Background of the Invention

[0001] The present invention relates to an apparatus for substantial continuous processing of a material.

Description of the Prior Art

[0002] US10632728B2 relates in general to recycling of polymer matrix composite. In particular, the invention relates to a process for separating reinforcement material from polymer matrix composite comprising the reinforcement material within a thermoformed polymer matrix.

[0003] However, this approach is limited to batch based processing/separation of materials, which limits throughput and risks exposing dangerous chemicals to the working environment and operators.

[0004] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Summary of the Present Invention

[0005] In one broad form, the present invention seeks to provide an apparatus for processing a material, the apparatus including: a blender that is configured to blend material with a solvent to thereby at least partially impregnate the material with the solvent and form an impregnated material; a compressor that is configured to at least partially compress the impregnated material to thereby at least one of: further impregnate the material with the solvent; and, remove excess solvent; a heat treatment chamber that is configured to heat the impregnated material to: at least partially remove the solvent; and, form heat treated material; and, a separator that is configured to separate the heat treated material into at least a first product and a second product. [0006] In one embodiment, the blender is configured to blend the material through mechanical agitation.

[0007] In one embodiment, the blender includes a plurality of blades.

[0008] In one embodiment, the plurality of blades are configured to: fragment the material into a smaller size; and, at least partially assist the solvent to thereby at least partially impregnate the material.

[0009] In one embodiment, the plurality of blades rotate about an axis that is substantially perpendicular to the flow path of the material.

[0010] In one embodiment, the plurality of blades are mounted on a ratable shaft extending across a flow path from the blender.

[0011] In one embodiment, the blender includes: a solvent inlet configured to receive solvent from solvent supply; and, a material inlet valve configured to receive material from a material supply.

[0012] In one embodiment, the compressor is configured to exert pressure to at least one of: squeeze the impregnated material causing excess solvent to be removed from the impregnated material; further impregnate the material with the solvent; and, at least partially impregnate the material that was not exposed to the solvent with the solvent.

[0013] In one embodiment, the compressor includes a pressure wall and the compressor is configured to exert pressure by pressing the impregnated material contained in the conveyor against the pressure wall.

[0014] In one embodiment, the compressor includes a hydraulic press.

[0015] In one embodiment, the compressor includes at least one of: a screw threaded conveyor; and, a pig conveyor.

[0016] In one embodiment, the compressor is configured to substantially continuously receive impregnated material from the blender. [0017] In one embodiment, the compressor includes an impregnated material inlet and the compressor is configured to receive the impregnated material through the impregnated material inlet.

[0018] In one embodiment, the heat treatment chamber includes: an impregnated material inlet configured to receive impregnated material from the compressor; a heated fluid inlet configured to receive heated fluid; a heat treated material outlet configured to output the heat treated material; and, a fluid outlet configured to output heated fluid and solvent.

[0019] In one embodiment, the heat treatment chamber is configured to separate at least partially removed solvent from the heat treated material.

[0020] In one embodiment, heat treatment chamber has a conical shape and is configured so that heated fluid entering the chamber generates a cyclonic flow within the treatment chamber to: expose the material to heated fluid and thereby generate heat treated material; and, separate the heated fluid and solvent from the heat treated material, so that the heated fluid and solvent exit via the fluid outlet and heat treated material is output through the heat treated material outlet.

[0021] In one embodiment, the heat treatment chamber is connected to a boiler that is configured to supply the heated fluid.

[0022] In one embodiment, the impregnated material inlet is coupled to the heated fluid inlet so that heated fluid entering the heated fluid inlet creates a venturi effect to draw the impregnated material into the impregnated material inlet.

[0023] In one embodiment, the impregnated material inlet includes a closeable valve configured to control the flow of the impregnated material from the compressor to the heat treatment chamber.

[0024] In one embodiment, the heat treatment chamber is configured to separate at least partially removed solvent and the heated fluid from the heat treated material.

[0025] In one embodiment, the heat treatment chamber is configured to use the cyclonic effect to separate at least partially removed solvent and the heated fluid from the heat treated material. [0026] In one embodiment, the heat treated material outlet supplies the heat treated material to the separator.

[0027] In one embodiment, the fluid outlet is attached to a fluid separator that is configured to separate solvent from the heated fluid.

[0028] In one embodiment, the separated fluids can be stored for subsequent use.

[0029] In one embodiment, the separator includes: a first outlet that is configured to output at least some of the first product; and, a second outlet that is configured to output the second product.

[0030] In one embodiment, the separator includes a heat treated material inlet that is configured to receive the heat treated material from the heat treatment chamber.

[0031] In one embodiment, the separator has a double conical shape and is configured so that the heat treated material entering the separator generates a cyclonic flow within the separator to at least partially separate the first product from the heat treated material: so that at least some of the first product exits via the first outlet at an end of a first cone; and, so that a resultant second product exits via the second outlet at an end of a second cone.

[0032] In one embodiment, the apparatus includes a tertiary separator that: includes a resultant product inlet that is configured to receive resultant product from the separator; has a double conical shape and is configured so that the resultant product entering the tertiary separator generates a cyclonic flow within the tertiary separator to at least partially separate the first product from the resultant product: so that at least some of the first product exits via a first tertiary outlet at an end of a first tertiary cone; and, so that a tertiary resultant second product exits via a second tertiary outlet at an end of a second tertiary cone; and, the second tertiary outlet is configured to output the tertiary resultant product to a subsequent tertiary separator.

[0033] In one embodiment, the apparatus includes the minimum number of tertiary separators such that at least one of: the resultant second product only includes significantly less first product than the heat treated material; and, the tertiary resultant second product only includes significantly less first product than the resultant second product. [0034] In one embodiment, the significantly less is at least one of: 10% or less; 5% or less; 1% or less; 0.5% or less; 0.1% or less; and, 0.01% or less.

[0035] In one embodiment, the separator and the tertiary separator are configured to receive separator fluid that assists the separator and the tertiary separator to generate a cyclonic flow.

[0036] In one embodiment, the separator and one or more of the tertiary separators can have a different at least one of: shape; inlet position; inlet angle; inlet velocity; and, size to assist separating the first product and second product.

[0037] In one embodiment, the second outlet includes a chopper that is configured to chop the second product to a required size.

[0038] In one embodiment, the apparatus includes a material supply that is configured to supply the material to the blender.

[0039] In one embodiment, the material supply includes a cutting apparatus that is configured to cut the material to a required size.

[0040] In one embodiment, the material supply includes a tertiary conveyor that is configured to at least substantially continuously supply the material to the blender and wherein the tertiary conveyor is at least one of: a pig conveyor; and, a screw threaded conveyor.

[0041] In one embodiment, tertiary conveyor is configured to transfer the material cut by the cutting apparatus to the blender.

[0042] In one embodiment, the material supply includes a hopper that is configured to control the rate of supply of the material to the blender.

[0043] In one embodiment, the hopper is configured to supply the material to the blender so that the blender substantially continuously blends the material.

[0044] In one embodiment, the hopper includes a cyclone.

[0045] In one embodiment, the apparatus includes a one way air vent. [0046] In one embodiment, the one way air vent allows air to enter the apparatus and prevents vapour from exiting the apparatus.

[0047] In one embodiment, the one way air vent is connected to at least one of: the compressor; and, the heat treatment chamber.

[0048] In one embodiment, the material is polyvinyl chloride.

[0049] In one embodiment, the first product is polyvinyl chloride wool and the second product is polyvinyl chloride flakes.

[0050] In one embodiment, the solvent is acetone.

[0051] In one embodiment, the heated fluid is steam.

[0052] It will be appreciated that the broad forms of the invention and their respective features can be used in conjunction and/or independently, and reference to separate broad forms is not intended to be limiting. Furthermore, it will be appreciated that features of the method can be performed using the system or apparatus and that features of the system or apparatus can be implemented using the method.

Brief Description of the Drawings

[0053] Various examples and embodiments of the present invention will now be described with reference to the accompanying drawings, in which: -

[0054] Figure 1A is a schematic drawing of an example of part of a continuous processing apparatus including a pipe, a first section and a venting pipe;

[0055] Figure IB is a schematic drawing of an example of part of a continuous processing apparatus including a pipe, a second section and a venting pipe;

[0056] Figure 2A is a schematic drawing of an example of part of a continuous processing apparatus provided in a first enclosed environment, including a first fluid reservoir and a firewall; [0057] Figure 2B is a schematic drawing of an example of part of a continuous processing apparatus provided in a second environment, including a blender, a blower, a separator and a second fluid reservoir;

[0058] Figure 3A is a schematic drawing of an example of a shredder or granulator and cyclonic vacuum;

[0059] Figure 3B is a schematic drawing of an example of a separator and a first and second component reservoir;

[0060] Figure 4A is a schematic drawing of an example of a convoluted pipe, a U-shaped convoluted first section and a U-shaped convoluted second section;

[0061] Figure 4B is a schematic drawing of an example of a convoluted pipe, a V-shaped convoluted first section and a V-shaped convoluted second section;

[0062] Figure 5 is a schematic drawing of an example of a mounted filter fan;

[0063] Figure 6 is a schematic drawing of an example a material being processed;

[0064] Figure 7 is a schematic drawing of an example of a continuous processing apparatus including a blender, compressor, heat treatment chamber and separator;

[0065] Figure 8 is a schematic drawing of an example of a compressor;

[0066] Figure 9A is a schematic drawing of an example of a blender;

[0067] Figure 9B is a plan drawing of an example of a blender;

[0068] Figure 10A is a schematic drawing of an example of a heat treatment chamber;

[0069] Figure 10B is a plan drawing of an example of a heat treatment chamber;

[0070] Figure 11A is a schematic drawing of an example of separators;

[0071] Figure 1 IB is a plan drawing of an example of a separator;

[0072] Figure 11C is a schematic drawing of an example of a chopper; [0073] Figure 1 ID is an exploded drawing of an example of a chopper;

[0074] Figure 12 is a schematic drawing of an example of a material supply; and,

[0075] Figure 13 is a schematic drawing of an example of a material being processed.

Detailed Description of the Preferred Embodiments

[0076] An example of an apparatus for processing a material will be discussed with reference to Figure 7.

[0077] In this example, the apparatus 700 includes a blender 710, a compressor 720, a heat treatment chamber 730 and a separator 740.

[0078] The blender 710 blends a material with a solvent (not shown) to thereby at least partially impregnate the material with the solvent and form an impregnated material. Blending the material with a solvent can treat, prime and/or loosen the construction of the material. Blending the material with a solvent in this manner may expose the material to the solvent more effectively than other methods, such as soaking.

[0079] An example of this increased effectiveness can be seen when seeking to impregnate plastics with acetone. In a more conventional method, large batches of plastics can be immersed in vats of acetone, allowing the acetone to slowly seep into and impregnate the plastic from the outside in. In order for the entire body of plastic to be sufficiently impregnated, the batch of plastic may need to be submerged in acetone for hours or days, making this process very slow and ineffective for applications seeking a substantially continuous supply line. The conventional method also introduces potential risks, for example open to air vats of acetone can lead to a build-up of acetone vapour which is highly flammable and therefore presents a significant safety risk. Additionally, an open to air vat of acetone could potentially spill (especially when a batch of plastic is lowered or retrieved from the vat) and cause injury to nearby persons or damage to equipment.

[0080] In contrast to the conventional immersion method, blending the material (i.e. a plastic) with a solvent (i.e. acetone) circumvents the above mentioned issues. Blending the material divides it into smaller portions, increasing the effective surface area that the solvent is being exposed to and reducing the time taken to impregnate the material, whilst agitation of the material during blending helps expose all of the material to the solvent. Additionally, blending the material in this manner can be undertaken within a closed/vented environment (as shown in Figure 7A) and thereby reduces the possibility of spillages and unwanted emission of solvent vapour.

[0081] The compressor 720 is configured to at least partially compress the impregnated material, which can assist with the material being further impregnated with the solvent and/or allowing excess solvent to be removed.

[0082] While the blender 710 is effective for impregnating the material with the solvent, a person skilled in the art would appreciate that there remains the possibility that not all of the material supplied to compressor 720 will be fully impregnated. This possibility increases when the blender 710 blends material in a substantially continuous manner, where material is not confirmed to be impregnated before being transferred to the compressor 720. However, at least partially compressing the material can assist in pushing solvent through the material, ensuring all material is exposed to the solvent, resulting in material being further impregnated.

[0083] While the blender 710 can reduce the total amount of solvent required to impregnate the material, the material received by the compressor 720 may still include an excessive amount of solvent. The compressor 720 at least partially compressing the impregnated material can assist in draining excess solvent from the impregnated material, allowing the excess solvent to be more easily recovered for reuse.

[0084] The heat treatment chamber 730 is configured to heat impregnated material to at least partially remove the solvent and/or form heat treated material.

[0085] Following compression of the impregnated material, it is desirable to remove any solvent not impregnated in the impregnated material prior to separation of the material. This allows the solvent to be recovered for reuse. Additionally, heat is used to heat the impregnated material so that the solvent and material react to form heat treated material which at least partially prepares the heat treated material to be separated.

[0086] A person skilled in the art would appreciate that there are a multitude of methods to achieve this. For example, the heat treatment chamber 730 could heat the impregnated material with a heated fluid. This heated fluid could be applied over the impregnated material, removing solvent from the surface of the impregnated material. This heated fluid could also heat the impregnated material, which treats the impregnated material into heat treated material. Continuing the previous example, impregnated plastics enter the heat treatment chamber and are exposed to a heated fluid (i.e. steam). Following exposure to the steam, the impregnated plastic forms plastic popcorn. Plastic popcorn can be subsequently separated into plastic fibres and/or plastic wool for additional uses.

[0087] The separator 740 is configured to separate heat treated material into a first product and a second product.

[0088] A person skilled in the art would appreciate that there are a multitude of methods to achieve this. For example, the separator 740 could be a cyclonic chamber, including a plurality of outputs, where the cyclonic chamber directs the first product to one output and the second product to a second output.

[0089] The above example may provide a number of advantages over conventional methods. Firstly, it allows for the processing of materials in a substantially continuous manner which allows for better scalability and efficiency in material processing. Secondly, this example allows for the processing of materials in a sealed or substantially sealed environment, reducing the risks associated with conventional methods (i.e. open air vats of solvents).

[0090] A number of further features will now be described.

[0091] In one example, the blender 710 is configured to blend the material through mechanical agitation. This can be achieved in a number of ways, but in one specific example the blender 710 includes a plurality of blades and the plurality of blades are configured to fragment the material into a smaller size and at least partially assist the solvent to at least partially impregnate the material. Through mechanical agitation, the material is fragmented into a smaller size and is physically agitated in conjunction with the material's exposure to the solvent. This physical agitation (and the smaller size of the material) further encourages the material to be exposed to the solvent and thereby further facilitates the impregnation of the material. Additionally, cutting the material into a smaller size increases the effective surface area of the material being exposed to solvent which also increases the speed of the impregnation. [0092] In one example, the plurality of blades rotate about an axis that is substantially perpendicular to the flow path of the material and/or the plurality of blades are mounted on a rotable shaft extending across a flow path from the blender 710. Additionally, the blender 710 includes a solvent inlet configured to receive solvent from the solvent supply and a material inlet valve configured to receive material from the material supply, directing both the solvent and material into the flow path through the blender, so that the solvent and material are exposed to the rotating blades.

[0093] In one example, the apparatus 700 includes a material supply that is configured to supply the material to the blender 710. The material supply typically includes a cutting apparatus that is configured to cut the material to a required size. To improve efficiency of the supply to the blender 710, a material supply can be configured to supply material to the blender 710 and, in particular, supply material to the blender 710 at a required size and/or controlled rate. A person skilled in the art will appreciate that depending on the material being processed, the required size and volume supplied to the blender 710 may vary. Therefore, by cutting the material to a required size prior and controlling the rate of supply, this can improve the performance of the blender 710 and subsequent impregnation of the material.

[0094] In one example, the material supply includes a tertiary conveyor that is configured to at least substantially continuously supply the material to the blender and wherein the tertiary conveyor is a pig conveyor or a screw threaded conveyor, which can facilitate a substantially continuous supply of material to the blender 710. Additionally, the tertiary conveyor is configured to transfer the material cut by the cutting apparatus to the blender.

[0095] In one example, the material supply includes a hopper that is configured to control the rate of supply of the material to the blender 710. Additionally, the hopper is configured to supply the material to the blender 710 so that the blender 710 can substantially continuously blend the material. In one example, the hopper includes a cyclone, which can help control a rate of supply of material, allowing the system to process materials at different rates, for example, depending on the nature of the material or the like.

[0096] In one example, the compressor 720 is configured to exert pressure to squeeze the impregnated material causing excess solvent to be removed from the impregnated material, further impregnate the material with the solvent and/or at least partially impregnate any of the material that was not exposed to the solvent with the solvent.

[0097] By exerting pressure on the material, excess solvent can be squeezed out of the impregnated material. While it is desirable for the material to be covered in solvent, as it may be necessary for the heat treatment process, but an excess amount of solvent can increase the time taken to heat treat the impregnated material or potentially overload the heat treatment chamber 730. Therefore, squeezing out excess solvent can increase the speed of the apparatus and improved reliability.

[0098] Further impregnating the material with the solvent and at least partially impregnating material that was not exposed to the solvent with the solvent can ensure that more of the material is sufficiently impregnated with solvent. The heat treatment process may require that all of the material is sufficiently impregnated with solvent to successfully heat treat the impregnated material. As such, exerting pressure on material insufficiently impregnated with solvent to ensure that more material is sufficiently impregnated with solvent may allow for more consistent heat treatment of the impregnated material.

[0099] In one example, the compressor 720 may include a hydraulic press and the pressure exerted may be induced by the hydraulic press. The inclusion of a hydraulic press can mitigate a number of risks associated with other compression devices. For example, other compression devices may require the use of electrical actuation, which could create electrical hazards. Additionally, hydraulic presses can generate high pressures with potentially much lower cost and complexity than other compression devices.

[0100] In another example, the compressor 720 includes a screw threaded conveyor or a pig conveyor. In this example, the compressor 720 may include a pressure wall and the compressor 720 is configured to exert pressure by pressing the impregnated material contained in the conveyor against the pressure wall. Utilising a conveyor system allows for a substantially continuous method for exerting pressure on the impregnated material. In contrast to non- continuous methods (i.e. presses) which requires the press to be opened and closed and thereby only exerts pressure in 'batches', a conveyor can substantially continuously operate and thereby allow material to substantially continuously be received to the compressor 720 and substantially continuously exert pressure onto the impregnated material.

[0101] The inclusion of the pressure wall helps allow for substantially continuous pressure to be exerted on the impregnated material without the need for complicated mechanisms, which can be expensive or potentially unreliable.

[0102] In one example, the compressor 720 is configured to substantially continuously receive impregnated material from the blender 710. Additionally, the compressor 720 may include an impregnated material inlet and the compressor 720 is configured to receive the impregnated material through the impregnated material inlet. This can run in contrast to conventional methods, where the compressor 720 may receive impregnated material in a semi-continuous batch supply.

[0103] In one example, the heat treatment chamber 730 includes an impregnated material inlet configured to receive impregnated material from the compressor 720, a heated fluid inlet configured to receive heated fluid, a heat treated material outlet configured to output the heat treated material and a fluid outlet configured to output heated fluid and solvent. The heat treatment chamber 730 receives a heated fluid, such as steam, which can be subsequently utilised to heat treat the impregnated material and separate heat treated material from the solvent.

[0104] In one example, the heat treatment chamber 730 is configured to separate at least partially removed solvent from the heat treated material. As discussed in previous paragraphs, in order to separate the heat treated material, it may be necessary to remove excess solvent from the heat treated material.

[0105] In one example, the heat treatment chamber 730 has a conical shape and is configured so that heated fluid entering the chamber generates a cyclonic flow within the treatment chamber to expose the material to heated fluid and thereby generate heat treated material and separate the heated fluid and solvent from the heat treated material, so that the heated fluid and solvent exit via the fluid outlet and heat treated material is output through the heat treated material outlet. In this regard, the conical shape/cyc Ionic effect of the heat treatment 730 allows for the heat treatment of impregnated material and separation of heat treated material from the heated fluid and solvent without requiring the use of complicated mechanisms and simultaneously allowing for substantially continuous processing.

[0106] Exposing the solvent to the heated fluid can significantly increase the temperature of the solvent. For example, where the solvent is acetone and the heated fluid is steam, exposing acetone to a sufficient amount of steam may cause the vapourisation of the acetone. Exposing the impregnated plastic to vapourised acetone and steam facilitates the popcorn effect to form plastic popcorn.

[0107] In one example, the impregnated material inlet is coupled to the heated fluid inlet so that as the heated fluid flows through the heated fluid inlet, this creates a venturi effect, lowering pressure in the impregnated material inlet, which in turn draws the impregnated material through the impregnated material inlet and entrains this within the flow of heated fluid. Utilising a venturi effect can ensure that material does not block the impregnated material inlet, as the use of negative pressure encourages material away from the inlet and not towards it. Additionally, utilising a venturi effect to draw impregnated material into the impregnated material inlet allows for substantially continuous processing as a venturi effect can create negative pressure to draw impregnated material substantially continuously, which improves the consistency and speed of the apparatus 700.

[0108] The heat treatment chamber 730 may be connected to a boiler that is configured to supply the heated fluid, and in particular generates steam, which is then output to the heated fluid inlet.

[0109] In one example, the impregnated material inlet includes a closeable valve configured to control the flow of the impregnated material from the compressor 720 to the heat treatment chamber 730. The inlet can further include a nozzle which can be configured to control the flow of the heated fluid.

[0110] Additionally, the heat treated outlet supplies the heat treated material to the separator 740. For example, the heat treated outlet can be fluidly connected to the separator 740 and be encouraged to transfer to the separator 740 by a number of methods. The heat treated material may exit the heat treated outlet with sufficient velocity to transfer to the separator 740 without additional assistance. Alternatively, a venturi effect could be used to induce negative pressure and thereby encourage movement of the heat treated material towards the separator 740. A person skilled in the art would also appreciate there are other methods to transfer heated treated material to the separator 740.

[0111] In one example, the fluid outlet may be attached to a fluid separator that is configured to separate solvent from the heat fluid and further the separated fluid may be stored for subsequent use. Separating the fluid into solvent and heat fluid can allow them to be recycled (if required) and subsequently used in the future. Doing so reduces the waste produced and potentially reduces costs as it may significantly reduce the amount of heated fluid and solvent required to be replaced in order to operate the apparatus 700.

[0112] For example, if the heated fluid is steam and the solvent is acetone, then fractional distillation could be used to separate these fluids. Since steam and acetone have different vapourisation temperatures, acetone could be vapourised and collected (via a gas capture system) while condensing steam into water so that it can be collected (via a liquid capture system).

[0113] In one example, the separator 740 includes a first outlet that is configured to output at least some of the first product and a second outlet that is configured to output the second product. Additionally, the separator 740 includes a heat treated material inlet that is configured to receive the heat treated material from the heat treatment chamber 730.

[0114] In one example, the separator 740 has a double conical shape and is configured so that the heat treated material entering the separator 740 generates a cyclonic flow within the separator 740 to at least partially separate the first product from the heat treated material so that at least some of the first product exists via the first outlet at an end of a first cone and so that a resultant second product exits via the second outlet at the end of a second cone. The cyclonic flow can encourage the heat treated material to separate into constituent products. For example, this might occur due to different densities or aerodynamic properties of the products.

[0115] Typically, the first product will be have a lower density than the heat treated material and so can exit via the first outlet in an upper end of the separator, as products with lower densities may flow upwards towards the first outlet, while products with heavier densities may flow downwards towards the second lower outlet. Preferably, the cyclonic effect and separator 740 will be designed such that only the first product can exit via the first outlet. Depending on the material being processed and the properties of the heat treated material that the separator 740 may require different configurations to separate the first and second product. Depending on the material being processed, the inlet angle, cone angle, flow velocity, flow pressure may be varied to for encourage separation of the first product and second product.

[0116] The use of a cyclonic effect in the separator 740 allows for at least partial separation of the heat treated material without complicated mechanisms which can reduce the reliability of the apparatus 700. Additionally, the use of a cyclonic effect can allow for substantially continuous separation as the separator 740 can substantially continuously receive heat treated material to separate and is not restricted to 'batch' processing.

[0117] In one example, the apparatus 700 includes one or more tertiary separators that includes a resultant product inlet that is configured to receive resultant product from the separator 740. The tertiary separators have a similar configuration, and hence have a double conical shape and are configured so that the resultant product entering the tertiary separator generates a cyclonic flow within the tertiary separator to at least partially separate the first product from the resultant product so that at least some of the first product exists via a first tertiary outlet at an end of a first tertiary cone and so that a tertiary resultant second product exits via a second tertiary outlet at the end of a second tertiary cone. The second tertiary outlet is configured to output the tertiary resultant product to a subsequent tertiary separator. A person skilled in the art will appreciate that not necessarily all of the first product will exit via the first outlet. For example, a portion of the first product, the second product and other miscellaneous products (which can be considered the resultant product) may exit via the second outlet. Additionally, the separator 740 and tertiary separator may be configured to receive separator fluid that assists the separator 740 and the tertiary separator to generate a cyclonic flow.

[0118] Similarly to the separator 740, the tertiary separators can receive resultant product and use a cyclonic effect to further separate the resultant product. As discussed in the above paragraphs, the separator 740 may not necessarily completely separate the first product and second product from the heat treated material. Therefore, multiple tertiary separators can be provided in series to progressively purify the output from a previous separator until a sufficient degree of separation has occurred. Providing tertiary separators reduces the pressure placed on the separator 740, allowing a larger amount of heat treated material to be separated and increasing the tolerances allowable in the separator 740.

[0119] In one example, the apparatus 700 includes the minimum number of tertiary separators such that the resultant second product only includes significantly less first product than the heat treated material; and, the tertiary resultant second product only includes significantly less first product than the resultant second product. For example, the resultant second product may contain less than 10%, less than 5%, less than 1%, less than 0.5%, less than 0.1%, less than 0.01% by weight of first material. A person skilled in the art will appreciate that the apparatus 700 need only include the minimum number of separators 740/tertiary separators as required to adequately separate the first product (and potentially the second product) from the heat treated material.

[0120] In one example, the second outlet includes a chopper that is configured to chop the second product to a required size, prior to this being supplied to the tertiary separators.

[0121] In one example, the separator 740 and one or more of the tertiary separators can have a different shape, inlet position, inlet angle, inlet velocity or size to assist separating the first product and second product. A person skilled in the art will appreciate that depending on the material being processed and the properties of the heat treated material that the separator 740 and tertiary separators may require different configurations to sufficient separate the first and second product. Additionally, with the separator 740 and tertiary separators having different configurations can allow them to more effectively separate the first and second product. For example, the separator 740 can have an inlet velocity that is designed to more quickly separate the heat treated material without thoroughly separating the heat treated material. The tertiary separators can then be configured with a different inlet velocity does not quickly separate the resultant products, allowing for a finer separation to occur. Such an arrangement can lead to more quick and more effective separation than the separator 740 and tertiary separators having similar configurations.

[0122] In one example, the apparatus 700 includes a one way air vent and the one way air vent may allow air to enter the apparatus 700 and prevent vapour from exiting the apparatus 700. Additionally, the one way air vent may be connected to the compressor 720 or the heat treatment chamber 730. The one way air vent may allow additional air to enter the apparatus 700 and further encourage transfer of the impregnated material from the compressor 720 to the heat treatment chamber 730. In an example, the air vent may be connected to the compressor 720 and thereby provide positive pressure against the impregnated material to thereby encourage the impregnated material to transfer to the heat treatment chamber 730.

[0123] An example of a compressor will now be described with reference to Figure 8.

[0124] In this example, a compressor 820 includes an impregnated material inlet 821, an impregnated material outlet 822, compressor arms 823 and an air valve 824.

[0125] The impregnated material inlet 821 allows the compressor 820 to receive impregnated material that is to be compressed. Consequently, the impregnated material outlet 822 allows the compressor 820 to transfer impregnated material that has been compressed out of the compressor 820. While the compressor arms 823 are in a retracted position (shown), impregnated material can be received into or transferred out of the compressor 820.

[0126] To compress the impregnated material, the compressor arms 823 move to a compressed position (not shown) in order to exert pressure onto the impregnated material and thereby compress it. In this example, the compressor arms 823 may move from their retracted position to their compressor position (and vice versa) through a hydraulic compressor system, which has been further described in the above examples.

[0127] In this example, the air valve 824 is fluidly connected to the compressor 820 and allows the compressor 820 to receive air and/or allow excess air to be vented during compression. In this example, the compressor 820 may be sealed and otherwise unable to receive and/or vent excess air. The air valve 824 therefore allows the compressor 820 to receive/vent air.

[0128] An example of a blender will now be described with reference to Figures 9A and 9B.

[0129] In this example, a blender 910 includes a solvent inlet 911, a material inlet 912, a impregnated material outlet 913, a plurality of blades 914, a blade axle 915 and a blade motor 916. [0130] The blender 910 can receive solvent and material from the solvent inlet 911 and material inlet 912 respectively. The material can firstly be exposed to solvent before coming into contact with the plurality of blades 914, initialising the impregnation of the material. As material passes the plurality of blades 914, the rotation of the plurality of blades 914 causes mechanical agitation which cuts the material to a smaller size. Both mechanically agitating the material and cutting the material to a smaller size assists in exposing as much surface area of the material to the solvent, thereby increasing the amount of material that is impregnated by the solvent. The plurality of blades 914 are rotated by the blade axle 915 and the blade axle 915 is rotated through the blade motor 916. Following at least partial impregnation of the material with the solvent, the solvent can be transferred out of the blender 910 through the impregnated material outlet 913.

[0131] An example of a heat treatment chamber will now be described with reference to Figures 10A and 10B.

[0132] In this example, a heat treatment chamber 1030 includes an impregnated material inlet 1031, a heat treated material outlet 1032, a fluid outlet 1033, an upper chamber section 1034 a lower chamber section 1035 and a heated fluid inlet 1036.

[0133] The heat treatment chamber 1030 can receive impregnated material and heated fluid from the impregnated material inlet 1031 and heated fluid inlet 1036 respectively. The heat treatment chamber 1030 can receive heat fluid at a sufficient velocity to create a venturi effect, which thereby assists in transferring impregnated material into the impregnated material inlet 1031. Exposing the impregnated material to the heated fluid assists in cleaning any excess solvent from the surface of the impregnated material and heat treats the impregnated material into heat treated material. Where the impregnated material is plastic, exposure to heat forms plastic popcorn from impregnated plastic. Heat treated material and fluids (including solvent and the heated fluid) entering the heat treatment chamber 1030 creates a cyclonic effect which assists in separating the heat treated material and fluids.

[0134] As the heat treated material has a higher density than the fluids, it will fall to the lower chamber section 1035 and subsequently be transferred out of the heat treatment chamber 1030 through the heat treated material outlet 1032. As the fluids are lower in density than the heat treated material, they will rise to the upper chamber section 1034 before being transferred out of the heat treatment chamber via multiple outlets connected to a manifold, eventually exiting through the fluid outlet 1033.

[0135] An example of separators and a chopper will now be described with reference to Figures 11A, 11B, 11C and 11D.

[0136] In this example, the separators are split into primary separator 1140 and tertiary separators 1160. The primary separator 1140 includes a heat treated material inlet 1141, a first outlet 1142, a second outlet 1143, a first zone 1144 and second cone 1145. The tertiary separators 1160 include a resultant product inlet 1161, first outlets 1162 and second outlets 1163. A chopper 1150 includes a resultant product inlet 1151 and a resultant product outlet 1152.

[0137] The primary separator 1140 receives heat treated material from the heat treated material inlet 1141. Depending on the material being processed the separator may also receive separator fluid from the heat treated material inlet 1141. Also depending on the material being processed, the heat treated material inlet 1141 can transfer heat treated material (and potentially separator fluid) with different angles, position on the primary separator 1140 and/or heat treated material velocity. The primary separator 1140 will then separate the heat treated material into a first product and a resultant product. The first product will typically be a lower density than the resultant product, rise to the first outlet 1142 through the first cone 1144 and thereby be transferred out of the primary separator 1140. The resultant product will typically be made up of the remaining products from the heat treated material and be a higher density than the first product, lower to the second outlet 1143 through the second cone 1145 and thereby be transferred out of the primary separator 1140.

[0138] The resultant product is then transferred to the chopper 1150 through the resultant product inlet 1151. The chopper 1150 may include a plurality of blades 1153 which can cut the resultant product into a smaller size. The resultant product is then transferred out of the chopper 1150 through the resultant product outlet 1152 into the tertiary separators 1160.

[0139] The tertiary separators 1160 receive resultant product from the resultant product inlet 1161. Depending on the material being processed, the heat treated material inlet 1161 can transfer resultant product with different angles, position on the tertiary separators 1160 and/or resultant product velocity. The tertiary separators 1160 will then separate the resultant product into a first product and a tertiary resultant product. The first product will typically be a lower density than the tertiary resultant product, rise to the first outlet 1162 and thereby be transferred out of the tertiary separator 1162. The tertiary resultant product will typically be made up of the remaining products from the resultant product and be a higher density than the first product, lower to the second outlet 1163 and thereby be transferred out of the tertiary separator 1160. While it is shown for there to be two tertiary separators 1160 in Figure 11A, a person skilled in the art would appreciate that there could be more or fewer tertiary separators 1160 depending on the material being processed and desired speed of the processing.

[0140] An example of a material supply will now be described with reference to Figure 12.

[0141] The material supply 1270 includes a material inlet 1271 a material outlet 1273 and a cutter 1272.

[0142] The material supply 1270 receives material through the material inlet 1271. Depending on the implementation of the invention, material may be supplied that is too large in size to be adequately blended. The material supply 1270 may then include a cutter than can cut the material to a suitable size for a subsequent blender. Following any cutting, the material can then be transferred out of the material supply 1270 through the material supply outlet 1273 using an auger screw 1272 to control the rate of supply such that there is a consistent supply of material to any subsequent devices/apparatuses.

[0143] In this example, the material supply 1270 is in the form of a cyclone hopper, but a person skilled in the art would appreciate that the material supply 1270 could take other forms.

[0144] An example of how a material can be processed using the apparatus will now be described with reference to Figure 13.

[0145] Firstly, the material may be supplied to a material supply 1370. The material supply 1370 can include a preliminary cutter which can cut material to a smaller size if material supply to the apparatus 1300 is too large. The material supply 1370 then releases material to a blender 1310 in a manner appropriate depending on the implementation of the invention. Typically, material will be supplied from the material supply 1370 in a substantially continuous manner.

[0146] Secondly, the blender 1310 receives material from the material supply 1370 and solvent from a fluid apparatus 1380. The blender 1310 includes a plurality of blades which cut (or further cut if the material supply preliminarily cut the material) the material into a smaller size through mechanical agitation. By cutting the material into a smaller size and mechanically agitating the material, the material has more surface area exposed to the solvent, thereby reducing the time taken for the material to become impregnated by the solvent. Following at least partial impregnation, the impregnated material is transferred from the blender 1310 to a compressor 1320.

[0147] Thirdly, the compressor 1320 compresses the impregnated material to further impregnate the material and/or remove excess solvent from the impregnated material. While blending the material with solvent encourages the material to be impregnated, there remains the possibility that not all material is sufficiently impregnated. By applying pressure through the compressor 1320, material that has not been sufficiently impregnated will be further exposed to the solvent. Additionally, impregnated material placed under pressure will have at least some of the excess solvent removed. Following compression, the impregnated material is transferred from the compressor 1320 to a heat treatment chamber 1330.

[0148] Fourthly, the heat treatment chamber 1330 receives impregnated material from the compressor 1330 and heated fluid from the fluid apparatus 1380. Exposing impregnated material to the heated fluid can clean at least some of the remaining solvent on the surface of the impregnated material. Additionally, exposing impregnated material to the heated fluid can heat treat the material. In an example where the material is plastic and the solvent is acetone, heat treating plastic that is impregnated with acetone can form plastic popcorn. The combination of the heated fluid and impregnated material undergoes a cyclonic effect within the heat treatment chamber. The cyclonic effect separates the heat treated material from the other fluids.

[0149] The larger density heat treated material falls to the lower section of the heat treatment chamber 1330 and can subsequently transferred to a separator 1340. The lower density fluids rise to the higher section of the heat treatment chamber and can subsequently transferred to the fluid apparatus 1380. The fluid apparatus 1380 can subsequently separate the fluids (into heated fluid and solvent) for their recycling and/or reuse.

[0150] Fifthly, the separator 1340 receives heat treated material from the heat treatment chamber 1330. Depending on the material being processed and the volume of material being processed, heat treated material can be supplied to the separator 1340 at different angles, velocities, temperatures etc. The separator 1340 uses a cyclonic effect to separate the heat treated material into a first product and a resultant product. The first product, which is typically lower in density, rises to the top of the separator 1340 and can be stored for subsequent use/storage. The resultant product, which is typically larger in density, lowers to the bottom of the separator 1340 and can be transferred to a chopper 1350.

[0151] Sixthly, the chopper 1350 receives resultant product from the separator 1340. The chopper 1350 includes cutting blades which cut the resultant product into a smaller size. Following this cutting, the resultant product is transferred to tertiary separators 1360.

[0152] Seventhly, the tertiary separators 1360 receive resultant product from the chopper 1350. Resultant product can be supplied to the tertiary separators 1360 at different angles, velocities, temperatures etc. than the heat treated material was supplied to the separator 1340. The tertiary separators use a cyclonic effect to separate the resultant product into a first product and a tertiary resultant product. The first product, which is typically lower in density, rises to the top of the tertiary separators 1360 and can be stored for subsequent use/storage. The tertiary resultant product, which is typically larger in density, lowers to the bottom of the tertiary separators 1360 and can be transferred to subsequent tertiary separators 1360 or transferred out of the final tertiary separator 1360 as the second product.

[0153] In this example, the apparatus 1300 may be split into a first environment 1301, a second environment 1302 and a third environment 1303. These environments may be enclosed from each other and thereby separated from each other using firewalls 1304. Depending on the desired implementation of the apparatus 1300, the solvent may be a flammable substance. The use of a flammable substance may potentially result in a fire hazard. The inclusion of firewalls 1304 between the first 1301, second 1302 and/or third 1303 environments may reduce damage the apparatus 1300 takes if a flammable substance ignites by localising the damage to a single environment. To further reduce the risk of fires, the second environment might be configured to not include electrical equipment, for example, by using hydraulic and pneumatically driven conveyors in the second environment.

[0154] Another example of an apparatus for processing a material will be discussed with reference to Figures 1A and IB.

[0155] In this example, the apparatus includes a pipe 100, a conveyor (not shown) and a venting pipe 130.

[0156] The pipe 100 includes a first section 110 and a second section 120. The first section 110 (shown in Figure 1 A), is at least partially filled with a first fluid while the second section 120 is at least partially filled with a second fluid.

[0157] The conveyor conveys material (not shown) through the first section 110 and second section 120 so that the material is exposed to the first and second fluid. The use of a conveyor allows for a sealed and vented safe continuous movement of the material throughout the apparatus, rather than requiring an open exposed batch type process.

[0158] The material may be first exposed to the first fluid, where exposure to the first fluid treats or primes the material. An example of the first fluid may be a hazardous substance, such as a solvent, which loosens the construction of the material, prepping the material to be treated by the second fluid. The material may then be secondly exposed to the second fluid, where exposure to the second fluid cleans or performs a secondary treatment of the material. An example of the second fluid may be a caustic substance, which could clean the surface of the material, or water for washing and/or secondary treatment of the material. A person skilled in the art will appreciate that the purpose and order of the material’s exposure to the first and second liquids and the first and second liquid themselves can vary depending on the desired implementation of the invention.

[0159] The venting pipe 130 is in fluid communication with the pipe 100, and by extension one or both of the first section 110 and second section 120, to thereby remove vapour generated by the first and/or second fluids. As described above, the first and/or second fluids may be hazardous or caustic substances and thereby generate vapours on use. These vapours, if not extracted from the apparatus or not extracted from the apparatus in a safe manner, may result in a drop in efficiency of the process of the material or increase the danger to users operating the apparatus. For example, in the event that one of the fluids is a flammable solvent, these often have a low evaporation temperature, which can lead to build up of flammable vapour in an environment, leading to risk of explosions. However, the inclusion of the venting pipe 130 allows for the continuous extraction of vapours from the apparatus, removing any vapour and reducing explosive risks, whilst also facilitating the continuous processing of the material, and optionally reuse of the fluids. Accordingly, the above process seeks to improve over the prior art by facilitating a safe, sealed and vented continuous process for the processing/separation of materials.

[0160] A number of further features are now described.

[0161] In one example, the conveyor includes a first screw thread conveyor in the first section 110 and a second screw thread conveyor in the second section 120. A screw threaded conveyor may be submerged in the first or second liquid and operate without danger of contamination of or chemical reaction with the first or second fluids, irrespective of whether the first or second fluids are hazardous, caustic, flammable or another other type of dangerous fluid. An advantage of using a screw threaded conveyor is that it allows the material to be continuously conveyed throughout the first section 110 and second section 120. Due to the infinitely rotating nature of a screw thread conveyor, material can be continuously fed at one end of the conveyor, for that material to be conveyed throughout the first section 110 and second sections 120 without requiring the screw thread conveyor to pause to be refilled with material.

[0162] Additionally, the first and second screw threaded conveyors could also include openings in at least some of the screw threads to drain the first or second fluids to the first section 110 or second section 120. As the screw threaded conveyors convey the material, they may also convey part of the fluid the material was exposed to. While operating the conveyor over a period of time, the continuous movement of material may result in fluid being unintentionally conveyed from the intended section (i.e. first fluid from the first section 110 being conveyed to the second section 120). By including openings in at least some of the screw threads, fluid that is conveyed by the material will pass through the openings and reduce the possibility that fluid is unintentionally conveyed to a different section.

[0163] Additionally, the conveyor could alternatively include a pig that is driven through the pipe 100. The pig can be inserted into the pipe 100 at a launching station, using a cable within the pipe 100, or another suitable propulsion mechanism, to drive the pig along the pipe 100 into the first 110 and second sections 120. The pig could be used to deliver the material, first and/or second liquid to the pipe 100, reducing the possibility of cross contamination without halting the continuous use of the apparatus. Alternatively, the pig could be used to clean pipes or unblock obstructions in the pipe 100.

[0164] In one example, the first section 110 includes a first inlet and a first outlet and a first depression between the first inlet and outlet containing the first liquid; and, the second section 120 includes a second inlet and second outlet and a second depression between the second inlet and outlet containing the second fluid. The first 110 and/second section 120 could be convoluted in shape, and could be U shaped, V shaped, or the like, depending on the preferred implementation, and in particular the type of conveyor used. As discussed above the first and/or second liquid may be caustic, flammable or otherwise hazardous and potentially result in an adverse reaction if the first liquid and second liquid were to be exposed to one another. By including a first and second depression located between the first and second inlets and first and second outlets, movement of the first and second liquid may be further restricted to the first 110 and second sections 120. Reducing the possibility that the first and/or second liquid escapes their respective sections reduces the risk of the first and/or second liquid can damage other components of the apparatus or be harmful to a user.

[0165] Further, the first outlet can be positioned above the first inlet and/or the second outlet can be positioned above the second inlet. With continuous operation of the apparatus, the conveyor and natural viscosity of the first and/or second liquid may result in the first and/or second liquid exiting the first 110 or second sections 120, resulting in potential damage to the apparatus, dangerous exposure to a user and undesirable exposure of the first liquid to the second liquid. By positioning the first and second outlets above the first and second inlets, the risk of the first and/or second liquid escaping the first 110 and second sections 120 is reduced. [0166] Additionally, the first outlet may be positioned above the second inlet to allow material to be transported from the first section 110 to the second section 120. Depending on the desired implementation of the apparatus and the potential dangers of the first and second liquid, the first outlet and second inlet may not be directly connected. In order to allow transfer of the material (after being exposed to the first liquid) from the first section 110 to the second section 120, the first outlet may be positioned above the second inlet, allowing the material to vertically drop to the second inlet. Doing so has the additional benefit of not requiring mechanical devices to drive this transfer, reducing costs and failure points in the apparatus. Further, the vertical drop may facilitate certain implementations of the apparatus, where the material (after being exposed to the first liquid) requires being dropped, at velocity, into the second liquid. A person skilled in the art could appreciate that the distance between the first outlet and second inlet could vary to allow for the desired velocity of the material.

[0167] In one example, the pipe 100 includes a third section between the first 110 and second sections 120, the material being transported through the third section, the third section including a third inlet and a third outlet. Additionally, the third inlet could be positioned above the third outlet; the third inlet could be in communication with the first outlet; and, the third outlet could be in fluid communication with the second inlet to prevent mixing of the first and second fluids. The apparatus could include a third section, between the first 110 and second sections 120, in order to separate the first 110 and second sections 120 from one another to reduce the risk of mixing the first and second fluids. By introducing a third section, if any liquids were to escape the first 110 and/or section sections 120, the third section could act as an intermediary, preventing the first and/or second liquid from immediately mixing. The person skilled in the art would appreciate that there are many methods/apparatuses that could be utilised within the third section to prevent this mixing.

[0168] In one example, the venting pipe 130 is in fluid communication with the first inlet to the first section 110, a third section between the first 110 and second sections 120 and/or a second outlet of the second section 120. As previously discussed, the use of the first and/or second liquid may result in the generation of vapours, the concentration of which would be undesirable to the continuous operation of the apparatus. The venting pipe 130 could then be in fluid communication with the first 110, second 120 and/or third sections of the apparatus which require vapour venting, to thereby reduce the risk continuous vapour build up. [0169] In one example, the venting pipe 130 extends to a condenser that condenses the vapour after the vapour has been removed from the pipe. Additionally, the condenser could be configured to separate the first and second fluids so that the first and second fluids can be reused, reducing waste production of the apparatus.

[0170] In one example, the apparatus includes a first enclosed environment containing at least the first section 110 and a first fluid reservoir containing the first fluid, the first fluid reservoir being in fluid communication with the first section 110 to supply first fluid thereto. The apparatus can further include a second environment containing at least the second section 120 and a second fluid reservoir containing the second fluid, the second fluid reservoir being in fluid communication with the second section 120 to supply second fluid thereto. As the material is exposed to the first and second fluids, some of the first and/or second fluids may be removed from the first 110 and second sections 120 (i.e. the first and/or second fluid may attach to the material, exposure to the material may cause the first and/or second fluid to partially evaporate and be removed by the venting pipe 130 etc.). With continuous use, the levels of the first and/or second fluid in the first 110 and/or second sections 120 may reduce to the point where the apparatus can no longer process the material. The first and second fluid reservoirs can then supply additional first and second liquid to the first 110 and second sections 120 to continuously maintain the desired level of first and second liquid, thereby allowing continuous, uninterrupted, use of the apparatus. Alternatively, the first 110 and second sections 120 could only be supplied with additional first and second liquid when the levels of the first and/or second liquid reach critical levels, allowing for a majority of the first and/or second fluid to be replaced while allowing continuous use of the apparatus. A person skilled in the art would appreciate that depending on the implementation of the apparatus, the first environment may not necessarily be enclosed, while the second environment may instead be enclosed. Additionally, either the first and second environments or neither the first and second environments could be enclosed.

[0171] In one example, the first enclosed environment is separated from at least the second environment, and more typically all other parts of the environment, using a firewall. Depending on the desired implementation of the apparatus, the first and/or second liquid may be a flammable substance. The use of a flammable substance may potentially result in a fire hazard. The inclusion of a firewall between the first enclosed environment and second environment may reduce the damage the apparatus takes if a flammable substance ignites by localising the damage to a single environment. To further reduce the risk of fires, the first environment might be configured to not include electrical equipment, for example, by using hydraulic and pneumatically driven conveyors in the first environment.

[0172] In one example, the apparatus includes a blower configured to generate air flow within the pipe to thereby at least partially dry the material after it is exposed to at least one of the first and second liquids, and optionally to also facilitate transfer of vapour into the venting tube. Depending on the implementation of the apparatus, mixing of the first and second liquid may result in a harmful effect. After exposure to the first liquid, the material may be at least partially coated in the first liquid (or a residual of the first liquid after being exposed to the material) that could react with the second liquid. To prevent this combination, air blowers (generating an air flow) could be used to dry, and thereby remove, any undesirable liquids/residuals from the material, reducing the risk of a harmful reaction.

[0173] In one example, the first fluid is at least one of: a hazardous substance; a caustic substance; a flammable substance; a solvent; and, acetone. Further, exposing the material to the first fluid may treat the material to form a first treated material. Depending on the implementation of the apparatus, a plurality of different types of fluids could be potentially treat the material being exposing the material to the second liquid. For example, PVC (the material) could be exposed to acetone, to thereby treat PVC and form soaked PVC.

[0174] In one example, the second fluid is at least one of: a non-hazardous substance; water; and, boiling water. Further, exposing the first treated material to the second fluid treats the first treated material to form a second treated material. Depending on the implementation of the apparatus, a plurality of different types of fluids could be potentially treat the material being exposing the material to the second liquid. For example, soaked PVC could be exposed to boiling water, to thereby treat soaked PVC and form bubbled PVC.

[0175] In one example, the apparatus includes a shredder configured to shred material and supply shredded material to the first section. Depending on the implementation of the apparatus, it may be preferable to supply a shredded material. For example, by shredding PVC into shredded PVC, the shredded PVC will be treated into soaked PVC at a much faster rate than if supplied with non- shredded PVC. However, it will be appreciated this may not be required, for example if the material is pre-shredded, or if shredding is not required.

[0176] In one example, the apparatus includes a separator to separate the material into a first component and a second component. Further, the separator could be a cyclone device, a static electricity device, a pulsing air device, an agglomerator a shaking table device, a drum combing device or the like. Depending on the desired implementation of the invention, the process the apparatus could be performing would be to separate a material to obtain at least one desired component of the material. For example, bubbled PVC can be separated into PVC wool and PVC flakes using a static electricity device. A person skilled in the art would appreciate that an appropriate separator would be used depending on the material to be separated.

[0177] In one example, the pipe 100 includes stainless steel grade 316. Depending on the implementation of the apparatus, the vapours generated by the first and/or second liquid may potentially accelerate erosion and/or corrosion of the pipe 100. To improve the longevity of the apparatus and reduce the possibility of corrosion, the pipe 100 could be constructed with, lined with, or otherwise include stainless steel grade 316.

[0178] An example of the orientation of the first, second and third sections and the venting pipe will now be described in more detail with reference to Figures 1A and IB.

[0179] Figure 1A shows the first section 110, the venting pipe 130 and a third section 140. The first section 110 includes a first inlet 111 and a first outlet 112, where, in this example, the first outlet 112 is positioned above the first inlet 111. The first fluid (not shown) resides in the first section 110 and, due to gravity, will flow towards the first inlet 111, reducing the possibility that the first fluid will flow into the third section 140. In this example, the first section 110 may be filled with the first fluid up to the first fluid level 114. A person skilled in the art would appreciate that the first fluid level 114 could be raised or lowered depending on the desired implementation of the invention.

[0180] The third section 140 includes a third inlet 141 and a third outlet 142. In this example, the third inlet 141 is in fluid communication with the first outlet 112 and is positioned above the third outlet 142 which is in fluid communication with a second inlet 121. The third section 140 allows for material transfer between the first 110 and second sections 120 and, in this example, allows for the material to be dropped into the second section 120, which may be desirable depending on the material being processed. For example, if soaked PVC enters the third section 140 and is dropped into the second section 120 it will form bubbled PVC.

[0181] Figure IB shows the second section 120. The second section 120 includes a second inlet 121 and a second outlet 122, where, in this example, the second outlet 122 is positioned above the second inlet 121. The second fluid (not shown) resides in the second section 120 from a second fluid reservoir 125 and, due to gravity from the second fluid reservoir 125, will form a predetermined second fluid level 124 within the section second 120, reducing the possibility that the second fluid will flow into the subsequent parts of the apparatus (i.e. the separator).

[0182] The second fluid may generate vapours upon exposure to the material, the vapour may travel along any one of the second section 120, third section 140 or a venting inlet 131, transfer to the venting pipe 130 and be captured by the condenser 154. The condenser 154 may then condense the vapour into a fluid to be stored in the second fluid reservoir 125. The second fluid reservoir can then distil and/or separate to then return the condensed vapours back to the second section 120 to ensure that the fluid level of the second section 120 remains consistent. Alternatively, the condensed vapours can be returned to the second fluid reservoir 125. The condenser 154 may be electrically fan cooled or water cooled. The first and/or second fluids may be separated downstream of the condenser through stills or filter apparatus before the first and/or second fluids are returned to the first and/or second fluid reservoirs.

[0183] Both Figures 1A and IB show the venting pipe 130 including the venting inlet 131 which, in this example, fluidly connects the first 110, second 120 and third sections 140 of the pipe 100 to the venting pipe 130 to allow for extraction of vapours generated by the first and/or second fluids.

[0184] An example of the first and second fluid reservoirs, first enclosed environment, second environment and blowers will now be described with reference to Figures 2 A and 2B.

[0185] Figure 2A shows the first section 110, a first enclosed environment 250, a first fluid reservoir 251 and a firewall 252. The first enclosed environment 250, in this example, includes the first fluid reservoir 251 and first section 210. The first enclosed environment 250 is separate from the second environment to minimise the risk of cross contamination, fire spread and electrical hazards. To further ensure the isolation of the first enclosed environment 250 and second environments, the first enclosed environment 250 includes a firewall 252 that acts to insulate the first enclosed environment 250 from the second environment.

[0186] The first fluid reservoir 251 contains the first fluid and is in fluid communication with the first section 210. As the apparatus is continuously operated, the first liquid may evaporate or flow out of the first section 210, reducing the effectiveness of the apparatus or prevent it from functioning. As the first liquid levels drop, the first fluid reservoir 251 can transfer first fluid to the first section 210 to ensure it maintains a consistent fluid level at the first fluid level 114. The apparatus could also include an expended fluid reservoir 253 which is in fluid communication with either the first 210 or second sections 220 to receive fluids expended in the process that require cleaning or waste disposal. Returned and filtered fluids from the expended fluid reservoir 253 may be used to fill the first fluid reservoir 251 via an air actuated diaphragm pump or explosion proof electrical pump and sensor device, though a person skilled in the art will appreciate that alternative apparatuses could be used to facilitate the transfer of fluid between expended fluid reservoir 253 and the first fluid reservoir 251.

[0187] Figure 2B shows the second section 220, a second environment 260, a cyclonic extractor 261 and a second material reservoir 262. Similarly to the first enclosed environment 250, the second environment 260 is separated from the first enclosed environment 250 to minimise the risk of cross contamination, fire spread and electrical hazards.

[0188] Blowers 263 can generate air flow within the pipe 100 in order to at least partially dry the material after it is exposed to the first and/or second fluids. For example, after PVC (the material) is exposed to acetone (the first fluid), the blowers 263 may induce an air current in the first section 210 which encourages any remaining acetone on the soaked PVC to flow off of the soaked PVC or encourage the acetone to evaporate to thereby at least partially dry the soaked PVC before the soaked PVC is dropped into the second section 220. Similarly, after the soaked PVC is exposed to boiling water (the second fluid), the blowers 263 may induce an air current in the second section 220 which encourages any remaining water on the bubbled PVC to flow off of or evaporate off of the bubbled PVC to thereby at least partially dry the bubbled PVC before the bubbled PVC is transferred to the separator. [0189] Both Figures 2A and 2B include blenders 255. The blenders 255 may have integrated tanks connected above or below the conveyor to facilitate additional shredding of the material. A person skilled in the art would appreciate that the number, strength or necessity of blenders 255 will vary depending on the desired implementation of the invention.

[0190] An example of the shredder, separator and component reservoirs will now be described with reference to Figures 3 A and 3B.

[0191] Figure 3A shows a shredder 370, a shredded material container 374 and the first section 310. The shredder can be utilised to shred and/or granulate the material, to then provide shredded material to the first section 310. The shredded material may be supplied to the first section 310 via an integrated cyclone. Depending on the implementation of the apparatus, shredding the material (with a subsequent secondary granulating of the material) may result in a more effective or faster process (i.e., shredding and then potentially granulating PVC into shredded and/or granulated PVC may reduce the time it takes to soak the PVC composite fabric in acetone). A person skilled in the art will appreciate that shredded material could be supplied to the first section 310 without the need for shredder built into the apparatus itself and that shredded material is not necessary for the apparatus to function.

[0192] Figure 3B shows a separator 371 a first component reservoir 372 and a first component filter 373. The separator 371 separators the material into at least a first and a second component (i.e. separating bubbled PVC into PVC wool and PVC flakes) where the first and second components can be utilised in different applications. The separator 371 can be one of many different types of separation devices and a person skilled in the art will be able to determine which separator device is most appropriate for their desired implementation of the invention. Following separation of the material, the first component may be stored in the first component reservoir 372 and the second component may be stored in a second component reservoir for later access.

[0193] The separator 371 may receive dried mixed material and use blades to move the dried material through cyclonic action to separate heavy particular to the base of the separator 371 and lighter materials to the top of the separator 371. The first component reservoir 372 and first component filter 373 may also act to separate dust and flake particles from heavier materials. [0194] An example of convoluted pipes will now be described with reference to Figures 4A and 4B.

[0195] Figure 4A shows the pipe 400, a U-shaped first section 410 and a U-shaped second section 420. In this example, the pipe 400, first section 410 and second section 420 are formed into convoluted shapes. The first section 410 is U-shaped and includes a first depression 413, where the pipe 400 is elevated in position to the first section 410. The first section 410 includes the first fluid up to a first fluid level 414, where material is exposed to the first fluid as the material is conveyed through the first section 410. The second section 420 is U-shaped and includes a second depression 423, where the pipe 400 is elevated in position to the second section 420. The second section 420 includes the second fluid up to a second fluid level 424, where material is exposed to the second fluid as the material is conveyed through the second section. The U-shaped first section 410 and second section 420 facilitate the use of a pig conveyor.

[0196] Figure 4B shows the pipe 400, a V-shaped first section 410 and a V-shaped second section 420. In this example, the pipe 400, first section 410 and second section 420 are formed into convoluted shapes. The first section 410 is V-shaped and includes a first depression 413, where the pipe 400 is elevated in position to the first section 410. The first section 410 includes the first fluid up to a first fluid level 414, where material is exposed to the first fluid as the material is conveyed through the first section 410. The second section 420 is V-shaped and includes a second depression 423, where the pipe 400 is elevated in position to the second section 420. The second section 420 includes the second fluid up to a second fluid level 424, where material is exposed to the second fluid as the material is conveyed through the second section. The V-shaped first section 410 and second section 420 facilitate the use of a screw threaded conveyor.

[0197] Both Figures 4A and 4B may also include the third section 440 which connects the first section 410 to the second section 420 where the third section 440 is elevated in position compared to both the first 410 and second sections 420 but the pipe 400 is elevated in position compared to the third section 440. [0198] A person skilled in the art will appreciate that the pipe 400, first section 410, second section 420 and third section 440 may be of different convoluted shapes (or a non -convoluted shape) depending on the desired implementation of the invention.

[0199] An example of a mounted filter fan will now be described with reference to Figure 5.

[0200] Figure 5 shows a mounted filter fan 580. The mounted filter fan 580 may be externally or internally mounted to the second environment. The mounted filter fan 580 draws air through the condenser in order to draw air through the venting pipe 130 to extract vapours from generated by the first and/or second liquids.

[0201] An example of how a material can be processed using the apparatus will now be described with reference to Figure 6.

[0202] Firstly, the material may be shredded by the shredder 670 in order to supply shredded material to the apparatus. Depending on the implementation of the invention, the material may be only shredded, shredded then granulated, only granulated or neither shredded nor granulated. The shredded material is then transferred to the shredded material container 674 so that it may be fed to the pipe 600 in a controlled manner.

[0203] Secondly, the shredded material is transferred from the shredded material container 674 to the pipe 600 and into the first section 610. In the first section 610, a first fluid (not shown) at least partially fills the first section 610. The shredded material is conveyed through the first section 610 with a conveyor, allowing the shredded material to be exposed to the first fluid. Depending on the implementation of the invention, the conveyor may take the form of a screw threaded conveyor, a pig system or the like. After exposure to the first fluid, the shredded material forms a first treated material.

[0204] Thirdly, the first treated material is transferred from the first section 610 to the third section 640. The third section 640 connects the first section 610 to the second section 620.

[0205] Fourthly, the first blended material is transferred into the second section 620. The second section 620 is at least partially filled with a second fluid (not shown). The level of the second fluid may be maintained in the second section 620 by the second fluid reservoir 625. As the first treated material is conveyed through the second section 620, it is exposed to the second fluid, forming a second treated material. The second treated material can be subsequently blended by the blenders 655 to form a second blended material. Additionally, if desired by the implementation of the invention, an air blower 663 may be used to blow air on the second blended material in order to dry the second blended material, forming a dried material.

[0206] In a specific example, the first treated material is soaked PVC, and the soaked PVC is dropped into the second section 620, becoming exposed to boiling water (the second liquid). Following exposure to the boiling water, the soaked PVC forms PVC popcorn (or bubbled PVC). As the PVC popcorn is conveyed along the second section 620, blenders 655 may be included to further blend the PVC popcorn into smaller pieces.

[0207] Fifthly, the dried material is transferred from the second section 620 to the separator 671. The separator 671 separates the dried material into a first and second component. An example of a separator 671 may be a cyclone separation device, which uses centrifugal force to separate heavier materials from lighter materials. The separator 671 then transfers the first component to a first component filter 673 and the second component to a second component reservoir 662. The second component can then be later accessed from the second component reservoir 662 when desired. The first component can be further filtered by the first component filter 673 and transferred to a first component reservoir 672, the filtered first component can be then later accessed from the first component reservoir 672.

[0208] The venting pipe 630 can be used to extract undesirable vapours from the apparatus in order to ensure the continuous functioning of the apparatus and safety of users. The venting pipe 630 can be connected to any part of the apparatus where required by the implementation of the invention. Examples of such connections can be seen in Figure 6, where the venting pipe 630 is fluidly connected to the first 610, second 620 and third sections 640 and separator 671. The condenser 654 receives vapours extracted from the venting pipe 630 and condenses them. Depending on the implementation of the invention, the condenser 654 may condense vapours for waste disposal, separate the vapours into component liquids (i.e. separating the vapours into the first liquid and second liquid) or the like. The mounted filter fan 680 is also connected to the condenser 654 draws air through the condenser 654 in order to draw air through the venting pipe 630 to extract vapours from the apparatus. [0209] An example of the apparatus for processing a material will now be described with reference to the continuous processing and separation of polyvinyl chloride (PVC) into PVC wool and PVC flakes.

[0210] Firstly, a shredder may be configured to shred the PVC into shredded PVC before being supplied to the apparatus. A person skilled in the art will appreciate that a shredder is not required in order to supply shredded PVC to the apparatus, nor that shredded PVC is required for the apparatus to function. Supplying shredded PVC to the apparatus may result in a more efficient process for separating the PVC.

[0211] The pipe 100 includes a first section 110 at least partially filled with a first fluid and a second section 120 at least partially filled with a second liquid. The first liquid may be acetone while the second liquid may be water at any temperature between 80°C to 100°C. A person skilled in the art would appreciate that another substance could be used for the second liquid, so long as the other substance has a boiling point higher than the boiling point of acetone.

[0212] The conveyor conveys the shredded PVC through the first section 110 firstly, to thereby expose the shredded PVC to acetone. As the shredded PVC is conveyed through the first section 110, the shredded PVC is soaked in acetone, with the chemical soaking between the mixed composite fabric layers of PVC to thereby treat the shredded PVC into soaked PVC.

[0213] The conveyor conveys the soaked PVC through the second section 120 secondly, to thereby expose the soaked PVC to near boiling/boiling water (‘water’). As the soaked PVC is conveyed through the second section 120, the soaked PVC is soaked in water, resulting in the soaked PVC having its outer surface bubbled, forming bubbled PVC.

[0214] As the conveyor conveys the shredded/soaked PVC through the pipe 100, the venting pipe 130 is in fluid communication with the pipe 100 in order to remove vapour generated by the acetone and water. As the acetone is exposed to the shredded PVC, potentially hazardous vapours are produced as a result of loosening the bonds of the shredded PVC. Additionally, a continual accumulation of vapours in the first section 110 of the pipe 100 may result in damage done to the conveyor or a reduction in the efficiency/speed of the loosening process. [0215] As water is exposed to the soaked PVC, potentially a significant amount of steam may be produced. This steam may be hazardous to the users operating the apparatus should they become exposed to steam contaminated by acetone remaining on the soaked PVC. Additionally, non-contaminated steam may accumulate in the second section 120 resulting in accelerated corrosion of the pipe 100.

[0216] The venting pipe 130 thereby allows continuous extraction of vapours produced by the acetone/water to facilitate the apparatus continuously separating PVC.

[0217] The apparatus may further include a separator configured to separate the bubbled PVC into PVC wool and PVC flakes.

[0218] The separator acts to separate the bubbled PVC into its component parts, which may be achieved using a cyclone device. The cyclone device may be a centrifugal separator where components of the bubbled PVC may be separated due to their relative mass. A person skilled in the art would appreciate that other separator devices may be used (such as a static electricity device, a pulsing air device, drum combing device, an agglomerator and/or a shaking table device) depending on the desired implementation of the apparatus.

[0219] The conveyor may also include a drying system, which dries the bubbled PVC before the separator separates the PVC into PVC wool and PVC flakes.

[0220] The above described examples focus on the use of acetone as a solvent for treating plastics or other similar materials. However, it will be appreciated that the above described apparatus could be used with a wide range of different solvents and could be used to treat a wide range of different materials.

[0221] For example, the solvent could be an acid or other chemical, which is then used to perform leaching and thereby remove impurities from materials. One specific example of this is to use sulphuric or another similar acid to remove impurities, such as copper chrome arsenic (CCA), from material such as wood chips. The solvents could be polar or non-polar and may include protic and aprotic solvents. More typically the solvents are industrial solvents, and particularly industrial solvents exhibiting potential health hazards, such as flammability. Specific examples of solvents that could be used include Ethanol, Methanol, Acetone, Tetrachloroethylene, Toluene, Methyl acetate, Ethyl acetate, Hexane, Benzene, acids, Turpentine, Diethyl ether, Dichloromethane, 1,4-Dioxane, Acetonitrile, Acetic acid, or the like.

[0222] Similarly, the materials that could be treated include any material that interact with, or contains impurities of chemicals that interact with the solvent. Example materials, include polymers, plastics, wood, wood chips, fabrics, including material, woven or non-woven fabrics, paper, or the like.

[0223] Throughout this specification and claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers. As used herein and unless otherwise stated, the term "approximately" means ±20%.

[0224] Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.