Patent Description:
The invention relates to the technical field of bottle flakes recycling and pelletizing, specifically to a high-quality apparatus and process for bottle flakes recycling and pelletizing.

The existing processes for bottle flakes recycling and pelletizing differ among the suppliers. The existing process is that after the initial sorting, smash, wash, drying, the recycled bottle flakes enter the screw extruder for melting and pelletizing. The said bottle flakes are 3A grade (namely the PET drinks bottles from towns, after initial sorting, smash, wash and drying treatment, named as 3A grade bottle flakes). The PVC content of this kind of bottle flakes is <NUM>-<NUM>/Kg, the polyolefin content about <NUM>-<NUM>/kg, water content of <NUM>%, powder content <NUM>-<NUM>/kg, and other dust (sand, metal) about <NUM>-<NUM>/kg.

There is much dust inside the bottle flakes, which can influence the downstream pelletizing and products performance index. In addition, the equipment under this process doesn't have high demand for the granular, so most products produced can only be used to make low quality products. What's more, the batch yield of the existing bottle flakes recycling and pelletizing is not big, normally ranging from several tons to <NUM> tons. With the recycled bottle flakes as raw material, its quality is not same. The small batch production will lead to the instability at different time, uneven molecular chain length, and other problems. So, it cannot provide the material with stable quality and quantity, and it brings too much inconvenience for the stable use of the downstream customers. Generally, the existing process has the following main problems: firstly, the chips and bottle flakes produced have low performance index and quality; secondly, for different batch products, their weights are not the same, no big batch stale supply; thirdly, with the recycled bottle flakes as raw material, so its quality is not same, for different batches, the granular produced differ in the parameters, due to this difference, the products performance index is not continuous, stable and different, even under standard, for example, when making filament, may have broken filament and break filament, when dyeing, may lead to difficulty in dyeing and nonuniform dyeing. <CIT> discloses a process for producing a regenerated polyester chip by using a regenerated bottle chip and a device thereof. The device comprises a chip bin, a centrifugal dryer, an underwater granulator, a No.<NUM> filter, a No.<NUM> filter, a screw extruder, a pre-spinning bin, a feeding winch and a high-speed mixer in turn, wherein the high-speed mixer is provided with a metering tank; the metering tank is provided with the bottle chip bin; the bottle chip bin is provided with a cyclone separator; a metering pump is arranged between the No.<NUM> filter and the No.<NUM> filter; a casting band head is arranged on the No.<NUM> filter; the centrifugal dryer is connected with a vibrating screen and a Roots blower in turn; and the cyclone separator is connected with a No.<NUM> large rotary outlet air supply pipeline. <CIT> refers to recycle method for providing a polyester resin composition capable of manufacturing a bottle of an equal quality again from a used PET bottle (bottle to bottle). For that, a substantially completely cleaned waste PET bottle flake is mixed with a monomer PEN flake or a substantially completely cleaned waste PEN flake in a predetermined ratio. The mixed flake, which is dried to <NUM>-<NUM> ppm by a reduced-pressure vacuum drying, is kneaded in a twin kneading extruder heated to <NUM>-<NUM> filled with dried inert gas with addition of a condensation agent. Although hydrolysis occurs due to incomplete drying of both PET and PEN, two benzene nuclei possessed by a dicarboxylic acid of the PEN produced by the hydrolysis causes a strong induced linkage aiding an ester linkage by the action of the condensation catalyst to link between the PETs prior to melting, thereby preventing reduction of entire molecular weight and recovering an IV value.

The invention aims to solve the existing problems and provide an apparatus and process for high-quality bottle flakes recycling and pelletizing. The invention can enhance the product quality and the performance stability and continuity of the products, and improve the environment of the bottle flakes recycling and pelletizing.

On the one hand, the invention provides an apparatus according to claim <NUM> for high-quality bottle flakes recycling and pelletizing, including the bottle flakes feeding apparatus and a screw extrusion pelletizing apparatus. With 3A grade bottle flakes as raw material, there is a dust removing and drying apparatus between the bottle flakes feeding apparatus and screw extrusion pelletizing apparatus. The said dust removing and drying apparatus includes an eddy current separator, material sorter, fluid bed, round vibrating sieve and drying reaction tower. The said screw extrusion pelletizing apparatus connects a material mixing hopper at an output end.

The said fluid bed pre-heats the bottle flakes to remove their surface moisture and dry the sand on the surface of the bottle flakes, which makes it easier for the round vibrating sieve to sieve out the residual sand. The drying tower allows further drying of the bottle flakes and completely removes the moisture on the surface and inside the bottle flakes, which can avoid e bubbles and even breaking of the inside or on the surface of the granule during the die head and pelletizing processes. Thus, high quality of the granules and its uniformity is achieved.

Further, the said bottle flakes feeding apparatus includes a crane, a bottle flakes feeding hopper and a bottle flakes storage hopper. The crane is on the upside of the bottle flakes feeding hopper. The material outlet of said bottle flakes feeding hopper connects with the material inlet of the said bottle flakes storage hopper through material pipe.

Further, the said bottle flakes recycling and pelletizing apparatus, is characterized in that the said screw extrusion pelletizing apparatus includes the screw extruder, two-stage melt filter, die head, sink, pelletizer, dryer and the vibrating sieve, the material outlet of the said screw extruder connects with the material inlet of the said two stage melt filter, the material outlet of the said two-stage melt filter connects with the material inlet of the die head, the material inlet of the said die head connects with the material inlet of the said pelletizer through said sink, the material outlet of the said pelletizer connects with the material inlet of the dryer, the material outlet of the said dryer connects with the material inlet of the said vibrating sieve, the material outlet of the said vibrating sieve connects with the said mixing hopper through material pipe.

Further, the said multiple-hopper material mixing apparatus includes material mixing hoppers. There is material inlet, material mixing inlet, gas outlet, material outlet on the said material hopper. The material outlet of the said material mixing hopper connects with the material inlet of the said bottle flakes storage hopper and the automatic packing machine through material pipe,.

Well selected, the quantity of the said material mixing hopper is at least two, with volume of more than <NUM> t/hopper. The material outlet of the said material mixing hopper connects with the packing machine through material pipe, the gas outlet of the mixing hopper connects with the cyclone separator through the gas pipe, at the bottom of the said cyclone separator is a dust bin.

On the other hand, the invention provides a process according to claim <NUM> for bottle flakes recycling and pelletizing, its characteristic being that using the said high-quality bottle flakes obtained via the present invention. With 3A grade bottle flakes, or the flakes after initial selection, crushing, washing and drying as raw material, makes the following steps for the recycled bottle flakes.

Further, the said step <NUM>, the heating drying time is <NUM>-<NUM> hours.

Further, the process temperature in the said step <NUM> is <NUM>-<NUM>, the second filtration accuracy of the said step <NUM> is <NUM>.

Further, in step <NUM>, the material in the material mixing hopper, under the impact of the corresponding rotary valve and conveying blower, flow from the material outlet (<NUM>), through the material pipeline and material mixing outlet (<NUM>), into the material mixing hopper again, making sufficient mixing to the granules of different time to make the IV uniform.

Further, in step <NUM>, when one mixing hopper is mixing the material, the other mixing hopper will receive and store the sieved granules.

The positive effect of the invention: with the 3A standard bottle flakes as raw material, removable of the metal, label, sand and other residues, and through melting and filtration remove the impurities in the raw material through the process of the eddy current separator, material sorter and pre-heating, remove the dust and purify the bottle flakes in the screw extruder to reduce the polyvinyl chloride (PVC) content from <NUM>∼<NUM>/Kg to <NUM>/Kg below, the dust content from <NUM>∼<NUM>/Kg to <NUM>/Kg, other impurities (sand, metal) content from <NUM>~<NUM>/Kg to <NUM>/Kg below. In this case, the product quality will improve a lot, then through multiple-hopper mixing apparatus, uniformly mix the chips or granule of different batches several times to get the uniform IV chips in this hopper and provide high quality chips for the downstream customers to improve the product stability and reliability of the downstream production. In spinning field, will reduce the possibility of the filament break and broken. In dyeing field, improve the uniformity and possibility of the dyeing. The filling capacity of each mixing hopper in the multiple-hopper material mixing apparatus is at least <NUM> t chips, then make multiple mixing and uniform IV output to provide stable quality and quantity products for the downstream.

The apparatus and process have the characteristic of high accuracy, and shield the shortcomings of the existing production system, such as high cost, low quality, low yield. The granule produced by the apparatus can be used to produce high quality products, even the food grade products.

<FIG> is indication drawing of the connecting relation of the apparatus in the invention.

In the drawing: bottle flakes feeding hopper-<NUM>, storage silo-<NUM>, the first rotary valve-<NUM>, the first conveying blower-<NUM>, crane-<NUM>,
the first spiral conveyor-<NUM>, eddy current separator-<NUM>, the second spiral conveyor-<NUM>, the third spiral conveyor-<NUM>, vibrating feeder-<NUM>, material sorter-<NUM>, the first centrifugal fan-<NUM>, feeding hopper-<NUM>, Vacuum hopper-<NUM>, the second rotary valve-<NUM>, middle hopper-<NUM>, the third rotary valve-<NUM>, fluid-bed-<NUM>, round vibrating sieve-<NUM>, the forth rotary valve-<NUM>, the second conveying blower-<NUM>, drying reaction tower-<NUM>, the second centrifugal fan-<NUM>, crystallizing heater-<NUM>, cyclone separator-<NUM>, vacuum blower-<NUM>, drying heater-<NUM>, high pressure dehumidifier-<NUM>, screw extruder-<NUM>, the first melt filter-<NUM>, pressure increase pump-<NUM>, the second melt filter-<NUM>, die head-<NUM>, pelletizer-<NUM>, dryer-<NUM>, direct vibrating sieve-<NUM>, the fifth rotary valve-<NUM>, the third conveying blower-<NUM>, sink-<NUM>, waste material hopper-<NUM>, the first hopper-<NUM>, material inlet of the mixing hopper-<NUM>, material mixing inlet of the mixing hopper-<NUM>, gas outlet of the mixing hopper-<NUM>, material outlet of the mixing hopper-<NUM>, the sixth rotary valve-<NUM>, the fourth conveying blower-<NUM>, cyclone separator-<NUM>, dust bin-<NUM>, the second mixing hopper-<NUM>, the seventh rotary valve-<NUM>, the fifth conveying blower-<NUM>, the first automatic packaging machine-<NUM>, the second automatic packaging machine-<NUM>.

The invention is now described by the intuitive attached Figure and some best examples.

Implement example: see the <FIG>, a high-quality apparatus and process for bottle flakes recycling and pelletizing. With the 3A grade bottle flakes as raw material, the said apparatus configurates bottle flake feeding apparatus, dust-removing and drying apparatus, screw extrusion pelletizing apparatus and multiple-hopper mixing apparatus, among which the bottle flakes feeding apparatus includes bottle flakes feeding hopper <NUM> and bottle flakes storage hopper <NUM>. The material outlet of the bottle flakes feeding hopper connects with the material inlet of the bottle flakes storage hopper through material pipe. On the material pipe at the material outlet of the bottle flaks feeding hopper, there is the first rotary valve <NUM> and the first conveying blower <NUM>.

The dust removing drying apparatus configures the eddy current separator <NUM> , material sorter <NUM>, fluid bed <NUM>, round vibrating sieve <NUM> and drying tower <NUM>, among which at the material outlet of the bottle flakes storage hopper <NUM>, there is the first spiral conveyor <NUM>, eddy current sorter <NUM>, the second spiral conveyer <NUM>, the third spiral conveyor <NUM>, the vibrating feeder <NUM>, material sorter <NUM>. The eddy current separator is TLFXP-<NUM> model from Dongyan Tianli Electromaganetic-electric Equipment Co. The sorter <NUM> is 6SXZ-300CL from HEFEI MEYER OPTOELECTRONIC TECHNOLOGY INC.

At the material outlet of the material sorter <NUM>, through the material pipe, configures vacuum hopper <NUM>, the second rotary valve <NUM>, middle hopper <NUM>, the third rotary valve <NUM>, fluid bed <NUM>, round vibrating sieve <NUM>, the fourth rotary valve <NUM>. The second conveying blower <NUM>, drying reaction tower <NUM>, high pressure dehumidifier <NUM>, the second centrifugal fan <NUM> on the fluid bed <NUM>, crystallizing heater <NUM>, cyclone separator <NUM> connected by the material pipe in turn. The round vibrating sieve is on the material pipe between the material outlet of the fluid bed <NUM> and the fourth rotary valve <NUM>. The round vibrating valve <NUM> adopts XF1500DE model manufactured by Xinxiang Pioneer Vibration Machinery Co. The make of the high-pressure dehumidifier is TPE-<NUM> model from Wuxi Topair Equipment Co.

The screw extrusion pelletizing apparatus configurates screw extruder <NUM>, the two-stage melt filter composed by the first melt filter <NUM>, pressure increase pump <NUM> and the second melt filter <NUM>, die head <NUM>, sink <NUM>, dyer <NUM>, vibrating sieve <NUM>. The material outlet of the pelletizer <NUM> connects with the material inlet of the dryer <NUM>. The material outlet of the dryer <NUM> connects with the material inlet of the vibrating sieve <NUM>. The material outlet of the vibrating sieve <NUM> connects with the waste material hopper <NUM> and multiple-hopper mixing apparatus by material pipe. On the material pipe of the material outlet of the vibrating sieve <NUM>, there are the fifth rotary valve <NUM> and the third conveying blower <NUM>. The screw extruder <NUM> is <NUM> from Shanghai Jwell Chemical Fibre Machinery Co. The two-stage melt filter is CPF-PT-15C from Zhejiang Yufeng Chemical Fibre Machinery Co. The pelletizer <NUM> that consist of die head <NUM>, sink <NUM>, dryer <NUM> and vibrating sieve <NUM> adopts the TSQW200Z model from CAMA(LUOYANG) ELECTOMECHANIC CO.

Multiple-hopper material mixing apparatus includes material mixing hoppers which include the first material mixing hopper <NUM> and the second material mixing hopper <NUM>. On the body of the first mixing hopper <NUM>, configurate material inlet <NUM>, mixing inlet <NUM>, gas outlet <NUM>. At the bottom, there is material outlet <NUM>, mixing outlet <NUM> and mixing inlet <NUM>. Through the connection between the sixth rotary valve <NUM> and the fourth conveying blower <NUM> by material pipe, the material outlet of the mixing hopper <NUM> connects with the first automatic packaging machine <NUM> by material pipe.

On the body of the first mixing hopper <NUM> configurates material inlet, mixing inlet, gas outlet and the material mixing outlet at the bottom of the mixing hopper. The material outlet of the mixing hopper connects with the material mixing inlet through the material pipe of the seventh rotary valve <NUM> and the fifth conveying blower <NUM>. The material outlet of the second mixing hopper <NUM> connects with the second packaging <NUM> through the material pipe. The two packaging machines <NUM> and <NUM> are LPS-1000GF model from Li Gu Weighing Industrial Co.

The material mixing inlet of the first mixing hopper <NUM> and the second mixing hopper <NUM> connects with the material outlet of the vibrating <NUM> through material pipe.

The gas outlet of the mixing hopper connects with the cyclone separator <NUM> through gas pipe. There is dust bin <NUM> at the bottom of the cyclone separator <NUM>.

A process for bottle flakes recycling and pelletizing, with 3A grade bottle flakes, or the flakes after initial select, crush, wash and dry as raw material, make the following steps for the recycled bottle flakes.

As per the attached <FIG>, the control for the process steps of the
apparatus as below:
The recycled the PET bottles from the town, after initial sorting, smash, wash and drying, become 3A grade standard bottle flakes, or directly recycle the 3A grade bottle flakes and transfer them into the feeding hopper <NUM> through truck <NUM>. Through the first rotary valve <NUM> and the first conveying blower <NUM>, the bottle flakes flow into the storage hopper <NUM> whose volume is <NUM> t/hopper. Then through the first spiral conveyor <NUM>, the materials are conveyed to material inlet of the eddy current separator <NUM>. Through the vibration the smooth material flow through the eddy current separator where the possible copper, aluminum, steel, and other metal material are separated.

After removing metals, the bottle flakes through the leading of the second spiral conveyor <NUM>, flow into the third spiral conveyor <NUM> from where the material is fed to feeder <NUM> for vibration, then the smooth material flow into the material inlet of the material sorter <NUM>. Inside the sorter <NUM>, remove the non-PET label paper and non-white PET flakes. Then the sorted flakes enter the vacuum hopper <NUM>, after the pre-heating of the fluid bed <NUM> to remove the surface moisture.

After that the flakes flow into the round vibrating sieve <NUM> by flakes gravity, inside the sieve <NUM>, a small quantity of sand on the flakes surface is removed through vibration. After dust removing, the content of the metal, label, white PET flakes, sand and other impurities should be under <NUM>/Kg. And then through the fourth rotary valve <NUM> and the second conveying blower <NUM>, the materials are transferred into the drying reaction tower <NUM> for heating and drying.

Inside the drying reaction tower <NUM>, the flakes are heated by the heater <NUM> and high-pressure dehumidifier <NUM> and stay for <NUM>-<NUM> hours to make the moisture content below <NUM> ppm, then flow into the screw extruder <NUM>. At the heating area of the screw extruder, the flakes are heated to process temperature <NUM> and become melting status. Through the filtration of the first melt filter <NUM>, pressure increase of the pump <NUM>, the filtration of the second melt filter <NUM>, the flakes flow into the die head, after cooling in the sink <NUM>, pelletizing by the pelletizer <NUM>, drying by the dryer <NUM> to achieve moisture content under <NUM>%, which can avoid agglomeration due to too much moisture to make the vibrating sieve no function. After drying, enter into the vibrating sieve to remove the knife material and powder by the vibrating sieve <NUM>, through the fifth rotary valve <NUM> and the third conveying blower <NUM>, the flakes are conveyed to waste hopper <NUM> or the first mixing <NUM> and the second mixing hopper <NUM>. The waste hopper <NUM> collect the non-standard material.

Claim 1:
A bottle flakes recycling and pelletizing apparatus, including a bottle flakes feeding apparatus and screw extrusion pelletizing apparatus with 3A grade bottle flakes as raw material, said 3A grade bottle flakes as defined in the description,
wherein between the bottle flakes feeding apparatus and screw extrusion pelletizing apparatus, a dust removing and drying apparatus is located,
wherein said dust removing and drying apparatus includes an eddy current separator (<NUM>),
characterized in that said dust removing and drying apparatus also includes a material sorter (<NUM>), a fluid-bed apparatus (<NUM>), a round vibrating sieve (<NUM>) and a drying tower (<NUM>), and in that the said screw extrusion pelletizing apparatus has a multiple-hopper material mixing apparatus at the output end.