Abstract:
System and method for comminuting gypsum wallboard received from a series of processing hoppers and milling hoppers by discharge into an assembly including a feed hopper, a barrel and trommel screen assembly for separation and final removal of paper and non-ferrous materials from comminuted gypsum wallboard, and separate assembly for receiving and conveying processed barrel screen discharge waste and gypsum.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     None. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     None. 
     REFERENCE TO A MICRO-FICHE APPENDIX 
     None. 
     TECHNICAL FIELD 
     This invention relates generally to portable apparatus which readily can be conveyed from site to site and utilized to comminute or pulverize gypsum wallboard for recycling, and in particular, to a system and method for improved separation and final removal of paper and non-ferrous materials from the comminuted gypsum wallboard. 
     BACKGROUND OF THE INVENTION 
     The following Patents or Patent Publications are believed to be representative of the art: U.S. Pat. No. 5,630,556, issued May 20, 1997; U.S. Pat. No. 6,739,532, issued May 25, 2004; U.S. Pat. No. 6,164,572, issued Dec. 26, 2000; U.S. Pat. No. 5,238,195, issued Aug. 24, 1993; U.S. Pat. No. 5,183,213, issued Feb. 2, 1993; U.S. Pat. No. 5,593,096, issued Jan. 14, 1997; U.S. Pat. No. 4,807,817, issued Feb. 28, 1989; U.S. Pat. No. 7,073,736, issued Jul. 11, 2006; U.S. Pat. No. 4,896,836, issued Jan. 30, 1990; U.S. Pat. No. 4,815,667, issued Mar. 28, 1989; U.S. Pat. No. 4,634,060, issued Jan. 6, 1987; U.S. Pat. No. 4,801,101, issued Jan. 31, 1989; U.S. Pat. No. 5,452,860, issued Sep. 26, 1995; and U.S. Pat. No. 4,420,390, issued Dec. 13, 1983. 
     My portable apparatus for comminuting gypsum wallboard as described and claimed in U.S. Letters Patent 5,630,556 (the “&#39;556 Patent”) is incorporated herein by reference for all purposes. A preferred embodiment of system and method for improved separation and final removal of paper and non-ferrous materials from the comminuted gypsum wallboard disclosed in this application is suitable for integration into the apparatus of the &#39;556 Patent to receive material discharged from the chain mill [FIG. 5 of the &#39;556 Patent]. It will be understood, however, that the system and method for improved separation and final removal of paper and non-ferrous materials from the comminuted gypsum wallboard disclosed in this application is equally applicable to systems lacking any final stage capability to separate non-ferrous waste from comminuted gypsum wallboard. 
     BRIEF SUMMARY OF THE INVENTION 
     Disposal of scrap and waste wallboard material poses many challenges, from environmental concerns to economies of scale. The principal objective to maximize recovery and recycling of scrap or waste wallboard material is separation of paper from the gypsum board. 
     An improved portable system and apparatus for comminuting gypsum wallboard of the &#39;566 Patent includes: 1) a first hopper having a plurality of rotary milling units, each unit including an elongated shaft with each shaft having tines with distal ends projecting outward from the shaft, whereby milling tines of adjacent milling units intermesh forming numerous restricted passageways; 2) means for receiving and conveying first hopper discharge; 3) a second hopper for receiving first hopper discharge and having means for further comminuting the wallboard, magnetic means for separating ferrous metal material from the wallboard particles, and means for collecting non-ferrous metals and waste from the comminuted gypsum wallboard within the second hopper; and 4) means for receiving and conveying second hopper discharge. 
     In a preferred embodiment of the system and method for separation and final removal of paper and non-ferrous materials (waste) from the comminuted gypsum includes a revolving barrel trommel screen assembly of the third hopper for separation and final removal of paper and non-ferrous materials (waste) from the comminuted gypsum. It is appreciated that the &#39;566 Patent generally shows the component configuration of the other two hoppers and connecting belts. Added to the &#39;566 Patent is a third hopper for receiving relatively high volume system throughput rates of second hopper discharge and delivering the second hopper discharge into a revolving barrel trommel screen assembly for separation and final removal of paper and non-ferrous materials from the comminuted gypsum wallboard, and separate assemblies for receiving and conveying barrel screen discharge waste and gypsum. 
     An embodiment of a revolving barrel trommel screen assembly for separation and final removal of paper and non-ferrous materials from the comminuted gypsum wallboard, and separate assemblies for receiving and conveying barrel screen discharge waste and gypsum at a high volume system throughput rates, is disclosed and provided as a stand alone component for finished treatment in waste wallboard recycling systems lacking such capabilities. 
     It is, therefore, one object to provide a new and useful system and method to separate paper and other non-ferrous waste from pulverized gypsum board. 
     A further object is to provide a cost effective system and method to separate paper and other non-ferrous waste from pulverized gypsum board. 
     It is yet another object to provide a universal system and method to separate paper and other non-ferrous waste from pulverized gypsum board which may either be a stand alone, portable unit or a component of an entire gypsum wallboard comminuting system or apparatus, such as the &#39;566 Patent. 
     It is a further object to provide an inexpensive system and method to separate paper and other non-ferrous waste from pulverized gypsum board. 
     It is yet a further object to provide a system and method to separate paper and other non-ferrous waste from pulverized gypsum board which can match high volume throughput rates of an entire gypsum wallboard comminuting system or apparatus, such as the &#39;566 Patent. 
     A system and method for improved separation and final removal of paper and non-ferrous waste material from gypsum wallboard is thus adapted for entire gypsum wallboard comminuting system or apparatus. In its broad form, this system and method can be portable or fixed. Embodiments are suitable as a stand alone system and method for final removal of high throughput volumes of paper and non-ferrous waste material from comminuted gypsum wallboard. 
     In a preferred embodiment, the system and method is adapted to the &#39;556 Patent. 
     Related features, objects and advantages of the present invention will be apparent with reference to the following description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is right side elevation view of apparatus constructed in accordance with the teaching of the system and method to separate paper and other non-ferrous waste from pulverized gypsum board. 
         FIG. 2  is a partial back end view of apparatus constructed in accordance with the teaching of the system and method to separate paper and other non-ferrous waste from pulverized gypsum board. 
         FIG. 3  is a partial top plan view of apparatus constructed in accordance with the teaching of the system and method to separate paper and other non-ferrous waste from pulverized gypsum board. 
         FIG. 4  is a side elevation view of apparatus constructed in accordance with the teaching of the system and method to separate paper and other non-ferrous waste from pulverized gypsum board. 
         FIG. 5  is a side elevation view of a stand alone embodiment apparatus constructed in accordance with the teaching of the system and method to separate paper and other non-ferrous waste from pulverized gypsum board. 
         FIG. 6  is a flow chart depicting a portion of the method for improved separation and final removal of paper and non-ferrous waste material from the comminuted gypsum using the system depicted in  FIGS. 1-4 , either as a stand alone system or as a portion of the &#39;566 Patent. 
         FIG. 7  is a flow chart depicting a portion of the method for improved separation and final removal of paper and non-ferrous waste material from the comminuted gypsum using the system depicted in  FIGS. 1-4 , either as a stand alone system or as a portion of the &#39;566 Patent. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to the drawings, an embodiment of a system and method for improved separation and final removal of paper and non-ferrous waste material from the comminuted gypsum is disclosed,  FIGS. 1-7 . 
     The portable system  100  for comminuting gypsum wallboard includes a unitary, rigid frame having a set of parallel inclined upper rails  102  running substantially the length of the frame. Legs  104  each having two ends, with one end of each leg attached to and supporting the frame inclined upper rails  102  in an acute angle upward from a generally flat surface. This assembly provides a substantially frame high end and a frame low end. Cross members  106  provide stability and support to the legs  104  and frame inclined upper rails  102 . Driving rollers  112  and carrier rollers  110  are rotatably attached to the upper rails  102  and evenly spaced along the upper rails  102 . A rotating cylindrical drum assembly  114  is mounted for rotational movement on top of the frame rails  102 , communicating with the driving rollers  112  and carrier rollers  110 . The drum assembly  114  defines a cylindrical drum longitudinal centerline  116  and a substantially uniform drum diameter. 
     An embodiment of the system provides a drum assembly  114  having a five foot diameter and a sixteen foot length. A preferred embodiment of the system provides a drum assembly  114  having a five foot diameter and a thirty foot length. 
     In the preferred embodiment, the drum assembly  114  includes an open end at the frame high end of the drum assembly with a feed hopper provided by the apparatus of the &#39;556 Patent. In an alternate embodiment, the drum assembly  114  includes an open end at the frame high end of the drum assembly with a feed hopper  108  supported by the frame into the open end. The drum assembly  114  further includes an open end at the frame low end. 
     At least one cylindrical trommel screen assembly  122  is fixedly mounted within the drum assembly, each trommel screen assembly sized to fit symmetrically about the drum longitudinal centerline and rotatably turn with the drum assembly  114 . At least one gypsum discharge hopper  124  is attached to the frame in a position substantially parallel to the longitudinal centerline  116  below the at least one trommel screen  122 . A first conveyor assembly  126  for receiving trommel screen  122  gypsum discharge is mounted on the frame below each gypsum discharge hopper  124 . A second conveyor assembly  130  for receiving non-ferrous waste discharge is mounted on the frame below the frame low end drum assembly. A drum drive motor  120  is included on the frame for driving the drum assembly  122 . A first conveyor drive motor  128  is included on the frame for driving the first conveyor assembly  126 . A second conveyor drive motor  132  is included on the frame for driving the second conveyor assembly  130 . 
     An embodiment of the trommel screen  122  includes a uniform screen mesh size of 5/32 of an inch. An alternate embodiment of the trommel screen  122  includes a uniform screen mesh size of 3/16 of an inch. Trammel screen mesh size can range from ⅛ of an inch to one inch, depending upon the upstream comminuting system efficiency and processing. The trommel screen  122  is detachable from the drum assembly  114  for changing the screen mesh size as may be required by the comminuted gypsum feedstock. The preferred screen mesh of the trommel screen  122  is stainless steel. 
     The portable system  100  includes at least two internal spines  118  affixed to the drum assembly  114  substantially parallel to the drum longitudinal centerline  116  the length of the drum assembly  114 , spaced at equal angles about the centerline  116 , and having substantially uniform widths projecting radially into the drum assembly  114  and trommel screen  122  interiors along at uniform lengths. 
     A preferred embodiment of the portable system  100  has four spines  118 , each spine spaced at ninety degrees from its adjacent spines about the drum longitudinal centerline  116 . 
     The first conveyor drive assembly  126  and second conveyor drive assembly  130  each include a hydraulic drive motor,  128  and  132  respectively, the hydraulic motors  128  and  132  being in operative association with the source of pressurized fluid  134 . 
     The first conveyor assembly  126  for receiving trommel screen gypsum discharge is disposed at an incline substantially parallel to the frame rails  102  for transporting gypsum discharge to a finished recycle collection point beyond the frame assembly high end. 
     The second conveyor assembly  130  for receiving non-ferrous waste discharge is disposed at an acute incline angle opposed to the frame inclined rails  102  for transporting non-ferrous waste to a waste collection point beyond the frame assembly low end. 
     An embodiment of the portable system  100  includes at least two wheels. For a preferred embodiment with wheels, each of two wheels is rotatably connected to a frame high end leg  104  end not attached to the frame,  FIG. 5 . In this manner the portable system  100  can be positioned as desired within a variety of gypsum processing or recycling systems. 
     In the preferred embodiment, a central source of pressurized hydraulic fluid and the prime-mover hydraulic pump combination for providing pressurized fluid to the drum drive motor  120  and the gypsum and waste conveyor drive motors,  128  and  132 , respectively, are provided in the apparatus of the &#39;556 Patent. 
     For an alternate embodiment, the drum drive motor  120  includes a central source of pressurized hydraulic fluid  134  and a prime mover driven pump  136  for providing pressurized fluid to the drum drive motor  120  and the gypsum and waste conveyor drive motors,  128  and  132 , respectively. 
     The method  500  for improved separation and final removal of paper and non-ferrous waste material from comminuted gypsum wallboard,  FIGS. 6 and 7 , includes the following steps:
         a)  510  providing a system  100  for improved separation and final removal of paper and non-ferrous waste material from comminuted gypsum wallboard;   b)  520  providing a source of comminuted gypsum wallboard into a feed hopper  108  of the system  100 ;   c)  530  delivering the comminuted gypsum wallboard from the feed hopper  108  to an open end of a rotating drum  110  and trommel screen  122  assembly of the system  100 ;   d)  540  receiving separated gypsum fines from the rotating drum  110  and trommel screen  122  assembly of the system  100  into a gypsum discharge hopper  124  of the system  100 ;   e)  550  discharging the separated gypsum fines from the gypsum discharge hopper  124  to a gypsum conveyor  126  of the system  100 ;   f)  560  recovering the separated gypsum fines from the discharge of the gypsum conveyor  126  for recycle;   g)  570  receiving separated non-ferrous waste from the rotating drum  110  and trommel screen  122  assembly of the system  100  into a waste conveyor  130  of the system  100 ; and   h)  580  disposing of the separated non-ferrous waste received from the waste conveyor  130 .       

     As can be seen from the foregoing, the system and method for improved separation and final removal of paper and non-ferrous waste material can be installed and utilized as a stand alone system or as a component of an entire apparatus such as the &#39;556 Patent. The preferred embodiment of the system and method can handle throughput rates of an entire gypsum wallboard comminuting system or apparatus, such as the &#39;566 Patent, of 120 to 130 tons-per-hour. 
     For the purposes of promoting an understanding of the principles of the present invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the present invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
     It should be understood that the invention is not intended to be limited by the specifics of the above-described embodiments, but rather by the accompanying claims.