APPARATUS AND METHOD FOR SEPARATING FIBRES FROM PLANTS

Abstract

The present disclosure relates to separating fibres from plant straw where the separated fibres retain properties that are favourable for manufacturing textiles. Some embodiments of the present disclosure relate to an apparatus that comprises multiple separation-units for separating the desired fibres from the other constituent components of the plant straw. The apparatus may further comprise a recycling system for fluids used within the one or more separation units. Some embodiments of the present disclosure relate to a method for separating fibres from the other constituent components of the plant straw.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of co-pending International Application No. PCT/CA2017/050993 filed Aug. 23, 2017, which is incorporated herein by reference in its entirety, and additionally claims priority from U.S. Provisional Application No. 62/378,506 filed Aug. 23, 2016, which is incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates to the field of textiles made from plant materials and, in particular, to an apparatus and method for separating fibres from plants for producing fibres with the desirable characteristics of cotton for use in the textile or apparel industries.

BACKGROUND

Plant fibres are used to produce textiles from which a wide variety of fabrics and cloths can be manufactured. The demand for plant fibres continue to grow with a growing consumer demand for natural materials and products. However, before a plant fibre can be used for large-scale textile applications desirable textile-properties must be met. Examples of these desirable textile-properties include, but are not limited to: uniformity, flexibility, fineness, cohesiveness, tenacity, absorbency, pliability, and amenability to various textile processing and/or treatments must be met.

The fibres of plants such as hemp, flax, jute, nettle, ramie and the like, are known to have such desirable textile-properties and have been utilized for a wide variety of different textiles. For example, grass, rush, hemp, and sisal are used in making rope. Coir (coconut fibre) is used in making twine, mats, and sacking. Fibres from pulpwood trees, cotton, rice, hemp, and nettle are used in making paper. Flax, jute, hemp, ramie, bamboo, and even pineapple fibres are used in clothing. However, the applications of these fibres are currently somewhat limited as compared to more typical plant-based fibres, such as cotton.

One plant which has not been widely utilized for the production of textiles is the rape plant, which is a plant in the genus Brassica. The most commonly recognized variety of the rape plant is the low erucic acid and low glucosinolate variety known as canola, rapeseed 00, or double zero rapeseed. There are many species of rape plants that fall within the genus Brassica, all of which are collectively referred to herein as canola plants or canola.

Canola is one of the world's main oilseed crops. Canola is grown as a source for two primary products: canola oil and canola meal. The round canola seeds are crushed to produce canola oil and the remainder is processed into a high-protein meal. Canola plants can also be used as an input for biodiesel production. Beyond these products, the canola plant does not have widely recognized value. As a result, approximately 40 million tons of canola stalks are available after harvesting of the round seeds. The stalks are a by-product material that is typically considered waste and it is ploughed back into the soil, burned, or used as animal bedding. Commercial application of this canola by-product would, therefore, be desirable to maximizing the economy of this valuable resource.

PCT/CA2014/050892 entitled Textile Fibres and Textiles From Brassica Plants of Sevenhuysen et al., the entire disclosure of which is incorporated herein by reference, describes how Brassica fibres may provide at least some of the desirable textile-properties described above. Sevenhuysen et al. described one or more retting processes and fibre-isolation processes that can produce fibres of a suitable quality for manufacturing textile fibres with “cotton-like” characteristics. However, the fibre-isolation process described by Sevenhuysen et al. is meticulous and detailed work that may not be amenable to large-scale fibre isolation and textile production.

SUMMARY

Embodiments of the present disclosure relate to isolating plant fibres from a pre-processed plant input.

Some embodiments of the present disclosure relate to an apparatus that comprises one or more separating units that separate a fibre component from other constituent components of the pre-processed plant input. The apparatus may also comprise a drying-unit for drying and further isolating individual fibres from each other. Optionally, the apparatus may also comprise a fluid-recycling system for reducing the overall liquid input and disposal requirements of the apparatus. The apparatus may also comprise one or more conveying systems for moving inputs and processed intermediate-products through portions or all of the apparatus.

A first separation-unit receives the pre-processed plant input. The first separation-unit is configured to physically separate a gel component and a fibre component from a straw component of the pre-processed plant input. The second separation-unit substantially separates and discards the straw component from the gel component and the fibre component. The third separation-unit separates the fibre component from some, most or substantially all of the gel component. The fourth separation-unit separates the fibre component from any residual gel component through a series of treatment processes.

In some embodiments of the present disclosure, the pre-processed plant input is a product of a non-mechanical process step, for example a retting process that produces a retted plant-product from plant straw. The first separation-unit comprises a friction-based separation step, a pressure-based separation step or combination thereof to separate the gel component and the fibre component from the straw component of the retted plant product. The first separation-unit loosens the fibre, gel and stalk components from each other. All components may remain in a fluid that flows or is otherwise moved together to the second separation-unit. The first separation-unit comprises one or more fluid jets that provide fluid to wet the fibre, gel and stalk components and to assist with moving the intermediate materials to the second separation-unit. Without being bound by any particular theory, wetting the fibre, gel and stalk components may minimize damage caused to the fibre component and/or promote movement of all components to the second separation-unit.

In some embodiments of the present disclosure, the second separation-unit receives the fibre, gel and stalk components from the first separation-unit as a stream of material carried in the fluid that is flowing through and from the first separation-unit. Within some embodiments of the second separation-unit, a conveying system comprises an endless-loop belt made from at least one of canvas, plastic or rubber and/or a studded material. This belt separates the stalk component from the gel and fibre components, and allows the stalk component to be collected separately from the gel and fibre components.

In some embodiments of the present disclosure, the third separation-unit receives an intermediate material that comprises the gel and fibre components from the second separation-unit. Within the third separation-unit, the conveying system may comprise an endless-loop belt made of a mesh material and one or more liquid jets that direct one or more pressurized liquid streams to facilitate separating the fibre component from the gel component. The third separation-unit also comprises a compression system that compresses the fibre component and the gel component to force the gel component through the endless mesh-belt, which separates the fibre component from the gel component. In some instances, after passing through the second separation-unit, the separated fibre component comprises some residual gel component.

In some embodiments of the present disclosure, the fourth separation-unit receives an intermediate material that comprises the separated fibre component and some residual gel component. The fourth separation-unit may comprise a portion of the conveying system of an endless-loop belt made of steel-mesh to move the fibre and gel components received from the third separation-unit through a series of chemical-based treatment processes of the fourth separation-unit. Alternatively, the chemical-based treatment processes may all occur in a single container. Each treatment process of the fourth separation-unit exposes the fibres and residual gel material to a chemical treatment for removing the residual gel component or other plant materials from the surfaces of each individual fibre within the fibre component. Between each chemical treatment, and after the last treatment, the fibre component is rinsed with water. At this point in the apparatus, the separated fibres are referred to as individualized fibres.

In some embodiments of the present disclosure, a drying-unit receives the individualized fibres from the fourth separation-unit 40 into two handling-parts. The two handling-parts are arranged in a sequence with an input end at the beginning of the series and a final-product end at the end of the series. The first handling-part allows the fibres to be layered. The second handling-part dries the layered fibres. At this point in the apparatus, the dried individualized-fibres are suitable for further processing to produce a textile product.

In some embodiments of the present disclosure, a fluid-recycling system receives the gel component from the third separation-unit. Within the fluid-recycling system the gel component is suspended in water. The liquid recycling system is used to recover and recycle any processing fluids that are used within one or more processing sections or steps and that may include some or most or all of the gel component that is separated from the retted-plant input and the fibre component by the apparatus. The liquid recycling system separates some or most or all of the gel component from the processing fluid so that the processing fluid can be recycled back into the apparatus and used at one or more different processing sections.

Some embodiments of the present disclosure relate to a method of separating a fibre component of a pre-processed plant-straw input from a stalk component and a gel component. The method comprises the steps of: physically separating the stalk component from the fibre component and the gel component by applying friction and/or pressurized fluid to the pre-processed plant-straw product; and separating the gel component from the fibre component by compressing the gel component through a mesh material.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the present disclosure will become more apparent in the following detailed description in which reference is made to the appended drawings:

FIG. 1 is a side-elevation view schematic that shows one embodiment of an apparatus according to the present disclosure;

FIG. 2 is a side-elevation view schematic that shows one embodiment of an apparatus according to the present disclosure;

FIG. 3 is a side-elevation view schematic that shows another embodiment of an apparatus according to the present disclosure;

FIG. 4 is a side-elevation view schematic that shows one embodiment of a first separation-unit according to the present disclosure;

FIG. 5 shows one embodiment of a second separation-unit according to the present disclosure, wherein FIG. 5A shows a side-elevation view schematic of the second separation-unit and FIG. 5B shows an upper surface of a conveying belt for use with the second separation-unit;

FIG. 6 is a side-elevation view schematic that shows one embodiment of a third separation-unit according to the present disclosure;

FIG. 7 is a side-elevation view schematic that shows a partial cut-away of one embodiment of a portion of a fourth separation-unit according to the present disclosure;

FIG. 8 is a schematic that shows one embodiment of a drying unit according to the present disclosure, wherein FIG. 8A shows a side-elevation partial cut-away view and FIG. 8B shows a top-plan view of a portion of the drying unit;

FIG. 9 is an isometric view schematic that shows one embodiment of a liquid recycler system for use with the apparatus according to the present disclosure;

FIG. 10 is a logic-flowchart that shows one embodiment of a process for separating fibres from an input according to the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure relate to an apparatus and a method for separating constituent components of plant straw from each other for isolating fibres that can then be used to make textiles and cloths.

Some embodiments of the present disclosure relate to an apparatus that receives a pre-processed plant-straw product as an input from which several constituent components may be separated, including a fibre component, a gel component and a stalk component. As used herein, the term “straw” refers to the plant material that is left behind after other components of the plant have been harvested. As used herein, the terms “fibre component”, “bast-fibre” and “fibre” all refer to a component of the straw that is useful in making textiles. As used herein, the terms “gel component” and “gum” both refer to a heterogeneous plant material that may include lignins, pectins and other plant-based gums. As used herein, the terms “stalk component” and “stalk” refer to a component of the straw that is left over after the fibre component and the gel component are separated from the straw. As used herein, the term “about” refers to an approximately +/−10% variation from a given value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.

The apparatus comprises one or more separation units for separating the fibre component from the other constituent components of the pre-processed plant-straw product. Furthermore, the apparatus may comprise a system for processing and recirculating liquids that are used in the one or more separation units to reduce liquid-input requirements of the apparatus.

Some embodiments of the present disclosure relate to a method for separating fibres from plant straw. The method may comprise the steps of collecting plant straw, pre-processing the plant straw to produce a pre-processed plant-straw input and separating fibres from the pre-processed plant-straw input by either water jets, friction, compression or combinations thereof. The method may further comprise a step of collecting and recirculating liquids to reduce the liquid input requirements of the method.

Fibres that are separated by embodiments of the present disclosure may be further processed to produce textiles with the desirable qualities of uniformity, flexibility, fineness, cohesiveness, tenacity, absorbency, pliability, and amenability to various textile processing and/or treatments.

Optionally, the plant may be a canola plant. However, a pre-processed straw from other plants may be used when the straw components of those plants include bast fibres in the outer layers of the branches or stems and gel components. Some embodiments in the present disclosure relate to an apparatus and a method for separating fibres from the straw of plants other than canola, such as flax, ramie, kenaf, jut, nettle, okra and hemp.

According to some embodiments of the present disclosure, the pre-processed plant-straw product is a retted straw that is used as an input. Retting is a process whereby chemicals or more specifically enzymes partially degrade or disassociate tissues within the plant straw. For example, retting is useful for separating fibres that are found within the sclerenchyma of plant straw, also known as bast fibre, which is a layer of tissue that surrounds the phloem tissue and the xylem tissue in the plant straw. As will be appreciated by one skilled in the art, the pre-processed plant-straw product may also be prepared by means other than retting so that the pre-processed plant-straw product can be used as an input for embodiments of the present disclosure.

Sevenhuysen et al. describe one or more retting processes that produce a retted product that is a suitable input for embodiments of the present disclosure. The term “retted product” refers to the plant material that may be heterogeneous in that it contains the retted plant straw's constituent components. As used to herein, the term “fully-retted product” and “input” refers to all of the fibre component having been separated from other plant components without any or with minimal damage to the content, structure or integrity of fibres in the fibre component during a retting or similar process.

The person skilled in the art will appreciate that the separating that occurs during the retting process does not produce fibres that are readily useful for producing textiles and further processing or treatments are required for this purpose. For example, the fully-retted product contains the fibre component and the gel component within distinct structures that are sometimes referred to as bundles or fibre bundles. The bundles may be adhered to parts of the stalk component. This adhesion is thought to occur because the fibres are attached through various mechanisms, including the plant materials called lignin and pectin that create fibre bundles, the plant materials called gums that create waterproof barriers, the plant materials called cellulose that create stalk nodes and branches in the straw. A fully-retted product may have bundles of fibre component and gel component that can be fully separated from the stalk component with mechanical action that is designed to maintain the content, structure or integrity of fibres within the fibre component.

The gel component may comprise, but is not limited to: pectin, lignin, other polysaccharides and calcium ions. The fibre component is made up of individual fibres that may be suitable for further processing to produce textiles once they are further separated from the gel component and the stalk component.

FIG. 1 shows one embodiment of the present disclosure that relates to an apparatus 100 that comprises at least one of the following processing units: a first separation-unit 10, a second separation-unit 20 and a third separation-unit 30, a fourth separation-unit 40, a drying-unit 50 and an optional fluid-recycling system 60. The apparatus 100 may further comprise a conveying system 90 that conveys materials (inputs, intermediate products or final products) into, through and from the processing units of the apparatus 100. In some embodiments of the present disclosure, the conveying system 90 can comprise one or more endless loop belts that conduct any materials thereupon in a given direction within or between one or more processing units. Optionally, the materials upon the one or more belts of the conveying system 90 may receive a treatment while upon the one or more belts. In a further option, the one or more belts of the conveying system 90 themselves may contribute towards a treatment of the materials thereupon. For example, one or more of the belts of the conveying system 90 may facilitate separation of different components of the material thereupon. Additional to the conveying system 90 or alternative thereto, the inputs, intermediate products and final products can move into, through and out of the apparatus 100 while flowing under gravity while entrained in a fluid. In some embodiments of the present disclosure there may also be bulk movements of intermediate products between or from one or more of the processing units.

In some embodiments of the present disclosure, the apparatus 100 may have an input end 100A and an output end 100B with the first, second, third, fourth separation-units 10, 20, 30, 40 and the drying unit 50 arranged therebetween. In some embodiments of the present disclosure the first, second third, fourth separation-units and the fifth drying unit, 10, 20, 30, 40 and 50 are arranged in series between the input and output ends 100A, 100B.

FIG. 2 shows one embodiment of the apparatus 100 that is supported upon a frame 110. The frame 110 supports the first separation-unit 10 above the second separation-unit 20, which is supported above the third separation-unit 30. Materials within the apparatus 10 may move therewithin by gravity (or fluid pressure) acting upon a fluid in which the materials are entrained, floating within or simply being moved by. The first separation-unit 10 receives a pre-processed plant-straw product, which is also referred to herein as the input (shown as the curved arrow in FIG. 4). In some embodiments of the present disclosure, the input is a fully-retted product. The first separation-unit 10 separates a gel component and a fibre component from a stalk component of the input by reducing the adherence of the gel and fibre component to the stalk component. The input may be placed on a first belt 91 of the conveying system 90 for conveying the input into the first separation-unit 10 in a first direction. The arrangement of the input may influence the fibre product yield and quality in the drying unit 50. Stalks should be placed on belt 91 in parallel to the rollers of separation-unit 10 and with gaps between stalks that prevents two or more stalks from passing between the rollers at the same time. Alternatively, the input may be placed directly into the first separation-unit 10 by a belt (not shown) that is part of a hopper system 120 (shown as dashed-line box in FIG. 2), where the hopper system 120 temporarily holds the input and one or more belts place a desired amount of the input and in a desired orientation on the belt 91.

As shown in FIG. 4, the first separation-unit 10 comprises either or both of at least two opposed rollers 12 and one or more liquid jets 14. The at least two rollers 12 may be horizontally positioned. The at least two rollers 12 are positioned to come into contact with the input as it passes between the at least two rollers 12. In some embodiments of the present disclosure, the at least two rollers 12 comprise a first roller 12A and a second roller 12B. The first and second rollers 12A, 12B each have a substantially contiguous externally facing surface that is covered in bristles or other textured points that extend away from the externally facing surface. The bristles extend between about 0.5 inches and about 2.0 inches away from the externally facing surface. The first and second rollers 12A, 12B rotate about their respective longitudinal axes. The bristles may be covered in a cloth. Suitable examples of the cloth include but are not limited to: polyester, rayon, microfiber, a cellulosic fabric or combinations thereof. In some embodiments of the present disclosure, the first and second rollers 12A, 12B rotate at different speeds and/or in different directions.

When the input passes through and into contact with the first and second rollers 12A, 12B, the cloth, the differential rotational speed of the first and second rollers 12A, 12B or the combination of both substantially loosen and/or separate the stalk component from the gel component and the fibre component of the input (shown as the straight arrow in FIG. 4). In some instances, the separated stalk component may also include a portion of the gel component adhered to or otherwise associated with the separated stalk component. Through one or more of a physical act of rubbing, wiping or stripping, the first and second rollers 12A, 12B physically separate the stalk component from the gel component and the fibre component. Optionally, the cloth may be selected to provide an optimized co-efficient of friction for the externally facing surface of the first and second rollers 12A, 12B that contacts the input. The individual rotational speed of the first and second rollers 12A, 12B may also be selected to optimize the frictional engagement of the input to increase the physical separation of the stalk component from the gel component and the fibre component.

Additionally or alternatively, the first separation-unit 10 comprises the one or more jets 14 positioned above and below the rollers 12A and 12B. The jets 14 direct pressurized processing fluids at the input while passing between the rollers 12A and 12B. The pressure of the processing fluids may range from between about 1 psi to about 10 psi. In some embodiments of the present disclosure the pressure of the processing-fluid is ejected from the one or more jets 14 at a pressure of about 3 psi. The volume and pressure of the processing fluids applied to the input that is passing between rollers 12A and 12B is sufficiently high to physically separate the stalk component from the gel component and the fibre component. Preferably the pressure of the processing fluids is not so great as to cause significant damage to the structural integrity of the individual fibres within the fibre component. In some embodiments of the present disclosure, the processing fluids may be a liquid that is obtained from the fluid-recycling system 60 or it may be obtained from other sources. In some embodiments of the present disclosure, the processing fluids is a liquid that is primarily water or it may be entirely water. In other embodiments of the present disclosure, the processing fluids may be another inert fluid.

FIG. 5 shows one embodiment of the second separation-unit 20 that receives an intermediate product of the first separation-unit 10, which comprises a mixture of the stalk component, the gel component and the fibre component (shown as the straight arrow in FIG. 5A). The fibre component is often still adhered to the majority or all of the gel component. The flow of fluids associated with the stalk, fibre and gel components from the first separation-unit 10 may move some or substantially all of this material on to a second belt 92 which is part of the conveying system 90. Some, most or substantially all of the fibre component and the gel component remain within the flow that continues under gravity (or further pressure provided by the one or more jets 14) to the third separation-unit 30 below (see larger curved arrow in FIG. 5A). The stalk component, however, remains upon the second belt 92. As described further below, the second belt 92 separates the stalk component from any of fibre and gel components that have not already flowed onto the third separation-unit 30 below.

The second belt 92 has a first end 92A and a second end 92B. The second belt 92 may be made of rubber, plastic, canvas, metal-links or other materials than can convey the material received from the first separation-unit 10 towards a stalk container 24 (see smaller curved arrow in FIG. 5A). An upper surface 92A of the second belt 92 receives the material from the first separation-unit 10 and, optionally, may include one or more protrusions 94 that provide textured portions of the second belt 92 (see FIG. 5B). In operation, the upper surface 92A moves in a direction from the first end 92A to the second end 92B. The one or more protrusions 94 may all be raised the same height above the upper surface 92A of the second belt 92, or they may be different heights. In some embodiments of present disclosure, one or more of the protrusions 94 may be raised between about 0.1 inches to about 2 inches above the upper surface 92A of the second belt 92. In some embodiments of the present disclosure, one or more of the protrusions 94 may be raised between about 0.25 and about 0.5 inches above the upper surface 92A of the second belt 92. In some embodiments of the present disclosure, one or more of the protrusions 94 may be raised between about 0.25 inches above the upper surface 92A of the second belt 92. Optionally, the upper surface 92A of second belt 92 is ribbed, studded, folded or otherwise textured to enhance separation of the stalk component from the gel and fibre components. The stalk component may be moved to the stalk container 24 by the second belt 92. The second end 92B of the second belt 92, which is shown in FIG. 5A as being the end that is closest to the stalk container 24 can be elevated as compared to the first end 92A. This elevation may allow substantially some or all fluids—and the fibre component and gel component therein—to flow downwardly towards and off the first end 92A. In some embodiments of the present disclosure, the second belt 92 is a studded canvas belt. In some embodiments a stalk comb 26 can be positioned upon a portion of the frame 110 between the second end 92B and the stalk container 24. The stalk comb 26 can catch or remove some or substantially all of any stalk that doesn't fall off the belt 92 into the stalk container 34.

FIG. 6 shows one embodiment of the third separation-unit 30 that receives an intermediate product from the second separation-unit 20 (shown by the vertical arrow in FIG. 6) due to the flow of fluids from the second separation-unit 20. This intermediate product comprises the gel component and the fibre component and it is preferably substantially free of the stalk component. The third separation-unit 30 comprises a third belt 93 that is at least partially comprised of a mesh. The third belt 93 has a first end 93A and a second end 93B. The mesh defines holes therethrough of a specific gauge from between about 150 microns (μm) to about 250 μm. In some embodiments of the present disclosure the holes have a median gauge of about 177 μm. In some embodiments of the present disclosure, the third belt 93 may be an endless loop that has an upper level 93C and a lower level 93D. The upper and lower levels 93A, 93B may be substantially horizontal and parallel. The upper and lower levels 93A, 93B may be supported by and separated by at least two rollers that are positioned at opposite ends of the third belt 93. In operation, the upper layer 93C moves from the first end 93A towards the second end 93B.

As the gel component and the fibre component move upon the third belt 93 a further one or more jets 14¹ may apply processing fluids, such as water or otherwise, to rinse the gel component and the fibre component. The further jets 14¹ may be positioned between the first end 93A and the second end 93B and the further jets 14¹ are configured to direct the processing fluids at the material upon the upper layer 93C.

The third separation-unit 30 also comprises at least one set of substantially opposed rollers 32 that are positioned above and below the upper layer 93C. In some embodiments of the present disclosure, the substantially opposed rollers 32 comprise an upper roller 32A and a lower roller 32B. As the fibre component and the gel component pass between the upper and lower rollers 32A, 32B, the fibre component and the gel component pass through a pinch point where they directly contact both of the upper and lower rollers 32A, 32B. At this pinch point, at least some of the gel component is compressed and pushed through the holes defined by the third belt 93. The one or more further jets 14¹ direct pressurized processing fluids at or near the pinch point to facilitate pushing at least some of the gel component through the second belt 93. The pushed gel component and some or most or all of the processing fluids that is directed at the pinch point is collected in one or more collection trays 62 that are positioned between the upper and lower levels 93C, 93D. As will be discussed further below, the fluids within the one or more collection trays 62 may be transported within the fluid-recycling system 60 for further processing and further use within the apparatus 10. While FIG. 6 only shows one collection tray 62 the person skilled in the art will understand that more collection trays 62 can be present at different positions between the first end 93A and the second end 93B and between the upper and lower layer 93C, 93D.

Because some or most or all of the fibres within the fibre component are larger than the holes in the third belt 93, the fibre component remains on an upper surface of the upper level 93C. As the fibre component reaches the end of the upper level 93A, in the area where the upper level 93A passes around one of the rollers and transitions in to the lower level 93B, some or most or all of the fibre component falls off of the third belt 93 into one or more fibre collection trays 28 (shown as the curved arrow in FIG. 6). Any portions of the fibre component that do not fall of the third belt 93 are washed off the lower level 93B by pressurized processing fluids that are directed at the upper level 93A, for example by the fluid delivered from the further jets 14¹. The portion of the fibre component that is washed off the lower level 93B is collected by further collection trays 28. FIG. 2 shows one embodiment of a further collection tray 28 and FIG. 3 shows another embodiment of a further collection tray 28A. As shown, the further collection tray 28A may extend a greater distance between the first end 93A and the second end 93B and it may include a ramp 29 that collects the processing fluids and the fibre component therein that drop off the third belt 93 at a position other than proximal the second end 93B.

FIG. 7 is a drawing of one embodiment of the fourth separation-unit 40 that receives the fibre component from the further collection trays 28 (or 28A as the case may be) of the third separation-unit 30. In some instances, the fibre component may still have some residual gel adhered thereto, which causes a portion or all of the individual fibres within the fibre component to adhere to each other. To facilitate removal of some or most or all of this residual gel and to separate the individual fibres from each other, the fibre component is moved to the fourth separation-unit 40.

In some embodiments of the present disclosure, the fourth separation-unit 40 may comprise between about 1 and 10 separate treatment processes that treat the fibre in batches. For example, some embodiments of the present disclosure may have multiple fibre-cleaning sections arranged in series. The fourth separation-unit 40 may comprise one or more containers 42 with one or more filters 44 positioned therein and each treatment processes occur within container 42. For example, the one or more containers 42 may be vertically oriented, cylinders made of steel, plastic, other synthetic materials and the one or more filters 44 may be made of cloth, plastic, stainless steel or combinations thereof. The containers 42 can receive different treatment liquids from holding tanks 46 via one or more conduits 48. The cylindrical container 42 can move to agitate the fibre component and treatment liquids horizontally, vertically or both for a period of time referred to herein as a treatment cycle. After the treatment cycle, is complete the treatment liquids are drained from the cylindrical container 42 and the fibres remain within the cylindrical container 42 and they are rinsed with water. After rinsing is complete, the rinse water is drained and the fibres remain within the cylindrical container 42. In some embodiments of the present disclosure, the fibres can then be moved to another container 42 for a further treatment process or one container 42 can be used for all treatment processes, as described further herein below.

In some embodiments the present disclosure, seven treatment processes A, B, C, D, E, F and G may be arranged in series. In each treatment process, the fibre is agitated within the treatment fluid for a sufficiently long time to obtain a cleaning effect or a surface modification or both. The fibre may then be rinsed with water between the treatment processes. The fibre component that exits treatment process G is not rinsed.

For treatment process A, the cylindrical container 42 contains water as the treatment liquid TLA. The fibres are placed in the water and the fibre-water mixture is continuously agitated and heated to about 92° C. The treatment cycle during which the fibre-water mixture is exposed to the maximum temperature has a duration of between about 1 minute and about 20 minutes. Some treatment cycles of the treatment process A have a median duration of about 3 minutes. After which, the hot water is drained and the fibre component is cooled to about 40° C. or lower. Without being bound by any particular theory, the treatment process A may decrease the adhesion of the other components to the fibre surfaces.

For treatment process B, the cylindrical container 42 contains a treatment liquid TLB that is a mixture of water, anionic surfactants, alkaline builders, water softening agents such as those that are present in most commercially-available laundry detergents (collectively the “detergent-like components”). The detergent-like components are present within the TLB in a concentration that ranges between about 1% wt/wt to about 5% wt/wt of. In some embodiments of the present disclosure the concentration of the detergent-like components within the TLB is about 2% (wt/wt). The treatment cycle during which the fibres are exposed to the TLB has a duration of between about between 2 minutes and about 30 minutes. Some treatment cycles of the treatment process B have a duration of about 7 minutes. Without being bound by any particular theory, the treatment process B may remove plant materials that adhere to the fibre surfaces by a hydrophilic mechanism.

For treatment process C, the cylindrical container 42 contains a treatment liquid TLC that is a mixture of water and an oil component. The oil component can be selected from one or more of vegetable oil, mineral oil or a synthetic oil. The oil component can have a concentration within the treatment liquid C that ranges from 40% wt/wt to 60% wt/wt. In some embodiments of the present disclosure the concentration of the oil component within the TLC is about 50% (wt/wt). The treatment cycle during which the fibres are exposed to the treatment liquid TLC has a duration of between about 5 minutes and about 30 minutes. Some treatment cycles of the treatment process C have a duration of about 14 minutes. After the treatment process C is completed and the treatment liquid TLC is substantially drained, some pressure is applied to the fibres to remove some or all of the remaining treatment liquid TLC was adhered to the fibre surfaces and this remaining treatment fluid TLC is drained. Without being bound by any particular theory, the treatment process C may remove some or all of the plant materials that adhere to the fibre surfaces via a lipophilic mechanism.

For treatment process D, the cylindrical container 42 contains a treatment liquid TLD that is a mixture of water, one or more surfactants, a hydrotrope, and one or more salts, such as those types of components that found in commercially available kitchen soaps (collectively the “soap-like components”). The soap-like components are present in the TLD within a concentration that ranges from about 0.5% wt/wt to about 5% wt/wt. In some embodiments of the present disclosure the concentration of the soap-like components within the TLD is about 2.5% (wt/wt). The treatment cycle during which fires are exposed to the TLD has a duration of between about 2 and about 30 minutes. In some embodiments of the present disclosure the duration of the treatment cycle with the TLD is about 7 minutes. Without being bound by any particular theory, the treatment process D may remove plant materials that adhere to the fibre surfaces due to either or both of a hydrophilic mechanism and a lipophylic mechanism.

For treatment process E, the cylindrical container 42 contains a treatment liquid TLE that is a mixture of water and live yeast culture, with an initial concentration yeast in the water is within a range of about 0.01% wt/wt to about 1% wt/wt. In some embodiments of the present disclosure the concentration of the yeast has an initial median concentration of about 0.1% (wt/wt). In some embodiments of the present disclosure, the TLE may additionally or alternatively to the yeast culture, contain a mixture of water and an amylase enzyme or one or more others enzyme with a similar function (collectively the enzyme component). The enzyme component can be present in the TLE within a concentration that ranges from about 0.05% wt/wt to about 2% wt/wt. In some embodiments of the present disclosure the concentration of the enzyme component is about 0.5% (wt/wt). The treatment cycle during which time for exposure of the fibres to the TLE depends on the weight of fibre being treated, the concentration of the yeast and water mixture, and the temperature of the mixture. For example exposing the fibres to a high concentration of yeast at 30° C. for between about 1 minutes to about 5 minutes may suffice whereas exposing the fibres to a low concentration of yeast at 20° C. may require about an hour. Without being bound by any particular theory, the treatment process E may reduce a chemical reactivity of the surface of the fibres.

For treatment process F, the cylindrical container 42 contains a treatment liquid TLF that is a mixture of water and protein. In some embodiments of the present disclosure, the protein or exudate of the protein can alter the chemical reactivity of the surface of the fibres. Some examples of the proteins include, but are not limited to: albumin, ovalbumin, muco-proteins and globulins, the denatured state of these proteins, synthetic proteins, manufactured protein and combinations thereof. The concentrations of protein in the TLF ranges from about 1% to about 50%. In some embodiments of the present disclosure the concentration of protein in the TLF is about 20%. The treatment cycle for treatment process F has a duration of about 1 minute to about 5 minutes. Without being bound by any particular theory, treatment process F may reduce the chemical reactivity of fibre surfaces.

For treatment process G, the cylindrical container 42 contains a treatment liquid TLG that is a mixture of water, one or more detergents and one or more industrial fabric softeners. The detergent may have a concentration that ranges from about 0.5% wt/wt to about 3% wt/wt. In some embodiments of the present disclosure the concentration of the detergent is about 1.5% (wt/wt). The industrial fabric softener may have a concentration that ranges from about 0.5% wt/wt to 3% wt/wt. In some embodiments of the present disclosure the concentration of the industrial fabric softener is about 1.5% (wt/wt). The treatment cycle during which the fibres are exposed to the detergent and the industrial fabric softener has a duration of between about 2 and about 30 minutes. In some embodiments of the present disclosure the treatment cycle of treatment process G is about 7 minutes. Without being bound by any particular theory, treatment process G may reduce adhesion of one fibre to other fibres.

The person skilled in the art will appreciate that the order of treatment processes A, B, C, D, E, F and G described may differ, or two or more treatment processes maybe combined, or treatment processes may be omitted and these variabilities can result from the type of fibre that the apparatus 100 is being used to isolate. The person skilled in the art will also appreciate that the treatment process A, B, C, D, E, F and G may occur in single container 42 or in multiple containers 42.

In some embodiments of the present disclosure a single enzyme-treatment with an enzyme, such as pectinase, or an enzyme or an enzyme mixture with a similar function to pectinase, may be incorporated into the seven treatment processes A, B, C, D, E, F and G. In some embodiments of the present disclosure the enzyme-treatment may replace one or more of the seven treatment processes A, B, C, D, E, F and G.

FIG. 8 shows one embodiment of the dryer unit 50, which is also referred to herein as the fifth separation-unit. The dryer unit 50 receives individualized fibres from the fourth separation-unit 40 by a bulk transfer, such as by hand or tool, or by another belt (not shown) of the conveying system 90. The fifth separation-unit 50 may dry the isolated and collected fibres in a batch process to produce individualized fibres. The fifth separation-unit 50 may comprise a fan 52, a container 54 and a collection filter or bag 56. In operation, the fibres are placed inside of the container 54 and the fan 52 moves air through the container 54 into the filter 56. Air in the separation-unit 50 moves from the fan 52 to the filter 56 under the substantially lowest pressure that is required to move the air through the filter 56. All components of the fifth separation-unit 50 can be sealed to be airtight except for the fan 52 and the filter 56. Wet fibres may be placed in container 54 when no air is moving through an access hole that can be closed with a sealable and removable lid. Equipment 58 may also be positioned within the container 54 such as one or more interacting combs, brushes and studded surfaces that can be used to agitate, by lifting and separating, the wet fibres from each other. Substantially air-tight gloves 59 can extend through a sidewall of the container 54 so that a user can agitate the fibres therein with one or more of the tools 58. In some embodiments of the present disclosure, the collection filter 56 may be made of woven or non-woven polyester, a woven or non-woven stainless steel mesh, synthetic material, of any material that can function as a filter with the openings that are sized between about 5 μm and about 25 μm.

Agitating the wet fibres causes the fibres therein to be at least partially individualized and at least partially dried. Optionally, the flow of inert gas pushes the at least partially individualized and at least partially dried fibres onto a fibre filter for collection.

In some embodiments of the present disclosure, the equipment 58 in container 54 may comprise two or more rotating brushes where the bristles of one brush overlap with the neighbouring brush. The brushes rotate in opposite directions. One can brush pick up wet fibres from a solid surface and the wet fibres are then passed from one brush to the next, and the solid surface, until the fibres are dry. The moving air in container 54 moves the dry fibres from the brushes to the fibre collection filter 56.

In some embodiments of the present disclosure, the equipment 58 can comprise a cone-shaped circular surface one or more projections that extend away from the surface and above the surface, and one or more rotating members with filaments that project away from the members and below the members. The rotating members move in a plane that is substantially parallel to the cone-shaped circular surface. The filaments that rotate above the cone-shaped circular surface move between the projections reach this surface. The one or more rotating members may be connected to a rotating support member, a central hub or other suitable means for supporting and rotating the one or more rotating members.

The wet fibres are dropped on to the projections at the highest point of the cone-shaped surface. The movement of the filaments of the rotating members push the wet fibres towards a peripheral edge of the cone-shaped circular surface. Optionally, a substantially constant flow of inert gas is directed towards the first surface to help dry out the wet fibres while they are being agitated.

In some embodiments of the present disclosure, the fifth drying-unit 50 may comprise a liquid container with an inert fluid that does not react with the material components of the fibres. Examples of the inert fluid include, but are not limited to: a fluid-fluorocarbon and other natural or synthetic inert fluids, or combinations thereof. The individualised fibres may be placed in the liquid container, and the fluid and fibres are stirred in a circular direction. The inert fluid replaces the water adhering to the fibres which has the effect of drying the fibres. The inert fluid adhering to the fibres can then be removed by moving air.

FIG. 9 shows one embodiment of the fluid-recycling-system 60 that receives processing fluids from at least the third separation-unit 30. The fluid-recycling-system 60 collects and recycles processing fluids that are used by the apparatus 100, specifically the third separation-unit 30. The fluid-recycling-system 60 comprises one or more tanks 62 that are fluidly connected with one or more pumps by one or more fluid conduits. The processing of plant straw to produce fibres that are suitable for making textiles requires relatively large amounts of processing fluids and particularly liquids. The present disclosure discusses water with a portion of the gel component suspended therein as gel particles as an example of a suitable processing fluid. It is understood that other processing fluids may also be produced and collected and reused in a similar fashion by the fluid-recycling-system 60, as described herein below.

The use of water during mechanical separation processes may reduce the damage and breakage of the individual fibres within the fibre component. The fluid-recycling-system 60 reduces the water requirements from external sources. In effect, the recycling system 60 may improve the economics of the apparatus 100 and decrease the environmental impact of such water input and disposal requirements.

Water may have a portion of the gel component therein as a suspension of gel particles. In some embodiments, the fluid-recycling-system 60 separates some or most or all of the gel component from the water so that the water can be recycled back into the apparatus 100. The water collected by the fluid-recycling-system 60 is directed to a separation tank 62 by one or more conduits.

The separation tank 62 introduces air into the suspension by a mixing action. Without being bound by any particular theory, the air can attach to the suspended gel-particles causing the gel particles to collect into a layer of floating gel-particles. In some embodiments of the present disclosure, the separation tank 62 includes one or more rotatable blades, wires or fixtures designed to mix, agitate or froth liquid mixtures that can rotate at around 1000 to 1800 rpm. Optionally, the rotatable blades are positioned below the surface of the suspension, for example between about 2.5 cm to about 7.5 cm below the surface. When the rotatable blades are rotating at or near these speeds, they can create a vortex within the suspension, which forces the air into the suspension.

In some embodiments of the present disclosure, it has been observed that about 98% of the floating gel-particles are positioned at or near the surface of the tank 62 after only about 3 minutes of rotation of the rotating blades. The layer of floating gel-particles needs between 2 and 3 minutes to form on top of the liquid and suspension in tank 62. Tank 62 is configured to maintain a substantially calm-surface. After some time, the majority of the floating gel-particles float up and collect upon the substantially calm-surface of the liquid in the tank 62.

In some embodiments of the present disclosure, the layer of floating gel particles is then conveyed by the moving liquid in tank 62. The liquid in tank 62 moves through tank 62 when the liquids from the third separation-unit 30 enter tank 62 at one end of the tank and one or more pumps remove the liquids from the opposite end of tank 62. Tank 62 comprises a separator 64 that can be a skimming floater or a rotating disc, as described further below. The skimming floater is in fluid communication with a suction pump 66 that removes the floating gel-particles, which may also be referred to herein as gum, from the surface of the skim tank 62. The suction pump can attach to a hose that redirects the gum to a container outside the tank.

Alternatively, the separator 64 is one or more rotating discs of which the bottom half is submerged in the water. The discs can be positioned vertically or slanted while positioned in the water. The surface of the discs would attract the floating or suspended gums, which may consist of material that attracts gums, such as Teflon™, aluminum oxide, fabrics or sponges of any suitable type. As the discs rotate they lift gums out of the water. A boom comprised of a length of metal, plastic or synthetic material touches the half of the disc that is not in the water and wipes, scrapes or rubs the gums off of the discs. The surface of this boom may be grooved to allow the gums being removed to flow down the boom and can attach to a hose that redirects the gum to a container outside the tank. Optionally, the removed gel-particles may be collected for further use.

Once some or substantially all of the gel-particles are removed from the suspension, the gel-particle content of the suspension is substantially decreased. For the purposes of the present disclosure, at this point the suspension is a liquid that is substantially water, which is referred to herein as recovered water. For example, in using some embodiments of the present disclosure, it has been observed about 1% to 3% (wt/wt) of gel-particles remain in the recovered water. The recovered water may then be introduced back into the apparatus 100 by a pump and one or more of the jets 14, 14¹ for use in one or more of the separation units 10, 20, 30, 40 or at other positon within the apparatus 100.

Substantially decreasing the gel-particle content of the recovered water avoids introducing gel particles into the apparatus 100, which is desirable because reintroduced gel-particles may interfere with some of the various functions of the apparatus 100. Among other things, reintroduced gel-particles can interfere with one or more belts or rollers of the conveying system 90, one or more rollers of the first and second separation-units 10, 20 and possibly one or more of the various components of the third separation-unit 30.

Some embodiment of the present disclosure use one or more jets 14¹¹¹ at various points within the apparatus 100. The jets 14¹¹¹ can be advantageous in separating the fibre component from the stalk component and/or the gel component. In some embodiments of the present disclosure, the fluid-recycling-system 60 reduces the loss of processing fluids and, therefore, the more jets 14¹¹¹ may be used without substantially increasing the processing fluid input requirements. For example, in some embodiments of the present disclosure, the apparatus 100 comprises at least two sets of further jets 14¹¹¹ that direct a pressurized processing fluids at the fibre component and the gel component upon the third belt 93 before the opposed rollers 32.

In use, the apparatus 100 performs a method of processing plant straw for separating the fibre component from the stalk component and the gel component. The method comprises at least the steps of collecting plant straw; retting the plant straw to produce a pre-processed plant-straw product for use as a process input; separating the stalk component of the input from a fibre component and a gel component by friction and spraying with the processing fluid under medium pressure. The method further comprises the steps of transferring most of the stalk component away from the fibre component and the gel component for drying and later use; separating the gel component from the fibre component by compressing the gel component through a mesh and collecting the fibre component from a first side of the mesh and collecting a suspension of gel particles in the processing fluid.

Optionally, the method further comprises the steps of collecting the processing fluid; mixing the processing fluid to introduce air therein for causing the suspended gel particles within the processing fluid to float; removing and collecting the floating gel-particles to produce recovered water. Optionally the recovered water can be used during one or more of the steps described above.

FIG. 10 shows a logic-flowchart that depicts another embodiment of the present disclosure that relates to a method for separating a fibre component from a retted-straw input. The dotted lines represent optional process-steps that include a second water and detergent recycler for processing larger amounts of fibre.

Claims

1. An apparatus for separating one or more fibres from a pre-processed plant-straw input, the apparatus comprising:

a first separation-unit for receiving the pre-processed plant-straw input and for separating a stalk component from a fibre component and a gel component of the pre-processed plant-straw product by friction and/or pressure; and

a third separation-unit for separating at least a portion of the gel component from the fibre component by compressing the at least a portion of the gel component through a mesh.

2. The apparatus of claim 1, wherein the third separation-unit comprises a belt that is at least partially made up of the mesh and wherein the belt is configured to receive the gel component and the fibre component.

3. The apparatus of claim 2, wherein the third separation-unit comprises a pair of opposed rollers that are positioned above and below the mesh and wherein the opposed rollers define a pinch point where the at least a portion of the gel component is compressed through the mesh.

4. The apparatus of claim 3, further comprising one or more jets for directing a pressurized flow of process fluids towards the mesh.

5. The apparatus of claim 4, further comprising one or more jets for directing a pressurized flow of process fluids towards or proximal to the pinch point.

6. The apparatus of any one of claim 5, further comprising a collection tray for receiving the gel component that has been compressed through the mesh and wherein the collection tray is positioned below the mesh.

7. The apparatus of any one of claim 6, further comprising a further collection tray for receiving the fibre component from the mesh and wherein the collection tray is positioned below the mesh.

8. The apparatus of claim 1, wherein the first separation-unit comprises a pair of opposed rollers for receiving the pre-processed plant-straw input therebetween and wherein the pair of opposed rollers apply friction to the pre-processed plant-straw input.

9. The apparatus of claim 8, wherein the pair of opposed rollers comprise bristles and/or are covered in a cloth selected from a group consisting of: polyester, rayon, microfiber, a cellulosic fabric and combinations thereof.

10. The apparatus of claim 9, wherein the pair of opposed rollers rotate at the same speed or different speeds.

11. The apparatus of claim 10, wherein the pair of opposed rollers rotate in the same direction or different directions.

12. The apparatus of claim 10, further comprising one or more jets that direct a pressurized treatment fluid at or proximal to between the pair of opposed rollers.

13. The apparatus of claim 1, further comprising a second separation-unit for receiving an intermediate material from the first separating-unit, wherein the second separation-unit comprises a textured belt for separating the stalk component from the fibre component and the gel component.

14. The apparatus of claim 1 further comprising a fourth separation-unit for receiving the fibre component from the third separating-unit, wherein the fourth separation-unit comprises a container and internal filter and the container is configured to treat the fibre component with one or more chemical-based process treatments for separating the fibre component from a residual gel-component.

15. The apparatus of claim 14, wherein the chemical-based process treatments are selected from a group consisting of: exposure to water and heat; exposure to a mixture of water and one or more detergent-like compounds; exposure to a mixture of water and one or more oils; exposure to a mixture of water and one or more soap-like compounds; exposure to a mixture of water and one or more proteins; exposure to a mixture of water, one or more detergent-like compounds and one or more industrial fabric softener compounds; and combinations thereof.

16. The apparatus of claim 1, further comprising a fluid recycling-system for recovering process fluids from the apparatus and for separating gel particles from the process fluid to produce recovered water.

17. The apparatus of claim 16, further comprising one or more conduits for conducting the recovered water for use in the apparatus.

18. The apparatus of claim 16, wherein the fluid recycling-system comprises a collection tank for receiving process fluids with a gel component therein from the apparatus and a separator for causing particles of the gel component to float.

19. A method of processing a pre-processed plant-straw input for producing a fibre, the method comprising steps of:

a. separating a stalk component, a fibre component and a gel component from the pre-processed plant-straw input by applying friction and/or pressurized treatment fluids to the pre-processed plant-straw product; and

b. separating the gel component from the fibre component by compressing the gel component through a mesh.

20. The method of claim 19, further comprising steps of:

c. collecting processing fluids used during step a or step b;

d. reducing an amount of the gel component in the collected processing fluids to produce recovered water; and

e. using the recovered water as at least part of the treatment fluids in step a and/or as a treatment fluid in step b.