SYSTEM AND PROCESS FOR RECOVERING CLEAN CELLULOSE FIBRES FROM DISPOSABLE PACKAGE WASTE

Abstract

ABSTRACT SYSTEM AND PROCESS FOR RECOVERING CLEAN CELLULOSE FIBRES FROM DISPOSABLE PACKAGE WASTE The present invention discloses a system and a process for recovering clean cellulose fibres from disposable package waste. The system (102) churns the disposable package waste with a first chemical solution to form a slurry. The system (102) filters metal foils and polymers from the slurry. The system (102) spreads a cellulose fibre suspension on a continuous conveyor belt to form a mat of cellulose fibres. The system (102) removes the first chemical solution with residues from the mat of cellulose fibres. The system (102) impregnates the mat of cellulose fibres with a second chemical solution, a third chemical solution, and a fourth chemical solution. The system (102) washes the mat of cellulose fibres with water. The system (102) squeezes the cleansed mat of cellulose fibres. The system (102) segregates the metal foils, the polymer, and the cellulose fibres from the disposable package waste to recover the clean cellulose fibres. Figure 1

Specification

Description:FIELD OF INVENTION

[0001]Embodiments of the present invention relate to paper recycling processes and more particularly relate to a system and a process for recovering clean cellulose fibres from disposable package waste.

BACKGROUND

[0002]Paper recycling has become increasingly important in recent years as societies strive to reduce waste and conserve natural resources. Recycling of disposable package waste, including paper containers, aseptic cartons, and paper tissues, presents both opportunities and challenges for waste management and resource recovery.

[0003]Traditional paper recycling processes have focused primarily on recycling printed disposable package waste and unprinted disposable package waste that are minimally contaminated and lightly laminated with other materials. Nevertheless, the traditional paper recycling processes are inadequate for recycling disposable package waste that are highly contaminated and heavily laminated. The traditional paper recycling processes involve pulping the disposable package waste in water, screening out the contaminants, de-inking a pulp, and forming new paper products. While effective for many types of the disposable package waste, the traditional paper recycling processes struggle with more complex disposable package waste that incorporates one or more components that are difficult to separate or is contaminated with food residues.

[0004]The paper containers present a unique recycling challenge due to polyethylene coating. The polyethylene coating makes the paper containers liquid-resistant. The polyethylene coating makes it difficult to separate cellulose fibre from one or more polymers using conventional recycling methods. Similarly, the aseptic cartons are used for packaging beverages and liquid foods and consist of multiple layers of paper, the polymers, and aluminium foil (metal foil), making the aseptic cartons particularly challenging to recycle using the traditional paper recycling processes.

[0005]Post-consumer paper tissues pose another set of challenges for recycling. The post-consumer paper tissues are contaminated with various substances and may be mixed with other types of waste, making collection, sorting, and processing of the post-consumer paper tissues more complex. Additionally, the cellulose fibre used in tissue production may be difficult to recover and reuse in high-quality paper products.

[0006]In the existing technology, a method and an apparatus for separating the cellulose fibre and the polymers from mixed waste materials and products obtained thereby are disclosed. The method involves agitating mixed waste materials containing the cellulose fibre, the polymers and the metal foils in the water to form a slurry. The slurry is then separated into a cellulose fibre portion and a polymer and metal foil portion. Nevertheless, aggressive agitation required to separate the one or more components may lead to a reduction in cellulose fibre quality, limiting the potential uses of the recycled material. Additionally, the apparatus may not be optimized for handling specific types of disposable package waste, such as polyethylene-coated paper containers or multi-layer aseptic cartons, which require more specialized separation techniques.

[0007]Furthermore, the traditional paper recycling processes do not address the challenges of efficiently removing ink particles and adhesive particles from the cellulose fibre, which is crucial for producing high-quality recycled pulp. The lack of an effective de-inking process may result in recycled paper products with lower brightness and more visible contaminants, reducing a market value and potential applications of the recycled pulp.

[0008]Another limitation of the existing technologies is scalability and adaptability to different types and quantities of the disposable package waste. Many current recycling systems are designed for large-scale operations, making the current recycling systems unsuitable for smaller communities or specialized recycling needs. There is a growing demand for more flexible and efficient recycling solutions that may handle a variety of disposable package waste streams at different scales.

[0009]The environmental impact of paper recycling processes is also a concern. Traditional methods require large amounts of water and energy and may generate significant wastewater that requires treatment. Developing more sustainable recycling technologies that minimize resource consumption and environmental impact remains an important goal in the field.

[0010]As the composition of the disposable package waste continues to evolve with changing consumer products and packaging designs, there is an ongoing need for innovative recycling technologies that may effectively separate and recover valuable one or more components from complex disposable package waste. Improving the efficiency, quality, and sustainability of the paper recycling processes remains a critical challenge in the pursuit of a more circular economy.

SUMMARY

[0011]This summary is provided to introduce a selection of concepts, in a simple manner, which is further described in the detailed description of the disclosure. This summary is neither intended to identify key or essential inventive concepts of the subject matter nor to determine the scope of the disclosure.

[0012]In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem by providing a system for recovering clean cellulose fibres from disposable package waste.

[0013]In accordance with an embodiment of the present invention, the system for recovering the clean cellulose fibres from the disposable package waste is disclosed. The system comprises a churning unit, a first screening unit, a second screening unit, a stock distributor unit, a first vacuum suction unit, a multistage counter-current liquid-liquid extraction (MCCE) unit, a second vacuum suction unit, a squeeze rolling unit, and a drying unit.

[0014]In an embodiment, the churning unit comprises a container with a plurality of rotating blades. The churning unit is configured to churn the disposable package waste with a first chemical solution at a temperature range between 30 degrees Celsius (°C) and 90 degrees Celsius (°C) to form a slurry. The slurry is formed with a pre-defined slurry consistency ranges from 2 percent to 8 percent. The first chemical solution is formed with a pre-defined concentration ranges from 1 percent to 10 percent based on a grade of the disposable package waste. The disposable package waste comprises at least one of: post-consumer paper containers formed with cellulose fibres, polymers, and contaminants in form of traces of beverages, pre-consumer production waste of paper containers formed with the cellulose fibres and the polymers, paper-based aseptic cartons formed with the cellulose fibres, the polymers, metal foils, and the traces of beverages and pre-consumer production waste of the aseptic cartons formed with the cellulose fibres, the polymers, and the metal foils, and post-consumer paper tissues.

[0015]In an embodiment, the first screening unit is configured with a mechanical filtration mechanism. The first screening unit is operatively connected at an outlet of the churning unit through a knife gate valve. The first screening unit is configured to screen the slurry for filtering out the metal foils, while retaining both the cellulose fibres and the polymers within the slurry.

[0016]In an embodiment, the second screening unit is configured with a multi-stage counter-current mechanical filtration mechanism. The second screening unit is operatively connected to the first screening unit through a screw pump unit. The second screening unit is configured to screen the slurry for filtering out the polymers and obtaining a cellulose fibre suspension.

[0017]In an embodiment, the stock distributor unit is operatively connected to the second screening unit. The stock distributor unit is configured to spread the cellulose fibre suspension on a continuous conveyor belt to form a mat of cellulose fibres with a weight ranging from 500 grams per square meter (gsm) to 1500 grams per square meter (gsm).

[0018]In an embodiment, the first vacuum suction unit of a plurality of vacuum suction units is operatively positioned around the continuous conveyor belt. The first vacuum suction is configured to remove the first chemical solution along with residues from the mat of cellulose fibres through a vacuum suction for obtaining a solid consistency of the mat of cellulose fibres ranging from 8 percent to 12 percent.

[0019]In an embodiment, the removed first chemical solution along with the residues is subjected to a membrane filtration mechanism to separate the residues from the removed first chemical solution for recovering 99 percent of a purified first chemical solution to be reused again in the system.

[0020]In an embodiment, the MCCE unit is configured with a multi-stage counter-current displacement washing mechanism. The MCCE unit is operatively attached to the continuous conveyor belt. The MCCE unit is configured to impregnate the mat of cellulose fibres with at least one of: a second chemical solution, a third chemical solution, and a fourth chemical solution for eliminating traces of the residues from the mat of cellulose fibres. Impregnating the mat of cellulose fibres undergoes two stages to four stages and composition of least one of: the second chemical solution, the third chemical solution, and the fourth chemical solution are based on the grade of the disposable package waste. The residues comprise at least one of: ink particles, the contaminants, and adhesive particles.

[0021]In an embodiment, the MCCE unit is configured to wash the mat of cellulose fibres with freshwater to optimal replacement of at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution, with the freshwater for obtaining a cleansed mat of cellulose fibres with the solid consistency ranging from 8 percent to 12 percent, thereby recovering at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution. The multi-stage counter-current displacement washing mechanism is configured to dispense the fresh water at a displacement ratio of 1:1 with respect to replacing at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution to avert effluent generation.

[0022]At least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution are selected from a group comprises at least one of: an industrial strength degreaser, a caustic soda-based degreaser with phosphate additives, a silicate-based degreaser, a surfactant-based degreaser, and a GreenC degreaser.

[0023]In an embodiment, the second vacuum suction unit of the plurality of vacuum suction units is configured to dewater the cleansed mat of cellulose fibres to obtain the solid consistency ranging between 12 percent and 25 percent.

[0024]In an embodiment, the squeeze rolling unit comprises at least two rollers. The squeeze rolling unit is operatively connected in-line with the continuous conveyor belt to receive the cleansed mat of cellulose fibres. The squeeze rolling unit is configured to squeeze the cleansed mat of cellulose fibres for squeezing the freshwater from the cleansed mat of cellulose fibres to obtain the solid consistency ranging between 30 percent and 50 percent.

[0025]In an embodiment, the drying unit comprises at least one of: air heaters, hot air generators, and air blowers. The drying unit is configured to dry the cleansed mat of fibres moving on the continuous conveyor belt into a hot air chamber maintained at temperature ranging between 150 degrees Celsius (°C) and 250 degrees Celsius (°C) to obtain a predetermined moisture level ranging from 8 percent to 12 percent. The system is configured to segregate at least one of: the metal foils, the polymer, and the cellulose fibres, from the disposable package waste to recover the clean cellulose fibres.

[0026]In accordance with an embodiment of the present invention, a process for recovering the clean cellulose fibres from the disposable package waste is disclosed. In the first step, the process includes churning the disposable package waste with the first chemical solution at the temperature range between 30 degrees Celsius (°C) and 90 degrees Celsius (°C) to form the slurry. The disposable package waste comprises at least one of: the post-consumer paper containers formed with the cellulose fibres, the polymers, and the contaminants in form of the traces of beverages, the pre-consumer production waste of paper containers formed with the cellulose fibres and the polymers, the paper-based aseptic cartons formed with the cellulose fibres, the polymers, the metal foils, and the traces of beverages, and the pre-consumer production waste of the aseptic cartons formed with the cellulose fibres, the polymers, and the metal foils, and post-consumer paper tissues.

[0027]In the next step, the process includes screening the slurry by the mechanical filtration mechanism to filter out the metal foils, while retaining both the cellulose fibres, and the polymers within the slurry.

[0028]In the next step, the process includes screening the slurry by the multi-stage counter-current mechanical filtration mechanism to filter out the polymers for obtaining a cellulose fibre suspension.

[0029]In the next step, the process includes spreading the cellulose fibre suspension on the continuous conveyor belt to form the mat of cellulose fibres with the weight ranging from 500 grams per square meter (gsm) to 1500 grams per square meter (gsm).

[0030]In the next step, the process includes removing the first chemical solution along with the residues from the mat of cellulose fibres through the vacuum suction to obtain the solid consistency of the mat of cellulose fibres ranging from 8 percent to 12 percent.

[0031]In the next step, the process includes impregnating the mat of cellulose fibres with at least one of: the second chemical solution, the third chemical solution, and the fourth chemical solution to eliminate traces of the residues from the mat of cellulose fibres by the multi-stage counter-current displacement washing mechanism.

[0032]In the next step, the process includes washing the mat of cellulose fibres with freshwater by the multi-stage counter-current displacement washing mechanism for optimal replacement of at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution, with the freshwater for obtaining the cleansed mat of cellulose fibres with the solid consistency ranging from 8 percent to 12 percent to recover at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution.

[0033]In the next step, the process includes dewatering the cleansed mat of cellulose fibres through the vacuum suction to obtain the solid consistency ranging between 12 percent and 25 percent.

[0034]In the next step, the process includes squeezing the cleansed mat of cellulose fibres between at least two rollers to obtain the solid consistency ranging between 30 percent and 50 percent. The process is configured to segregate at least one of: the metal foils, the polymer, and the cellulose fibres, from the disposable package waste to recover the clean cellulose fibres.

[0035]To further clarify the advantages and features of the present invention, a more particular description of the invention will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the invention and are therefore not to be considered limiting in scope. The invention will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

[0036]Figure 1 illustrates an exemplary block diagram depicting a system for recovering clean cellulose fibres from disposable package waste, in accordance with an embodiment of the present invention;

[0037]Figure 2A illustrates an exemplary first schematic diagram depicting a churning unit, a first screening unit and a second screening unit associated with the system, in accordance with an embodiment of the present invention;

[0038]Figure 2B illustrates an exemplary second schematic diagram depicting a multi-stage counter-current displacement washing mechanism, in accordance with an embodiment of the present invention;

[0039]Figure 2C illustrates an exemplary third schematic diagram depicting a drying unit associated with the system, in accordance with an embodiment of the present invention; and

[0040]Figure 3 illustrates an exemplary flow diagram depicting a process for recovering the clean cellulose fibres from the disposable package waste, in accordance with an embodiment of the present invention.

[0041]Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the method steps, chemical compounds, equipment, and parameters used herein may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0042]For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

[0043]The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more components, compounds, and ingredients preceded by "comprises... a" does not, without more constraints, preclude the existence of other components or compounds or ingredients or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0044]Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

[0045]In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms "a", "an", and "the" include plural references unless the context clearly dictates otherwise.

[0046]Embodiments of the present invention relate to a system for recovering clean cellulose fibres from disposable package waste.

[0047]Figure 1 illustrates an exemplary block diagram 100 depicting the system 102 for recovering the clean cellulose fibres from the disposable package waste, in accordance with an embodiment of the present invention;

[0048]Figure 2A illustrates an exemplary first schematic diagram 200A depicting a churning unit 104, a first screening unit 106, and a second screening unit 108 associated with the system 102, in accordance with an embodiment of the present invention;

[0049]Figure 2B illustrates an exemplary second schematic diagram 200B depicting a multi-stage counter-current displacement washing mechanism, in accordance with an embodiment of the present invention; and

[0050]Figure 2C illustrates an exemplary third schematic diagram 200C depicting a drying unit 118 associated with the system 102, in accordance with an embodiment of the present invention.

[0051]According to an exemplary embodiment of the disclosure, the system 102 for recovering the clean cellulose fibres from the disposable package waste is disclosed. The system 102 comprises the churning unit 104, the first screening unit 106, the second screening unit 108, a stock distributor unit 110, a first vacuum suction unit 112a, a multistage counter-current liquid-liquid extraction (MCCE) unit 114, a second vacuum suction unit 112b, a squeeze rolling unit 116, and the drying unit 118.

[0052]In an exemplary embodiment, the churning unit 104 comprises a container 206 with a plurality of rotating blades 204. The churning unit 104 is configured to churn the disposable package waste in a precisely prepared first chemical solution to form a slurry. The first chemical solution is formulated at a pre-defined concentration, ranging between 1 percent and 10 percent, depending on a grade of the disposable package waste being processed. A formulation of the first chemical solution and a time taken for the churning depends on the grade of the disposable package waste. The first chemical solution is configured to soften and break down the disposable package waste, ensuring that one or more components of the disposable package waste are adequately separated. A temperature of churning is controlled between 30 degrees Celsius (°C) and 90 °C, a range that assists in optimizing a chemical activity without degrading the one or more components within the disposable package waste. The temperature of churning may vary depending on the disposable package waste. The one or more components may comprise, but not restricted to, at least one of: metal foils, polymers, cellulose fibres, and the like.

[0053]For churning, the disposable package waste along with the first chemical solution is placed in the container 206, and the plurality of rotating blades 204 initiates a physical process of churning the disposable package waste until the one or more components are separated. A first driver 202 is configured to rotate the plurality of rotating blades 204 for stirring the disposable package waste in the first chemical solution, thereby promoting even distribution of the first chemical solution and ensuring that the disposable package waste is effectively broken down. The plurality of rotating blades 204 is configured to create a sufficient mechanical force to disperse the disposable package waste evenly within the first chemical solution, thereby maintaining a pre-defined slurry consistency. The pre-defined slurry consistency ranges between 2 percent and 8 percent. Henceforth, the churning unit 104 forms the slurry of the one or more components in the first chemical solution.

[0054]In another exemplary embodiment, the churning is conducted in at least one of: a batch mode and a continuous mode. The batch mode involves processing the disposable package waste at one time, thereby allowing for precise control over each batch. The continuous mode operates without interruption, continuously feeding the disposable package waste in the container 206 for ongoing processing, which enhances efficiency for large-scale operations.

[0055]The pre-defined concentration of the first chemical solution is intended to vary based on the grade of the disposable package waste being processed. This variability allows for the adjustment of strength of the first chemical solution to accommodate the one or more components with diverse compositions, ensuring efficient segregation.

[0056]The disposable package waste may comprise, but not restricted to, at least one of: post-consumer paper containers formed with the cellulose fibres, the polymers, and contaminants in form of traces of beverages, pre-consumer production waste of paper containers formed with the cellulose fibres and the polymers, paper-based aseptic cartons formed with the cellulose fibres, the polymers, the metal foils, and the traces of beverages, pre-consumer production waste of the aseptic cartons formed with the cellulose fibres, the polymers, and the metal foils, post-consumer paper tissues, and the like.

[0057]In an exemplary embodiment, the first screening unit 106 is configured with a mechanical filtration mechanism. The first screening unit 106 is operatively connected at an outlet of the churning unit 104 through a knife gate valve 208. The knife gate valve 208 is configured to ensure a controlled flow of the slurry into the first screening unit 106. The first screening unit 106 is configured to screen the slurry for filtering out the metal foils, while retaining both the cellulose fibres and the polymers within the slurry. The metal foils are filtered out using the mechanical filtration mechanism. The first screening unit 106 is configured to ensure that larger contaminants, such as the metal foils found in inner layers of the paper-based aseptic cartons, are effectively removed, thereby preserving the valuable cellulose fibres and the polymers for further processing. The metal foils that comprise, but not constrained to, one of: a poly aluminium, a nickel, a chromium, and the like.

[0058]The mechanical filtration mechanism utilized in the first screening unit 106 is a rotary screen 212 constructed from a durable metal mesh, with pore size ranging from 20 millimetres (mm) square to 30 mm square. The metal mesh is configured to trap the contaminants that are larger than the pore size, specifically targeting the metal foils in certain types of the disposable package waste. A second driver 210 is configured to drive the rotary screen 212. The rotary screen's 212 continuous movement ensures efficient separation, preventing clogging and ensuring that the rotary screen 212 may handle a high throughput of the slurry.

[0059]In an exemplary embodiment, in a first tank 216 (as shown in Figure 2A), the cellulose fibres, the polymers, and the first chemical solution are agitated using a third driver 214 and the plurality of rotating blades 204 to maintain homogeneity. The cellulose fibres, the polymers, and the first chemical solution are then transferred via a screw pump unit 218 towards the second screening unit 108. The screw pump unit 218 efficiently moves the slurry containing the cellulose fibres, the polymers, and the first chemical solution towards the second screening unit 108.

[0060]In an exemplary embodiment, the second screening unit 108 is configured with a multi-stage counter-current mechanical filtration mechanism. The second screening unit 108 is operatively connected to the first screening unit 106 through the screw pump unit 218. The second screening unit 108 is configured to filter out the polymers and obtain a cellulose fibre suspension for further processing. The consistency of the slurry, consisting of the cellulose fibres, the first chemical solution, and the polymers is around 2 percent to 6 percent. The multi-stage counter-current mechanical filtration mechanism utilizes at least one of, but not limited to, a primary screen 224a, a secondary screen 224b, a tertiary screen 224c, and the like. Before entering the primary screen 224a, the slurry is diluted to a lower consistency, ranging from 0.5 percent to 2 percent, using "accepts" obtained from the secondary screen 224b. At least one of: the primary screen 224a, the secondary screen 224b, the tertiary screen 224c, and the like in the system 102 is a rotary cylinder made from perforated plates with a pore size ranging from 2mm to 8mm. At least one of: the primary screen 224a, the secondary screen 224b, the tertiary screen 224c, and the like are driven by a fourth driver 226, a fifth driver 228, a sixth driver 230, and the like respectively. The multi-stage counter-current mechanical filtration mechanism is configured to allow the cellulose fibres to pass while retaining the polymers. The first driver 202, the second driver 210, the third driver 214, the fourth driver 226, the fifth driver 228, and the sixth driver 230 may be, but not restricted to, at least one of: an electric motor, a hydraulic driver, a pneumatic actuator, and the like.

[0061]The primary screen 224a separates the cellulose fibres, which are free from the polymers referred to as "accepts". The "rejects" from the primary screen 224a, comprising the polymers along with 2 percent to 10 percent cellulose fibres, are sent to the secondary screen 224b. Here, the slurry undergoes further screening after being diluted with the "accepts" from the tertiary screen 224c. The secondary screen 224b captures more cellulose fibres, which are fed back to the primary screen 224a for reprocessing using a plurality of pumps 222. This ensures that the maximum amount of the cellulose fibres is recovered. The "rejects" from the secondary screen 224b, now mostly the polymers along with less than 3% cellulose fibres, are passed to the tertiary screen 224c for final filtration.

[0062]At the tertiary screen 224c, the slurry is diluted with the first chemical solution stored in a designated tank to maintain a required pulp consistency. The counter-current nature of the multi-stage counter-current mechanical filtration mechanism allows the same first chemical solution to flow backward from the tertiary screen 224c to the primary screen 224a using the plurality of pumps 222, ensuring optimal dilution and cellulose fibre recovery at each stage. The tertiary screen 224c captures nearly all remaining cellulose fibres, which are fed back to the secondary screen 224b using the plurality of pumps 222, while the final "rejects", consisting mainly of the polymers along with less than 0.5% cellulose fibres, are discarded. The multi-stage counter-current mechanical filtration mechanism maximizes cellulose fibres recovery while minimizing the presence of the polymers in the cellulose fibre suspension. The multi-stage counter-current mechanical filtration mechanism is configured to cyclically filter the polymers using the plurality of pumps 222. This configuration ensures repeated filtration to enhance a separation efficiency of the polymers.

[0063]In an exemplary embodiment, the stock distributor unit 110 is operatively connected to the second screening unit 108. The stock distributor unit 110 comprises a stock distributor 232. The stock distributor 232 is configured to spread the cellulose fibre suspension on a continuous conveyor belt 234 to form a mat of cellulose fibres. The stock distributor 232 is configured to convert pipe flow to plate flow, ensuring an even and uniform application of the cellulose fibre suspension onto the continuous conveyor belt 234. The mat of cellulose fibres is configured with a weight ranging from 500 grams per square meter (gsm) to 1500 grams per square meter (gsm). The mat of cellulose fibres allows for the even distribution of the cellulose fibre suspension to expose a maximum surface area of the cellulose fibre suspension.

[0064]In an exemplary embodiment, the first vacuum suction unit 112a of a plurality of vacuum suction units 112 is operatively positioned around the continuous conveyor belt 234. The first vacuum suction unit 112a is configured to remove the first chemical solution along with residues from the mat of cellulose fibres through a vacuum suction. The vacuum suction is configured to ensure the quality and purity of the cellulose fibres, particularly when recycling the disposable package waste. The residues are found in printed and laminated disposable package waste. The residues contaminate the cellulose fibre and reduce a usability of the cellulose fibre for producing new products. Therefore, separating the residues from the cellulose fibre is a vital step to ensure a cleaner final product.

[0065]For the removal of the residues, the mat of the cellulose fibres is subjected to the vacuum suction. The vacuum suction effectively pulls the first chemical solution along with the residues out of the cellulose fibre suspension. The vacuum suction is configured to obtain the mat of cellulose fibres with a solid consistency range between 8 percent and 12 percent. The vacuum suction is executed by a first vacuum blower 242a of a plurality of vacuum blowers (as shown in Figure 2B). The first vacuum blower 242a is configured to create the vacuum suction (suction force) that extracts both the first chemical solution and the residues that have adhered to the mat of cellulose fibre. The extracted first chemical solution mixed with the residues is collected and pumped into a chemical storage tank 244 using a first pump 222a of the plurality of pumps 222. This ensures that the first chemical solution may be treated, filtered, and reused in subsequent cycles, thereby reducing waste.

[0066]In an exemplary embodiment, the removed first chemical solution, containing the residues is subjected to a membrane filtration mechanism to purify the first chemical solution for reuse. The membrane filtration mechanism employs dedicated membranes with the pore size in a colloidal range, approximately 0.1 microns. The dedicated membranes are configured to allow dissolved the first chemical solution to pass through, while trapping the residues. By filtering out the unwanted residues, the system 102 ensures that the first chemical solution remains effective for further use. The residues may comprise, but not constrained to, at least one of: ink particles, the contaminants, adhesive particles, and the like. The ink particles are recovered and disposed off as per statutory standards.

[0067]Through the membrane filtration mechanism, 99 percent of the first chemical solution is recovered in a purified form, ready to be reintroduced into the system 102. This high recovery rate not only reduces the need for fresh first chemical solution but also minimizes waste generation, making the system 102 more environmentally friendly and cost-efficient. The use of such dedicated membranes guarantees that the residues are effectively removed, ensuring the purity and consistency of the first chemical solution.

[0068]In an exemplary embodiment, the MCCE unit 114 is configured with a multi-stage counter-current displacement washing mechanism. The MCCE unit 114 is operatively attached to the continuous conveyor belt 234. The MCCE unit 114 is configured to impregnate the mat of cellulose fibres with at least one of: a second chemical solution, a third chemical solution, a fourth chemical solution, and the like to eliminate traces of the residues completely. The at least one of: the second chemical solution, the third chemical solution, the fourth chemical solution, and the like are introduced via the plurality of pumps 222 to further break down and remove remaining residues. Each chemical solution has a specific function in loosening or dissolving the adhesive particles and the ink particles, enabling easier separation from the mat of cellulose fibres. The plurality of pumps 222 ensures that the appropriate amount of at least one of: the second chemical solution, the third chemical solution, the fourth chemical solution, and the like are sprayed across the entire mat of cellulose fibres for uniform treatment. This step is critical for ensuring that the cellulose fibres are as clean as possible, which is necessary for the quality of the final recycled product. Impregnating is carried out through the multi-stage counter-current displacement washing mechanism which removes the residues through repeated washing cycles. The multi-stage counter-current displacement washing mechanism allows the at least one of: the second chemical solution, the third chemical solution, the fourth chemical solution, and the like to be sprayed on top of the mat of cellulose fibres for a complete deinking and adhesive removal process.

[0069]An impregnation process takes place over two to four stages, depending on the quality and composition of the disposable package waste. At least one of: the second chemical solution, the third chemical solution, the fourth chemical solution, and the like are selected based on the type of contaminants and the grade of the disposable package waste.

[0070]In an exemplary embodiment, the MCCE unit 114 is configured to wash the mat of cellulose fibres through the multi-stage counter-current displacement washing mechanism using fresh water. The MCCE unit 114 is configured to replace at least one of: any traces of the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like with the fresh water. At the end of washing, 95 percent to 99 percent of the at least one of: any traces of the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like in the mat of the cellulose fibre is replaced with the fresh water. The MCCE unit 114 is configured to completely remove at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like that remain on the mat of cellulose fibres.

[0071]The multi-stage counter-current displacement washing mechanism allows the fresh water to pump on the moving mat of the cellulose fibre using the plurality of pumps 222. This counter-current approach maximizes the displacement of at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like from the mat of cellulose fibres, making the washing process more effective.

[0072]Moreover, the multi-stage counter-current displacement washing mechanism is configured to use the fresh water at a displacement ratio of 1:1, meaning that the amount of water dispensed is precisely matched to the volume of the chemical solutions (first chemical solution, second chemical solution, third chemical solution, fourth chemical solution, and the like) being removed. The displacement ratio is optimized to achieve thorough cleaning while minimizing the overall water usage.

[0073]By efficiently displacing the at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like with the fresh water, the system 102 prevents the unnecessary production of liquid waste (effluent), reducing the environmental impact of the recycling process. This controlled displacement not only assists in achieving a high level of cleanliness for the cellulose fibres but also ensures that the system 102 adheres to strict environmental standards, making the system 102 more sustainable and eco-friendly. Henceforth, after washing, a cleansed mat of cellulose fibres is obtained. The obtained cleansed mat of cellulose fibres is configured with the solid consistency ranging from 8 percent to 12 percent. By recovering and reusing the chemical solutions, the system 102 promotes sustainability while maintaining the quality of the cellulose fibre cleansing process. This approach reduces chemical consumption, enhances efficiency, and lowers an environmental footprint.

[0074]The multi-stage counter-current displacement washing mechanism ensures that at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like may be handled independently, for reuse in the system 102 or depending on the need. At least one of: any portion of the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like are collected in separate storage tanks respectively.

[0075]The at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like are selected from a group that comprises, but not constrained to, at least one of: an industrial strength degreaser, a caustic soda-based degreaser with phosphate additives, a silicate-based degreaser, a surfactant-based degreaser, a GreenC degreaser, and the like. The at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like are tailored to address different contaminants based on the type and the grade of the disposable package waste being processed. The use of a variety of chemical solutions provides flexibility for handling different grades of the disposable package waste. The composition of at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like depends on the grade of the disposable package waste.

[0076]In an exemplary embodiment, the second vacuum suction unit 112b of the plurality of vacuum suction units 112 is configured to dewater the cleansed mat of cellulose fibres. The second vacuum unit 112b is a second vacuum blower 242b. Any portion of at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like and the water are removed from the cleansed mat of cellulose fibres using the second vacuum blower 242b. The second vacuum blower 242b extracts the residual chemical solutions and the water from the mat of cellulose fibres, leaving behind the cleansed cellulose fibre. The second vacuum blower 242b is configured to reduce moisture content and obtain the solid consistency of the cleansed cellulose fibre ranging between 12 percent and 25 percent.

[0077]In an exemplary embodiment, the squeeze rolling unit 116 comprises at least two rollers (220a, 220b). The squeeze rolling unit 116 is operatively connected in-line with the continuous conveyor belt 234. The squeeze rolling unit 116 is configured to receive the cleansed mat of cellulose fibres which are partially dried. The cleansed mat of cellulose fibres undergo further drying through mechanical squeezing. A first roller 220a of the at least two rollers (220a, 220b) (as shown in Figure 2C) applies downward pressure while a second roller 220b of the at least two rollers (220a, 220b) provides an upward force, effectively compressing the cleansed cellulose fibres. At least two rollers (220a, 220b) are configured to squeeze the cleansed mat of cellulose fibres to remove additional moisture, resulting in a higher solid consistency of the cleansed cellulose fibre, ranging between 30 percent and 50 percent. This mechanical squeezing step ensures that a significant portion of the fresh water is removed before thermal drying.

[0078]In an exemplary embodiment, the drying unit 118 may comprise, but not limited to, at least one of: air heaters 236, hot air generators, air blowers 238, and the like. The drying unit 118 is configured to dry the cleansed mat of fibres moving on the continuous conveyor belt 234.

[0079]The drying begins with the air blowers 238. An output from the air blowers 238 is cold dry air, which serves as the starting point for the drying. The cold dry air is critical for maintaining a controlled atmosphere, ensuring that the initial air introduced is free from excess moisture. The primary function of the air blowers 238 is to channel the cold dry air towards the air heaters 236 for further processing.

[0080]Once the cold dry air reaches the air heaters 236, the cold dry air is heated to the required temperature, thereby transforming the cold dry air into the hot air. The hot air is then directed towards a hot air chamber 240. The cellulose fibre is passed into the hot air chamber 240. The hot air chamber 240 is configured to blow the hot air onto the squeezed cellulose fibre, thereby reducing the moisture content to a predetermined moisture level, which ranges from 8 percent to 12 percent. The hot air chamber 240 operates at a temperature range between 150 °C and 250 °C, ensuring effective moisture removal without damaging the cellulose fibre. The hot air chamber 240 is also referred to as a hot air distributor, which evenly distributes the hot air over the cleansed mat of cellulose fibres as the cleansed mat of cellulose fibre moves along the continuous conveyor belt 234. Hot air nozzles are strategically positioned on the hot air chamber 240 to ensure the even distribution of the hot air over the moving mat of cellulose fibres. The even distribution ensures that the moisture is effectively removed from the cleansed mat of cellulose fibre, facilitating efficient drying. The spacing of the hot air nozzles and air velocities depend on the input dryness and porosity of the mat of cellulose fibre.

[0081]Henceforth, the drying unit 118 is configured to dry the cleansed mat of fibres moving on the continuous conveyor belt 234 into the hot air chamber 240 to obtain the predetermined moisture level. The predetermined moisture level is crucial to maintaining the quality and usability of the dried cellulose fibre.

[0082]After the drying and squeezing, the fresh water used along with some traces of the chemical solutions, is collected in a storage tank 246. The fresh water is supplied from a Reverse Osmosis (RO) unit 248. The RO unit 248 is configured to ensure a continuous supply of the fresh water for the washing process. The collected water may either be treated or recycled. By capturing the water and any traces of the chemical solutions, the system 102 minimizes the waste and ensures that the water and any traces of the chemical solutions are handled efficiently for reuse or disposal, contributing to overall efficiency and environmental sustainability.

[0083]The system 102 is configured to segregate at least one of: the metal foils, the polymer, and the cellulose fibres, from the disposable package waste to completely remove the metal foils and the polymer and recover the clean cellulose fibres.

[0084]Figure 3 illustrates an exemplary flow diagram depicting a process 300 for recovering the clean cellulose fibres from the disposable package waste, in accordance with an embodiment of the present invention.

[0085]According to an exemplary embodiment of the disclosure, the process 300 for recovering the clean cellulose fibres from the disposable package waste is disclosed. At step 302 of the process 300, the disposable package waste is subjected to a churning operation with the first chemical solution, where the temperature is maintained between 30°C and 90°C. The churning ensures thorough mixing of the disposable package waste with the first chemical solution, thereby effectively breaking down the one or more components. The elevated temperature assists in softening the one or more components and enhancing chemical reactions, thereby forming the homogenous slurry.

[0086]The disposable package waste may comprise, but not constrained to, at least one of: the post-consumer paper containers formed with the cellulose fibres, the polymers, and the contaminants in form of the traces of beverages, the pre-consumer production waste of paper containers formed with the cellulose fibres and the polymers, the paper-based aseptic cartons formed with the cellulose fibres, the polymers, the metal foils, and the traces of beverages, the pre-consumer production waste of the aseptic cartons formed with the cellulose fibres, the polymers, and the metal foils, post-consumer paper tissues, and the like.

[0087]At step 304, the process 300 includes screening the slurry using the mechanical filtration mechanism. The mechanical filtration mechanism is configured to effectively filter out the metal foils from the slurry, ensuring that only the cellulose fibres and the polymers are retained within the slurry.

[0088]At step 306, the process 300 includes screening the slurry by the multi-stage counter-current mechanical filtration mechanism to filter out the polymers for obtaining the cellulose fibre suspension. The multi-stage counter-current mechanical filtration mechanism is configured to separate the polymers from the slurry, leaving behind the cellulose fibre suspension. Through multiple stages of counter-current filtration, the process 300 ensures that the polymers are efficiently removed, optimizing the purity of the cellulose fibre suspension.

[0089]At step 308, the process 300 includes spreading the cellulose fibre suspension onto the continuous conveyor belt. This step 308 forms the uniform mat of cellulose fibres, with the weight ranging between 500 gsm and 1500 gsm.

[0090]At step 310, the process 300 entails the removal of the first chemical solution along with the residues from the mat of cellulose fibres using the vacuum suction. The vacuum suction is configured to obtain the solid consistency of the mat of cellulose fibres that ranges from 8 percent to 12 percent.

[0091]At step 312, the process 300 includes impregnating the mat of cellulose fibres with at least one of: the second chemical solution, the third chemical solution, the fourth chemical solution, and the like. This impregnation is performed using the multi-stage counter-current displacement washing mechanism. The multi-stage counter-current displacement washing mechanism is configured to effectively eliminate any remaining traces of residues from the mat of cellulose fibres.

[0092]At step 314, the process 300 includes washing the mat of cellulose fibres with the freshwater using the multi-stage counter-current displacement washing mechanism. The multi-stage counter-current displacement washing mechanism is configured to optimize the replacement of at least one of: any portions of the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution with the freshwater. The freshwater acts as a displacement agent to displace the at least one of: any portion of the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like from the mat of cellulose fibre, rinsing out the contaminants that were loosened or dissolved during chemical impregnation. The objective is to obtain the cleansed mat of cellulose fibres, maintaining the solid consistency ranging from 8 percent to 12 percent. This washing step not only enhances the purity of the cellulose fibres but also facilitates the recovery of the chemical solutions, allowing for reuse in the process 300. By minimizing the chemical waste and maximizing resource efficiency, the process 300 contributes to a more sustainable production cycle. The multi-stage counter-current displacement washing mechanism is configured to perform the process 300 of the cellulose fibre on the continuous conveyor belt constructed from appropriate materials and featuring suitable hole sizes for optimal functionality.

[0093]At step 316, the process 300 includes dewatering the cleansed mat of cellulose fibres using the vacuum suction. This step 316 is crucial for removing excess moisture from the cleansed mat of cellulose fibres, resulting in the solid consistency that ranges between 12 percent and 25 percent. The application of the vacuum suction enhances the efficiency of moisture removal from the cleansed mat of fibres.

[0094]At step 318, the process 300 entails squeezing the cleansed mat of cellulose fibres between at least two rollers, which effectively reduces the moisture content and increases the solid consistency of the mat of cellulose fibres to a range of 30 percent to 50 percent. Additionally, the process 300 is meticulously configured to segregate the one or more components from the disposable package waste, thereby ensuring the recovery of the clean cellulose fibres. This segregation is pivotal for achieving a high-quality end product while minimizing contamination and maximizing the efficiency of the recycling process.

[0095]In an exemplary embodiment, the process 300 includes screening, drainage, multiple chemical impregnations, final washing, pressing, and drying of the cellulose fibres are all integrated onto the single continuous conveyor belt. The continuous conveyor belt allows for a continuous flow of the cellulose fibres, enhancing efficiency and reducing handling time between each operation.

[0096]Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, the system for recovering the clean cellulose fibres from the disposable package waste is disclosed. The system efficiently separates and recovers the cleansed cellulose fibre, the polymers, and the metal foils from the disposable package waste. The system ensures minimal cellulose fibre loss (less than 0.5 percent) and produces clean one or more components that may be sold or repurposed. The metal foils and the polymers are dried and stored suitably for sale. The system allows for the efficient recycling of the one or more components, even when contaminated with the beverages and contaminated paper tissues. The system provides a solution for recycling difficult-to-process items such as post-consumer paper containers and the aseptic cartons, reducing an environmental burden.

[0097]The system is also configured for small-scale, on-site recycling, which allows businesses, institutions, and municipalities to recycle post-consumer paper products locally. This reduces the need for transporting the disposable package waste to large, centralized recycling facilities and addresses the logistical challenges of segregating and transporting the disposable package waste. The clean separation of the one or more components produces high-quality, reusable materials. The cleansed cellulose fibre is free from the contaminants and may be reused for paper manufacturing or other fibre-based products. The system significantly reduces the amount of the disposable package waste going to landfills by recycling a wide range of post-consumer paper products. This is especially important for materials such as the paper containers and the aseptic cartons, which are otherwise difficult to recycle and end up in the landfills. The system is configured to handle the disposable package waste ranging from 1 kg per hour to 100 kg per hour.

[0098]The system is configured to scale up to larger capacities if needed, making the process adaptable to different levels of waste processing demands. The at least one of: the first chemical solution, the second chemical solution, the third chemical solution, the fourth chemical solution, and the like used in the system are highly efficient and may be reused multiple times, reducing operational costs and minimizing environmental impact. By enabling local recycling, the system promotes sustainability, reduces reliance on imported wastepaper, and assists in generating employment in small towns and rural areas, particularly for women. The system supports the concept of a circular economy by creating valuable one or more components from the disposable package waste. The system is configured to ensure no liquid effluent generation, as the fresh water used in the multi-stage counter-current displacement washing mechanism is controlled and reused. This makes the system environmentally friendly and suitable for areas with limited water resources.

[0099]The system is configured to recycle the post-consumer paper containers which include the paper containers contaminated with the beverages such as coffee, tea, juice, herbal drinks, water, and the like, the pre consumer production waste including trimmings, the post-consumer paper based aseptic cartons which includes cartons contaminated with milk, butter milk, juice, alcoholic drinks, and the like, and the post-consumer paper tissues used for wiping water.

[0100]The system is configured to recycle multiple disposable package waste in small quantities at source in multiple environments such as corporate offices, attorney offices, government offices, airports, railway stations, bus stands, schools, colleges, shopping malls, food/beverage retail outlets, hotels and convention centres, apartments and gated communities, police stations and offices of the defence forces and security agencies, material recovery facilities of waste management companies, material recovery facilities of government civic bodies, and the like.

[0101]While specific language has been used to describe the invention, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0102]The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
 
, Claims:I/We Claim:
1. A system (102) for recovering clean cellulose fibres from disposable package waste, comprising:
a churning unit (104) comprises a container (206) with a plurality of rotating blades (204), configured to churn the disposable package waste with a first chemical solution at a temperature range between 30 degrees Celsius (°C) and 90 degrees Celsius (°C) to form a slurry,
wherein the disposable package waste comprises at least one of:
post-consumer paper containers formed with cellulose fibres, polymers, and contaminants in form of traces of beverages;
pre-consumer production waste of paper containers formed with the cellulose fibres and the polymers;
paper-based aseptic cartons formed with the cellulose fibres, the polymers, metal foils, and the traces of beverages; and
pre-consumer production waste of the aseptic cartons formed with the cellulose fibres, the polymers, and the metal foils, and post-consumer paper tissues;
a first screening unit (106) configured with a mechanical filtration mechanism operatively connected at an outlet of the churning unit (104) through a knife gate valve (208), to screen the slurry for filtering out the metal foils, while retaining both the cellulose fibres and the polymers within the slurry;
a second screening unit (108) configured with a multi-stage counter-current mechanical filtration mechanism operatively connected to the first screening unit (106) through a screw pump unit (218), to screen the slurry for filtering out the polymers and obtaining a cellulose fibre suspension;
a stock distributor unit (110) operatively connected to the second screening unit (108), configured to spread the cellulose fibre suspension on a continuous conveyor belt (234) to form a mat of cellulose fibres with a weight ranging from 500 grams per square meter (gsm) to 1500 grams per square meter (gsm);
a first vacuum suction unit (112a) of a plurality of vacuum suction units (112) operatively positioned around the continuous conveyor belt (234), configured to remove the first chemical solution along with residues from the mat of cellulose fibres through a vacuum suction for obtaining a solid consistency of the mat of cellulose fibres ranging from 8 percent to 12 percent;
a multistage counter-current liquid-liquid extraction (MCCE) unit (114) configured with a multi-stage counter-current displacement washing mechanism operatively attached to the continuous conveyor belt (234), wherein the multistage counter-current liquid-liquid extraction (MCCE) unit (114) configured to:
impregnate the mat of cellulose fibres with at least one of: a second chemical solution, a third chemical solution, and a fourth chemical solution for eliminating traces of the residues from the mat of cellulose fibres, and
wash the mat of cellulose fibres with freshwater to optimize replacement of at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution, with the freshwater for obtaining a cleansed mat of cellulose fibres with the solid consistency ranging from 8 percent to 12 percent, thereby recovering at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution;
a second vacuum suction unit (112b) of the plurality of vacuum suction units (112) configured to dewater the cleansed mat of cellulose fibres to obtain the solid consistency ranging between 12 percent and 25 percent; and
a squeeze rolling unit (116) comprises at least two rollers (220a, 220b) operatively connected in-line with the continuous conveyor belt (234) to receive the cleansed mat of cellulose fibres, configured to squeeze the cleansed mat of cellulose fibres for squeezing the freshwater from the cleansed mat of cellulose fibres to obtain the solid consistency ranging between 30 percent and 50 percent,
whereby the system (102) configured to segregate at least one of: the metal foils, the polymer, and the cellulose fibres, from the disposable package waste to recover the clean cellulose fibres.
2. The system (102) as claimed in claim 1, wherein the slurry is formed with a pre-defined slurry consistency ranges from 2 percent to 8 percent, and
the first chemical solution is formed with a pre-defined concentration ranges from 1 percent to 10 percent based on a grade of the disposable package waste.
3. The system (102) as claimed in claim 1, wherein at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution are selected from a group comprises at least one of: an industrial strength degreaser, a caustic soda based degreaser with phosphate additives, a silicate based degreaser, a surfactant based degreaser, and a GreenC degreaser.
4. The system (102) as claimed in claim 1, wherein the impregnating the mat of cellulose fibres undergoes two stages to four stages and composition of least one of: the second chemical solution, the third chemical solution, and the fourth chemical solution are based on the grade of the disposable package waste,
the residues comprise at least one of: ink particles, the contaminants, and adhesive particles.
5. The system (102) as claimed in claim 1, wherein the multi-stage counter-current displacement washing mechanism is configured to dispense the fresh water at a displacement ratio of 1:1 with respect to replacing at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the chemical solution to avert effluent generation.
6. The system (102) as claimed in claim 1, wherein the system (102) comprises a drying unit (118),
the drying unit (118) comprises at least one of: air heaters (236), hot air generators, and air blowers (238) configured to dry the cleansed mat of fibres moving on the continuous conveyor belt (234) into a hot air chamber (240) maintained at temperature ranging between 150 degrees Celsius (°C) and 250 degrees Celsius (°C) to obtain a predetermined moisture level ranging from 8 percent to 12 percent.
7. The system (102) as claimed in claim 1, wherein the removed first chemical solution along with the residues is subjected to a membrane filtration mechanism to separate the residues from the removed first chemical solution for recovering 99 percent of a purified first chemical solution to be reused again in the system (102).
8. A process (300) for recovering clean cellulose fibres from disposable package waste, comprising:
churning (302) the disposable package waste with a first chemical solution at a temperature range between 30 degrees Celsius (°C) and 90 degrees Celsius (°C) to form a slurry,
wherein the disposable package waste comprises at least one of:
post-consumer paper containers formed with cellulose fibres, polymers, and contaminants in form of traces of beverages;
pre-consumer production waste of paper containers formed with the cellulose fibres and the polymers;
paper-based aseptic cartons formed with the cellulose fibres, the polymers, metal foils, and the traces of beverages; and
pre-consumer production waste of the aseptic cartons formed with the cellulose fibres, the polymers, and the metal foils, and post-consumer paper tissues;
screening (304) the slurry by a mechanical filtration mechanism to filter out the metal foils, while retaining both the cellulose fibres, and the polymers within the slurry;
screening (306) the slurry by a multi-stage counter-current mechanical filtration mechanism to filter out the polymers for obtaining a cellulose fibre suspension;
spreading (308) the cellulose fibre suspension on a continuous conveyor belt (234) to form a mat of cellulose fibres with a weight ranging from 500 grams per square meter (gsm) to 1500 grams per square meter (gsm);
removing (310) the first chemical solution along with residues from the mat of cellulose fibres through a vacuum suction to obtain a solid consistency of the mat of cellulose fibres ranging from 8 percent to 12 percent;
impregnating (312) the mat of cellulose fibres with at least one of: a second chemical solution, a third chemical solution, and a fourth chemical solution to eliminate traces of the residues from the mat of cellulose fibres by a multi-stage counter-current displacement washing mechanism;
washing (314) the mat of cellulose fibres with freshwater by the multi-stage counter-current displacement washing mechanism for optimal replacement of at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution, with the freshwater for obtaining a cleansed mat of cellulose fibres with the solid consistency ranging from 8 percent to 12 percent to recover at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution;
dewatering (316) the cleansed mat of cellulose fibres through the vacuum suction to obtain the solid consistency ranging between 12 percent and 25 percent; and
squeezing (318) the cleansed mat of cellulose fibres between at least two rollers (220a, 220b) to obtain the solid consistency ranging between 30 percent and 50 percent,
whereby the process (300) configured to segregate at least one of: the metal foils, the polymer, and the cellulose fibres, from the disposable package waste to recover the clean cellulose fibres.
9. The process (300) as claimed in claim 8, wherein at least one of: the first chemical solution, the second chemical solution, the third chemical solution, and the fourth chemical solution are selected from a group comprises at least one of: an industrial strength degreaser, a caustic soda based degreaser with phosphate additives, a silicate based degreaser, a surfactant based degreaser, and a GreenC degreaser.
10. The process (300) as claimed in claim 8, wherein the process (300) comprises drying the cleansed mat of cellulose fibres moving on the continuous conveyor belt (234) by at least one of: air heaters (236), hot air generators, and air blowers (238) into a hot air chamber (240) maintained at temperature ranging between 150 degrees Celsius (°C) and 250 degrees Celsius (°C) to obtain a predetermined moisture level ranging from 8 percent to 12 percent.
11. The process (300) as claimed in claim 8, wherein the removed first chemical solution along with the residues is subjected to a membrane filtration mechanism to separate the residues from the removed first chemical solution for recovering 99 percent of a purified first chemical solution to be reused again in the process (300).





Dated this 12th day of November 2024


Vidya Bhaskar Singh Nandiyal
Patent Agent (IN/PA-2912)
IPexcel Services Pvt. Ltd
AGENT FOR THE APPLICANT

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