Glassware crushing, grading, screening and collecting dry-type method and apparatus

Abstract: A method and apparatus for crushing glassware such as glass bottles and the like, and for grading, screening and collecting the crushed glass in accordance with the size of the crushed glass, said method comprising the steps of: supplying glassware 12, 74, 104 such as glass bottles to a glassware charging frame 14, 76, 106; supplying the glassware 12, 74, 104 to a first crusher 18, 66; crushing the glassware by means of a first crusher 18, 66; removing metal from the glassware 12, 74, 104 crushed by the first crusher 18, 66; supplying the glassware 12, 74, 104 with the iron piece being removed to the last crusher 34, 70; supplying the glassware 12, 74, 104 being crushed by the last crusher 34, 70 to a sieve device 41, 72; selecting the glassware being crushed by the last crusher in accordance with the grain size by the sieve device 41, 72; and collecting the glassware selected in accordance with grain size.

Description: This invention relates generally to a method and apparatus for crushing glassware such as glass bottles and the like and, particularly, to a glassware crushing, grading, screening and collecting dry-type method and apparatus. Crushing is effected to crush glassware into a grain size not larger than a predetermined size. Grading is effected to select and collect the crushed glass according to size or the grading thereof. Prior Art Heretofore, a large number of used glass bottles have been conveyed to bottle making factories and crushed into cullet. The cullet having a predetermined size (the size or the diameter is about 2.5 - 5.0 cm) is utilized as a raw material for making new bottles, however, a finely crushed portion has usually been treated as industrial waste and drained off together with cleaning water. Further, it is inefficient to transport used empty glass bottles from a place far from a recycling factory. Therefore, waste bottle recovery in such places has not been substantially utilized. In Japanese Patent Application 5-141958, there is proposed a cullet producing machine which enables crushing of used glass bottles, which have been collected at liquor shops or supermarkets, into cullet on the spot, so that the cullet can be conveyed to bottle making factories. Transportation efficiency can thereby be improved and a large amount of cullet can be recovered from regions far from the glass bottle making factories. In accordance with the improvement in transportation efficiency, it has become possible to recover cullet from distant places in a country and thus a shortage of cullet for bottle factories is alleviated. However, owing to an increase in transportation costs it is now unprofitable to convey cullet to bottle factories. As a result, the recovery of used glass bottles is not performed, thus contributing to pollution and resource waste. DE-A-2638608 relates to a method and device for preliminary processing of empty bottles or other used glass articles with metal components. A first embodiment comprises a collection or feed container having a lower feed funnel and a shaking device. above an inclined rising conveyor belt which leads to an inspection station for sorting the types of glass, such as for example sorting white glass from coloured glass articles, and then to a coarse crusher with about 20 mm particle size. From this, the coarsely crushed glass material reaches a magnetic separator which separates magnetic metal components from the glass material and diverts it into a collection container The remaining glass drops onto an inclined rising conveyor belt and is transported by this to a fine crusher. with about 10 mm particle size, in which the non-magnetic metal components are squashed flat. The finely crushed glass components and flat pressed non-magnetic components fall onto a shaking sieve with slantingly sloping parallel strips or grooves with open parallel slots therebetween. The flat pressed metal parts are captured by the parallel strips or grooves and carried away by their own weight and the shaking arrangement of the shaking sieve into a connection container. The finely crushed glass components or glass material fall through the parallel slots of the strips onto the shaking sieve therebeneath and from this onto the beginning of a slantingly outwardly extending conveyor belt from which they are fed into a collection container or directly into the glass melt. US 4795103 relates to apparatus for producing pulverized glass which is free from non-glass particles, in which a glass supply is transferred to an impactor to pulverize the glass and also is subjected to magnetic means to remove metal and vacuum means to remove dust, paper, plastic and the like. The pulverized glass is screened as to size and passed once again past a magnet means prior to depositing the sized pulverized glass in a collection bin. Oversized products do not pass through the screen but fall into a refuse chute which deposits the unwanted oversized particles in a refuse bin. It is contemplated that two different sized screens may be used in separating specific sizes of glass particles, and in fact, to produce final products of different sizes or degree of uniformity. Oversized products may be recycled back to a bin for repeating processing. Accordingly, the inventor has researched and studied the reuse of used glass bottles and, found that finely crushed glass, which has been formed during the making of cullet and treated as industrial waste and drained off together with cleaning water, can be utilized as a substitute for natural sand. Natural sand is utilized as an aggregate of concrete, a colored pavement material, as a material for a white line on an asphalt road, various abrasive materials, raw materials of pottery, construction materials for outer walls and the like and raw materials for construction blocks, and the like. Thus, heavy demands are made on this natural resource and it is highly desirable to reuse used glass bottles and the like as a substitute for natural sand. According to one aspect of the present invention, there is provided a method for crushing glassware such as glass bottles and the like, and for grading, screening and collecting the crushed glass in accordance with the size of the crushed glass, as defined in independent claim 1. According to a further aspect of the present invention, there is provided an apparatus for crushing glassware such as glass bottles and the like, and for grading, screening and collecting the crushed glass in accordance with the size of the crushed glass, as defined in independent claim 2. Preferred embodiments of the invention are defined in. the dependent claims. Further objects and advantages of the present invention will become apparent from the following detailed description showing some preferable embodiments of the present invention. However, it will be noted that the present invention is not limited to these embodiments and, various changes and modifications can easily be made for those skilled in the art within the scope of the present invention as defined by the claims. FIG. 1 is a schematic side view of a dry-type glassware crushing, grading, screening and collecting device according to a first embodiment of the present invention; FIG. 2 is a schematic side view of a dry-type glassware crushing, grading, screening and collecting device according to a second embodiment of the present invention; FIG. 3 is a schematic side view of a dry-type glassware crushing, grading, screening and collecting device according to a third embodiment of the present invention; FIG. 4 is a plan view showing a device according to the present invention and being mounted on a load carrying platform of a vehicle; FIG. 5 is a plan view showing another example of the device according to the present invention and being mounted on a load carrying platform of a vehicle; FIG. 6 is a plan view showing a further example of the device according to the present invention and being mounted on a load carrying platform of a vehicle; FIG. 7 is a plan view of the device of FIG. 6 with the portion of the vehicle being removed, and FIG. 8 is a view showing a modified form of FIG. 7. A dry-type glassware crushing, grading, screening and collecting device 10 according to a first embodiment of the present invention is shown schematically in FIG. 1. In the device 10, glassware 12 such as used glass bottles and the like are supplied to a glassware charging frame 14. The glassware 12 supplied to the glassware charging frame 14 are conveyed by a first conveyor 16 being driven by a driving source such as an electric motor and the like to a primary or a first crusher 18. The first crusher 18 is constituted of a receiving portion 20 for receiving the glassware to be crushed, a crushing portion 22, and a carrying out portion 24. The receiving portion 20 is a hopper for receiving the glassware 12 which is conveyed by the first conveyor 16. The crushing portion 22 has a rotor therein for crushing the glassware 12 falling from the receiving portion 20. The glassware 12 being crushed in the crushing portion 22 falls into the carrying out portion 24. Preferably, a selection machine 26 is provided between the crushing portion 22 and the carrying out portion 24 as shown in FIG. 1. The selection machine 24 selects out paper and the like such as labels attached to the bottle crushed by the crusher 18, the cap and the like formed of a metal or cork and the like, glass pieces not being crushed by the crusher 18 and having a size larger than a predetermined size, and discharges out of the crusher 18. Incidentally, the selection machine 26 may be omitted when the glassware is cleaned by water with the label and the like being removed and any cap also being removed. Articles being crushed and collected by the carrying out portion 24 are supplied to a second conveyor 30 through a magnetic selection conveyor 28. Metal pieces such as caps and the like and mixed in the article being crushed are attracted by the magnetic selection conveyor 28 and are received finally by a metal receiving container 32. Articles supplied to the second conveyor 30 through the magnetic selection conveyor 28 are sent to a second crusher 34 (in the embodiment shown in FIG. 1, the last crusher). The second crusher 34 comprises a receiving portion 36 for receiving the article being conveyed through the second conveyor 30, a crushing portion 38 for finely crushing the article, and a carrying out portion 40 for selecting the crushed article in accordance with the grain size and carrying out the selected article. The receiving portion 36 is a hopper for receiving the glass article being crushed by the first crusher 18 and conveyed by the second conveyor 30. The crushing portion 38 comprises a rotor for finely crushing the article supplied from the receiving portion 36. As compared with the rotor in the crushing portion 22 of the first crusher 18, the rotor in the crushing portion 38 has a space between its blades which is narrower than that of the first crusher 18 and/or the rotational speed higher than that of the first crusher 18. Further, in the embodiment shown in FIG. 1, two rotors are provided for finely crushing the glass. A dust collector 42 is connected to the crushing portion 38 to remove from the crushing portion 38 minutely crushed glass powder or the dust generated by the rotor rotating at high speed. The crushed glassware formed by the crushing portion 38 fall into a carrying out portion 40. A sieve device 41 consisting of a plurality of sieves having various dimensions and constituting a multiple stage is provided in the carrying out portion 40. And usually, the sieves are vibrated so as to improve the efficiency of the sieve device 41. The finely crushed glassware formed in the crushing portion 38 are sent to vibrating multiple stage sieve device 41, and sorted in accordance with the size of the sieves. The size or the mesh of the sieve is, according to a preferable embodiment of the invention, is about 5.0 mm in the highest or the first stage, about 2.5 mm in the next stage, and about 1.0 mm in the lowest or the last stage. The crushed glass not passing through the highest sieve and having the size generally larger than 5.0 mm are supplied to a return conveyor 44 to be crushed again by the second crusher 34. The crushed glass passing through the highest sieve and not passing through the sieve of the next stage and having generally a size of 2.5 mm - 5.0 mm are collected in a container 46. The crushed glass of this size have the rounded broken surface and, are particularly adapted for use as, and substituting, the sand in the promenade. The crushed glass passing through the second sieve and not passing through the sieve of the next stage and having generally the size of 1.0 mm - 2.5 mm are collected in a container 48. The crushed glass of this size are particularly adapted for use such as the aggregate of asphalt. The crushed glass or the glass powder passing through the last sieve and having generally the size of 1.0 mm or lower are collected in a container 50. The glass powder having the size of 1.0 mm or lower can be utilized as building material, abrasive material or road pavement material. The material not passing through either of the sieves of the sieve device 41 are collected by a container 52. The material collected into the container 52 are sent to the return conveyor 44 similar to that which could not pass through the first sieve. The material conveyed by the return conveyor 44 is sent to a paper sorting portion 54. The paper sorting portion acts to assist the paper selection machine 26 such that the paper not removed by the paper selection machine 26 are mainly separated from the glass by the second crusher 34 and the sieve device 41, and the paper sorting portion 54 acts to remove remaining paper. The material passing through the paper sorting portion 54 are sent to the second crusher 34. By repeating the crushing, it is possible to produce the crushed glass product being classified into three types according to grain size. FIG. 2 shows another embodiment of the present invention. The crushing, grading, screening and collecting device 60 shown in the drawing differs from the device 10 shown in the first embodiment in that the whole device including the first crusher and the second crusher is vertically arranged and are received in a process tower 62 thereby decreasing the ground area. There are provided inside of the process tower 62, a receiving hoppper 64, a first crusher 66, a selection portion 68, a second crusher 70, a vibration sieve device 72 and the like. There are provided outside of the process tower 62, a glassware receiving frame 76 for receiving glassware 74 such as used glass bottles and the like, a first conveyor 78 for conveying the glassware from the glassware receiving frame 76 to the process tower 62, a working platform 80 for the operator, and the like. In the crushing, grading, screening and collecting device 60 shown in FIG. 2, glassware 74 such as used glass bottles and the like is supplied to a glassware charging frame 76. The glassware 74 supplied to the glassware charging frame 76 is conveyed by a first conveyor 78 being driven by a driving source such as a well known electric motor and the like not shown in the drawing to the receiving hopper 64 provided at the highest portion of the process tower 62. The glassware 74 is sent from the receiving hopper 64 to the first crusher 66. The first crusher 66 has, similar to the first crusher 18 in FIG. 1, a rotor 84 driven by a driving source 82 such as an electric motor and acts to crush the glassware 74 dropping through the hopper 64. The glassware crushed by the first crusher 66 is sent to the selection portion 68. The selection portion 68 takes out paper and the like such as labels attached to the glass bottles crushed by the crusher 66, caps and the like formed from metal or cork and the like, glass pieces not being sufficiently crushed by the crusher 66 and having a size larger than a predetermined size, and being discharged out of the crusher 66. Labels and the like are discharged out of the system. Incidentally, the selection portion 68 may be omitted when the glassware are beforehand cleaned by water, with labels and the like being removed and the caps also being removed. The crushed glassware passed through the selection portion 68 are supplied to the second crusher 70 through the magnetic selection conveyor 86. The magnetic selection conveyor 86 attracts metal such as the caps of bottles out of the crushed article, and such metal pieces are received in the iron piece receiving container. Next, the glassware to be crushed is sent to the second crusher 70 through the magnetic selection conveyor 86 and finely crushed. Similar to the first embodiment, as compared with the rotor in the crushing portion 84 of the first crusher 66, the rotor in the second crusher 70 has the space between blades narrower than that of the first crusher 66 and/or the rotational speed higher than that of the first crusher 66. Further, in the embodiment shown in FIG. 2, two rotors are provided for finely crushing the glass. Similar to the first embodiment, a dust collector is connected to the second crusher 70 to remove minutely crushed glass powder or the dust generating by the rotor rotating at high speed. The crushed glassware formed by the second crusher 70 falls into and is supplied to a vibration sieve device 72. The sieve device 72 consists, similar to that used in such as a combined harvester and thresher for agricultural usage, of a plurality of sieves having various dimension respectively and constituting a multiple stage. The crushed glassware supplied to the vibrating sieve device 72 is sorted according to the size of the sieves. Similar to the first embodiment, the sieve device 72 includes the uppermost sieve having the mesh size of about 5.0 mm, an intermediate sieve having the mesh size of about 2.5 mm, and the lowest stage of sieve having a mesh size of about 1 mm. The crushed glassware not passing through the uppermost sieve and having the size of about 5.0 mm or more are supplied to the return conveyor 90 and crushed again in the second crusher 70. The glass powder passing through the uppermost sieve and not passing through the intermediate sieve with the size being about 2.5 mm - 5.0 mm are received in a container 92. Crushed glass of this size has a rounded broken surface and, is particularly adaptable for use as a substitute, for natural sand in pavements. Crushed glass passing through the second sieve and not passing through the sieve of the last stage and having generally the size of 1.0 mm - 2.5 mm is collected in a container 94. Crushed glass of this size is particularly adaptable for use as an aggregate of asphalt. Crushed glass or glass powder passing through the last sieve and having generally the size of 1.0 mm or lower is collected in a container 96. The glass powder having a size of 1.0 mm or lower can be utilized as a building material, abrasive material or road pavement material. The crushed glassware not passing through either one of sieves in the sieve device 72 is collected in a container 98. The glassware collected in the container 98 is supplied to the return conveyor 90. The return conveyor 90 is preferably a bucket conveyor. In the embodiment, the crushed glassware conveyed by the return conveyor 90 is returned to the upper portion of the magnetic selection conveyor 86. However, it is possible to return directly to the second crusher 70. Further, it is also possible to return to the selection portion 68 such that the crushed glassware with paper such as labels attached thereto thereby being prevented from passing through the uppermost sieve can be separated from the paper. The crushed glassware conveyed by the return conveyor 90 is crushed again by the second crusher 70. By repeating the crushing operation, it is possible to produce crushed glass sorted into three types in accordance with grain size. The embodiment shown in FIG. 3 is substantially similar to the second embodiment, but the first conveyor 78 in the second embodiment is substituted by a bucket conveyor 108, thereby decreasing further the ground area. Particularly, the glassware crushing, grading, screening and collecting apparatus 100 shown in FIG. 3 includes a process tower 102 substantially similar to the process tower 62 in the second embodiment, a glassware charging frame 106 for receiving glassware 104 such as used glass bottles, a bucket type first conveyor 108 for supplying the glassware to the process tower 102, and a supplying conveyor 110 for sending the glassware 104 from the glassware charging frame 106 to the first conveyor 108. In the third embodiment shown in FIG. 3, the glassware 104 such as used glass bottles is supplied to the glassware charging frame 106. The glassware 104 is supplied to a lower charge opening (not shown in the drawing) of the bucket conveyor 108 by the horizontal conveyor 110 driven by a drive source (not shown) such as a well known electric motor. The glassware charging frame 106 and the horizontal conveyor 110 may be omitted by providing a hopper in the lower portion of the bucket conveyor 108 and charging the glassware, thereby the ground area can further be reduced. The glassware 104 supplied to the bucket conveyor 108 is sent to a receiving hopper 64a being similar to the hopper 64 in the second embodiment and, thereafter, are routed sequentially a first crusher 66a, a selection portion 68a, a magnetic selection conveyor 86a, a second crusher 70a, a vibration sieve device 72a, and the like being generally similar to respective devices shown in the second embodiment. Thus, the crushed glassware are sorted according to the grain size. The crushed glass having the grain size larger than a predetermined size are, similar to the second embodiment, returned by a return conveyor 90a to repeat the crushing operation. In FIG. 3, shown at 112 is a platform, and at 114 is a strut. In these embodiments, the second crushers constitute the last crushers, however, it is possible to provide one or more auxiliary crushers between the first crusher and the last crusher, and carry-in conveyor and carry-out conveyor may be provided separately for the auxiliary conveyor. The size of the mesh in the sieves and the number of sieves can be determined according to the use of the final product and as desired. Above described embodiments are mass production type apparatus fixed on a ground or on a floor, however, it is possible to reduce the size such that the apparatus can be mounted on a load carrying platform B of a vehicle A as shown in FIG. 6. In such case, as shown in FIG. 4, a glassware charging frame 14, a first crusher 22, a second crushing portion 38 and a paper selection machine 54 are arranged in for and aft directions as shown in the drawing, such that the glassware are conveyed from the glassware charging frame 14 to the first crushing portion 22 by a forwardly and upwardly inclined conveyor 16a, that the glassware are sent back to the paper selection machine 54 by rearwardly and upwardly inclined conveyor 28a, and are sent again to the second crushing 38 by upwardly and forwardly inclined conveyor 30a. Incidentally, the conveyor denoted by numeral 44a is a return conveyor inclined rearward and upward. Further, as shown in FIG. 5, it is possible to arrange parallel the glassware charging frame 14 and the second crushing portion 38, to arrange parallel the first crusher 22 and the paper selection machine 54, and to connect these elements with one another through conveyors 16b, 28b, 30b and 44b having respectively the function same to those shown in FIG. 4. Further, the device shown in FIG. 2 or FIG. 3 may be substituted by a device shown in FIGS. 6 and 7, in which a glassware charging frame 76, a first crusher 66, and a second crusher 70 and a vibration sieve device 72 are arranged on a straight line, and which are connected with each other through rearwardly and upwardly inclined conveyors 78c and 86c, thereby similar effects can be obtained. Further, FIG. 8 shows another embodiment in which, a glassware charging frame 76, a first crusher 66, a second crusher 70 and a vibration sieve device 72 are arranged generally in a U-shape with these devices being connected by conveyors 78d and 86d. A working space S is provided around the glassware charging frame 76. The fixed type devices shown in FIG. 1 through FIG. 3 have large size, and high performance. Thus, it is possible for used glass bottles and the like to be collected from various districts, including distant places, with glass sand products being formed on a large scale and stored at predetermined stockyard, and then products being conveyed to the places of usage as desired. However, the devices shown in FIG. 4 through FIG. 8 can be adapted to be mounted on a vehicle such as a truck and the like, and made portable to obviate the need to convey used glass bottles over a long distance, to provide a stockyard for storing glass sand products, and to reduce transportation costs. In the embodiments, there is provided between the first crusher and the second crusher a metal removing device, but the metal removing device may be omitted as desired and the first and the second crushers may be connected directly. Such arrangement is advantageous in mounting on a vehicle. As described heretofore in detail, the present invention overcomes the problem in the prior art cullet producing device in that although used glass bottles can efficiently be recycled a large amount of finely crushed glass has been abolished as industrial waste. According to the present invention, the glassware are crushed finely as compared with the cullet, and are utilized, according to a size, as a substitute for natural sand used in pavements, as an aggregate of asphalt, and as a building material, abrasive material or road pavement material according to the size of the glass powder.

Claims: A method for crushing glassware such as glass bottles and the like, and for grading, screening and collecting the crushed glass in accordance with the size of the crushed glass, said method comprising the steps of: supplying glassware (12,74,104) such as glass, bottles to a glassware charging frame (14,76,106); supplying glassware (12,74,104) to a first crusher (18,66); crushing the glassware by the first crusher (18,66); removing the metal from the glassware (12,74,104) crushed by the first crusher (18,66); supplying the glassware (12,74,104) with metal being removed to a last crusher (34,70); supplying the glassware (12,74,104) being crushed by the last crusher (34,70) to a sieve device (41,72); selecting the glassware being crushed by the last crusher in accordance with the grain size by the sieve device (41,72); and collecting the glassware being selected in accordance with the grain size, wherein the crushed and selected glassware having the size exceeding a predetermined size is sent to a paper sorting device (54) and is then sent to the last crusher (34,70) and repeatedly crushed. A device (10,60,100) for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size, said device comprising: a glassware charging frame (14,76,106) for receiving the glassware (12,74,104) such as glass bottles; a first conveyor (16) for conveying the glassware from the glassware charging frame (14,76,106) to a first crusher (18,66); a rotor provided in the first crusher (18,66) for crushing the glassware (12,74,104) so as to have a size less than a predetermined size; a paper sorting device (54) for separating paper from glassware a second conveyor (30) arranged to convey the crushed glassware (18, 66) from said paper sorting device (54) to a last crusher (34,70); sieve means (41,72) for selecting the crushed glassware in accordance with the grain size; accumulating containers for accumulating the crushed glassware in accordance with the grain size; and a return conveyor (44) for supplying the glassware having the grain size larger than a predetermined size to said paper sorting device. A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in Claim 2 in which said return conveyor (44) acts to return the glassware having the grain size larger than the predetermined size to a following crusher. A device for crushing a glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in Claim 2, in which there is further provided a magnetic separation conveyor (28), which supplies the glassware being crushed by the first crusher to a following crusher. A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in Claim 4 in which said glassware charging frame (14,76,108), said first crusher (18,66) and said last crusher (34,70) are connected laterally through said first conveyor (16) and said magnetic separation conveyor (28). A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in Claim 4. in which said first crusher (18,66), said last crusher (34,70) and said sieve means (41,72) are vertically connected through said magnetic selection conveyor (28). A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in any one of Claims 2 through 6 in which a paper selection machine (26) is provided below the first crusher (18,66). A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in Claim 6 in which the glassware such as a glass bottle is supplied from the glassware charging frame (14,76,106) to the first crusher (18,66) through a carrying conveyor. A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined an Claim 6, in which the glassware such as a glass bottle is supplied from the glassware charging frame (14,76,106) to the first crusher (18,66) through a bucket conveyor. A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in any one of Claims 2 through 9, in which said last crusher is a second crusher. A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in any one of Claims 2 through 10, in which an auxiliary crusher is provided between said first crusher and said last crusher. A device for crushing glassware such as glass bottles and selecting and collecting the crushed glassware in accordance with the grain size as defined in any one of Claims 2 through 11, in which said device is mounted on a displaceable vehicle.

Inventors: SATO KOITHI, SATO, KOITHI, Sato, Koithi, c/o Kaneto Co., Ltd.
Applicants: KANETO CO LTD, KANKYO HOZEN SERVICE CO LTD, KANETO CO., LTD., KANKYOHOZENSERVICE CO., LTD.
Application year: 1997
Main classification: B02C19
IPC codes: B03B9, B02C23, B02C19, C03C1