A mobile installation for processing waste plastic materials.

TECHNICAL FIELD

The invention relates to the field of recycling of waste plastic materials and in particular the invention pertains to a mobile application for processing waste plastic materials into a processed plastic end item. More in particular the invention describes a mobile installation for processing waste plastic materials into a processed plastic end item.

BACKGROUND OF THE INVENTION

Economic development and subsequent economic consumption across the world has resulted in an increase of plastic waste, which is piling up around the globe. Resources on earth are limited in quantity and availability, and continued economic growth in particular of less-developed countries put a heavy burden on the future availability of resources, but also on the still increase pile of waste. The burning of waste is nowadays not the desired solution as this is adding to the CO ₂ problem. Reducing of waste, combined with reuse of resources are important for a sustained development of our environment.

As plastic materials does not biodegrade in the environment, recycling efforts has resulted in many recycling techniques of processing waste plastic materials into a processed plastic end item. There are several plastic recycling systems for processing of kind of types of waste plastic materials. A typical recycling system implements separate collection of waste flows, in which the plastic waste flow are collected and transported to a recycling plant. Such recycling solutions are focussed on so-called high quality monostreams of plastic waste, thus only recycling one type of plastic material. This requires next to a careful selection, also an additional cleaning and drying step in order to present a high quality monostream of one type of plastic waste to the recycling plant.

These recycling techniques are complex and expensive due to all process steps (selection, cleaning, drying) prior to the recycling step, as well as due to the transportation of the waste to the recycling plant.

Thus, it is an object of the invention to provide for an improved recycling or processing installation of waste plastic materials, which is compact, energy-efficient and easy to install and to control, even at remote locations. SUMMARY OF THE INVENTION

According to a first aspect of the mobile installation for processing waste plastic materials into a processed plastic end item, the mobile installation defines a process path line for waste plastic materials, having a main process inlet for waste plastic materials and a main process outlet for processed plastic end items, the mobile installation at least comprising:

* a first housing compartment comprising along the process path line: a shredding unit for shredding an inlet stream of waste plastic materials into a stream of plastic flakes having a first size; a metal separation unit for separating metal parts from the stream of plastic flakes having the first size; and a crushing unit for crushing the stream of plastic flakes having the first size into a stream of plastic flakes having a second size, the second size being smaller than the first size,

* a second housing compartment comprising along the process path line: a melting unit for melting the stream of plastic flakes; and a processing unit for processing the molten stream of plastic flakes in processed plastic end items.

This example allows to a simple yet compact and easy to install mobile installation allowing the processing of waste plastic materials locally, not requiring complex and expensive collection techniques using transportation vans and an expensive and complex recycling plant.

The example according to the invention allows for the processing of waste plastic material in a decentralized manner, for example directly near an economic activity which generates a significant pile of waste plastic materials, even in a continuous manner. Such economic activity can be of a more permanent nature, such as a landfill or of a temporary nature, such a music festival or sporting event. The processed plastic end items thus obtained can be semi-finished products intended for a further processing step, or can be end-products, so-called fit-for-purpose plastic products. The processed plastic end items can have polymer-sand composition or can be a plastic with a composite or any other mineral, such as crushed waste glass particles, fly-ash, etc.

According to a further improved example, the melting unit can be configured as an extruder unit, whereas the processing unit is one selected but not limited from the group of a molding unit, a palletizing unit, a compacting unit. This allows a more versatile implementation of the mobile recycling installation, as to the processing of the waste plastic materials in any desired plastic end item, and also dependent on the composition of the waste plastic material stream to be processed.

Additionally, a conditioning unit is implemented structured to control at least one environmental condition within the first and/or second housing compartment, such as a temperature, or a humidity. Herewith the recycling process within the mobile installation can be accurately controlled, thus guaranteeing an energy-efficient recycling of the waste plastic materials resulting in plastic end items of a standardized quality.

In some examples, the conditioning means comprise a heating unit and/or a cooling unit.

In an advantageous more versatile example of the mobile installation, the process path line further comprises a supplement unit structured to supply a supplement additive to the crushed stream of plastic flakes of the second size. Herewith it is possible to produce specific processed plastic end items with a new functionality, such as roof tiles, plastic bricks, etc.

Preferably, the supplement unit is positioned along the process path line between the crushing unit and the melting unit, wherein in particular the supplement unit is positioned in the second housing compartment.

In an further example, the process path line further comprises a washing unit, and/or a filter unit.

By providing the mobile installation with a levelling unit structured to level the first and/or second housing compartment with respect to a ground level, the mobile installation can effectively installed at rural and remote locations.

Preferably, the first and/or second housing compartments have an air tight construction and/or dust tight construction and/or fire resistant construction, which not only guarantees safe recycling conditions, but also further reduces any pollution load of the mobile installation on the environment.

Preferably, to maintain overall governance and quality assurance of the recycling process of the waste plastic materials, the mobile installation further comprises a mobile installation control unit for controlling the several units forming the process path line.

In addition, the mobile installation may comprise a data-communication unit connected to the mobile installation control unit and arranged for operatively interconnecting the mobile installation control unit via a data-communication network with a mobile installation system control unit located remote from the site of the mobile installation, wherein the mobile installation control unit is structured for obtaining and storing parameter data pertaining to parameters related to the processing of waste plastic materials in the process path line, as well as transmitting, via the data-communication network, the parameter data to the mobile installation system control unit and wherein the mobile installation system control unit is structured to receive, via the data-communication network, the parameter data transmitted from the mobile installation system control unit, compare the parameter data with pre-determined reference parameter data, and controlling, based on the comparison, the processing of waste plastic materials in the process path line.

This creates a sophisticated yet de-central system, wherein the mobile installation can be operated from a distance, which is beneficial in situations where the mobile installation is operating at a remote location, even for a long period of time. By measuring in real time various process parameters of the recycling process taking place in a mobile installation and transmitting these data to an off-site system control unit for monitoring and comparing these data with desired, pre-determined process parameters, the mobile installation can be effectively remotely operated, not requiring operators near or at the location of the mobile installation. With the remote monitoring of the recycling process, quality control is ascertained and adapting or interrupting the recycling process in the event of malfunction is safeguarded.

In a further more sustainable and independent example, the mobile installation is provided with a solar panel assembly mounted on the first and/or second housing compartment and arranged for providing supply power to the mobile installation. The solar panel assembly may be comprised of multiple interconnected solar panels for an improved energy creation.

More effectively, the housing is structured as a transporting container. This can be preferably a standardized transporting container used worldwide for certain transport and logistic applications, such as so-called TEU (Twenty Foot Equivalent Unit). Mobiliteit, container op trailer/trekker combi/schip (korte keten dicht bij de bron), 2x TEU (40 foot)

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be discussed with reference to the drawings, which show in:

Figure 1 a schematic view of an example of a mobile installation according to the invention; Figures 2-3a-3b detailed views of the mobile installation of Figure 1.

DETAILED DESCRIPTION OF THE INVENTION

For a proper understanding of the invention, in the detailed description below corresponding elements or parts of the invention will be denoted with identical reference numerals in the drawings.

Figure 1 shows an overview of an example of the mobile installation according to the disclosure, which installation is suitable processing a mix of waste plastic materials into a processed plastic end item on-site. With on-site it is meant, a temporary location, even an ad-hoc location or a remote location not being an industrial installation or recycling plant.

In the prior art, a typical recycling system suitable of processing waste plastic materials implements separate collection of waste flows, in which the plastic waste flow are collected and transported to a recycling plant. Such recycling solutions are focussed on so- called high quality monostreams of plastic waste, thus only recycling one type of plastic material. This requires next to a careful selection, also an additional cleaning and drying step in order to present a high quality monostream of one type of plastic waste to the recycling plant.

The mobile installation according to the disclosure provides an improved recycling or processing installation of waste plastic materials, which is compact, energy- efficient and easy to install, even at remote locations. As shown in Figure 1 , the mobile installation is denoted with reference numeral 10 and the installation defines a process path line for waste plastic materials. The process path line lies between a main process inlet 100a for waste plastic materials and a main process outlet 100b for processed plastic end items.

In particular the mobile installation 10 is composed of at least a first housing compartment 100-1 and a second housing compartment 100-2, which are placed along the process path line between the main process inlet 100a and the main process outlet 100b. The whole installation 10 is preferably placed on stable ground 1.

Both first housing compartment 100-1 and second housing compartment 100-2 are placed on site, for example a remote site in any configuration necessary for a proper collection and processing of waste plastic materials. In the example of Figure 1 , both first housing compartment 100-1 and second housing compartment 100-2 are placed at opposite locations from each other, with the intermediate area between both housing compartments being covered or shielded by a covering 200.

In another configuration, both housing compartments 100-1 and 100-2 can be placed in alignment of each other, preferably in an abutting alignment, with the intermediate process outlet 100b’ of the first housing compartment 100-1 being interconnected with the intermediate process inlet 100a’ of the second housing compartment 100-2. Herewith, the process path line between the main process inlet 100a and the main process outlet 100b of the mobile installation 10 extends uninterrupted between both housing compartments 100-1 and 100-2.

Figure 2 depicts both housing compartments 100-1 and 100-2, each having a process path inlet, that is the main process inlet 100a and the intermediate process outlet 100b’ of the first housing compartment 100-1 and the intermediate process inlet 100a’ and the main process inlet 100b of the second housing compartment 100-2. Alternatively, each housing compartment 100-1, 100-2 can be provided with side doors 100’ to provide proper access to the several units of the mobile installation 10, which units process the waste plastic materials.

In Figure 3a an example is shown of a housing compartment of the mobile installation 10. In this example, the first housing compartment 100-1 is disclosed which is placed at the beginning of the process path line, and which housing compartment comprises several units for processing waste plastic materials.

In particular, the first housing compartment 100-1 comprises along the process path line 101 a shredding unit 106. The shredding unit 106 is positioned next to the main process inlet 100a and receives an inlet stream of (being a monostream or a mix of) waste plastic materials entering the mobile installation 10 / the first housing compartment 100-1 via the main process inlet 100a. The shredding unit 106 shreds the inlet stream of waste plastic materials into a stream of plastic flakes or granules. The shredded parts of plastic flakes or granules have a first size.

The stream of plastic flakes or granules having the first size exits the shredding unit 106 and is fed to a metal separation unit 107 which is positioned within the first housing compartment 100-1 next to the shredding unit 106. The metal separation unit 107 separates any metal parts from stream of shredded plastic flakes. These metal parts are separated from the main process path line as a separated, recycled metal stream.

Reference numeral 108 denotes a crushing unit, which crushes the metal- free stream of shredded plastic flakes or granules having the first size into a stream of crushed plastic flakes or granules having a second size. The second size of the crushed plastic flakes or granules is smaller than the first size of the shredded plastic flakes or granules exiting the shredding unit 106.

The stream of crushed plastic flakes of the second size exiting the crushing unit 108 leaves the first housing compartment 100-1 via the intermediate process outlet 100b’ and is fed to a supplement unit 110, also being part of the process path line. The supplement unit 110 is structured to supply a supplement additive to the crushed stream of plastic flakes of the second size. The supplement additive can be rubber, sand, quartz, crushed glass, fly-ash or a composite or other type of mineral. Herewith it is possible to produce specific processed plastic end items with a new functionality, such as roof tiles, plastic bricks, etc.

Preferably, the supplement unit 110 is positioned along the process path line between the crushing unit 108 and the second housing compartment 100-2 as shown in Figure 1. In another example the supplement unit 110 is positioned in the second housing compartment 100-2. The latter example provides an mobile installation 10 composed of two housing compartments 100-1 and 100-2, which facilitates the transporting of the housing compartments to a remote location significantly and also enables a quick and easy setup of the mobile installation 10 on-site.

As shown in Figure 3b, the second housing compartment 100-2 of the mobile installation 10 comprises along the process path a melting unit 109 for melting the stream of crushed plastic flakes of the second size together with the supplement additive (sand or composite material), that is added via the supplement unit 110 to the stream of crushed plastic flakes or granules.

As shown in Figure 3b, the supplement unit 110 is positioned in the second housing compartment 100-2, but at least - seen along the process path line - after the crushing unit 108 (see Figure 3a) but before the melting unit 109. In an alternative, which is depicted in Figure 1 , the supplement unit 110 is positioned outside the second housing compartment 100-2 and placed between the area between both housing compartments 100-1 and 100-2 as shielded by the cover 200, but again - seen along the process path line - after the crushing unit 108 placed in the first housing compartment 100-1 but before the melting unit 109 placed in the second housing compartment 100-2.

The molten stream of plastic flakes or granules together with the supplement additive are fed to a processing unit 113, which processes the molten stream in suitable processed plastic end items. These processed plastic end items exit the mobile installation 10, in particular the second housing compartment 100-2 via the main process outlet 100b for further handling, such as packing, storing and further transportation. The processed plastic end items thus obtained can be semi-finished products intended for a further processing step, or can be end-products, so-called fit-for-purpose plastic products. The processed plastic end items can have polymer-sand composition or can be a plastic with a composite or a rubber or any other mineral, such as crushed waste glass particles, fly-ash, etc.

This configuration of a mobile installation allows to a simple yet compact and easy to install mobile installation allowing the processing of waste plastic materials locally, not requiring complex and expensive collection techniques using transportation vans and an expensive and complex recycling plant.

The example according to the invention allows for the processing of waste plastic material in a decentralized manner, for example directly near an economic activity which generates a significant pile of waste plastic materials, even in a continuous manner.

The processing unit 113 can be at least one selected but not limited from the group of a molding unit, a palletizing unit, a compacting unit. This allows a more versatile implementation of the mobile recycling installation 10, as to the processing of the waste plastic materials in any desired processed plastic end item, and also dependent on the composition of the waste plastic material stream to be processed.

Reference numeral 112 denotes a conditioning unit, which unit is structured to control at least one environmental condition within either first and/or second housing compartment 100-1 and 100-2. The environmental condition can be a temperature either inside the housing compartment in question or of the (molten) stream of plastic granules. The environmental condition can also be a humidity exiting within the housing compartment 100-1 and/or 100-2. Herewith the recycling process within the mobile installation can be accurately controlled, thus guaranteeing an energy-efficient recycling of the waste plastic materials resulting in plastic end items of a standardized quality.

Accordingly, the conditioning unit 112 implements one or more environmental sensors 112a, such as a temperature sensor and/or a humidity sensor, and its sensor readings are used to monitor and control the recycling process within the mobile installation 10. For example, the conditioning unit 112 may comprise a heating unit and/or a cooling unit which are activated and controlled based on the sensor readings of the temperature and/or humidity sensors 112a.

In an further example, the mobile installation 10 may further comprises along its process path line a washing unit, and/or a filter unit. Preferably the washing unit and/or the filter unit are placed high (upstream) in the process path line, in particular in the first housing compartment 100-1, and more in particular directly before (upstream) or directly after (downstream) the shredding unit 106. By providing the mobile installation 10 and in particular both the first and second housing compartments 100-1 and 100-2 with a levelling unit 111 a- 111b structured to level the first and/or second housing compartment 100-1 and 100-2 with respect to a ground level 1, the mobile installation 10 can effectively installed at rural and remote locations.

Preferably, the first and/or second housing compartments 100-1 and 100-2 have an air tight construction and/or dust tight construction and/or fire resistant construction, which not only guarantees safe recycling conditions, but also further reduces any pollution load of the mobile installation on the environment.

Preferably, to maintain overall governance and quality assurance of the recycling process of the waste plastic materials, the mobile installation 10 further comprises a mobile installation control unit 102. The mobile installation control unit 102 controls the several units 106-107-108-109-110-112-113 which form the process path line 101 via suitable control signal lines 102b.

In an example, one mobile installation control unit 102 is implemented, which controls all units in either the first and second housing compartments 100-1 and 100-2, or each housing compartment 100-1 and 100-2 has their own mobile installation control unit 102 for only controlling the respective units mounted within the respective housing compartment 100-1 or 100-2.

Preferably, the mobile installation 10 may comprise a data-communication unit 105 (for the whole installation 10 or for each separate housing compartment), which is connected to the mobile installation control unit 102. The data-communication unit 105 is structured for operatively interconnecting the mobile installation control unit 102 via a data- communication network 105a with a mobile installation system control unit (not shown) located remote from the site of the mobile installation 10. Accordingly, the mobile installation control unit 102 is structured for obtaining and storing parameter data pertaining to parameters related to the processing of waste plastic materials in the process path line 101, as well as transmitting, via the data-communication network 105a, the parameter data to the mobile installation system control unit 102.

For storing the parameter data pertaining to parameters related to the processing of waste plastic materials the mobile installation control unit 102 implements a control unit storage device 102a, such as a hard drive, or a USB drive.

Furthermore, the mobile installation system control unit 102 can be structured to receive, via the data-communication network 105a, the parameter data transmitted from the mobile installation system control unit, and compare the parameter data with pre-determined reference parameter data, and controlling, based on the comparison, the processing of waste plastic materials in the process path line 101.

This creates a sophisticated yet de-central system, wherein the mobile installation 10 can be operated autonomous from a distance, which is beneficial in situations where the mobile installation 10 is operating at a remote location, even for a long period of time. By measuring in real time various process parameters of the recycling process taking place in the mobile installation 10 (housing compartments 100-1 and 100-2) and transmitting these data to an off-site system control unit for monitoring and comparing these data with desired, pre-determined process parameters, the mobile installation 10 can be effectively remotely operated, not requiring operators near or at the location of the mobile installation. With the remote monitoring of the recycling process, quality control is ascertained and adapting or interrupting the recycling process in the event of malfunction is safeguarded.

In a further more sustainable and independent example, the mobile installation 10, in particular one or both housing compartments 100-1 and 100-2, is provided with a solar panel assembly 103 mounted on the first and/or second housing compartment. The solar panel assembly 103 is provided with a solar panel 103a suitable to providing via a solar panel power supply line 103b supply power to several units within the mobile installation / housing compartments 100-1 and 100-2. In Figure 3a and 3b the power supply line 103b interconnects the solar panel assembly 103 directly with the control unit 102, which in turn provides supply power to the several other units in the respective housing compartment 100-1 and 100-2. The solar panel assembly 103 may be comprised of multiple interconnected solar panels 103a for an improved energy creation.

As an alternative, each housing compartment 100-1 and 100-2 can be provided with an external power supply 104, such as an AC means supply (110V/220V), supplying power to the control unit 102, which in turn provides supply power to the several other units in the respective housing compartment 100-1 and 100-2.

More effectively, each housing compartment 100-1 and 100-2 is structured as a transporting container. This can be preferably a standardized transporting container used worldwide for certain transport and logistic applications, such as so-called TEU (Twenty Foot Equivalent Unit).

Accordingly, accommodating the mobile installation for processing waste plastic materials into a processed plastic end item according to this disclosure in one or two housing compartments 100-1 and 100-2 allows for a compact and energy-efficient application for recycling waste plastic materials, which is easy to install and to control, even at remote locations.

In particular, such mobile waste plastic material process installation 10 can be readily transported from and to any (remote) location. Additionally, the mobile nature of the waste plastic material process installation 10 according to the disclosure can be improved, by installing the waste plastic material process installation 10 on a ship 1000 whilst sailing across the sea 1 , as depicted in Figure 4a, or on a train or on a truck-trailer combination 2000 as shown in Figure 4b.

LISTING OF REFERENCE NUMERALS

1 ground level

1 water body (such as the sea)

10 mobile installation

100-1/100-2 first/second housing compartment / transportation container

100 access doors or openings

100a main process inlet of mobile installation

100a’ intermediate process inlet of mobile installation

100b main process outlet of mobile installation

100b’ intermediate process outlet of mobile installation

101 process line path

102 control unit

102a control unit storage device

102b control signal lines

103 solar panel assembly 103a solar panel 103b solar panel power supply line

104 external power supply

105 data-communication unit 105a data-communication network

106 shredding unit

107 metal separating unit

108 crushing unit

109 melting unit

110 supplement unit

111a-111b levelling unit 112 conditioning unit 112a environmental sensor 113 processing unit 200 (temporary) roofing 1000 ship 2000 truck-trailer combination