[0001] The present disclosure relates generally to systems and methods for reclaiming a settable material adhered to an object and recycling the settable material for re-use. The disclosure particularly relates to removing a settable mould adhered to an object formed by the mould and recycling the reclaimed mould.

Background

[0002] Formative processes, such as moulding or casting, for fabricating an object typically involve constructing a mould defining a cavity, introducing substantially liquid material into the cavity, and curing the material in the cavity, resulting in a substantially solid object formed from the material. The geometry of the cavity retains the material in the mould whilst the material solidifies and consequently defines (forms) the shape of the resulting object. This process is used in a wide range of industries, for example, formworks are often employed during construction of a building to retain concrete in a specific shape to form a part of the building, such as a foundation structure.

[0003] A significant drawback with known formative processes is the limited scope for different object geometries able to be fabricated. This is because moulds are typically removed from the object after casting/moulding which requires either 'line of draw' geometry, such as draft angles, to be incorporated into the mould geometry to allow the mould to be released from the object, or the mould to be disassembled or destroyed to allow the mould to be released from the object. This is particularly problematic when the mould includes undercut/overhanging geometry which makes linear removal of the mould impossible.

[0004] One approach to address this issue is to fabricate the mould from a readily destructible material, such as polymeric foam, MDF or wax, allowing the mould to be broken into pieces and removed from the object. However, this approach is typically time and/or manual labour intensive and may not completely remove mould material from the object. This may mean that the object is also sprayed with solvents to facilitate removal of adhered portions of mould material, which is also time intensive and potentially harmful to the object. Furthermore, some mould/object geometries cause the mould, or a portion of the mould, to become encased in the object, meaning that access to and removal of the mould is difficult or impossible. Also, such approaches are typically expensive, as they often create significant waste mould material and requires multiple steps.

[0005] Any discussion of documents, acts, materials, devices, articles or the like included in the present specification is not to be taken as an admission that any or all of these matters form part of the common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.

Summary

[0006] In some embodiments of the disclosure, there is provided a system for reclaiming a settable mould adhered to an object formed by the settable mould and recycling the reclaimed mould, the system comprising:

a tank defining a chamber dimensioned to receive the object and the mould, the chamber of the tank, in use, containing a volume of liquid for immersing the object and the mould;

at least one first heating operable to heat the liquid contained in the tank to at least a melting temperature of the mould, causing the mould to detach from the object and form molten mould material entrained with the liquid;

a removal device arranged, in use, to be in contact with the liquid and configured to remove at least some of the molten mould material from the liquid; and a separation assembly in communication with the removal device to receive the molten mould material entrained with the liquid and configured to separate remaining liquid from the molten mould material. [0007] The separation assembly may include:

a container defining an enclosed chamber, an inlet arranged to receive the molten mould material entrained with the liquid, and an outlet arranged to convey the molten mould material, separated from the remaining liquid, out of the chamber; and at least one second heating element associated with the container and operable to heat the molten mould material entrained with the liquid in the chamber causing the liquid to evaporate, thereby separating the remaining liquid from the molten mould material.

[0008] The separation assembly may further include an element defining a surface arranged to receive the molten mould material entering the chamber through the inlet, and wherein the at least one second heating element is arranged to heat the surface. The chamber defines a floor and the element may be a plate angled away from the inlet towards the floor. The separation assembly may further include an evacuation device operable to maintain a pressure less than atmospheric pressure in the chamber.

[0009] The container may further define a port in communication with the evacuation device and arranged to evacuate the evaporated liquid from the chamber. The separation assembly may further comprise a condenser arranged downstream of the port to receive the evaporated liquid and operable to condense and collect the evaporated liquid.

[0010] The system may further comprise at least one pump arranged to receive and convey the molten mould material from the separation assembly.

[0011] The system may further comprise a reservoir arranged to receive an overflow from the chamber of the tank, whereby, in use, the overflow comprises at least the liquid entraining the molten mould material, the removal device including a skimming device arranged, in use, to skim the molten mould material from the liquid contained in the reservoir. At least a portion of the tank may define a weir arranged to direct the overflow towards the reservoir. [0012] The system may further comprise a recirculation apparatus arranged to convey the liquid from the reservoir to the tank. The recirculation apparatus may include a pump arranged to convey the liquid from the reservoir to the tank, a filter arranged to filter the liquid being conveyed from the reservoir to the tank, and a heating unit to heat the liquid being conveyed from the reservoir to the tank prior to reinjection of the liquid into the chamber of the tank.

[0013] The system may further comprise at least one agitator in communication, in use, with the liquid and configured to direct the liquid in the tank in one or more specific directions. The at least one agitator may be arranged to direct the liquid, in use, substantially across a surface of the liquid contained in the tank.

[0014] The at least one agitator may be arranged to direct the liquid, in use, towards at least one of the object and the wax adhered to the object. The at least one agitator is movable within the tank to vary the one or more specific directions in which the liquid is directed.

[0015] The system may further comprise a circulation mechanism arranged to be in communication, in use, with the liquid contained in the chamber of the tank and configured to induce flow of the liquid around the chamber.

[0016] The system may further comprise a filter arranged downstream of the separation assembly to receive and filter the molten mould material.

[0017] The system may further comprise an insulated casing substantially enclosing at least the tank.

[0018] In some embodiments of the disclosure, there is provided a separation assembly for separating molten settable material from an entrained liquid, the separation assembly comprising:

a container defining an enclosed chamber, an inlet arranged to receive the molten material and entrained liquid, and an outlet arranged to convey the molten material, separated from the liquid, out of the chamber;

an evacuation device operable to maintain a pressure less than atmospheric pressure in the chamber; and

at least one heating element associated with the container and operable to heat, in the chamber, the molten material entrained with the liquid causing the liquid to evaporate, thereby separating the remaining liquid from the molten mould material.

[0019] In some embodiments of the disclosure, there is provided a method for reclaiming a settable mould adhered to an object formed by the settable mould and recycling the reclaimed mould, the method including:

immersing the settable mould and the object in a liquid contained in a chamber defined by a tank dimensioned to receive the object and the mould;

heating the liquid contained in the tank to at least a melting temperature of the mould, causing the mould to detach from the object and form molten mould material entrained in the liquid;

removing at least some of the molten mould material from the liquid; and separating the remaining liquid from the molten mould material.

[0020] The object may be formed from a cementitious material cast against the mould, and heating the liquid may further comprise heating the liquid to less than 70°C.

[0021] The settable mould may be formed from a wax, and separating the remaining liquid from the molten mould material may further comprise arranging the molten mould material in an enclosed chamber having a pressure less than atmospheric pressure and heating the molten mould material entrained with the liquid to less than 90°C causing the liquid to evaporate and separate from the molten mould material.

[0022] Through the present disclosure reference is made to a settable mould, which will be appreciated to include within its scope all types of moulds, such as formworks, cores, mandrels, patterns, and the like, formed from any sort of settable material. [0023] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Brief Description of Drawings

[0024] Embodiments will now be described by way of example only with reference to the accompany drawings in which:

[0025] Figure 1 is a diagram of an embodiment of a system for reclaiming a settable mould adhered to an object formed by the settable mould and recycling the reclaimed mould; and

[0026] Figure 2 is a diagram of an alternative embodiment of a separation assembly of the system shown in Figure 1.

Description of Embodiments

[0027] In the drawings reference numeral 10 generally designates an embodiment of a system 10 for reclaiming a settable mould 12 adhered to an object 14 formed by the settable mould 12 and recycling the reclaimed mould 12. The system 10 includes a tank 16 defining a chamber dimensioned to receive the object 14 and the mould 12. In use, the chamber of the tank 16 contains a volume of liquid 18 for immersing the object 14 and the mould 12. At least one first heating element 20 is operable to heat the liquid 18 contained in the tank 16 to at least a melting temperature of the mould 12, causing the mould to detach from the object and form molten mould material entrained with the liquid 18. A removal device 26 is arranged, in use, to be in contact with the liquid 18 and configured to remove at least some of the molten mould material from the liquid 18. A separation assembly 40 is in communication with the removal device 26 to receive the molten mould material entrained within the liquid 18 and configured to separate remaining liquid 18 from the molten mould material. [0028] Typically a pump 42 is arranged downstream of the separation assembly 40 to receive and convey the molten mould material from the separation assembly 40 and out of the system 10. Also, typically a filter 44 is arranged downstream of the separation assembly 40 to filter the molten mould material prior to the evacuating the system 10.

[0029] In the embodiment shown in Figure 1, the settable mould 12 is formed from a wax and the system 10 is configured to reclaim and recycle the wax. It will be appreciated that the wax may be configured as any wax compound and includes any such compounds within the scope of this disclosure. Alternatively, the mould 12 may be formed from any other settable and meltable material, and this disclosure includes all such settable and meltable materials within its scope.

[0030] In the embodiment shown in Figure 1, the object 14 is formed from a cementitious material, such as concrete, which has been cast and therefore formed on the mould 12, and the system 10 is configured to reclaim the mould 14 from the cast cementitious object 14. Typically, the object 14 is configured as a construction element suitable for constructing a part of a building or similar structure and is therefore a large- scale body. For example, the object 14 may be configured as a decorative panel for cladding the building. It will be appreciated that the object 14 may alternatively be formed from any other material which can be formed by the mould 12. For example, the object 14 may be formed by successively spraying or laying up components of glass-fibre reinforced plastic in layers onto the mould 12 and at least partially curing the layers, prior to immersion in the liquid 18 contained in the tank 16. The tank 16 defines the chamber which is dimensioned to receive the mould 12, the object 14, and the liquid 18. The object 14 is spaced apart from a base of the tank 16 on supports 15. The at least one first heating element 20 is arranged to heat the liquid 18 in the chamber to a temperature at least equal to, and usually greater than, a melting temperature of the mould 12. For example, in the embodiment shown the mould 12 is formed from wax and the first heating element 20 heats the liquid 18 to at least 60°C to melt the wax. Melting the mould 12 causes the mould to become molten and disintegrate into globules 13 of molten mould material. The globules 13 are suspended and float upwards in the liquid 18 where the globules 13 coalesce to form a stratum 17 of molten mould material on a surface defined by the liquid 18, whereby the molten mould material in the stratum is entrained with some of the liquid 18.

[0031] In the embodiment shown in Figure 1, a plurality of the heating elements 20 are associated with the tank 16 and arranged adjacent to the base of the tank 16. It will be appreciated that the heating elements 20 may be arranged in other suitable positions around or in the tank 16, including in the liquid 18 and/or around walls of the tank 16. Alternatively, the heating elements 20 may remotely heat the liquid 18 and the heated liquid 18 is conveyed to and charges the tank 16. For example, the heating elements 30 may be associated with a circulation mechanism (not shown) arranged to circulate heated liquid 18 substantially continuously through the tank 16 to refresh to the liquid 18. In this scenario, the heating elements 20 may be arranged about, or within, conduits (not shown) conveying the liquid to the tank 16 from the circulation mechanism.

[0032] A reservoir 22 is arranged to receive an overflow from the tank 16, the overflow comprising at least some of the stratum 17 of molten mould material entrained with the liquid 18. In the embodiment shown in Figure 1, the reservoir 22 is joined to one side of the tank 16. That side of the tank 16 defines a weir 24 to direct the overflow towards the reservoir 22. The tank 16 and/or the reservoir 22 may

alternatively define other structures to direct fluid flow from the tank 16 to the reservoir 22, for example, the tank 16 may define one or more apertures (not shown), including an elongate slot (not shown), to direct the overflow towards the reservoir 22.

[0033] A chute 25 (Fig.4) is arranged downstream of the weir 24 which has a filtration system 27 arranged at an exit of the chute 25. The filtration system 27 comprises at least one coarse filter 29 arranged at an exit of the chute 25. Preferably, two such coarse filters 29 are provided. This enables one of the filters 29 to be removed for cleaning while the other is operational. Each coarse filter may, for example, be a 5mm mesh arranged across the exit of the chute 25. The chute 25 is shaped to increase velocity of the overflow and the coarse filter/s 29 removes particles, for example, fragments of the object 14, from the overflow. [0034] As shown in greater detail in Fig. 3 of the drawings, the weir 24 is formed by an insert 31 which is removably insertable into an opening 33 defined in the tank 16. This facilitates removal of the insert to be replaced by an insert 31.1 of a different height to cater for variations in the volume of liquid 18 contained in the tank 16 and/or dimensions of the object 14 and mould 12. Thus, for example, the insert 31 has a height of 3X, where X is any suitable height dimension whereas the insert 31.1 has a height of 2X. Each insert 31/31.1 has a notch 35 defined in its top surface to facilitate flow of liquid 18 from the tank 16 at a higher velocity to assist in driving the stratum 17 over the top of the weir 24.

[0035] Once the overflow is received in the reservoir 22, the liquid 18 and molten mould material settle and substantially separate, causing the molten mould material to coalesce on a surface defined by the liquid 18 to form another stratum 19 of molten mould material entrained within some of the liquid 18. Settling the liquid 18 and the molten mould material in the reservoir 22 also allows any fine fragments of the object 14, for example, cementitious dust, to sink to a base of the reservoir 22 to allow removal of the fragments from the liquid 18.

[0036] The reservoir 22 is connected to a recirculation apparatus 32 configured to recirculate the liquid 18 from the reservoir 22 to the tank 16. The recirculation apparatus 32 includes a pump 34 to pump the liquid 18 from the reservoir 22 to the tank 16, a filter (not shown) to filter the liquid 18 and a heating unit 36, such as a heat exchanger, to heat the liquid 18 being conveyed to the tank 16 prior to reinjection of the liquid 18 into the tank 16. The recirculation apparatus 32 is arranged to receive the liquid 18 from a location adjacent a base of the reservoir 22 and may be associated with a structure, such as a plenum 37, to decrease velocity of the liquid 18 so that the liquid 18 is forced through a circuitous route at the bottom of the reservoir 22 prior to being received by the recirculation apparatus 32. This arrangement optimises settling of the liquid 18 so that substantially all molten mould material and any other material, such as fragments of the object 14, are removed from the liquid 18 prior to being drawn into the recirculation apparatus 32. To enhance this, a further heating element (not shown) may be associated with an entry to the recirculation apparatus 32, such as housed in the plenum 37, to disperse any molten mould material towards the stratum 19.

[0037] One or more agitators 38 are associated with the tank 16 and direct flow of the liquid 18 in one or more directions. In the embodiment shown, the agitators 38 are jets in communication with the liquid 18 supplied by the recirculation apparatus 32 and arranged to direct recirculated liquid 18 within the tank 16. A first jet 381 is shown arranged adjacent a surface defined by the liquid 18 to direct the stratum 17 and liquid 18 across this surface towards the reservoir 22. It will be appreciated that, while the stratum 17 has been illustrated as a uniform layer of consistent thickness, in practice, the stratum 17 may be of variable thickness and be constituted by discrete patches on the surface of the liquid 18.

[0038] A second jet 382 is shown arranged below the surface defined by the liquid 18 and adjacent the object 14 to allow liquid to be directed at a specific portion of the object 14 and/or the mould 12. Optionally, the agitators 38 may be movable to control the direction the liquid 18, for example, to encourage molten mould material coalesced around a portion of the object 14 to disperse and float up to the stratum 17 or to more quickly melt off certain thicker sections of the mould 12, which would take longer to melt-off otherwise, reducing overall melt-off time for the mould 12. The jets 38 are configured to minimise turbulence in the liquid 18 to minimise exposure of the mould material to the object 14 and to the liquid 18 to reduce the likelihood of the mould material forming fine droplets. Fine droplets may increase the quantity of liquid 18 circulated in the system 10 downstream of the tank 16.

[0039] Also, the tank 16 may be associated with a circulation mechanism (not shown), such as one or more specifically arranged turbines or jets, to induce gentle, non-turbulent flow of the liquid 18 around the tank 16, the mould 12 and the object 14.

[0040] The removal device 26 may include a skimming device arranged to skim the molten mould material from the liquid 18. In the embodiment shown, the skimming device is arranged to skim the molten mould material from the stratum 19 formed on the liquid 18 contained in the reservoir 22. However it will be appreciated that the skimming device may alternatively be arranged in contact with the stratum 17 formed on the liquid 18 contained in the tank 16.

[0041] The skimming device is, in this embodiment, an oil skimmer-type device having a conveyer belt 28 mounted around at least two spaced rollers 30, at least one of which is driven to convey the belt 28 around the rollers 30. The belt 28 is coated with at least one of an oleophobic and hydrophobic material, such as PTFE, and arranged to collect molten mould material when rotated in the reservoir 22. The belt 28 has a wiper blade (not shown) arranged to wipe the belt 28 to remove molten mould material from the belt 28. The wiper blade is associated with a further heating element (not shown) to heat the blade to ensure molten mould material does not cool and collect on the blade. For example, the wiper blade has a heating element secured to an underside of it to facilitate heating of the blade. Further materials, such as pipework in contact with the mould material in transit from the reservoir 22, are preferably heated or temperature controlled to ensure the molten mould material remains fluid. A collection vessel (not shown) is arranged to collect the molten mould material removed by the wiper from the belt 28 to allow the molten mould material to be conveyed to the separation assembly 40.

[0042] An insulated housing 46, including a lid, is arranged around at least the tank 16 to assist controlling temperature of the liquid 18, mould 12, object 14 and environment surrounding the tank 16. In the embodiment shown, the insulated housing 46 substantially encloses the tank 16 and the reservoir 22. The housing 46 also insulates air in contact with the strata 17, 19 which means that the air is substantially the same temperature as the molten mould material. This advantageously reduces instances of a skin of cooled, partially solidified mould material forming on either stratum 17, 19 which may impede movement of the molten mould material, for example, flowing over the weir 24.

[0043] In addition, the system 10 is configured such that, when not in operation, the liquid 18 is pumped from the system 10 to one or more insulated storage tanks (not shown) to be kept at an elevated temperature. In this way, less energy is required to restart the system 10 when required.

[0044] The separation assembly 40 is arranged downstream of the tank 16 and removal device 26 and in communication with the removal device 26 to receive the molten mould material entrained within the liquid 18 which is removed from the reservoir 22. The separation assembly 40 includes a container 48 defining an enclosed chamber 62, an evacuation device 50 operable to maintain a pressure less than atmospheric pressure in the chamber 62, and at least one second heating element 52 associated with the container 48 and operable to heat the molten mould material entrained with the liquid 18 in the chamber 62 causing the liquid 18 to evaporate, thereby separating the remaining liquid 18 from the molten mould material. It is to be understood that, in practice, the molten mould material constitutes by far the larger portion of the mixture supplied to the separation assembly 40. This also causes air entrained within the molten mould material to be separated from the molten mould material through application of heat, reducing viscosity of the wax and/or the low gas pressure environment. In an embodiment, the chamber 62 may be maintained at a pressure of about 0.25 bar to effectively reduce an evaporation temperature of the liquid 18. The container 48 also defines an inlet 54 arranged to receive the molten mould material entrained within the liquid 18, and an outlet 56 arranged to convey the molten mould material, separated from the remaining liquid 18 and air, out of the chamber 62. Valves (not shown) are arranged across the inlet 54 and outlet 56 to control fluid flowing in to and out of the chamber 62.

[0045] In the embodiment shown, the separation assembly 40 also includes an element, in the form of a plate 58, angled towards a base of the chamber 62. The plate 58 defines a surface arranged to receive the molten mould material entrained within the liquid 18 entering the chamber through the inlet 54 and cause this to flow across the surface, forming a film. The at least one second heating element 52 is arranged to heat the surface thereby causing the liquid 18 to evaporate from the film supported on the surface of the plate 58. In the embodiment shown, the mould material is wax and heating the surface also causes the wax to become less viscous, which enhances dispersing the liquid 18 and air from the wax. It will be appreciated that the evacuation device 50 may be excluded from the separation assembly so that the molten mould material entrained within the liquid 18 is heated at atmospheric pressure. Similarly, it will be appreciated that the plate 58 may be embodied in other suitable forms to direct flow of the molten mould material entrained within the liquid 18 and enhance evaporation of the liquid 18.

[0046] The container 48 also defines a port 60 in communication with the chamber 62 and arranged to evacuate evaporated liquid 18 and air from the chamber 62. In the embodiment shown, the port 60 is in communication with the evacuation device 50 to enhance removal of the evaporated liquid 18 from the chamber 62 and assist refreshing air in the chamber 62. The port 60 may also be in communication with at least one of a dehumidifier 61 and refrigeration unit 63 to enhance removal of the evaporated liquid 18 from the chamber 62. The dehumidifier 61 and refrigeration unit 63 facilitate drying of air from the chamber 62. A further valve (not shown) is arranged across the port 60 to control fluid flow out of the port 60.

[0047] A pump 42 is arranged downstream of the separation assembly 40 to receive the molten mould material and convey the molten mould material out of the system 10. The pump 42 is a progressive cavity pump which is suitable for pumping the molten mould material at sufficient pressure. An optional further reservoir 65, with associated pump, may be arranged upstream of the separation assembly 40 to store a volume of molten mould material entrained within the liquid 18. This volume supplies the separation assembly 40 at a substantially constant rate thereby allowing continuous operation of the separation assembly 40 and reduces the need for the removal device 26 and the separation assembly40 to be run in tandem.

[0048] A filter 44 is arranged downstream of the pump 42 to remove particles dimensioned above a threshold from the molten mould material. In the embodiment shown, the filter 44 is in the form of a perforated cylindrical steel sheet having conical perforations dimensioned to be approximately 50 microns, the sheet housing a rotatable scraper blade to scrape against the sheet to assist the molten mould material passing through the perforations. Alternatively, the filter 44 may comprise one or more bag filters (not shown).

[0049] The system 10 components downstream of the removal device 26, including at least the floor of the container 48 and conduits upstream and downstream of the container 48, such as between the removal device 26 and the chamber 62, between the chamber 62 and the pump 42, and between the pump 42 and the filter 44, are associated with a temperature control system to control temperature of the molten mould material and maintain the molten state of the mould material. In the embodiment shown, the temperature control system includes a plurality of fluid-jackets 64 arranged about the respective conduits and arranged about at least the base of the container 48 (not shown). The fluid jackets 64 contain a common fluid, such as oil or water, heated by one or more heating elements (not shown) to achieve a target fluid temperature. The control system also includes a pump (not shown) to circulate fluid between the fluid jackets and the one or more heating elements.

[0050] The fluid jackets 64 of the temperature control system may also be used to allow for any mould material that may have solidified in the system 10 to be pre-melted before operating the system, especially if the system is being heated from below the melting point of the mould material.

[0051] Use of the system 10 illustrated in Figure 1 involves the tank 16 chamber being charged with sufficient liquid 18 to immerse the object 14 and the mould 12 adhered thereto, and the object 14 and mould 12 being placed in the tank 16, by one or more of manual and automated means. The liquid 18 is heated by the first heating elements 20 to at least a melting temperature of the mould 12 causing the mould 12 to melt and disintegrate into droplets of molten mould material. As the liquid 18 is selected to be more dense than the mould material , the droplets float upwards to substantially form the stratum 17 of molten mould material entrained within the liquid 18, the stratum 17 extending across the surface of the liquid 18. The first heating elements 20 are also operated to heat the liquid 18 to a temperature less than a threshold temperature which could cause degradation or damage to the object 14, and also a temperature less than a threshold temperature which could cause degradation of the mould material. For example, where the object 14 is formed from a cementitious material, the liquid 18 is heated to less than 70°C as temperatures above this threshold may cause ettringite formations to form in the cementitious material which can significantly degrade structural integrity of the object 14.

[0052] The object 14 is immersed in the liquid 18 until all of the mould 12 is melted and the molten mould material, entrained within the liquid 18, is reclaimed from the object 14. This process may be enhanced by directing one or more of the agitators 38 at specific portions of the object 14 and mould 12. For example, this may involve jetting high pressure and/or velocity liquid 18 at a particularly complex geometry portion of the object 14 which the mould 12 is firmly adhered to. Similarly, the agitators 38 may be operated to direct the liquid 18 at thick portions of the mould 12 so that the entire mould melts at a consistent rate.

[0053] Due to operation of the agitators 38 and/or a circulation mechanism (not shown), the stratum 17 of molten mould material entrained with the liquid 18 flows towards and over the weir 24 to be received in the reservoir 22. The liquid 18 and the molten mould material settles in the reservoir 22 and substantially separates, causing the molten mould material to again form a stratum 19 across the surface of, but entrained within, the liquid 18 contained in the reservoir 22. Settling also allows any particulate mixed with the liquid 18, for example, fine fragments of the object 14, to sink to the floor of the reservoir 22 for collection and removal from the liquid 18. The removal device 26 is operated in contact with the stratum 19 and the liquid 18 to remove at least some of the molten mould material from the reservoir 22. At least a small quantity of the liquid 18 and air remains entrained within the removed molten mould material, for example, less than about 10%, and is conveyed to the separation assembly 40.

[0054] In this regard, it is to be noted that a temperature of the liquid 18 within the reservoir 22 is able to be maintained at a higher temperature than that in the tank 16 due to not having to keep the mould material below 70°. This may necessitate the use of additional heat exchangers to cool the liquid 18 before re-injection into the tank 16 to maintain the temperature of the liquid 18 within the tank 16 below 70°.

[0055] The liquid 18 and air entrained within the molten mould material is conveyed into the chamber 62 of the container 48, which is maintained at lower than atmospheric pressure, and flows across the heated plate 58 causing the remaining liquid 18 to evaporate from the molten mould material. As the pressure within the container 48 is lower than atmospheric pressure, the liquid 18 evaporates at a temperature less than the boiling/evaporation temperature of the liquid 18, thereby limiting exposure of the molten mould material to heat which could degrade properties of the mould material. The molten mould material collect at a base of the container and coalesce to form a volume of molten mould material. The molten mould material is conveyed out of the outlet 56 by the pump 42 and then passed through the filter 44, causing particles to be removed from the molten mould material. The molten mould material is finally conveyed out of the system 10, for example, to a holding tank to allow re-use of the mould material. Alternatively, the material may be conveyed to another apparatus (not shown) to allow another mould 12 to be fabricated from the reclaimed and recycled mould material.

[0056] Operation of the system 10 is described above generally involves reclaiming the mould 12 to reveal the object 14 which has been formed by the mould 12. It will be appreciated that the system 10 may be operated in the same way to remove fragments of the object 14 from the mould 12. For example, the mould 12 may initially be removed from the object 14 by another process, such as a manually being broken off the object 14, and shards or chunks of the object 12 remain adhered to the mould 12. The system 10 may be operated to reclaim the mould material from these shards or chunks and recycle the mould material for re-use. Furthermore, the system 10 may similarly be operated to remove fine particles of object material, for example, cementitious dust, from the mould 12.

[0057] Figure 2 is a diagram of an alternative separation assembly 70 whereby common reference numerals indicate common features. The assembly 70 is also arranged downstream of the tank 16 and removal device 26 and in communication with the removal device to receive the molten mould material entrained with the liquid 18 which is removed from the reservoir 22. The assembly 70 includes the container 48 defining the enclosed chamber 62, the evacuation device 50 operable to maintain a pressure less than atmospheric pressure in the chamber 62, and the at least one second heating element 52 associated with the container 48 and operable to heat the molten mould material entrained within the liquid 18 in the chamber 62 causing the liquid 18 to evaporate, thereby separating the remaining liquid 18 from the molten mould material. Operation of the heating elements 52 also causes air entrained within the molten mould material to be released from the molten mould material. The container also defines the port 60 in communication with the evacuation device 50 and arranged to evacuate the evaporated liquid 18 and air from the chamber 62. The heating elements 52 are arranged proximal to a base of the container 48 to heat the molten mould material and evaporate the liquid 18. Typically, the heating elements 52 are configured as part of a water/oil jacket-type temperature control system arranged about at least a floor of the container 48.

[0058] Valves 72, 74, 76 are arranged across the inlet 54, outlet 56 and port 60 to allow the enclosed chamber to be sealed. The assembly 70 also includes a condenser 78 arranged downstream of the port 60 to condense and collect the evaporated liquid 18 evacuated from the chamber 62.

[0059] Use of the assembly 70 involves the inlet valve 72 opening to allow molten mould material entrained within the liquid 18, and entrained air, to flow into the chamber 62, which is maintained at a lower than atmospheric pressure by the evacuation device 50, and coalesce at the base of the chamber 62. The inlet valve 72 is then shut and the heating elements 52 operated to heat the molten mould material to evaporate the remaining liquid 18 from the molten mould material. The evaporated liquid 18 and air contained in the sealed chamber 62 is evacuated from the chamber 62 through the port 60 and the liquid 18 is condensed in the condenser 78. Only molten mould material remains in the chamber 62 after this evacuation stage. The outlet valve 74 is then opened and the molten mould material flows out of the chamber 62 to the pump 42 and filter 44.

[0060] The system 10 advantageously provides an efficient process for reclaiming a settable mould 12 from an object 14 and recycling the mould material. This is achieved by exposing the mould 12 and object 14 to the heated liquid 18 to melt the mould 12 and then separating the reclaimed mould 12, in the form of molten mould material, entrained within the liquid 18, to retrieve substantially pure mould material for re-use. This is particularly useful where the object 14 has complex geometry meaning that removal of the mould 12 from the object 14 by manual and/or mechanical techniques is awkward or impossible.

[0061] Operation of the system 10 can be configured to maintain desirable properties of the object 14 and the reclaimed mould 12, thereby enhancing the effectiveness of the recycling process as the reclaimed mould 12 retains substantially uncontaminated and unaffected material properties. For example, the liquid 18 is heated to an appropriate temperature to avoid degradation, such as by oxidation, of the reclaimed mould 12 and also avoid damage to the object 14. Similarly, the separation assembly 40 is pressurised and heated to avoid degradation of the reclaimed mould 12. This benefit is further enhanced by controlling the pressure of the separation assembly 40 chamber 62, as this effectively reduces the boiling/evaporation temperature of the liquid 18, limiting exposure of the mould material to substantial temperatures.

[0062] The separation assembly 40, 70 of the system 10 can advantageously be configured to provide substantially continuous or batch processing of reclaimed mould material, whereby one embodiment 40 can be operated to substantially continuously separate mould material entrained with the liquid 18, and another embodiment is configured to separate mould material entrained with the liquid 18 in staged batches.

[0063] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.