TECHNICAL FIELD

Example embodiments generally relate to the generation of useful fibers with specific properties, and more particularly relate to the provision of a mobile platform for processing of natural fiber material.

BACKGROUND

There are a number of tropical plants that produce fruit or other useful foodstuffs. These types of plants are popular for harvesting, and thus cultivation of such plants is common. However, with the exception of the fruit itself, the majority of the material associated with harvesting the fruit of these plants is generally considered to be waste material. Accordingly, the fibrous stalks of such plants are often disposed of in landfills or in other manners that are either not beneficial for the environment or, in some cases, may actually harm the environment. Although some of the discarded plant matter may be used as natural fertilizer, there may be still more uses for the fibrous stalks of some such plants.

Banana stalks are one example of a tropical plant that has a fibrous stalk that is often wasted. In this regard, the banana stalk dies after the fruit is produced and harvested, and it is common for the stalks, which are typically cut off to harvest the bananas, to be thrown away. These fibrous stalks of the banana tree and some other tropical plants can have as much as 93% to 96% of their weight comprised of water and natural latex content that may include a variety of resinous and gummy substances. Accordingly, in order to produce workable or useable fibers, the fibrous material must be cleaned and processed. In particular, much of the fluid within the stalks must be removed, and the latex or other natural resinous substances must also be extracted or washed out.

There have been a number of different processing methods developed for processing fibers. These processing methods take different amounts of energy, and have different advantages and disadvantages dependent upon the desired properties of the processed fiber that is expected to be achieved. The processing methods can also require the transportation of the fibrous materials to a processing facility, which may cost money and take time, especially when the distances are extreme. Thus, it should be appreciated that it may be desirable to develop a processing technique that is optimized for generation of useful fibers with consideration given to reducing transportation costs. BRIEF SUMMARY OF SOME EXAMPLES

Accordingly, some example embodiments may enable the provision of a natural mobile processing unit (NMPU) that can be transported from location to location. The NMPU can be set up at any desirable location to process natural fiber materials to generate useful fibers. Moreover, the NMPU may be capable of acting as a self reliant processing facility that can generate its own power, if needed, or use locally available sources of power, as appropriate.

In an example embodiment, a mobile processing unit may be provided. The mobile processing unit may include a mobile platform assembly, and a fiber separation assembly supported on the mobile platform assembly. The fiber separation assembly may be configured to receive tropical plant stalks and at least partially separate fibers thereof. The mobile processing unit may further include a press/drying assembly supported on the mobile platform assembly and a power assembly. The press/drying assembly may be configured to remove moisture from the fibers. The power assembly may be configured to provide power to the fiber separation assembly and the press/drying assembly.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 illustrates a block diagram of an NMPU according to an example embodiment;

FIG. 2 illustrates a diagram of one portion of a mobile platform for supporting an NMPU according to an example embodiment;

FIG. 3 illustrates a diagram of another portion of a mobile platform for supporting an NMPU according to an example embodiment;

FIG. 4 illustrates a diagram of still another portion of a mobile platform for supporting an NMPU according to an example embodiment; and

FIG. 5 illustrates an assembled mobile platform to support the NMPU in accordance with an example embodiment.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout.

It should be appreciated that although an example embodiment is described below in the context of banana stalks, alternative embodiments may also be practiced in connection with other tropical plants such as palm, pineapple and/or the like. Thus, the specific example described herein should be regarded as non-limiting with regard to the specific materials used. As such, banana stalks or other tropical plant materials that are naturally hydrophobic, but may be processed as described herein to generate improved or optimal absorption properties should be regarded as candidates for use in connection with the processes and materials described herein.

Some example embodiments relate to an NMPU that can be transported from location to location to be set up to process natural fiber materials to generate useful fibers. As indicated above, the NMPU may be capable of generating its own power, if needed, or may use locally available sources of power. Accordingly, the NMPU may be equipped to process plant materials in the field, at the dock, or at any other convenient location at which the plant materials can be processed within a supply chain. This provides the flexibility to utilize available power sources, regardless of location, to select the best location for processing within a supply chain to reduce transportation costs by reducing the weight of material transported over long distances. As such, for example, instead of transporting heavy stalks to a processing facility only to reduce their weight and volume during processing (perhaps by more than half), the processing facility can easily and cheaply be moved closer to the source of the stalks so that lighter weight and lower volume material only makes the potentially long journey to market, or to another facility at which such materials may be processed into a final product.

The NMPU may therefore represent a mobile processing platform configured to process the stalks of a banana tree (or other fibrous tropical plant) into a plurality of fibers that are optimal for use in the absorption of hydrocarbons or other fluids. In this regard, example embodiments provide a process for reduction of the banana tree stalk into separated fibers that can then be pressed to facilitate removal of naturally occurring resinous substances and/or latex. The pressing of the separated fibers may open the natural capillaries in the fibers to enhance absorptive characteristics, in some cases, relative to absorption of hydrocarbons or other targeted materials. Drying processes may then be employed to dry the fibers so they can be incorporated into materials or apparatuses that are suitable for absorption of hydrocarbons.

FIG. 1 illustrates a block diagram of an NMPU according to an example embodiment. In this regard, NMPU 100 may include a mobile platform assembly 110 and a plurality of functional assemblies such as, for example, a power assembly 120, a fiber separation assembly 130, and a press/drying assembly 140. The mobile platform assembly 110 may be a tractor trailer, or multiple tractor trailers, depending upon the scale of the operation. Of note, FIGS. 2-5 illustrate examples in which multiple flat bed trailers are combined to form the mobile platform assembly 110. However, it should be appreciated that train cars, covered trailers, wagons, barges, or any other mobile unit capable of supporting the power assembly 120, the fiber separation assembly 130, and the press/drying assembly 140, while maintaining mobility of the system may alternatively be employed.

In some embodiments, one mobile unit may be used for each respective functional assembly. However, multiple assemblies could be provided on a single mobile unit, or some functional assemblies could be split over multiple mobile units dependent upon the scale of the functional assemblies and the sizes of the mobile units. Moreover, in some embodiments, all of the functional units may be provided on a single mobile unit. Regardless of the number of mobile units employed, the mobile platform assembly 110 of some embodiments may include leveling equipment so that, once a suitable location for setup of the NMPU 100 is selected, all of the equipment may be leveled to ensure proper operation thereof. To the extent that all the equipment is supported on the mobile platform assembly 110, the leveling equipment may be used to level all of the equipment by leveling the mobile platform assembly 110. However, each piece of equipment could have its own leveling equipment in some cases.

In an example embodiment, the power assembly 120 may include one or more power generation units and/or control units that allow the desired power source to be selected for powering the other functional units. As such, the operator may be enabled to shift between different available sources. One or more of the sources may be external to the NMPU 100, while others may be operable entirely onboard the NMPU 100 to make the NMPU 100 self sustainable. External sources may include electric power receptacles that are configured to receive mains power from local sources. Onboard sources of power may include diesel engines, solar panels, battery packs, electric generators, and/or the like. The onboard sources may operate to generate electricity for powering one or more of the other functional assemblies. Moreover, in an example embodiment, any one of the sources may be used to further power a hydraulic power plant that may be used to provide hydraulic power to one or more of the other functional assemblies.

The fiber separation assembly 130 may include components that process incoming stalks by initially cutting or reducing the stalks after the stalks are introduced into the NMPU 100. As indicated above, the fiber separation assembly 130 may include equipment that utilizes electric and/or hydraulic power for operation, and such power may be provided by the power assembly 120. In some cases, conveyors or other automated transport processes may be utilized within the NMPU 100 to transport processed materials between the functional assemblies as the stalks are processed by the NMPU 100. Thus, in some examples, manual intervention may not be required after the stalks are entered into the NMPU 100. The fiber separation assembly 130 may be configured to perform stalk reduction and fiber separation. Stalk reduction may include cutting, agitating and/or otherwise processing the stalks to reduce them from stalk form into fibers that are separated from each other.

After separation of the fibers in the fiber separation assembly 130, the separated fibers may be passed along to the press/drying assembly 140. Although not required, the press/drying assembly 140 may include equipment for washing the separated fibers prior to (and/or after) pressing of the fibers. When washing is employed, washing of fibers may be performed in order to facilitate removal of latex and/or fluids in the fibers. The washing may be accomplished using water alone, or may further include the addition of a solution including potassium hydroxide, hydrogen peroxide, sodium hydroxide or the like.

In some embodiments, the press/drying assembly 140 may include an anaerobic digester that may be configured to separate water to be treated and recycled for use in the washing portion of the NMPU 100 as well as to be further treated so that potable water may be discharged. The anaerobic digester may also allow for the separation of solids and organic matter that are fed and converted into a biofuel that may be used as a fuel source for one or more components of the power assembly 120.

A press may be included in the press/drying assembly 140. The press may be a hydraulically operated press, screw press, belt press, or any other suitable pressing device. In an example embodiment, pressing of the fibers may remove a high percentage of excess natural resinous substances (e.g., latex), water, juice and/or other liquids from the fibers, which may have a water and natural liquid content of about 43% to about 48% by weight. Thus, a reduction from greater than 90% moisture content by weight to about 1/2 that amount may be achieved via the press in some cases. The pressing operation may remove the naturally resinous substances (e.g., latex) in a manner that opens the natural capillaries in the fiber when the latex and other fluids are extracted. The open capillaries may be more receptive to hydrocarbon absorption and therefore may facilitate the ultimate production of materials that are highly absorbent of hydrocarbons.

In an example embodiment, the press/drying assembly 140 may further include drying equipment. The drying equipment may employ halogen lamps, infrared heat generation means, kinetic thermal generation via agitation, airflow or any of a plurality of other heating and/or drying technologies to dry the fibers. In some embodiments, a kinetic disintegration system (KDS) may be employed in connection with drying the fibers. After the fibers have been dried, the processed fibers may be inert and pathogen free, ready for bagging, bailing or otherwise packaging such fibers for transport.

FIG. 2 illustrates a diagram of one portion of a mobile platform for supporting a portion of the NMPU 100 according to an example embodiment. In this regard, FIG. 2 illustrates a first mobile unit 200 in the form of a flatbed trailer (e.g., a 20 ft trailer) that supports components of the fiber separation assembly 130 such as a vibrating infeed conveyor 210 and a cutter 220. As shown in FIG. 2, the first mobile unit 200 may be elevated off of its wheels when leveling equipment 230 (e.g., jacks or leveling blocks) are employed to stabilize and level the mobile unit 200.

In an example embodiment, the vibrating infeed conveyor 210 may include a vibrating hopper that enables dirt, sand, rocks and other debris to exit through the conveyor bottom before the cutter 220 cuts the banana stems to a desirable length with a variable speed controlled hydraulic cutter. The cut stems may then be provided, again by conveyor, to the press/drying assembly 140, which may (in this example) be located at least partially on a separate mobile unit.

FIG. 3 illustrates a diagram of another portion of a mobile platform for supporting the NMPU 100 according to an example embodiment. In this regard, FIG. 3 illustrates a second mobile unit 300 in the form of a flatbed trailer (e.g., a 20 ft trailer). The second mobile unit 300 also includes leveling equipment 310. In some embodiments, the second mobile unit 300 may support a roll press de-watering unit 320 configured to dewater the cut stems via a roll press. After the stems are dewatered, in this example embodiment they may be conveyed to a roto-mix pulping station 330. The pulping station 330 may employ one or more large mixers to agitate the stems while applying heat from high temperature halogen lamps to further reduce moisture content of the fibers. In an example embodiment, the material processed by the pulping station 330 may thereafter be conveyed to another mobile unit on which yet further equipment of the press/drying assembly 140 may be located, as shown in FIG. 4.

FIG. 4 illustrates a diagram of still another portion of a mobile platform for supporting the NMPU 100 according to an example embodiment. In this regard, FIG. 4 illustrates a third mobile unit 400 in the form of a flatbed trailer (e.g., a 40 ft trailer). The third mobile unit 400 also includes leveling equipment 410. In some embodiments, the third mobile unit 400 may support equipment of the power assembly 120 and some equipment of the press/drying assembly 140. The third mobile unit 400 may further include a programmable logic controller (PLC) 420 that may control which power sources are selected for use and/or the at what speed various components are to operate. The PLC 420 may control the speed of any or all of the components of the NMPU 100 to provide for consistent operation speeds so that materials are not backed up at any one component.

As shown in FIG. 4, fuel tanks 430 may be provided to store fuel for use by a diesel engine 440. One or more electric motor/generators 450 may also be provided to power hydraulic pumps 460 and/or other components of the NMPU 100. An infeed conveyor 470 and a twin screw halogen conveyor 480 may also be employed for transport of material that may further be processed by KDS unit 490. The twin screw halogen conveyor 480 may pass materials under halogen lamps for further drying and for conditioning of the materials prior to processing in the KDS unit 490. The KDS unit 490 may finish drying using non-thermal drying means. In this regard, the KDS unit 490 may be configured to perform agitation or grinding of material while simultaneously drying the material using airflow. Thus, no heat input is required while grinding and drying are simultaneously accomplished in a one-step process. Screening of the output of the KDS unit 490 may be further employed to ensure that the resulting material is of the proper size before bagging, bailing and/or the like are performed.

In embodiments in which multiple mobile units are employed, the mobile units may be aligned in an end-to-end fashion so that one mobile unit links to equipment in an adjacent mobile unit to generate a continuous platform with linked assemblies. FIG. 5 illustrates an assembled mobile platform to support the NMPU 100 in accordance with an example embodiment. In this regard, as shown in FIG. 5, the first mobile unit 200, the second mobile unit 300 and the third mobile unit 400 are all aligned with each other to create a continuous system that may operate under the control of the PLC 420. Example embodiments may provide for the generation of useful fibers that, for example, may have exceptional characteristics relative to their properties for absorption of various materials. However, example embodiments may further generate such materials using a relatively self sustainable and mobile platform.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe exemplary embodiments in the context of certain exemplary combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. In cases where advantages, benefits or solutions to problems are described herein, it should be appreciated that such advantages, benefits and/or solutions may be applicable to some example embodiments, but not necessarily all example embodiments. Thus, any advantages, benefits or solutions described herein should not be thought of as being critical, required or essential to all embodiments or to that which is claimed herein. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.