Apparatus and method to render air bag inflators and other low level detonatable devices inert for recycling

1. An apparatus for rendering inert and separating components of detonable devices fabricated from metal and water soluble chemical explosive propellants, for recycling, the apparatus comprising:

a feeder configured to receive material including a plurality of the detonable devices;

a shred tower configured to convey the material in a downstream direction therethrough, the shred tower including a hopper, at least one shredder disposed within and/or downstream of the hopper, and a water sump disposed downstream of the at least one shredder;

a first conveyor operatively engaged with the feeder and the shred tower, the first conveyor configured to feed the material from the feeder to an upstream portion of the hopper at a controlled feed rate;

a feed valve disposed at the upstream portion of the hopper, the feed valve being selectively actuatable between open and closed positions to respectively permit and prevent the material from entering the upstream portion of the hopper;

an irrigation means to substantially prevent sparking and to begin to solubilize and separate chemicals from the metal during operation of the at least one shredder;

the water sump configured to receive the material from the at least one shredder to continue to solubilize and separate the chemicals from the metal;

a second conveyor configured to lift solids including shreds of the metal from the sump, wherein residual water runs from the solids back to the sump to produce dewatered solids; and

the second conveyor configured to feed the dewatered solids to a receiving box for metal scrap recycling.

2. The apparatus of claim 1 , wherein the at least one shredder comprises a primary shredder and a secondary shredder, the primary shredder configured to perform a coarse shred of the material, and the secondary shredder configured to receive the material from the primary shredder, and to perform a fine shred of the material.

3. The apparatus of claim 2 , wherein the feed valve comprises a rotary feed valve.

4. The apparatus of claim 3 , wherein the feed valve is disposed in the closed position during operation of the primary shredder and/or the secondary shredder to substantially prevent the material from exiting the hopper via the upstream portion thereof during shredding.

5. The apparatus of claim 2 , comprising a closed chute extending between the primary shredder and the secondary shredder, the closed chute having a hinged access to permit user access to clear jams.

6. The apparatus of claim 5 , further comprising at least one pressure sensor operatively engaged with at least one of the primary shredder and secondary shredder, the at least one pressure sensor communicably coupled to a processor, the processor communicably coupled to the first conveyor, the secondary conveyor, the primary shredder, and the secondary shredder, the processor configured to alter operation of the apparatus in the event of a jam detected by the at least one pressure sensor.

7. The apparatus of claim 6 , wherein the processor is configured to pause operation of components upstream of the jam until the jam is cleared.

8. The apparatus of claim 6 , wherein the processor is further configured to reverse and then restart shredding x times before stopping operation of the apparatus and signaling an operator of a jam.

9. The apparatus of claim 1 , wherein the irrigation means comprises a set of misting water spray nozzles configured to spray water onto the at least one shredder, and/or a bath containing the at least one shredder therein.

10. The apparatus of claim 9 , further comprising one or more deluge water spray nozzles communicably coupled to flame detector for activation upon detection of a flame, the deluge water spray nozzles configured to supply a high volume of water relative to the set of misting water spray nozzles.

11. The apparatus of claim 10 , wherein the flame detector comprises a UV/IR flame detector.

12. The apparatus of claim 1 , wherein the water soluble chemical explosive propellants are selected from the group consisting of ammonium nitrate, nitroguanidine, and combinations thereof.

13. The apparatus of claim 12 , wherein the detonable devices comprise charged air bag inflators.

14. The apparatus of claim 13 , wherein the charged air bag inflators comprise cylindrical metallic air bag inflators and puck shaped metallic air bag inflators.

15. The apparatus of claim 1 , further comprising one or more variable speed drives operatively engaged with the first conveyor and/or the second conveyor.

16. The apparatus of claim 15 , wherein the first conveyor comprises a cleated inclined conveyor belt.

17. The apparatus of claim 15 , wherein the second conveyor comprises an inclined auger screw.

18. The apparatus of claim 15 , wherein the material comprises receptacles containing the plurality of the detonable devices therein.

19. The apparatus of claim 18 , wherein the one or more variable speed drives are configured to provide the first conveyor with a controlled feed rate of 20 to 30 seconds per receptacle.

20. The apparatus of claim 18 , wherein the receptacles include cardboard boxes.

21. The apparatus of claim 20 , wherein the primary shredder includes relatively widely pitched teeth to tear open the cardboard boxes, and the secondary shredder includes relatively finely spaced teeth.

22. The apparatus of claim 1 , wherein the hopper is closed in 360 degrees about the downstream direction and is constructed of metallic plate of at least ⅜ inches thick.

23. The apparatus of claim 1 , wherein the water sump has a capacity of at least about 500 gallons up to about 1000 gallons.

24. The apparatus of claim 1 , further comprising a camera configured to enable a user to view operation of the apparatus remotely.

25. The apparatus of claim 1 , further comprising an incinerator configured to receive the metal from the receiving box to burn any remaining chemical residue prior to recycling.

26. The apparatus of claim 25 , wherein the incinerator comprises a rotary reactor incinerator configured to operate at a minimum temperature of about 1000 F.

27. An apparatus for rendering inert detonable devices such as charged air bag inflators for recycling, the apparatus comprising:

a feeder configured to receive cardboard boxes including a plurality of charged passenger side cylindrical metallic air bag inflators and charged driver side puck shaped metallic air bag inflators, the inflators including ammonium nitrate;

a shred tower and a cleated inclined conveyor belt with a variable speed drive configured to bring the boxes from the feeder to a top of the shred tower at a controlled feed rate of 20 to 30 seconds per box;

a first feed hopper at the top of the shred tower;

a primary shredder disposed within the hopper;

a rotary feed valve disposed within the hopper and configured to receive the boxes from the conveyor belt and to feed the boxes to the primary shredder for shredding;

the rotary feed valve configured to close the shredder after receipt of the boxes therein to substantially prevent metallic shards from escaping during said shredding;

the hopper being closed on all sides and constructed of metallic plate and including a hinged perforated metallic plate cover;

the hopper including continuous water spray nozzles aimed at shredder teeth to substantially prevent sparking and to wash chemicals from the inflators;

the primary shredder having relatively widely pitched teeth to tear open the boxes;

a secondary shredder disposed below the primary shredder and configured to receive the torn boxes and contents therefrom;

the secondary shredder having relatively finely spaced teeth;

the hopper including a CCTV camera to view operation remotely, and a UV/IR flame detector connected to a secondary water deluge nozzle to be activated upon detection of a flame;

a closed chute between the two shredders with a hinged side access door above the secondary shredder to clear jams;

a water sump of 500 to 1000 gallon capacity disposed below the secondary shredder, and equipped with a high capacity pump feeding to a storage tank;

a dual inclined auger screw configured to lift solids including metal and cardboard scraps from sump, wherein residual water runs from the solids back to the sump;

the shredders including pressure sensors configured to stop the units if a jam occurs, to auto-reverse, and then restart shredding x times before signaling an operator of a jam; and

a programmable logic controller (PLC) configured to operate the conveyor belt, the primary and secondary shredders, and the auger screw, and configured to pause operation of components upstream of the jam until cleared;

the auger screw configured to feed the dewatered metal solids to a rotary reactor incinerator feed pit operating at a minimum 1000 F temperature to destroy any remaining chemical residue and cardboard from box shredding, to leave metal suitable for shipping to metal scrap recyclers;

wherein the apparatus provides a low speed dual stacked hydraulic shredding operation to open the inflators under a continuous water spray and expose the ammonium nitrate to a water bath to solubilize it and separate it from the metallic components.

28. A method for rendering inert and separating components of detonable devices fabricated from metal and water soluble chemical explosive propellants, for recycling, the method comprising:

(a) receiving, with a feeder, material including a plurality of the detonable devices;

(b) conveying the material in a downstream direction through a shred tower including a hopper, at least one shredder disposed within and/or downstream of the hopper, and a water sump disposed downstream of the at least one shredder;

(c) feeding, with a first conveyor operatively engaged with the feeder and the shred tower, the material from the feeder to an upstream portion of the hopper at a controlled feed rate;

(d) selectively actuating a feed valve disposed at the upstream portion of the hopper, between open and closed positions to respectively permit and prevent the material from entering the upstream portion of the hopper;

(e) irrigating with irrigation means, to substantially prevent sparking and to begin to solubilize and separate chemicals from the metal during operation of the at least one shredder;

(f) shredding the material with the at least one shredder;

(g) receiving, in the water sump, the material from the at least one shredder to continue to solubilize and separate the chemicals from the metal;

(h) lifting, with a second conveyor, solids including shreds of the metal from sump, wherein residual water runs from the solids back to the sump to produce dewatered solids; and

(i) feeding, with the second conveyor, the dewatered solids to a receiving box for metal scrap recycling.

29. The method of claim 28 , wherein the at least one shredder comprises a primary shredder and a secondary shredder, and said shredding (f) further comprises using the primary shredder to perform a coarse shred of the material, and using the secondary shredder to receive the material from the primary shredder, and to perform a fine shred of the material.

30. The apparatus of claim 28 , wherein the irrigation means comprises a set of misting water spray nozzles configured to spray water onto the at least one shredder, and/or a bath containing the at least one shredder therein.