AU2021101768A4

AU2021101768A4 - A System and a Process for Formation of a Renewable Natural Coal from Waste Output of a Cattle/Agricultural based Biogas Plant

Info

Publication number: AU2021101768A4
Application number: AU2021101768A
Authority: AU
Inventors: Utkarsha Dharankar; Ankit Patil
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-04-07
Filing date: 2021-04-07
Publication date: 2021-10-28
Anticipated expiration: 2029-04-07

Abstract

The present disclosure seeks to provide a system and a process for formation of a renewable natural coal from cattle/agricultural waste output of a biogas plant. Coal is formed when dead plant matter decays into peat and is converted into coal by the heat and pressure of deep burial over millions of years. The similar geological principle is utilized in cattle waste biogas plant. The cattle waste decomposes and forms biogas. It comes out from another outlet which is called output slurry. First the water is removed from output slurry and that results in solid balls. Then the solid ball is burnt in open air and in less air. And finally, there is comparison between renewable natural coal and natural coal in terms of overall performance. This renewable natural coal helps to reduce consumption of natural coal, it also helps to restart shut down biogas plants and generate revenue and employability in rural areas. 13 rl 0 V(D M. 0) 0 Is v) 0O (D N ::3

Description

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A System and a Process for Formation of a Renewable Natural Coal from Waste Output of a Cattle/Agricultural based Biogas Plant

FIELD OF THE INVENTION

The present disclosure relates to a system and a process for formation of a renewable natural coal from waste output of a cattle/agricultural based biogas plant. The disclosure relates to a method and an arrangement of producing renewable natural coal , such as bio coal, a drying agent (bedding) or a torrefied biomass as an example, of biomass, like dry manure, dry biomass or cattle waste obtained from an output of a biogas plant or an organic feedstock. More specifically, the invention relates to producing renewable natural coal of biomass by thermochemical treatment.

BACKGROUND OF THE INVENTION

Solid fuels are abundant in nature and the use of solid fuels is the world's largest energy market. These solid fuels are primarily used for generating electric power in industries such as power plant, thermal power plant. These solid fuels can also be used in heavy metal industries such as, aluminum industry, steel industry, metallurgic and cement manufacturing industry. The market is dominated by non-renewable resources, principally coal, and to a lesser extent petroleum coke.

There is an urgency to switch to energy sources that will have less of an environmental impact, especially with regards to the emission of greenhouse gases. Biomass sources are an attractive alternative to conventional solid fuels, but high transportation costs and low energy density of the biomass materials have hampered the widespread of the use of coal. Prior art techniques that have been used to improve the fuel value and physical properties of a biomass range include, for example, drying the biomass for removing moisture contained therein without chemically altering the biomass, and producing charcoal from the biomass, where the biomass is chemically altered into fixed carbon. Dry biomass has low energy volumetric density, and its transportability is not improved over wet biomass. Producing charcoal is inefficient, with only 20% to 30% of the energy in the original biomass preserved in the charcoal.

The thermochemical treatment solutions are known for producing biofuel from biomass, such as torrefaction which is as a mild form of pyrolysis. Torrefaction is a thermal process to convert biomass into a coal-like material, which has better fuel characteristics than the original biomass. Torrefied biomass is more brittle, making grinding easier and less energy intensive. Compared to fresh biomass, storage of the torrefied material can be substantially simplified since biological degradation and water uptake is minimized. Torrefaction involves the heating of biomass in the absence of oxygen to a temperature of typically 200 to 400°C. The structure of the biomass changes in such a way, that the material becomes brittle, and more hydrophobic.

Although the weight loss is about 30%, the energy loss is only 10%. During torrefaction, the biomass properties are changed to obtain a much better fuel quality for combustion and gasification applications. The produced biofuel is e.g. bio-coal, which is dry product with no biological activity like rotting. The produced biofuel can also be densified so that they are logistically economic and easier to transport and store. The final product is the remaining solid, dry, blackened material which is referred to as "torrefied biomass" or "bio coal". However, there is a need for alternative arrangement or a method and an apparatus which permits for the widespread use of biomass as a solid fuel, which is more versatile, and which are energy efficient and even self- sustaining.

In order to overcome the aforementioned drawbacks there is a need to develop a system and a method for the formation of a biofuel from waste output of a cattle or agricultural waste biogas plant.

SUMMARY OF THE INVENTION

The present disclosure seeks to provide a system and a process for formation of a renewable natural coal from waste output cattle/ agricultural based biogas plant. Natural coal is formed when dead plant matter decays into peat and is converted into coal by the heat and pressure of deep burial over millions of years. The similar geological principle is utilized in cattle/agriculture waste biogas plant. The cattle/agricultural waste decompose and forms biogas. It comes out from another outlet which is called output slurry. First the water is removed from output slurry and that results in solid balls. Then the solid ball is burnt in open air and in less air (using gasifier). And finally, there is comparison between renewable natural coal and natural coal in terms of overall performance. This renewable natural coal helps to reduce consumption of natural coal, it also helps to restart shut down biogas plants and generate revenue and employability in rural areas.

Accordingly, one aspect of the present invention is to convert the output slurry obtained from the biogas plant into a usable biofuel, most commonly known as a biocoal. The output slurry from the biogas plant is a good fertilizer and is useful in farming purposes but only in a limited timeframe. This output slurry after a while converts into carbon which is responsible for destroying the crops in the farms. This unique result helps us to develop a new technique of utilizing the output slurry obtained from the biogas plant and converting the output slurry into a useful biofuel also known as the bio-coal. The gross calorific value of the obtained renewable natural coal falls in the range of 2989 Kcal/kg to 3439.94 Kcal/kg.

In an embodiment a system for formation of a biofuel from cattle/agricultural waste output of a biogas plant. The system 100 comprises: fresh cattle/agricultural waste is stored in a collection tank 102 before its processing to the said homogenization tank 104. A homogenization tank 104 equipped with a mixer to facilitate homogenization of fresh cattle waste stream; wherein said cattle/agricultural waste is decomposed by microorganisms under exclusion of light and oxygen and thereby organic material is converted into a biogas by a series of bacteria groups into methane and carbon dioxide; and a fermentation residue end storage tank 106 to receive fermented cattle waste to convert said fermented cattle waste into a biofuel (renewable natural coal).

In an embodiment, a process for converting fermented cattle/agricultural waste into a biofuel. The process 200 comprises the following steps: At step 102, converting fresh cattle waste stream into an output slurry; At step 104, removing water from output slurry of cattle/agricultural waste biogas plant and thereby preparing solid balls; and At step 106, burning solid balls in open air directly and in less air with the help of gasifier in presence of controlled air.

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a construction vehicle that:

•Reducing consumption of natural coal

• Restarting already closed biogas plants

• Generating revenue and employability in rural areas

To further clarify advantages and features of the present disclosure, a more particular description of the invention will be rendered by reference to specific embodiments there of, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF FIGURES

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates the system for formation of a renewable natural coal from cattle/agricultural waste output of a biogas plant in accordance with an embodiment of the present disclosure.

Figure 2 illustrates a processes for converting fermented cattle/agricultural waste into a renewable natural coal in accordance with an embodiment of the present disclosure.

Figure 3 illustrates a cattle/agricultural waste biogas plant in accordance with an embodiment of the present disclosure.

Figure 4 illustrates (a) Solid ball of output slurry; and (b)Bumt solid ball and crushing by hammer(c)a metal container with airtight lid and holes at bottom in accordance with an embodiment of the present disclosure.

Figure 5 illustrates (a) Specifications of renewable natural coal sample 1; (b) Specifications of renewable natural coal sample 2; and (c) Specifications of natural coal Gl3in accordance with an embodiment of the present disclosure.

Figure 6 illustrates (a) Various grades of natural coal; and (b)Final result comparing renewable natural coal to natural coal in accordance with an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present disclosure. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

Reference throughout this specification to "an aspect", "another aspect" or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by "comprises...a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.

Figure 1 illustrates the system for formation of a biofuel from cattle waste output of a biogas plant in accordance with an embodiment of the present disclosure.In an embodiment a system for formation of a biofuel from cattle waste output of a biogas plant. The system 100 comprises: fresh cattle/agricultural waste is stored in a collection tank 102 before its processing to the said homogenization tank 104. A homogenization tank 104 equipped with a mixer to facilitate homogenization of fresh cattle waste stream; wherein said cattle/agricultural waste is decomposed by microorganisms under exclusion of light and oxygen and thereby organic material is converted into a biogas by a series of bacteria groups into methane and carbon dioxide; and a fermentation residue end storage tank 106 to receive fermented cattle waste to convert said fermented cattle waste into a biofuel.

Figure 2 illustrates a process for converting fermented cattle/agricultural waste into a biofuel in accordance with an embodiment of the present disclosure. The process 200 comprises the following steps: At step 102, converting fresh cattle waste stream into an output slurry; At step 104, removing water from output slurry of cattle/agricultural waste biogas plant and thereby preparing solid balls; and At step 106, burning solid balls in open air or in closed environment in presence of controlled air using gasifier.

Figure 3 illustrates a cattle/agricultural waste biogas plant in accordance with an embodiment of the present disclosure. The fresh cattle/agricultural waste is stored in a collection tank before its processing to the homogenization tank which is equipped with a mixer to facilitate homogenization of the waste stream. In anaerobic digestion, the cattle/agricultural waste is decomposed by the microorganisms under exclusion of light and oxygen and the organic material is converted into a biogas by a series of bacteria groups into methane and carbon dioxide. The final product of the process is biogas with methane as the main ingredient. Once the cattle/agricultural waste has been fermented, it is transported to the fermentation residues end storage tank and can be retrieved from there for further utilization. These residues can be utilized as a high-quality fertilizer. The biogas manure has a lower viscosity and therefore penetrates into the ground more quickly. But drying it and subsequently using it as dry fertilizer is also an option us this fertilizer is no more useful for plants after three-four days coming out of the biogas digester in the form of output slurry, for fertilizer it has to use immediately in one to two days otherwise it converts to bad quality of carbon. This biogas manure is nothing but the output slurry.

Geology of coal: Coal is a combustible black or brownish sedimentary rock. Coal is mostly carbon with variable amounts of other elements like hydrogen, sulphur, oxygen and nitrogen. Coal is formed when dead plant matter decays into peat and is converted into coal by the heat and pressure of deep burial over millions of years. The similar geological principle is happened in cattle waste biogas plant. The cattle/agricultural waste is decomposes and formed biogas and coming out from another outlet which called output slurry. As shown in fig 3. The Gross calorific value of input material (Dry) is 3185.32 Kcal/kg and Gross calorific value of output material (Dry) is 2849.86 Kcal/kg.

Figure 4 illustrates (a) Solid ball of output slurry; and(b)Burnt solid ball and crushing by hammer(c)a metal container with airtight lid and holes at bottom in accordance with an embodiment of the present disclosure. Method of operation is discussed below: The processing of the output slurry includes storing the output slurry in the reservoir tank. The stored and exposed output slurry automatically forms a solid layer on the surface of the stored output slurry. The water is removed from the output slurry and solid balls are prepared from the remaining slurry. The obtained product is the dry solid balls of output slurry. The obtained dry solid balls of the output slurry are then burnt in the open air or in less air by using gasifier environment. The dry solid balls of the output slurry are also burnt in a gasifier which enables a user to calibrate the calorific value of the solid balls of the output slurry. The gasifier is a process unit which heats and decomposes the dry solid balls into synthesis gas, a mixture of hydrogen, carbon monoxide, and carbon dioxide, in a restricted oxygen environment. The reaction is a combination of thermal decomposition - commonly known as pyrolysis - and incomplete combustion, typically from air or pure oxygen.

1. Removing the water from output slurry and making solid balls

The processing of the output slurry includes storing the output slurry in the reservoir tank. The stored and exposed output slurry automatically forms a solid layer on the surface of the stored output slurry. The water is removed from the output slurry and solid balls are prepared from the remaining slurry. The obtained product is the dry solid balls of output slurry. The solid ball as shown in fig 4a.

2. The obtained dry solid balls of the output slurry are then burnt in the open air or in less air environment by using gasifier.

The dry solid balls of the output slurry are also burnt in a gasifier which enables a user to calibrate the calorific value of the solid balls of the output slurry. The gasifier is a process unit which heats and decomposes the dry solid balls into synthesis gas, a mixture of hydrogen, carbon monoxide, and carbon dioxide, in a restricted oxygen environment. The reaction is a combination of thermal decomposition - commonly known as pyrolysis - and incomplete combustion, typically from air or pure oxygen.

i. Burning solid ball in open air directly on stove flame and crush into a powder (sample 1) as shown in fig 4b.

ii. Burning solid ball in less air by using metal container with airtight lid and drilling small holes at the bottom of the container (sample 2) as shown in fig 4c.

3. Comparison of renewable natural coal with natural coal: Generally G13 grade coal use in thermal power plant in India. It is evident that as the ash value decreases the calorific value increases and the ash value increases when the dry solid balls of the output slurry are burnt in the open air. The amount of oxygen is responsible for increasing the ash value of the burning substrate. When the dry solid balls of the output slurry are burnt in the open air, the ash value is also increased, and the gross calorific value is decreased. When the dry solid balls of the output slurry are burnt in less air, the ash value gets decreased nearly equal to the G13 natural coal. Based on this, it can be observed that the gross calorific value of the sample 2 renewable natural coal is approximately equal to the G13 natural coal.

Figure 5 illustrates (a) Specifications of renewable natural coal sample 1; (b) Specifications of renewable natural coal sample 2; and (c) Specifications of natural coal G13 in accordance with an embodiment of the present disclosure. The obtained dry solid balls of the output slurry are then burnt in the open air (Figure 5a) or in closed environment (Figure b). The dry solid balls of the output slurry are also burnt in a gasifier which enables a user to calibrate the calorific value of the solid balls of the output slurry. The gasifier is a process unit which heats and decomposes the dry solid balls into synthesis gas, a mixture of hydrogen, carbon monoxide, and carbon dioxide, in a restricted oxygen environment. The reaction is a combination of thermal decomposition - commonly known as pyrolysis - and incomplete combustion, typically from air or pure oxygen. Figure 5c shows the specifications of natural coal when burnt for comparison with Biocoal (Figure 5a and 5b).

Figure 6 illustrates (a) Various grades of natural coal; and (b)Final result comparing biocoal to natural coal in accordance with an embodiment of the present disclosure. Comparison of renewable natural coal with natural coal: Generally G13 grade coal use in thermal power plant in India. The specifications of G13 coal are shown in Figure 6a and various other grades of coal are shown in Figure 6b. It is evident that as the ash value decreases the calorific value increases and the ash value increases when the dry solid balls of the output slurry are burnt in the open air. The amount of oxygen is responsible for increasing the ash value of the burning substrate. When the dry solid balls of the output slurry are burnt in the open air, the ash value is also increased, and the gross calorific value is decreased. When the dry solid balls of the output slurry are burnt in less air, the ash value gets decreased nearly equal to the G13 natural coal. Based on this, it can be observed that the gross calorific value of the sample 2 bio-coal is approximately equal to the G13 natural coal.

This renewable natural coal helps to reduce consumption of natural coal, it also helps to restart shutdown biogas plants and generate revenue and employability in rural areas. There are many biogas plants in rural areas of India has been shut down. This invention is a hope for future biogas programs in India.

The drawings and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. The scope of embodiments is at least as broad as given by the following claims.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any component(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or component of any or all the claims.

Claims

WE CLAIM

1. A system for formation of a biofuel from cattle/agricultural waste output of a biogas plant, the system comprises:

a homogenization tank equipped with a mixer to facilitate homogenization of fresh cattle/agricultural waste stream; wherein said cattle/agricultural waste is decomposed by microorganisms under exclusion of light and oxygen and thereby organic material is converted into a biogas by a series of bacteria groups into methane and carbon dioxide; and a fermentation residue end storage tank to receive fermented cattle/agricultural waste to convert said fermented cattle/ agricultural waste into a biofuel.

2. The system as claimed in claim 1, wherein said fresh cattle/agricultural waste is stored in a collection tank before its processing to the said homogenization tank.

3. The system as claimed in claim 1, wherein said residue is used as a high-quality fertilizer, wherein said residue is used as an output slurry for converting fermented cattle/agricultural waste into a biofuel.

4. The system as claimed in claim 1 and 3 comprises a reservoir tank for storing said output slurry for treating said output slurry in an open environment.

5. A process for converting fermented cattle/agricultural waste into a biofuel, the process comprises:

Converting fresh cattle/agricultural waste stream into an output slurry; Removing water from output slurry of cattle/agricultural waste biogas plant and thereby preparing solid balls; and Burning solid balls in open air or in closed environment in presence of controlled air.

6. The process as claimed in claim 5, wherein said output slurry is stored in said reservoir tank on daily basis which results in forming of solid layers on a surface of slurry.

7. The process as claimed in claim 5, wherein said dry solid balls of said output slurry are burnt in a gasifier which enables a user to calibrate calorific value of said solid balls.

8. The process as claimed in claim 5 and 7, wherein said solid balls are burned in less air by using metal container consisting small holes at a bottom of said container with an airtight lid.

9. The process as claimed in claim 5, wherein the water is removed from the output slurry by compressing of slurry or open-air evaporation or in the presence of sunlight.

10. The process as claimed in claim 5, wherein said gasifier is a process unit which heats and decomposes said dry solid balls into synthesis gas including mixture of hydrogen, carbon monoxide, and carbon dioxide, in a restricted oxygen environment.

Collection Tank Fermentation Homogenization Residue End (Input Slurry) Tank Storage Tank 102 104 106 Figure 1 07 Apr 2021 2021101768

Converting fresh cattle waste stream into an output slurry. 202 Removing water from output slurry of cattle waste 204 biogas plant and thereby preparing solid balls. Burning solid balls in open air or in closed 206 environment in presence of controlled air. Figure 2 07 Apr 2021 2021101768

Figure 3