SYSTEM FOR THE PROCESSING AND RESUPPLY OF PULP AS WELL AS A METHOD FOR THE CONSTRUCTION THEREOF

Abstract

The present disclosure relates to a system for pulp processing and resupply of production-quality pulp to at least one fiber molding system, where the system is constructed in scalable modular form. For this, the system includes at least one supply module (110) and one or more process modules (120). The supply module (110) and the process modules (120) are equipped with a plurality of interfaces (150), matched to one another in each case, in order to connect supply and process modules (110, 120) to one another. This may guarantee the infrastructure supply of the process modules (120). The pulp or the constituents and starting materials may be received via at least one inlet (130) and transported between the process modules (120) to provide the production-quality pulp (160) via an outlet (140) for use by at least one fiber molding system.

Description

TECHNICAL FIELD

Embodiments described herein relate to a system for pulp processing and resupply of production-quality pulp to at least one fiber molding system, wherein the system is constructed in scalable modular form, as well as a fiber molding system with such a system and also a method for the construction of such a system as well as a method for extending such a system.

BACKGROUND

It is desirable to protect citizens and the environment from plastic pollution. In particular, single-use plastic products such as packaging materials or plastic cutlery and tableware generate a large amount of waste. In this respect, there is an increasing need for substitutes for packaging materials and containers made of plastic, with which these products can be made from recyclable plastics, materials with less plastic content or even from plastic-free materials.

The idea of using natural fibers instead of conventional plastics in the extrusion process has existed at least since the early 1990s, see for example EP 0 447 792 B1. As in most fiber-processing processes, the basic raw material is pulp. In principle, pulp consists of water, natural fibers and a binder, such as industrial starch (potato starch) and has a paste-like consistency.

Since consumers are interested in a very wide variety of ecologically friendly products with different sizes, shapes, and requirements, and do not necessarily ask for them in very large quantities, it would be desirable to have available a process for producing environmentally friendly molded parts made of natural fibers and a corresponding machine, in order to be able to reproducibly produce these products (molded parts) effectively, flexibly and with a good level of quality. Moreover, it is very important here if the molded parts can be produced in large numbers in the shortest possible time, with the result that systems or stations with a large throughput are desirable.

A pulp can be used as starting material for producing products made of fibrous material. A liquid solution with a particular proportion of fibrous material is called pulp. For a high-quality and reproducible manufacture of products made of fibrous material, the pulp, as starting material, should therefore be produced in a controlled manner. For this, a fiber molding system uses a pulp bath, out of which the products made of fibrous material are molded as so-called blanks. Here, only a small part of the pulp from the pulp bath (or reservoir) is used for the respective forming procedure, which denotes the first arranging of the fibrous material into the desired product shape with a corresponding tool (for example a suction tool). In order that the pulp bath has sufficient quality over the entire production time with a plurality of successively performed forming processes, that is to say is present in a particular purity with a suitable concentration of fibrous material in the liquid solution and with the desired properties of the fibrous material (length of the fibers, low crosslinking of the fibers with one another, no clumping, etc.), the pulp present must be reprocessed and spent pulp must be reliably resupplied with a good level of quality. It is therefore necessary to equip the fiber molding system for producing products made of fibrous material with a system for the processing and resupply of pulp.

For an economical operation of the fiber molding system, it is also desirable if the setting up and commissioning of such a fiber molding system with a system for the processing and resupply of pulp is possible quickly and with little effort. Since fiber molding systems can differ greatly in their size, throughput and number per production plant, a system for the processing and resupply of pulp which could meet at least the essential requirements of different fiber molding systems and production plants equally and would still make a quick commissioning with low installation effort possible would be desirable.

SUMMARY

An object of the present disclosure is to provide a system for the processing and resupply of pulp which meets at least the essential requirements of different fiber molding systems and production plants equally and still makes a quick commissioning with low installation effort possible.

The object is achieved by a system for pulp processing and resupply of production-quality pulp to at least one fiber molding system, wherein the system is constructed in scalable modular form, with at least one supply module, which comprises or at least controls the machines and infrastructure supply units necessary for the operation of the system, and one or more process modules, in which the pulp is reprocessed and/or produced for resupply and then provided, wherein the supply module and the process module are equipped with a plurality of interfaces matched to one another in each case, in order to connect supply and process modules to one another, in order to guarantee the infrastructure supply of the process modules and to receive the pulp or the constituents and starting materials thereof via at least one inlet and to transport them between the process modules, and to provide the production-quality pulp via an outlet for use by at least one fiber molding system.

The term “pulp” (also called suspension) denotes the liquid matter which contains fibers or the fibrous material. The term “liquid” denotes here the aggregate state of the pulp, wherein the liquid pulp comprises the fibrous material in the form of fibers (liquid solution with the fibrous material). Here, the fibers can be present as individual fibers, as a fiber structure or fiber group composed of several connected fibers. The fibers represent the fibrous material irrespective of whether they are present in the pulp as individual fibers, as a fiber structure or a fiber group. Here, the fibers are dissolved in the liquid solution such that they float in the liquid solution with, as far as possible, the same concentration irrespective of location, for example as a mixture or suspension of liquid solution and fibrous material. For this, in some embodiments the pulp can, for example, be correspondingly heat-treated and/or circulated. The pulp possibly has a low stock consistency, i.e. a proportion of fibrous material in percent by weight of less than or equal to 18%. In an embodiment, a pulp with a proportion of fibrous material of less than 8%, preferably of less than 5%, is used as pumpable pulp, particularly preferably with a target concentration for the fiber molding process of between 0.75% and 1.25%. This low proportion of fibrous material can, among other things, prevent a clumping of the fibrous material in the liquid solution, with the result that the fibrous material can still be processed with a good level of quality. Although clumped fibrous material can be formed in the fiber molding system, it would probably result in a blank with fluctuating layer thickness, which is to be avoided in the production of the blanks as far as possible. In this respect, the proportion of fibrous material in the pulp should possibly be small enough that clumping or linking to one another does not occur or does so only to a negligible degree. The liquid solution can be any solution suitable for the fiber molding process. For example, the pulp can be an aqueous solution with the fibrous material. Among other things, an aqueous solution represents a solution that is easy to handle.

The resupply of production-quality pulp to the fiber molding system is necessary because, for each forming process, pulp or fibrous material is used up, i.e. removed from the pulp reservoir in the fiber molding system, during the process of forming the blanks out of the pulp in the fiber molding system. The properties of the remaining pulp are thereby altered over time. In order that a minimum quality of the molding process can be constantly guaranteed, production-quality pulp must be resupplied to the reservoir from pulp in the fiber molding system. For this, the system according to the disclosed embodiments must provide it. Here, the term “production quality” is meant as a relative term since different fiber molding processes can process different pulps with different levels of quality. Even for a particular fiber molding process it is only necessary to ensure that the production quality meets certain requirements. Here, the production quality of the pulp could even vary, as long as it does not fall below a minimum quality level. The quality of a pulp is calculated using a large number of parameters, such as for example the type and purity of the liquid solution, concentration of fibrous material in the liquid solution, properties of the fibrous material such as length of the fibers, degree of crosslinking of the fibers with one another, proportion of clumped fibers, etc. The thing which defines the production quality in each case depends individually on the respective fiber molding process in the fiber molding system. The term “fibrous material” denotes the fibrous materials of all types suitable for molding blanks, wherein these may possibly also be broken down under environmental influences such as humidity, temperature and/or light. Within the meaning of the present disclosure, fibrous materials are for example synthetic fibers or natural fibers obtained from cellulose, paper, cardboard, wood, grass, plant fibers, sugarcane residues, hemp etc. or from their constituents or parts thereof and/or correspondingly recycled material. However, the fibrous material can also denote synthetically produced fibers such as for example PLAs (polylactides) etc., which correspond to the above fibrous materials or have the properties thereof. The fibrous material is possibly compostable. Via its modular structure with the scalable number of process modules, the system according to the disclosed embodiments is suitable for providing different pulps with different properties, in order to satisfy different production qualities. Depending on the desired production quality and the required throughput, the system according to the disclosed embodiments can be correspondingly scaled and existing systems extended or modified without effort. The pulp with the desired level of production quality is provided for removal at the outlet of the system.

Pulp processing denotes on the one hand the processing of pulp from starting materials as well as the reprocessing of pulp by receiving pulp from a pulp reservoir of a fiber molding system, which is being or has been operated for the production of blanks from the pulp. Here, the “spent pulp” is fed back to the inlet of the system according to the disclosed embodiments via suitable means, such as for example return line(s), in order to be received in the system according to the disclosed embodiments via the inlet and then correspondingly processed, in order that production-quality pulp is available again at the end. Here, the process paths for reprocessing and for resupply from starting materials can be run separately and only mixed at the outlet or in a final pulp tank, or the spent pulp is fed into the process for resupply at an earlier point in the process and there processed further together with the “fresh” pulp. The portion of pulp which is produced from starting materials which are likewise fed into the system via the inlet is referred to here as fresh pulp.

The term “inlet” denotes one or more, possibly also separately mentioned interfaces with the outside, via which materials, whether starting materials for producing the pulp or “spent pulp”, are introduced into the system. For starting materials, the inlet can consist of a material hatch into which the starting material or materials are introduced, for example connected cellulose material for the production of the fibrous material present in the pulp. The outlet can denote one or more connected or separately implemented outlets from the system. Since the pulp is provided in the liquid state, the outlet can be designed as a pipe connection with an upstream valve for opening and metering the throughput through the pipe connection. In this respect, the inlet and the outlet likewise represent interfaces of the system with the outside.

Separate units, which are prefabricated with their constituents and can therefore be operated and linked to one another easily and with little effort, are referred to as modules. The term “supply module” denotes the modules which are provided solely for supplying to and operating the process modules. Because of their equipment, supply modules are not capable of being able to perform the processing and resupply process without the process modules, since no processing tanks are installed in them, for example. On the contrary, the machines and infrastructure supply units necessary for the process modules to carry out the process are installed in the supply modules. Here, the infrastructure supply comprises the supply of media, such as for example the water connections, power connections, possibly an internal power supply and control equipment for carrying out the process, such as for example computers with installed process control software, data cables, memories for process recording etc. The necessary machines comprise, for example, pumps for transporting material and liquid between the processing tanks in the process modules, valve controls and other necessary components. The term “process module” denotes the modules in which the processing tanks or process stations needed for the process for reprocessing spent pulp and/or the process for the resupply of fresh pulp are installed. Here, the individual process modules can differ depending on the desired process of the system. Here, for an increased throughput, the system can comprise several process modules with the same equipment. In differently implemented systems, for example, the individual process modules can all be implemented differently, if all process modules are to supplement one another for a common process. Here, in some systems according to the disclosed embodiments some process modules which are present in other systems according to the disclosed embodiments can be dispensed with depending on the desired production quality of the pulp provided. If, in place of supply and process modules, only modules are mentioned in the following, the statements relating to them apply to both the supply and the process modules, as long as this can be implemented within the scope of the disclosed embodiments.

The connections and transfer positions for media (power, water, compressed air, data cables etc.) and process constituents (starting materials, pulp intermediate and end stages) of the individual modules between one another are referred to as “interfaces” according to the present disclosure. In the case of pipe or tube connections, the interfaces can, for example, be implemented as compatible flanges. In the case of power or data cables, the interfaces can, for example, be implemented as connections that can be coupled according to the plug-socket principle. The interfaces can also comprise other coupling principles, as long as these make an uncomplicated, quick and reliable connection between the individual modules possible. The position of the interfaces on the respective modules is prefabricated and matched to one another such that direct couplings between the modules are made possible. The interfaces are possibly closed merely due to the direct arrangement of the modules next to one another. Whether all of the closed interfaces with the neighbouring module are also used then depends on the intended process. The unused interfaces can be used for a later connection of further modules, with the result that there is a scalability of the system according to the disclosed embodiments within the scope of the number of free interfaces. Due to the prefabricated interfaces, the system according to the disclosed embodiments thus has a scalable modular form. Moreover, the system can also be operated as a single-operator system with the minimum possible staffing requirements.

A system for the processing and resupply of pulp which meets at least the essential requirements of different fiber molding systems and production plants equally, and still makes a quick commissioning with low installation effort possible, is thus provided.

In one embodiment, the supply module is arranged as central module in the system and, in the case of several process modules, these are arranged around the supply module. The central supply module thus acts as central supply island of the system for all surrounding modules. Among other things, this makes a compact construction of the system possible, wherein this expressly also includes an arrangement of the modules one above another in addition to the arrangement of the modules in the same plane. For this, the supply and process modules also comprise interfaces not only laterally in the walls of the modules, but also in the base and/or in the top of the respective modules.

In a further embodiment, the supply module is composed of several sub-modules. This makes it possible for the sub-modules to be able to fulfil different supply tasks, as long as they are correspondingly equipped with different machines and/or infrastructure supply units. Among other things, this increases the further flexibility of the system.

In a further embodiment, the interfaces are implemented at least partially according to the plug-socket principle, possibly all interfaces are implemented according to the plug-socket principle. Among other things, this makes it possible to produce connections between the modules more quickly.

In a further embodiment, the outlet can be matched to the throughput of pulp of the connected fiber molding system via a corresponding valve. Control valves are known. Via a control of the valve, among other things, the pulp dispensed from the system can be continuously matched to the requirements of the fiber molding system.

In a further embodiment, the outlet is designed as a multiple outlet for connecting to several fiber molding systems. Among other things, several fiber molding systems can thus be connected to the same system for the resupply of production-quality pulp independently of one another. If one of these systems does not need any more pulp, for example because this system's production has been stopped, the other fiber molding systems can still be supplied further with pulp independently thereof. The use of a single system for pulp processing and resupply of production-quality pulp for several fiber molding systems also represents a sparing use of material and technology and makes an effective operation of the fiber molding systems and also of the system according to the disclosed embodiments possible, since the latter can thus be operated continuously over a longer period than would be the case in connection with only a single fiber molding system.

In a further embodiment, the multiple outlet is designed to be controllable for an individual throughput of pulp of the respective connected fiber molding system. For this, controllable valves can be used for the individual connections to the respective fiber molding systems. Such control valves are known. Via a control of the valve, among other things, the pulp dispensed from the system can be continuously matched to the requirements of the fiber molding system.

In a further embodiment, the system is operated such that it continuously provides a minimum amount of pulp at the outlet to be taken off by the connected fiber molding system. A continuous material flow at the inlet and outlet represents the operating scenario that is easiest to control for a system. However, the minimum amount must be taken off at the outlet in order to achieve a continuous process of the system over a long period. In a further embodiment, the system is therefore designed and controlled so as to be operated in a continuous mode at the inlet and at the outlet, with the result that a continuous amount of starting material for the pulp is taken off at the inlet and a continuous amount of production-quality pulp is provided at the outlet.

In a further embodiment, the system is provided so as to permit, in the continuous mode, a material flow varying between a minimum amount and a maximum amount at the inlet and/or at the outlet, without the continuous material flow at the inlet and at the outlet being interrupted. Here, although the amount of material at the inlet and at the outlet can fluctuate, a constant material flow into the inlet and out of the outlet is ensured. This operating mode is in contrast to a so-called batch process (discontinuous or intermittent process), where there are periods at the inlet and outlet when no material at all passes through the inlet or the outlet, respectively. As the actual process for producing the pulp within the system is such a batch process, such a possible variation between minimum amount and maximum amount is easier to handle for a transition between continuous material flow at the inlet and outlet. In order to make this transition from continuous operation from and to the outside to internal batch operation (discontinuous or intermittent operation) in the process modules easier, one or more buffer tanks are arranged in the process module or modules.

In a further embodiment, the process module or modules comprise several tanks as processing tanks or buffer tanks. The pulping process can thus be matched to the respective requirements. The tanks can be equipped with their own process machines (sensors, valves, stirrers etc.), which need to be arranged in or on the respective tanks in order to be able to carry out the process. However, these process machines are controlled by the supply module and provided with the media necessary for this.

In a further embodiment, at least some of the tanks have a base with a slope in the direction of an edge of the tanks, possibly the bases of all tanks have a slope, a reversibly sealable cleaning opening is particularly possibly arranged at this edge of the tank. Contaminants or constituents settling in the respective tanks are thereby concentrated at the lower edge of the tank, which among other things makes cleaning the tank easier and prevents or at least reduces dirtying of the tank content. In a further embodiment, for this purpose the slope is continuous, possibly the base is designed as a planar sloping surface. In a further embodiment, for this, as slope, the base has an angle α relative to the horizontal between 2 degrees and 15 degrees, wherein the slope to be chosen depends on the concentration of the fibrous material, possibly the angle is from 3 degrees to 10 degrees. A slope greater than 15 degrees would reduce the available volume of the tank too much and also would not be necessary for depositing the material at the edge of the tank.

In a further embodiment, the supply modules and process modules are provided as mobile containers, which, among other things, guarantees an easy transportability of these modules and also makes an easy and quick construction of the system according to the disclosed embodiments in modular construction possible, since the external dimensions of the containers are standardized. These can be so-called ISO containers with standard external dimensions, for example. Naturally, containers with individual dimensions can alternatively also be used.

In a further embodiment, the plurality of interfaces, matched to one another in each case, of the supply and process modules comprises a number which exceeds a minimum number of necessary interfaces in a basic configuration, with the result that a free scalability of the system remains guaranteed at all times.

The present disclosure furthermore relates to a fiber molding system comprising a system according to the disclosed embodiments for pulp processing and resupply of production-quality pulp to a pulp reservoir of the fiber molding system, possibly the fiber molding system comprises a return line from the reservoir to the system for processing the used pulp. A fiber molding system is a system in which a fiber molding process for producing blanks made of fibrous material is carried out starting from a pulp as starting material. The fiber molding process denotes the process steps in a fiber molding system which are involved in molding the molded part, starting with the provision of the pulp in the pulp reservoir, the forming of the molded part in the forming station out of the fibrous material made of the pulp, the pre-molding of the molded part in the pre-molding station, the hot pressing of the molded part in the hot-pressing station and possibly the coating of the molded part with functional layers, if desired. The blank is dispensed from the fiber molding system as a product at the end of the molding process.

A fiber molding system with a system for the processing and resupply of pulp which meets at least the essential requirements of different fiber molding systems and production plants equally, and still makes a quick commissioning of the system according to the disclosed embodiments with low installation effort possible, is thus provided.

The present disclosure furthermore relates to a method for the construction of a system according to the disclosed embodiments for pulp processing and resupply of production-quality pulp to at least one fiber molding system, comprising the steps of:

• • providing a supply module, which comprises or at least controls the machines and infrastructure supply units necessary for the operation of the system;
  • providing one or more process modules, in which the pulp is reprocessed and/or produced for resupply and then provided; and
  • connecting the supply module to the process module or modules via the plurality of interfaces, matched to one another in each case, of the supply and process modules, in order to guarantee the infrastructure supply of the process modules, in order that the pulp or the constituents and starting materials thereof can be received via at least one inlet and can be transported between the process modules for processing or resupply, and the production-quality pulp can be provided via an outlet for use by at least one fiber molding system.

A method for the construction of a system for the processing and resupply of pulp with which at least the essential requirements of different fiber molding systems and production plants are met equally, and a quick commissioning of the system according to the disclosed embodiments with low installation effort is still made possible, is thus provided.

The present disclosure furthermore relates to a method for extending a system according to the disclosed embodiments for pulp processing and resupply of production-quality pulp to at least one fiber molding system, comprising the following steps utilizing a scalable modular form of the system:

• • connecting the process modules needed for the extension to the still free interfaces of the already present process and supply modules; and
  • operating a system extended in this way for pulp processing and resupply of production-quality pulp to at least one fiber molding system.

With this method, a present system for the processing and resupply of pulp can be converted, with little installation effort for a quick commissioning, into a system which meets at least the essential requirements of different fiber molding systems and production plants equally, or such a system can be easily extended for further requirements of different fiber molding systems and production plants.

In a further embodiment, the method for extending comprises the further step of adding and connecting at least one further supply module to the already present process and supply modules via the still free interfaces of the already present process and supply modules.

It should be expressly mentioned that, as far as possible, “at least” expressions have been avoided for the sake of better readability. Instead, normally, an indefinite article (“one”, “two” etc.) is to be understood to mean “at least one, at least two, etc.”, unless the context reveals that “precisely” the specified number is meant there.

At this point it should also be mentioned that, within the scope of the present patent application here, the expression “in particular” is always to be understood to mean that an optional, preferred feature is introduced with this expression. Consequently, the expression is not to be understood to mean “in fact” or “namely”.

It is understood that features of the solutions described above or in the claims may also be combined where appropriate, in order to be able to implement the advantages and effects that can be achieved in the present case in a correspondingly cumulative manner.

BRIEF DESCRIPTION OF THE FIGURES

In addition, further features, effects and advantages of the present disclosure are explained with reference to the attached drawing and the following description. Components which at least essentially correspond in terms of their function in the individual figures are identified by the same reference symbols, with the components not having to be numbered and explained in all figures.

The drawings show:

FIG. 1: schematic representation of an embodiment of system for pulp processing and resupply of production-quality pulp to at least one fiber molding system;

FIG. 2: schematic representation of a further embodiment of a system according for pulp processing and resupply of production-quality pulp to at least one fiber molding system;

FIG. 3: schematic representation of the scalability of the system according to the disclosed embodiments;

FIG. 4: schematic representation of the scalability of the system according to the disclosed embodiments;

FIG. 5: schematic representation of a fiber molding system according to the disclosed embodiments;

FIG. 6: schematic representation of a method according to the disclosed embodiments for the construction of the system according to the disclosed embodiments; and

FIG. 7: schematic representation of a method according to the disclosed embodiments for extending the system according to the disclosed embodiments.

DETAILED DESCRIPTION

FIG. 1 shows a schematic representation of an embodiment of the system 100 for pulp processing and resupply of production-quality pulp 160 to at least one fiber molding system 200, wherein the system 100 is constructed in scalable modular form. Here, a supply module 110 is arranged between two process modules 120. The supply module 110 comprises the machines 112 necessary for the operation of the system, such as for example pumps etc. and infrastructure supply units 114, such as for example water, power, compressed air, gas, data cables etc., or controls components of the process modules 120. In contrast, the process modules 120 are there to reprocess and/or resupply and then provide the pulp. In the system, the supply module 110 and the process modules 120 are equipped with a plurality of interfaces 150, matched to one another in each case, in order to connect supply and process modules 110, 120 to one another, in order to guarantee the infrastructure supply of the process modules 120 and to receive the pulp or the constituents and starting materials thereof via at least one inlet 130 and to transport them between the process modules 120, and to provide the production-quality pulp 160 via an outlet 140 for use by at least one fiber molding system 200. For this, the interfaces 150 are implemented at least partially according to the plug-socket principle. All interfaces 150 are possibly implemented according to the plug-socket principle. As can be seen, the number of interfaces exceeds the number necessary for the operation of this system, which makes a later extension of the system at any time possible since the modules 110, 120 to be added later can be supplied via the free interfaces or connected to other modules 110, 120. Here, the outlet 140 is designed as a multiple outlet and can be matched to the throughput of pulp of the connected fiber molding systems 200 via a corresponding controllable valve 145. The system 100 can thus be operated such that it continuously provides a minimum amount of pulp at the outlet 140 to be taken off by the connected fiber molding system 200. Furthermore, the system 100 is designed and controlled so as to be operated in a continuous mode at the inlet 130 and at the outlet 140, with the result that a continuous amount of starting material for the pulp is taken off at the inlet 130 and a continuous amount of production-quality pulp is provided at the outlet 140. Furthermore, the system 100 is provided so as to permit, in a continuous mode, a material flow varying between a minimum amount and a maximum amount at the inlet 130 and/or at the outlet 140, without the continuous material flow at the inlet 130 and at the outlet 140 being interrupted. Since the system 100 in the process module or modules 120 is operated in a so-called batch process, for this it comprises one or more buffer tanks in the process modules 120. In this case, the process modules 120 are here equipped with the processing tank 3 and the buffer tanks 5 and 12. Here, the supply modules 110 and process modules 120 can be implemented as mobile containers.

FIG. 2 likewise shows a schematic representation of another embodiment of the system 100 for pulp processing and resupply of production-quality pulp 160 to at least one fiber molding system 200, wherein this system 100 is also constructed in scalable modular form. Here too, the supply module 110 is arranged as central module, wherein the several process modules 120 are arranged around the supply module 110. In FIG. 2, in contrast to FIG. 1, the supply module 110 is composed of two sub-modules 110a, 110b, in order to be able to operate the process modules 120 (in a greater number here than in FIG. 1) accordingly. Here, the sub-modules 110a, 110b can fulfil different supply tasks, for example, for which purpose they are correspondingly equipped with a different number of machines 112. For the further components not explained in detail here, reference is made to the statements regarding FIGS. 1 and 3. In the process modules, here in FIG. 2 the processing tanks 3, 6, 7, 8 and 11 and the buffer tanks 5, 9, 10, 12 as well as a water tank 4 are shown by way of example. Here, the tanks 1-12 are likewise only shown as an illustration of the pulping process. For a more detailed explanation of the functions of the tanks 1-12 shown here, reference is made to FIG. 3.

FIG. 3 shows a schematic representation of the scalability of the system 100 according to the disclosed embodiments. Different systems 100 can comprise different modules, which manifests itself in the different equipping with the tanks 1-13. Here, the equipping with the tanks 4, 8, 11 and 13, for example, can also be optional. As the modules 110, 120 comprise a large number of interfaces 150, matched to one another in each case, which exceeds a minimum number of necessary interfaces 150 in a basic configuration (for example the top configuration with the tanks 3-5 and 12-13), a free scalability of the system 100 remains guaranteed at all times, as is shown by the four different system types 100. The components or tanks 1-13 shown have the following functions:

Component 1 denotes a weighing machine for the entering cellulose or fiber pulp material as starting material for producing the fibrous material. The weighing machine acts as inlet 130 for the cellulose or fiber pulp material. Component 2 denotes a tank with a tilting-lever device for pouring the fiber pulp material into the tank 3, which acts as a so-called pulper, where a first mixture of solvent with fiber pulp material is produced or made up. Tank 4 denotes a water tank. Tank 5 denotes a buffer tank, tank 6 denotes a centrifuge for a fiber concentration of more than 8 wt.-% (percent by weight), in which the material present can be separated according to weight. In the pulp, tanks 7 and 8 denote a grinder for conditioning the fibrous material or a deflaker, in which small agglomerates of fibrous material can be separated or dissolved. Tanks 9 and 10 denote buffer tanks, in which additives are added. Tank 11 denotes a rotary sifter. Tank 12 likewise denotes a buffer tank and tank 13 again denotes a centrifuge, here for a fiber concentration of approximately 1 wt.-% (percent by weight).

FIG. 4 shows a tank 1-13 of the system 100 according to the disclosed embodiments with sloping base B in lateral section. Tank 1-13 has a base B with a slope, here in the direction of the right-hand edge R of the tank 1-13. In other embodiments, the edge can also be arranged on another side of the tank. A reversibly sealable cleaning opening RO is arranged on this edge R. Here, the slope is implemented continuously in that the base B is a planar sloping surface. As slope, the base B can have an angle α relative to the horizontal H between 2 degrees and 10 degrees. This angle is preferably 3 degrees.

FIG. 5 shows a schematic representation of a fiber molding system 200 according to the disclosed embodiments comprising a system 100 for pulp processing and resupply of production-quality pulp 160 to a pulp reservoir 210 of the fiber molding system 200 as well as a return line 220 from the reservoir 210 to the system 100 for processing the used pulp.

FIG. 6 shows a schematic representation of a method 300 according to the disclosed embodiments for the construction of the system 100 according to the disclosed embodiments for pulp processing and resupply of production-quality pulp 160 to at least one fiber molding system 200, comprising the steps of providing 310 a supply module 110, which comprises or at least controls the machines 112 and infrastructure supply units 114 necessary for the operation of the system 100; providing 320 one or more process modules 120, in which the pulp is reprocessed and/or produced for resupply and then provided; and connecting 330 the supply module 110 to the process module or modules 120 via the plurality of interfaces 150, matched to one another in each case, of the supply and process modules 110, 120, in order to guarantee the infrastructure supply of the process modules 120, in order that the pulp or the constituents and starting materials thereof can be received via at least one inlet 130 and can be transported between the process modules 120 for processing or resupply, and the production-quality pulp 160 can be provided via an outlet 140 for use by at least one fiber molding system 200.

FIG. 7 shows a schematic representation of a method 400 according to the disclosed embodiments for extending the system 200 according to the disclosed embodiments for pulp processing and resupply of production-quality pulp 160 to at least one fiber molding system 200, comprising, utilizing a scalable modular form of the system 100, the following steps of connecting 410 the process modules 120 needed for the extension to the still free interfaces 150 of the already present process and supply modules 110, 120; and of operating 420 a system 100 extended in this way for pulp processing and resupply of production-quality pulp 160 to at least one fiber molding system 200. Here, the method 400 can comprise the further step of adding and connecting 430 at least one further supply module 110 to the already present process and supply modules 110, 120 via the still free interfaces 150 of the already present process and supply modules 110, 120.

At this point it should be explicitly mentioned that features of the solutions described above or in the claims and/or figures may also be combined where appropriate, in order also to be able to implement or achieve explained features, effects and advantages in a correspondingly cumulative manner.

It is to be understood that the embodiment example explained above is merely a first design of the disclosed embodiments. In this respect, the design of the disclosed embodiments is not limited to this embodiment example.

The following numbered clauses set out various non-limiting embodiments disclosed herein:

Set A

A1. A system (100) for pulp processing and resupply of production-quality pulp (160) to at least one fiber molding system (200), wherein the system (100) is constructed in scalable modular form, with at least one supply module (110), which comprises or at least controls the machines (112) and infrastructure supply units (114) necessary for the operation of the system, and one or more process modules (120), in which the pulp is reprocessed and/or produced for resupply and then provided, wherein the supply module (110) and the process modules (120) are equipped with a plurality of interfaces (150) matched to one another in each case, in order to connect supply and process modules (110, 120) to one another, in order to guarantee the infrastructure supply of the process modules (120) and to receive the pulp or the constituents and starting materials thereof via at least one inlet (130) and to transport them between the process modules (120), and to provide the production-quality pulp (160) via an outlet (140) for use by at least one fiber molding system (200).
A2. The first molding station (1) according to any previous clause within set A, wherein the supply module (110) is arranged as central module and, in the case of several process modules (120), these are arranged around the supply module (110).
A3. The first molding station (1) according to any previous clause within set A, wherein the supply module (110) is composed of several sub-modules (110a, 110b), the sub-modules fulfilling different supply tasks and being correspondingly equipped with different machines (112) and/or infrastructure supply units (114).
A4. The first molding station (1) according to any previous clause within set A, wherein the interfaces (150) are implemented at least partially according to the plug-socket principle, possibly wherein all interfaces (150) are implemented according to the plug-socket principle
A5. The first molding station (1) according to any previous clause within set A, wherein the outlet (140) can be matched to the throughput of pulp of the connected fiber molding system (200) via a corresponding valve (145).
A6. The first molding station (1) according to any previous clause within set A, wherein the outlet (140) is designed as a multiple outlet for connecting to several fiber molding systems (200).
A7. The first molding station (1) according to any previous clause within set A, wherein the multiple outlet (140) is designed to be controllable for an individual throughput of pulp of the respective connected fiber molding system (200).
A8. The first molding station (1) according to any previous clause within set A, wherein the system (100) is operated such that it continuously provides a minimum amount of pulp at the outlet (140) to be taken off by the connected fiber molding system (200).
A9. The first molding station (1) according to any previous clause within set A, wherein the system (100) is designed and controlled so as to be operated in a continuous mode at the inlet (130) and at the outlet (140), with the result that a continuous amount of starting material for the pulp is taken off at the inlet (130) and a continuous amount of production-quality pulp is provided at the outlet (140).
A10. The first molding station (1) according to any previous clause within set A, wherein the system (100) is provided so as to permit, in the continuous mode, a material flow varying between a minimum amount and a maximum amount at the inlet (130) and/or at the outlet (140), without the continuous material flow at the inlet (130) and at the outlet (140) being interrupted.
A11. The first molding station (1) according to any previous clause within set A, wherein the system (100) in the process module or modules (120) is operated in a so-called batch process and for this comprises one or more buffer tanks (1-13) in the process module or modules (120).
A12. The first molding station (1) according to any previous clause within set A, wherein the process module or modules (120) comprise several tanks (1-13) as processing tanks or buffer tanks.
A13. The first molding station (1) according to any previous clause within set A, wherein at least some of the tanks (1-13) have a base (B) with a slope in the direction of an edge (R) of the tanks (1-13), preferably the bases (B) of all tanks (1-13) have a slope, particularly preferably a reversibly sealable cleaning opening (RO) is arranged at this edge (R) of the tank (B).
A14. The first molding station (1) according to any previous clause within set A, wherein the slope is continuous, preferably the base (B) is designed as a planar sloping surface.
A15. The first molding station (1) according to any previous clause within set A, as slope, the base (B) has an angle (a) relative to the horizontal (H) between 2 degrees and 15 degrees, preferably of from 3 degrees to 10 degrees.
A16. The first molding station (1) according to any previous clause within set A, wherein the supply modules (110) and process modules (120) are provided as mobile containers.
A17. The first molding station (1) according to any previous clause within set A, wherein the plurality of interfaces (150), matched to one another in each case, of the supply and process modules (110, 120) comprises a number which exceeds a minimum number of necessary interfaces (150) in a basic configuration, with the result that a free scalability of the system (100) remains guaranteed at all times.
A18. A fiber molding system (200) comprising a system (100) for pulp processing and resupply of production-quality pulp (160) to a pulp reservoir (210) of the fiber molding system (200) according to any previous clause within set A, wherein the fiber molding system comprises a return line (220) from the reservoir (210) to the system (100) for processing the used pulp.
A19. A method (300) for the construction of a system (100) according to any previous clause within set A for pulp processing and resupply of production-quality pulp (160) to at least one fiber molding system (200), comprising the steps of:

• • providing (310) a supply module (110), which comprises or at least controls the machines (112) and infrastructure supply units (114) necessary for the operation of the system (100);
  • providing (320) one or more process modules (120), in which the pulp is reprocessed and/or produced for resupply and then provided; and
  • connecting (330) the supply module (110) to the process module or modules (120) via the plurality of interfaces (150), matched to one another in each case, of the supply and process modules (110, 120), in order to guarantee the infrastructure supply of the process modules (120), in order that the pulp or the constituents and starting materials thereof can be received via at least one inlet (130) and can be transported between the process modules (120) for processing or resupply, and the production-quality pulp (160) can be provided via an outlet (140) for use by at least one fiber molding system (200).
    A20. A method (400) for extending a system (100) according to any previous clause within set A for pulp processing and resupply of production-quality pulp (160) to at least one fiber molding system (200), comprising the following steps utilizing a scalable modular form of the system (100):
  • connecting (410) the process modules (120) needed for the extension to the still free interfaces (150) of the already present process and supply modules (110, 120); and
  • operating (420) a system (100) extended in this way for pulp processing and resupply of production-quality pulp (160) to at least one fiber molding system (200).
    A21. The method (400) for extending according to clause A20 comprising the further step of adding and connecting (430) at least one further supply module (110) to the already present process and supply modules (110, 120) via the still free interfaces (150) of the already present process and supply modules (110, 120).

At this point it should be explicitly pointed out that features of the solutions described above or in the claims and/or figures can also be combined if appropriate in order to be able to implement or achieve the features, effects and advantages explained in a cumulative manner.

It goes without saying that the exemplary embodiment explained above is merely a first embodiment of the present disclosure. In this respect, the design of the disclosed embodiments is not limited to this exemplary embodiment.

Claims

1. A system for pulp processing and resupply of production-quality pulp to at least one fiber molding system, wherein the system is constructed in scalable modular form, with at least one supply module, which comprises or at least controls the machines and infrastructure supply units for the operation of the system, and one or more process modules, in which the pulp is reprocessed and/or produced for resupply and then provided, wherein the supply module and the process modules are equipped with a plurality of interfaces matched to one another in each case, in order to connect supply and process modules to one another, in order to provide the infrastructure supply of the process modules and to receive the pulp or the constituents and starting materials thereof via at least one inlet and to transport them between the process modules, and to provide the production-quality pulp via an outlet for use by at least one fiber molding system.