The Green Vulture’s unique design allows for cleaning and separation on multiple types of polymer and contaminants simultaneously. It can clean 5,000 to 10,000 pounds per hour depending on the size of the machine. The design allows for high speed processing using a small footprint. A line producing 10,000 pounds of material per hour can fit into 20,000 square feet or less, with small lines fitting into 400 square feet or less. The design allows for zero waste discharge in a total closed loop system. By-products can be collected in a single form and used in the original process for further breakdown or may be used in other applications. The energy consumption is very low due to the process design, and low energy loss.
There has long been the need for new and improved recycling technology that provides multiple uses for the cleaning of many products. Currently, typical recycling companies have one machine for each type of material. The Green Vulture’s technology is truly unique in the fact that it can clean and separate many different types of materials into full process of recycled carpets, bottles, paper and film products to name a few.
Green Vulture is uniquely different than existing technologies because:
» It has a patented, unique technology design
» It has an unrivaled efficiency process with proven test results
» It requires a low energy thru-put
» It requires minimum man-power to operate
» It is primarily an automated process
» It has adaptability and flexibility on volume of thru-put
Hammer Milling and Tearing Lines
Hammer milling and tearing lines require many steps to free latex based products from carpet. Each product passes through hammer mills typically four times or more, adding to the cost. Products are then blown with air through a pipe for further separation of undesirable fines. Although limited, polymer separation is achieved in the airing process. It will create a low end polymer that can be reused by adding virgin polymer to enhance strength and workability. Typically, the cost for hammer milling and tearing lines is 25 to 35 cents per pound. Creation of dust and airborne fines is hard to control and requires constant filtration.
Shearing is a machine that takes a rotating cutter to remove only the top part of the carpet. Though effective, this leaves, based on the face weight of the carpet, 50% or more of the reusable product, known as carcass, in the process. The leftover backing and face fibers typically end up in landfills, are used in RE2 (waste to energy) or another company attempts to further process it. There is some limited success in this approach, but cost can be a limiting factor particularly on light weight carpet. A typical example would be 32 ounce face weight per yard of carpet equals 16 ounces of usable fiber once it has been sheared. The remaining 16 ounces of fiber is buried in 28 ounce typical latex application, 3 ounce primary backing and the 3 ounces of secondary backing is all left behind. Typical cost scenario would be 10 cents for carpet, 3 cents for trucking and 15 cents for shearing, resulting in material loss in this process. A pound of usable fiber can exceed 45 to 55 cents per pound face weight.
This process was patented in 1997, though effective, the major drawback is a large waste stream associated with this process as well as over 50% waste which is being land filled. Typical costs to have materials tolled in this process can be 35 cents per pound or less. The average cost per pound to operate the centrifuge is 26 cents per pound plus vast amounts of waste.
This process, though unique, is very expensive to operate. De-polymerization is very effective in removing impurities and contaminants. Caprolactam is reclaimed in this process and converted back into nylon 6 pellets.