing material to the vortex cleaning plant including the predetermined step thereof in which predetermined step the material is divided into a first, finer, fraction and a second, coarser filler rich fraction;    
       ( b )  dispersing the second, coarser filler rich fraction in the mixing/dispersing stage to produce dispersed filler rich material;    
       ( c )  passing the dispersed filler rich material to the fractionation stage;    
       ( d )  in the fractionation stage, dividing the dispersed filler rich material into a third, fine fraction and a fourth coarser fraction; and    
       ( e )  returning the third fine fraction to an earlier point in the production process.   
     
     
       32. A method as recited in  claim 31  wherein step ( e )  is practiced to return the third fraction to the vortex cleaning plant.   
     
     
       33. A method of treating filler- containing material utilizing a vortex cleaning plant, the vortex cleaning plant having a plurality of steps including a step producing a coarse output, and utilizing a mixing/dispersing stage and a fractionation stage operatively associated with the vortex cleaning plant, said method comprising the steps of:    
       ( a )  passing filler - containing material to the vortex cleaning plant including the step producing a course filler rich output such that the coarse filler rich output is divided into a first, finer, fraction and a second, coarser filler rich fraction;    
       ( b )  dispersing, in the mixing/dispersing stage the second coarser filler rich fraction to produce dispersed filler rich material;    
       ( c )  passing the dispersed filler rich material to the first fractionation stage;    
       ( d )  in the first fractionation stage, dividing the dispersed filler rich material into a third, fine fraction and a fourth coarser fraction; and    
       ( e )  returning the third, fine fraction to a point in the vortex cleaning plant upstream of the vortex step having the coarse output.   
     
     
       34. Apparatus for treating filler- containing material comprising:    
         a vortex cleaning plant containing the filler - containing material, said vortex cleaning plant having a plurality of stages and producing a reject filler - rich material, and further treatment apparatus operatively associated with said vortex cleaning plant for treating the reject material therefrom, said further treatment apparatus comprising:    
         at least one mixing/dispersing device for dispersing the reject filler - rich material;    
       
         a first fractionation device operatively associated with said vortex cleaning plant and upstream of said at least one mixing/dispersing device, wherein said first fractionation device is separate from said mixing/dispersing device, and  
       
       
         a second fractionating device disposed on an opposite side of said at least one mixing/dispersing device from said first fractionation device. 
       
     
     
       35. Apparatus as recited in  claim 32  wherein said vortex cleaning plant is connected to a short circulation of a paper machine. 
     
     
       36. Apparatus as recited in  claim 32  wherein said at least one dispersing device comprises a plate grinder, cone grinder, or mill grinder.