GB2107241A - Densification of pulverised waste matter into fuel cubes - Google Patents

Abstract

The densified fuel cubes are made by extrusion from a roller and ring apparatus, of the waste matter which is fed into the apparatus as a mass of pulverized carbonaceous matter having a particle size not exceeding 3/8ths inch. The fuel cubes have a bulk density of between 30 and 60 pounds per cubic foot and a heat value of not less than 8000 btu. The fuel cubes (150) are broken off, on issuing radially outwardly from horizontal and circumferentially disposed extrusion passages, of stationary die means (90) which are clamped between plates (23, 25). The extrusion is effected by wheels (rollers) (66, 68), which freely rotate on spindles (69), mounted upon a driven shaft (40) for orbiting rotation radially interiorly of the die means (90). The pulverised matter is gravitationally fed at an inlet (21), onto an inverted feed cone (45) which is also rotated by the shaft (40), and carries paddles (49) which distribute the matter to fall through apertures (51) of the upper plate (23), into the path of the orbiting rollers (66, 68). The die passages are longitudinally grooved to increase compacting friction on the matter. <IMAGE>

Description

SPECIFICATION Densification system, device, method and product Various attempts have been made in the prior art to develop an effective system and device for densifying any and all waste matter into a solid mass form which may be, in turn, utilized as a fuel source. Conceptually, the goal is to utilize various forms of matter which have, in the past, been regarded as waste, and to compress the same into a solid cube form which may then be used as fuel source in devices such as boiler, furnaces, fireplaces and the like. Typically, the systems and devices available for densifying fuel matter have utilized a binder which is included with the waste matter such that the densification method relies upon the use of the binder to create the densified fuel cube.

With regard to the prior art, the concept of creating an artificial fuel cube is discussed in Patent No. 43,695. Pursuant to the teaching of this patent, in effect, there is disclosed the use of a binder which consists of peat which is mixed with coal-dust, which would otherwise be thrown away, to create lumps or cakes consisting of the coal-dust bound together by the peat. One of the obvious difficulties with attempting to create a fuel cube of that nature is the fact that it would require mixing devices which would carefully monitor and measure the amount of peat mixed with coal-dust in order to create an artificial fuel cube which would have burn characteristics.In addition, quite frequently burn characteristics of the binder emoloyed have not been carefully considered and, hence, an artificial fuel cube which incorporates therein a binder which is, in reality, a substance bounded to the material being compressed, creates potential health and related problems.

Still another attempt at creating an artificial fuel cube is disclosed in Patent No. 1,287,71 1, 267,711, wherein the patent teaches the concept of using compression to compress a pulverized form of coal into a fuel chip. The method and device taught therein consists of pair of movable plungers operating against a fixed mold into which the powdered or pulverized form of the coal is inserted. According to the patentee, the plungers are designed to apply a pressure of 10 ton per square inch of pressure in order to compress the finally divided coal powder into a solid briquette.

Hence, while there is a general teaching of the use of compressional force to force a finally divided powder through a tapered mold in order to create an artificial fuel cube, it is apparent that the particular device employed in the method and system disclosed in the patent is seriously lacking.

Indeed, in the past, most compressional types of densification devices have been constructed along a vertical plane for the reason that such devices have generally employed compression plungers of the type discussed in Patent No. 1,267,71 11. The result of creating devices of that type is to the effect that the vertical dimensions of the device to be utilized are significant and one of the reasons that such devices and systems have not become economically prevalent is due to the excessive sizes that the machinery would assume in order to produce the pressure levels necessary to create the densified fuel cube. In addition, uneven feeding will occur in vertical machines and therefore, dies toward the bottom of the device will wear much greater than the dies toward the top.

Another system for creating a fuel briquette is disclosed in Patent No. 1,132,527, which again, utilizes a cement to bind together the disintegrated fuel in order to create a briquette.

The problems associated with utilizing cement have been discussed heretofore, and it is generally for reasons of this nature that such artificial fuel cubes have never received any great degree of commercial success.

Another system for creating artificial briquettes or fuel blocks is disclosed in Patent No.

1,577,902. It is intended pursuant to the teachings of the aforementioned patent to take a substance identified as lignite, and to process the substance by first crushing it, storing it in a hopper for a period of time in order to permit moisture removal, drying the substance in a dryer, and then feeding the substance to a mold into which the material is compressed by means of a ramrod. It is apparent from the description contained therein, that the system necessarily requires the use of fairly cumbersome equipment, and more importantly, is a staged process which requires a fair amount of time. Just as importantly, it is to be noted that the process disclosed therein relates primarily to the densification of the carbonaceous matter known as lignite, and is not generally useful for any other substances.This is evident from the fact that the system employs a storage hopper or silo into which the material must sit for settling purposes in order to permit some of the moisture to escape from the lignite. In addition, this system employs a dryer which again is provided for the purpose of removing moisture incident to the process disclosed.

Insofar as the utilization of tapered dies is concerned, especially where it is intended to create an agglomerated substance such as a briquette or artificial fuel block, systems employing such tapered dies are well known. For example, in Patent No. 2,164,950, a device including a tapered die for the purpose of creating an agglomerated mineral material is disclosed. It will be also appreciated that the system disclosed therein requires the use of a binder including binding agents such as glue, molasses, starch, adhesive starch derivatives, clay and other similar substances. It will, therefore, be appreciated that even incident to the creation of an agglomerated mineral material, the binder is still taught as a necessary ingredient.

Various modern attempts have been made at providing mechanisms as well as systems for creating extruded bodies formed from carbonaceous waste matter to be used as artificial fuel. For example, Patent No. 4,049,390 relates to an extrusion apparatus for preparing a rod-like body from a coal-containing particulate mix.

Basically, the device contemplated therein employs a movable die which is controlled by hydraulic mechanisms thereby to control the consistency of the resulting briquette. It will be appreciated, however, that however effective a device of this type may be, the potential problems inherent with the control systems necessary for such machinery would be quite costly, and a possibility of breakdowns in the equipment with the attendant loss of use of the equipment during downtime is inherent therein.

Other typical forms of densification machinery would consist of the typical hay baler which is designed to take loose hay, and create densified bundles which may be more easily stored by the farmers for use as feed during the winter months.

Hay balers of this type basically use a compressional force in order to bundle the hay in a densified form for ease of transportation and storage.

In virtually most of all the systems known to date, the machinery as well as the system disclosed or known requires that the actual densifying machinery is usuaily disposed in a vertical plane since hydraulic rams or other such similar rams are utilized.

Pursuant to the present invention, it is believed desirable to provide a densification system and device which operates in a horizontal plane and therefore permits the creation of a smaller sized piece of machinery, as well as providing the operator thereof a great degree of flexibility in terms of the number of dies which may be used in a single piece of machinery. It is believed that the problems heretofore noted with prior art devices have therefore been minimized, and the actual cost per fuel cube has been drastically diminished.

Hence, the system of the present invention permits an artificial fuel cube to be created at relatively low cost with machinery which can be operated on, virtually, a 24 hour basis.

Objects and Advantages It is therefore the principal object of the present invention to provide a system for densifying carbonaceous matter into fuel cubes which employs a relatively smail dimension, but highly efficient densification device, which, in turn, permits the use of a plurality of dies simultaneously thereby to create a low cost artificial fuel cube per unit time of operation of the machinery.

In conjunction with the foregoing object, it is a further object of the present invention to provide a densification system for densifying pulverized waste matter into fuel cubes which is formed by a housing including receiving means positioned therein for receiving pulverized waste matter, a plurality of die means positioned in the housing circumferentially about the periphery of the housing, press means positioned in the housing adjacent to the die means, the press means mounted within the housing for rotational movement in a horizontal plane with respect to the housing and the die means for pressing the pulverized waste matter into and through the die means, feed means for feeding the pulverized waste matter into the path of the press means, drive means associated with the housing for driving the feed means to feed pulverized waste matter into the path of the press means and also for driving the press means to press the pulverized waste matter into and through the die means, and discharge means associated with the housing for effecting the discharge therefrom of the formed densified fuel cube.

In conjunction with the foregoing object, it is yet a further object of the invention to provide a system of the type described wherein the housing is circular in configuration, and the plurality of die means comprises a plurality of die blocks mounted circumferentially within the housing along the periphery thereof, each of the die blocks having an interior surface which is at least partially uniformly irregular in configuration.

In conjunction with the foregoing object, it is a further object to provide a densification system of the type described wherein the partially uniformly irregular interior surface of each of the die blocks is formed by a plurality of grooves formed in the interior surfaces thereof and extending along the path of travel of the waste matter as the same traverses the die block.

In accordance with the foregoing object, it is a further object of the invention to provide a densification system of the type described wherein the press means included therein is formed by at least one press wheel rotationally mounted for rotational movement within the housing and positioned immediately adjacent to the plurality of die blocks contained therein thereby to press waste matter fed into the path of the press wheel into and through each of the die blocks in sequential fashion.

Still in accordance with the above objects and advantages, it is a further object to provide a densification system of the type described wherein the feed means is formed by an inverted cone member fixedly secured to the drive means and positioned intermediate the inlet port and the press means, thereby to receive waste matter from the inlet port and distribute the same into the path of the press means throughout the entire circumferential extent of said housing.

Still a further object of the present invention is to provide a densification system of the type described wherein the drive means is formed by a drive shaft positioned substantially centrally within the housing and extending in a plane vertical with respect to the press means, the drive shaft including a top end and a bottom end, motor means associated with the system having the bottom end of the drive shaft connected thereto in order to effect a rotational movement therein, the top end of the drive shaft being connected to the feed means, and the press means being connected to the drive shaft intermediate the ends thereof, whereby the rotational movement of the main drive shaft will effect a simultaneous rotational movement of the feed means and the press means within the housing.

Another object of the present invention is to provide a densification device for compressing and densifying waste matter into fuel cubes which is formed by a housing having an inlet port and a discharge port, an upper support plate horizontally mounted within the confines of the housing, a lower support plate horizontally mounted within the confines of the housing and positioned in spaced relationship with respect to the upper support plate, a main shaft vertically supported within the confines of the housing and extending through the upper and lower support plates, drive means associated with the housing and having one end of the main shaft rotatingiy mounted on the drive means thereby to provide rotational movement to the drive shaft, a plurality of die means mounted within the housing and positioned substantially intermediate the upper and lower support plates along the periphery thereof, press means mounted within the housing intermediate the upper and lower support plates immediately adjacent the plurality of die means and fixedly secured to the main shaft, the press means being mounted on the main shaft in a manner which will effect the rotational movement thereof in a horizontal plane within the confines of the housing and intermediate the upper and lower support plates, the upper support plate provided with a plurality of feed apertures formed therein along the periphery thereof, feed means mounted within the housing for rotational movement on the opposed end of the main shaft within the housing and positioned above the upper support plate, and discharge means positioned in the housing to effect the discharge of densified fuel cubes formed therein which will effect the discharge therefrom to appropriate storage facilities.

Yet a further object of the present invention is to provide a method of forming a solid densified fuel cube from a mass of carbonaceous matter which includes the steps of providing a mass of pulverized carbonaceous matter having a particle size not exceeding 3/8th inch, providing at least one die having an interior surface which is, in part, uniformly irregular, providing press means adjacent to the die being movably mounted relative to the die, feeding the pulverized mass of carbonaceous matter into the path of the movable press means, compressing the pulverized carbonaceous matter into the die through the movement of the press means, and collecting the solidified and densified fuel cube after passage through the die.

In conjunction with the foregoing object, it is a further object to provide a method of the type described which further includes the step of providing a liquid petroleum based heat-enhancer thereby to enhance the heat value of the final fuel cube product formed thereby.

Another object of the present invention is to provide an artificial fuel cube which comprises a mass of pulverized carbonaceous matter compressed into a solid mass having a density of between 30 and 60 pounds per cu ft of bulk density, and having a heat value of not less than 8000 btu.

Further features of the invention pertain to the particular arrangement of the elements and parts whereby the above-outlined an additional operating feature thereof are attained.

The invention, both as to its organization and method of operation, together with further objects and advantages thereof, will best be understood by reference to the following specification, taken in connection with the accompanying drawings as will be more fully defined hereinafter.

Summary of the Invention In summary, the present invention provides a densification system, densification device, and method whereby a mass of carbonaceous waste matter may be pulverized, fed into a densification device, and continuously densified into a fuel cube which may then be discharged and collected for further use.The system incorporates multiple stations, including a pulverizing station in which the carbonaceous waste matter is pulverized into particle sizes not exceeding 3/8ths in. in size, feeding the pulverized mass to the densification device which is basically arranged along a horizontal plane, the densification device being generally circular in configuration and adapted to contain a plurality of die blocks mounted in circumferential arrangement about the periphery of the device, and press means rotationally mounted within the device immediately adjacent to the die blocks such that the rotational movement of the press wheels therein will force the pulverized carbonaceous waste matter into and through the die blocks on a continuous basis thereby to extrude the artificial fuel cubes therefrom, which are thereafter discharged and collected for further use.A description of the system and the densification device will necessarily describe the method by which an artificial fuel cube is created from a mass of carbonaceous waste matter which includes, among other steps, the steps of pulverizing the waste matter into a particle size not exceeding 3/8ths inch, feeding the same to a densification device which includes a plurality of dies therein, compressing the pulverized carbonaceous waste matter into the die blocks by the use of press wheel, compressing the same in the die blocks, and collecting the compressed and densified fuel cubes formed therein for further use.

Furthermore, the present invention contemplates the provision of an artificial fuel cube which is formed by a mass of pulverized carbonaceous matter compressed into a solid mass having a density of between 30 and 60 pounds per cubic foot of bulk density, and having a heat value of not less than 8000 btu.

Brief Description of Drawings Figure 1 is a top plan view showing the densification system of the present invention which includes a two station system formed by a pulverized station, and a densification station, dimensionally sized to fit on a flat bed trailer; Figure 2 is a side elevational view of the densification system shown in Fig. 1 which illustrates the two stationed densification system including the pulverizing station and the densification station, and the drive means incorporated therein in order to drive both the pulverizing and the densification stations; Figure 3 is a side elevational view, in cross section, showing the details of construction of the densification device incorporated in the densification system as disclosed in Figs. 1 and 2 of the drawings;; Figure 4 is a top plan view, partially in cross section, taken in the direction of the arrows along the line 4-4 of Fig. 3, and shows the interrelationship between the press means, and the die blocks contained within the densification device, and illustrat.ng the use of a plurality of die blocks therein; Figure 5 is a side elevational view of an alternate embodiment of the center support section of an expandable die wherein the side walls may be expanded outwardly and inwardly in order to increase or decrease the diametrical sizing of the die cavity depending upon material which is to be compressed and processed through the die cavity;; Figure 6 is a top cross-sectional view taken in the direction of the arrows along the line 6-6 of Fig. 5, showing the manner in which the side walls of the center support section of a die may be expanded or retracted by the tightening or the loosening of the bolt inserted therethrough; Figure 7 is a top cross-sectional view of a center support section of a die block as shown in Figs. 5 and 6 above, wherein the interior side walls of the die block are retracted to their smallest dimension vis-a-vis Fig. 6; Figure 8 is a plan view, showing the details of construction of a typical die mold, which in conjunction with an adjacent die mold, creates a die block for the movement of carbonaceous matter therethrough;; Figure 9 shows an alternate embodiment of a pair of die molds, which together create an alternate embodiment of a die block which is basically circular in configuration, and functions in accordance with the present invention to create a densified fuel cube material; Figure 10 illustrates still another alternate embodiment of a pair of die molds which together forms a die block which will, in turn, create still an alternate form of an artificial fuel cube; Figure 11 is a side elevational view, in cross section, showing still another embodiment of the wear-resistant die sleeve associated with each die mold, which in effect directs the path of travel of carbonaceous waste matter into the dies when under compressional force; and Figure 12 is a top cross-sectional view, partly broken away, showing a die mold insert which may be employed for insertion in a die cavity, for the purpose of decreasing the bore of the die cavity to accomplish the compression of other materials which require smaller bores than the dies as shown.

Detailed Description of Drawings With respect to Figs. 1 and 2 of the drawings, an overall plan view showing the system as contemplated is illustrated. It will be observed that the system has been designed such that it may be installed on a flat bed trailer, thereby creating a mobile system. As will be more evident in the description following hereinbelow, the provision of a densification device which is constructed to operate in a horizontal plane vis-a-vis a vertical plane is considered to be of key importance in the ability to create a system which permits mobility.

With regard to Figs. 1 and 2, an overall system, generally denoted by the numeral 10, comprises basically a two station system. The first station consists of the pulverizer 1 2 which is basically constructed in the manner commonly known in the art. The pulverizer 12 is shown to include an inlet opening 1 3 through which is fed the waste matter by means of a conveyor 14, from a source 1 5 as illustrated. As will be more fully described hereinafter, the pulverizer is designed to pulverize the waste matter to a particle size of not exceeding 3/8ths inch in order to achieve optimum densification of the waste matter to be processed to the system.

Once the waste matter has been pulverized, conveyor 1 7 carries the pulverized waste matter to the densification device generally denoted by the numeral 20. The details of construction of the densification device 20 will be set forth hereinafter, however, it will be apparent from Figs.

1 and 2 of the drawings, that the present system further contemplates a chip and dust return 1 8 whereby particles of the waste matter which have broken off from the artificial fuel cube formed therein may be returned to the pulverizer for recirculation through the system. It is contemplated that the provision of a chip and dust return 1 8 further rnaximizes the efficiency of the overall system, and more nearly assures that virtually all of the waste matter will be converted into the artificial fuel cubes.

Again, as indicated, the entire system 10 is shown to be included on a flat bed trailer 5 thereby lending portability and mobillty to the system. The system 10 is made operational by including a prime mover power unit 6 which provides hydraulic power to the pulverizer 1 2 as well as the densification device 20 and the conveyors associated with the system. The prime mover power unit 6 is made operational by providing diesel tanks 7 containing the fuel for operating the power unit 6. The flat bed trailer 5 is also provided with a hydraulic tank 8 which provides the source of hydraulic fluid for any of the hydraulics associated with the system.

It will, therefore, be appreciated with reference to Figs. 1 and 2 of the drawings, that the overall system 10 described herein basically consists of a first station including a pulverizer 12 which pulverizes the waste product to a particle size not exceeding 3/8ths inch, a feed conveyor 1 7 for feeding the pulverized material to the densification device 20, and a densification device 20 which receives the pulverized material, and functions in a manner to compress the material into solid densified fuel cubes which may then be collected and ultimately discharged from the densification device 20. The details of construction of the densification device will be set forth more fully hereinafter.

Densification Device The densification device 20 is more clearly illustrated in Fig. 3 of the drawings. As is evident therefrom, the densification device 20 is basically formed by an upper housing 22 and a lower housing 24. There is also provided an upper support plate 23, and a lower support plate 25, which are disposed in space relationship one with respect to the other, and to which the upper housing 22 and lower housing 24 are bolted. As shown in Fig. 3, the upper housing 22 is bolted to the upper support plate 23 by means of brackets 27, held in position by bolts 28. Similarly, the lower housing 24 is secured to the lower support plate 25 by means of a similar bracket 27 and threaded bolt 28.The upper support plate 23 and lower support plate 25, together, function to divide the housing into an upper chamber generally denoted by the numeral 29, and a lower chamber denoted by the numeral 31. It will also be apparent that the upper support plate 23 and lower support plate 25 are spaced apart from a distance D for a purpose which will be described hereinafter.

The upper chamber 29 of the housing 22 includes an inlet port 21 into which the pulverized waste matter coming from the pulverizer 12 is introduced into the densification device 20. The lower chamber 31 includes the drive mechanism 32 which may be a gear reduction-type drive mechanism, or a direct drive mechanism, both of which are well known in the art.

The upper support plate 23 is shown to include a shaft aperture 34, a shaft collar 35, while the lower support plate 25 is similarly provided with a shaft aperture 36, and shaft collar 37. Each of the shaft collars 35 and 37 respectively are threaded as generally indicated by the numeral 38 thereby to accommodate the provision of threaded cap 39 therein which functions to permit the operator to adjust the positioning of the main shaft 40 as will be described hereinafter.

The main shaft 40 includes an upper end 41, and a lower end 43 as shown in Fig. 3, the main shaft 40 being accommodated through the shaft apertures 34 and 36 of the upper support plate 23 and lower support plate 25, and through the shaft collars 35 and 37 respectively of support plates 23 and 25 respectively. The lower end 43 of the main shaft 40 is shown to be journaled in the drive mechanism 32 in a manner such that actuation of the drive mechanism 32 will cause a concomitant rotation of the main shaft 40 in a manner which is well known in the art.

The upper chamber 29 is shown to further include a feed mechanism which consists of an inverted cone member 45 supported by support rails 46 which are secured to a connecting collar 47 as illustrated. The main shaft 40 is provided with a threaded upper end 42 and as shown in Fig.

3 of the drawings, the inverted cone member 45 is connected to the main shaft 40 by sliding the connecting collar 47 thereof over the threaded upper end 42 of the main shaft 40 and bolting the same in place with a nut 44. If desired, the interior walls of the connecting collar 47 and the upper end 41 of the main shaft 40 may be splines respectively, such that a positive fit of the inverted cone member 45 is achieved on the upper end 41 of the main shaft 40.It will be appreciated that when the drive mechanism 32 is actuated, and the main shaft 40 is caused to rotate, a concomitant rotational movement will be achieved with regard to the inverted cone member 45 To further facilitate the feeding characteristics of the inverted cone member 45, the cone 45 may be provided with a series of feed paddles 49 which function to distribute the pulverized waste natter throughout the entire circumferential extent of the interior portion of the chamber 29 of the housing 22.

While the densification device shown in Fig. 3 includes an inverted cone member 45 as the feed mechanism, it will be appreciated that the feed member may be dome-shaped, or assume any other type of configuration, the only requirement being that basically the pulverized waste matter entering through the inlet port 21 will fall downwardly by gravitational force and be distributed throughout the entire circumferential extent of the device. It is contemplated that the feed paddles 49 will function to achieve a good distribution of the waste matter throughout the device as illustrated.

As shown in Figs. 3 and 4 of the drawings, the upper support plate 23 is shown to be circular in configuration, and extends around the entire circumferential extent of the densification device 20. The upper support plate 23 is shown to include a series of feed apertures 51 through which entrance is gained to the space measured by the distance d between the upper support plate 23 and the lower support plate 25.

If desired, and an alternate embodiment of the present invention would include a metering plate 50 which is designed to lie atop the upper support plate 23, and includes a plurality of secondary feed apertures 52 positioned therein. The metering plate would further include a series of key slots 53 which would be located along the outer periphery as well as the inner periphery of the metering plate 50. The upper support plate would include a series of upstanding slot guide bolts 54 which are keyed into the key slots 53 such that the metering plate 50 is slidably movable with respect to the upper support plate 23 to the extent that the slot guide bolts 54 are movable within the key slots 53.It will be appreciated that as the metering plate 50 is moved relative to the upper support plate 23, the openings in the feed apertures 51 of the upper support plate 23 may be alternatively opened and closed, thereby to control the rate of feed of the pulverized waste matter through the feed apertures 51 and into the path of the press wheels 66 and 68.

Press Means Again, with reference to Fig. 3 of the drawings, there is shown the space measured by the distance d between the upper support plate 23 and the lower support plate 25. Positioned within the spacing d is a press wheel holder arm 55 which is secured to the main shaft 40 by means of splines 57, and pin lock 56. The press wheel holder arm 55 is shown to be formed with opposed bifurcated outer arms 59 and 61 respectively. The bifurcated arms 59 and 61 are shown to be unitarily formed with the central hub 58 which, in turn, is splined in order to connect to the main shaft 40 in the manner described above.

The outer ends of the bifurcated outer arms 59 and 61 respectively are shown to be provided with wheel hubs 62 and 64 respectively, formed integrally therewith. Each of the wheel hubs 62 and 64 include a pivot pin aperture 63 and 65 respectively and as shown in Figs. 3 and 4 of the drawings, a pair of press wheels 66 and 68 are shown to be pivotally secured by means of a pair of pivot pins 67 and 69 journaled in the pivot pin apertures 63 and 65 respectively. In the preferred embodiment, the press wheels 66 and 68 are pivotally mounted by means of the pivot pins 67 and 69 and are further provided with appropriate bearings 70 in order to facilitate the rotational movement of the press wheels 66 and 68.As it will be further evident from Fig. 3 of the drawings, the press wheels 66 and 68 are designed to ride along the interior surface of the densification device 20 and are in linear alignment with the die molds 90 for a purpose to be described hereinafter. It will also be appreciated that by providing bifurcated outer arms 59 and 61 respectively, the press wheels 66 and 68 are adapted to be freely rotatable within the space provided between the bifurcation, such that the press wheels 66 and 68 are freely rotatable about their respective pivot pins 67 and 69. It will also be observed that the press wheels 66 and 68 are in direct linear alignment with the die molds 90 for a purpose to be described hereinafter.

From the above description, it will be appreciated that the press wheel holder arm 55, to which the press wheels 66 and 68 are mounted, as well as the inverted cone member feeder 45, are both mounted to the main shaft 40, such that actuation of the drive mechanism 32 will cause a concomitant rotational movement of both the press wheel holder arm 55 and the inverted cone member 45. In order to insure that the press wheel holder arm 55 and, therefore, the press wheels 66 and 68 are maintained in a proper alignment with regard to the die molds 90, it has been found to be preferable to employ a bearing arrangement for journaling the main shaft between the threaded caps 39.The bearing arrangement consists of a thrust tapered spherical bearing 78, which bears against the interior surface of the threaded cap 39, and against a split iocking ring 79, and having a spherical roller bearing 81 positioned immediately above the locking ring 79. It will be noted that the shaft collars 35 and 37 include undercut portions thereby to provide a shoulder for the spherical roller bearing 81 to bear against.It will further be noted that the bearing arrangement of both the upper support plate 23 and lower support plate 25, wherein the main shaft 40 is journaled, is constructed identicaily. It will also be appreciated that due to the bearing arrangement as described, and the pin lock 56, the main shaft may be moved vertically in order to adjust the linear alignment of the press wheels 66 and 68 relative to the die molds 90 in order to insure that the pulverized waste material will be compressed properly into the die molds. Hence, the threaded adjustment of the threaded caps 39 with respect to the upper support plate 23, as well as the lower support plate 25, will, in fact, adjust the positioning of the main shaft 40 within the device in order to achieve the proper linear alignment.It will be appreciated, however, that other bearing arrangements may be employed, and it is contemplated that the principal requirement is that the main shaft 40 be adjustable in order to insure that the press wheels 66 and 68 be properly linearly aligned.

Die Molds As will be noted in Fig. 3 of the drawings, each of the upper support plate 23 and lower support plate 25 include extension portions 73 and 75 respectively, which extend laterally outwardly from the outer confines of the corresponding upper housing 22 and lower housing 24 respectively. Each of the extension portions 73 and 75 respectively include recesses 74 and 76 respectively which are designed to accommodate the positioning of the die molds 90 therein. The construction of the die molds 90 is generally depicted in Figs. 8 through 10 of the drawings, and reference will be made to those figures hereinbelow.

With specific reference to Fig. 8, the die mold 90 generally contemplated by the present invention is illustrated. Each die mold 90 is shown to be constructed in the form of a die mold block which has a generally I-shaped configuration as generally depicted by the numeral 92. A center support 93 is shown to be recessed for a purpose to be described hereinafter. Each of the die mold blocks 90 is provided with one-half of the die cavity 95, and it will therefore be appreciated that to create the entire die cavity 95, a pair of die mold blocks 90 must be positioned in side by side relationship. The die mold blocks 90 are mounted to the densification device 20 by means of mounting apertures 96 extending through the center support section 93 of each of the die mold blocks 90. Each die mold 90 is preferably provided with two (2) mounting apertures 96.

As shown in Fig. 3, a threaded bolt and nut arrangement is employed for securely bolting each die mold block 90 to the extension portion 73 and 75 of the respective upper and lower support plates 23 and 25 respectively. As depicted in Fig.

4 of the drawings, a plurality of die mold blocks 90 are bolted around the entire circumferential periphery of the upper support plate 23 and lower support plate 25 and in side by side relationship such that the one-half die cavity 95 are brought together with adjoining one-half of a die cavity 95 in an adjoining die mold block 90 thereby creating a plurality of completed die cavities 95, again around the entire circumferential periphery of the device 20. Again as depicted in Fig. 8 of the drawings, each of the die cavities is shown to be provided with a top wall 97 and a bottom wall 98 and a side wall 99.In the preferred embodiment, the top wall 97 and bottom wall 98 are constructed to have a uniformly irregular surface, and as shown in Fig. 8, the uniformly irregular surfaces are formed by a plurality of grooves 101 which extend along and traverse the entire path of the die cavity 95. It will be observed that the grooves 101 run parallel to the path of travel of the pulverized waste matter as the same passes through the die cavity 95.

In Figs. 9 and 10 of the drawings, alternate embodiments showing other forms of a uniformly irregular die cavity surface are illustrated. In Fig. 9, half of the die mold block 90' shown to include a semi-circular die cavity half 95' which together with the adjoining die mold block 90', and the die cavity half 95' create a substantially circular die cavity having a uniformly irregular surface thereabout created by grooves 101'.

In Fig. 10, an alternate embodiment is illustrated wherein the die mold blocks 90" each have a die cavity half 95" incorporating grooves 101" such that, once again, uniformly irregular surfaces are created, and in both instances, the grooves formed therein are positioned in a path parallel to the path of travel of the pulverized waste matter as the same traverses through the die cavity 95, 95' and 95". The purpose for forming the die cavity 95 with a uniformly irregular surface will be described more fully hereinafter.

In Figs. 5, 6, and 7 of the drawings, an alternate embodiment of a die mold block 90 including an adjustable center support section 93 is illustrated.

The center support section 93 is shown to include the central die sleeve 105 having an elongated cone-shaped configuration. The central die sleeve 105 is shown to be formed by a top wall 106, and a bottom wall 107, which are tapered together adjacent to the forward end 108 of the central die sleeve 105, and tapered away from one another at the rearward end 109 thereof.

With regards to Figs. 6 and 7 of the drawings, in Fig. 6 of the drawings, a center support die sleeve is shown to be at its fully and normally rest position with the top wall 106 and bottom wall 107 being tapered, and spaced apart a distance measured by the center support section 93. In Fig.

7 of the drawings, the center die sleeve 11 5 is shown to have the top wall 11 6 and bottom wall 11 7 thereof being spread apart, which action is accomplished by screw threading the threaded bolt as shown therein until the rearward ends of the top wall 11 6 and bottom wall 11 7 are spread apart. It will be appreciated from a review of Figs.

6 and 7 of the drawings, that in Fig. 6, the center die sleeve 105 is adjusted to permit the maximum amount of waste matter to pass therethrough, whereas in Fig. 7, the spreading apart of the top wall 11 6 from the bottom wall 11 7 will have the effect of reducing the bore size of the die cavity 95, all of such adjustments being capable from external to the machine. It will also be appreciated that the provision of an adjustable central die sleeve 1 05 (11 5) lends a degree of flexibility to the densification device 20 in that the tightening or loosening of the threaded bolt maintaining the central die sleeves 105 (115) may be adjusted in order to render the die cavity 95 useful for a wide variety of materials.

In Fig. 11 of the drawings, an alternate embodiment of a die sleeve 125 is illustrated which again includes a top wall 126 and a bottom wall 1 27 which taper together at the forward end 128 and taper away from one another toward the rearward portion 129. A pair of mounting legs 131 and 133 are respectively formed integrally along the rearward portion 1 29 of the die sleeve 125, and are adapted to facilitate the mounting of the die sleeve 125 to the center support section 93. In this embodiment, it is contemplated that the center support section 93 would include relief cuts 94 having a depth approximately the same dimension as the thickness of the mounting legs 1 31 and 1 33 respectively.The central portion of the die sleeve 125 is threaded to accommodate a threaded bolt therein incident to the mounting process for mounting the die sleeve 125 onto the center support section 93. Once again, the provision of a die sleeve 125 as shown in Fig. 11 is to direct the flow path of the waste matter into the die cavity 95, as well as to provide an overall tapered die configuration which is an important factor incident to the densification process. In addition, the die sleeve 1 25 is removable by simply unscrewing the same via the bolt (not shown) being retracted from the central threaded opening thereof, such that the die sleeve 125 may be replaced in the event of excessive amount of wear of the die sleeve.

With further reference to Fig. 3 of the drawings, it will now be appreciated that each of the die mold blocks 90 is positioned in the recesses 74 and 76 formed in the extension portions 73 and 75 of the upper support plate 23 and lower support plate 25. Since the densification device 20 is circular in configuration, a plurality of die mold blocks 90 may be installed on the device. In one prototype form of the subject densification device 20, a series of 96 die mold blocks were installed in circumferential arrangement around the periphery of the housing. Again, with reference to Fig. 3 of the drawings, it will be observed that as indicated previously, it is necessary that the press wheels 66 and 68 be in direct linear alignment with each of the die mold blocks 90 throughout the entire circumferential periphery of the densification device 20.The linear alignment will require that the center line of the press wheels 66 and 68 be on center with the center point of the die cavity 95 of the die mold block 90 in order to achieve proper densification of the waste product during the passage of the material through the die cavity 95.

Further with reference to Fig. 3, it will be observed that the densification device 20 is further provided with an exterior housing 135 which is spaced from the lower housing 24 a distance slightly in excess of the lateral dimensions of the extension portions 73 and 75 respectively.

The exterior housing 135 is maintained in position by bolting the same to the upper support plate 23 at strategic points along the entire circumferential periphery of the device 20. The bottom of the exterior housing 135 is enclosed by a first apertured floor 137, and a second lower floor 139.

The second lower floor 139 includes a discharge chute 141 which is connected to the chip and dust return 1 8 for a reason as described hereinbelow.

Further with reference to Fig. 3, it will be appreciated that as the waste material is densified and solidified by passage through the die cavity 95 of the die mold block 90, the extruded fuel cube will strike against the interior surface of the exterior housing 135, and as extruded fuel cube is pushed out of the die cavity 95, portions of the fuel cube will break off and fall to the bottom of the exterior housing 135 landing on the first apertured floor 137. In practice, the apertures (not shown) in the floor 137 are sized smaller than the typical sections of artificial fuel cubes 1 50 which are typically broken off during the process, and therefore, retained within the exterior housing chamber 136.In practice, it has been observed that dust particles and chips from the artificial fuel cubes 1 50 are, from time to time, broken off, and particle sizes of this dimension will fall through the apertures in the apertured floor 137 and the second bottom wall 139. The chip and dust return 1 8 is generally made functional by means of a suction and vacuuming device which is attached to the discharge chute 141, thereby to vacuum by suction the dust and chip particles falling therein into the chip and dust return for passage back to the pulverizer 12, and recirculation through the entire system.

In the preferred embodiment, the fuel cubes 1 50 which are contained within the exterior housing chamber 136 are transported to a discharge outlet 145 by any suitable means, such as a normal vibratory feeder device (not shown).

Obviously, any suitable means may be used for transporting the artificial fuel cubes 1 50 to the discharge outlet 145, and it is contemplated that a storage bin of some form would be employed at the exit point of the discharge outlet 145 to store the artificial fuel cubes 1 50 formed during the operation of the densification device 20.

With further reference to the construction of the die mold blocks 90, as was indicated previously, it has been found desirable to form grooves 101 along the top wall 97 and bottom wall 98 thereof, along the entire length of the die cavity 95. It is known in the art that each material that is to be densified has a specific frictional drag coefficient which has an effect on the ability to densify the material. The typical dies have a specific set surface area which is usually stated in terms of square inches. Some materials to be densified due to the low coefficient of friction ratings, will slide through the die and fail to make a proper plug in the die. This will have the effect of creating a very light finished product that is not sufficiently densified, and will therefore have an unacceptable heat value as a fuel block for use by an ultimate user.It has therefore been found that pursuant to the present invention, if the surface area of the interior surfaces of the die cavity can be cut in a manner which will increase the frictional surface area, there will be an attendant increase in the frictional drag coefficient relative to any material that is forced through the die. It has been found that if grooves of the type depicted in the die cavities of Fig. 8 of the drawings, it will have the effect of increasing the frictional surface area in the die up to 50% which, in turn, will produce a much better plug within the die, and hence, a much more densified fuel cube product.

It has been found, for example, that where a die cavity may have a dimension of 11.75 inches by 2.5 inches, the total area will be 29.375 square inches. By adding five grooves in both the top wall as well as the bottom wall of the die cavity 1!8 inch in depth, and 1/8th inch across, it has been found that the total area will increase by 14.6888 square inches, which will yield a die cavity having a frictional surface area of approximately 50% more than the normal die cavity lacking any irregularities in the surface thereof.

It is also known in the art that the major area of wear and deterioration of the dies occurs at the inside tip, or the point nearest to the portion where the press wheel operates to compress waste matter into the die. While various manufacturers have employed various techniques such as adding hard face welding to this area of the die, the wear factor remains rather high.

Pursuant to the present invention, replaceable die tips which are bolted into position into the die blocks are provided, which are also tapered in configuration, as shown in Fig. 11. The tapered configuration functions to direct the path of the waste matter into the dies, as well as to create a tapered die cavity to aid and facilitate the densification of the waste product as it passes therein and through the die. It is contemplated that the replaceable die tips may be bolted into position from the exterior portions of the machine, and does not necessitate the removal of the entire die mold blocks in order to replace the same.

Operation From the above description, it will be now evident that the system of the present invention operates by first pulverizing the desired waste product into partic!es having a particle size not exceeding 3/8ths inch in diametric dimensions.

The pulverized waste matter is then transported from the pulverizing station by means of a chute or other appropriate means, to a densification device of the type described. Once the densification device is actuated, such as by energizing the drive mechanism, the main shaft is caused to rotate, which will in turn cause the rotation of the feeding means adjacen+ to the top of the densification device, as well as the rotational movement of the press wheels contained internally in the machine.

The upper support plate is provided with a plurality of feed apertures, and as the pulverized waste material falls into the inlet port, the inverted cone member having the feed paddles mounted thereon will cause a distribution of pulverized waste matter throughout the circumferential extent of the device. The pulverized waste matter will fall through the feed apertures located in the upper support pate and will fall into the path generally followed by the press wheels located between the upper and lower support plates. As indicated previously, it has been found that insofar as the prototype unit is concerned, a series of 96 die mold blocks were installed around the circumferential periphery of the densification device, the attendant production associated therewith is then only dependent upon the rpm at which the main shaft is operated.

Again, operationally, the press wheels will force the waste matter falling into its pathway into each of the die blocks sequentially in its path of travel, and commence the densification process. The waste matter will form a plug as the same compacts into the die cavity of the die blocks, and the process will continue so long as the device is kept operational. As indicated previously, as the plugs are formed and extruded from the outermost end of the dies, the plug will come into contact with the interior surface of the exterior housing, break off and fall to the first apertured floor of the exterior housing in the manner indicated previously.The device is further provided with a chip and dust return such that smaller particles which break off, will fall through the apertures into the lower section of the unit, there to be vacuumed by suction device and returned to the pulverizer for reprocessing.

In terms of overall capacity, it has been found that where the main shaft is caused to rotate at 500 rpm, and where the pulverized waste matter being extruded will be extruded at the rate of 1/32 of an inch of plug per roll of the press wheel per rpm around the circumference of the device, a total tonnage of 11.24955 tons per hour will be produced. If in fact, the device will operate only at a 70% efficiency level, it will be appreciated that the total tonnage produced is 7.8747 tons per hour.

Where the waste material to be extruded extrudes at the rate of 1/1 6th of an inch of plug per roll of the press wheel per rpm, it is found that a total of 21.976 tons per hour will be produced, or operated at 70% of the efficiency of the device, the total tonnage produced will be 15.38 tons per hour.

If the waste matter is such that it will extrude at the rate of 3/32 of an inch per roll of the press wheel per rpm, the tonnage that is produced is the equivalent of 32.6953 tons per hour, which reduced to a 70% efficiency level will yield an actual product of 22.8867 tons per hour.

If the product to be extruded or compressed will extrude at the rate of 1/8th of an inch per roll of the press wheel per rpm, the total tonnage which will be produced assuming 70% efficiency level of the device is 30.761 tons per hour.

From the above, it will be determined that the densification system and device disclosed herein is highly efficient and will function to yield significant fuel cube product per hour of operation.

Another significant factor incident to the system and device of the present invention is the fact that the present device will lend itself to the densification of a wide variety of materials. Such products include cotton gin trash, sawdust and wood chips, municipal solid waste, coal fines, baggasse, rice straws and hulls, fowl feathers, and a host of other material. It has been found that depending on the product to be densified, some minor adjustments may be made to the device in order to adapt the same and to achieve a product which is properly densified. For example, it has been found that it is desirable to reduce the square inch surface area of the die when coal fines are being processed into fuel cubes, and it is contemplated that the dies described herein may be adapted with an insert formed in a manner similar to the existing dies, except smaller in dimension.Given the tapered opening of the dies, an insert sleeve may be inserted therein which reduces the surface area of the die, and therefore renders the die suitable for densifying various other waste products.

In Fig. 12 of the drawings, a die insert 1 55 is shown to be included within the die cavity 95 formed by a pair of adjoining die blocks 90. The die insert 1 55 is shown to be provided with a pair of tapered away exterior side walls 1 56 and 1 58 respectively, which are designed to matingly engage the tapered top and bottom walls 126 and 127 of the die sleeve 125 which is bolted in position on adjoining die blocks 90.

For example, where a coal product is to be densified, it has been found desirable to reduce the surface area of the die cavity 95 by inserting a die insert 1 55 therein, for the reason that coal fines require a smaller square inch surface area of the die cavity 95.

With regard to the ultimate fuel cube produced in accordance with the system and method of the present invention, it has been found that the optimum final product will have a bulk density in the range of between 30 and 60 pounds per cubic foot. A final fuel cube product within that range of bulk density has been found to have ideal heat value and btu characteristics when used as a fuel, whereas a product having a bulk density of below 30 and above 60 pounds per cubic foot will have various problems associated therewith. For example, a product having a bulk density below 30 pounds per cubic foot will have a tendency to flake in storage, and therefore, the attendant loss of product greatly increases the cost per unit for the product.In addition, a product having a bulk density of below 30 pounds per cubic foot will have back-burn tendencies which are created such that the dust and fines of the cuves will start to burn prior to reaching the oven chamber. Similarly, a product having a bulk density in excess of 60 pounds per cubic foot will have a tendency to be overly densified, and when used as a fuel, will have a tendency to burn very slowly, and probably be deemed inefficient as a fuel source to the ultimate user.

As was indicated above, the final fuel cube product is ideally created with a bulk density of between 30 and 60 pounds per cubic foot. In terms of heat value, it has been found that the heat value should be no less than 8000 btu. By way of comparison, typical coal found in the western states of the United States averages between 8500 and 9000 btu per pound when burned. It is therefore deemed desirable to create fuel cubes according to the present invention which will have a heat value equivalent to the heat value of coal.

It has also been found desirable incident to the process as described herein to employ a heat enhancer, formed from one of any number of liquid petroleum products as is known in the art.

The heat enhancers would consist of substances such as paraffin, various grades of oil, and the like.

The value of such additives is that it will improve the heat value of the ultimate fuel cube formed in accordance with the present invention.

It will be appreciated that pursuant to the present invention, there has been provided a densification system which consists of basically a two station system including a pulverizing station for pulverizing a carbonaceous waste matter to particle size not exceeding 3/8ths inch in diametrical dimensions, and a densification station which functions to compact and densify the pulverized material into artificial fuel cubes having a bulk density of between 30 and 60 pounds per cubic foot. In addition, the present invention provides a novel densification device which is based upon a horizontally disposed die mold system having the press wheel operating in a horizontal plane thereagainst, thereby to decrease the height and size characteristics of the machinery necessary to produce an artificial fuel cube.In addition, the present invention provides a novel die mold construction pursuant to which the die cavities are provided with a uniformly irregular surface thereby to increase the frictional surface area of the die cavity resulting in properly densified final fuel cube product. The method of the present invention includes the further step of providing at least one die having a uniformly irregular surface through which the carbonaceous waste matter is compacted incident to the method of forming the artificial fuel cube. It will therefore be observed that pursuant to the above description, there has been provided an improved densification system, densification device, method and a resulting fuel cube product which satisfies these and other objects of the present invention.

While there has been described what is at present considered to be the preferred embodiments of the invention, it will be understood that various modifications may be made therein and it is intended to cover in the appended claims all such modifications as found in the true spirit and scope of the invention.

Claims (32)

1. The densification system for compressing and densifying pulverized waste matter into fuel cubes comprising, a housing, receiving means positioned in said housing for receiving pulverized waste matter, a plurality of die means positioned in said housing circumferentially above the periphery thereof for receiving said pulverized waste matter and compressing same, press means positioned in said housing adjacent to said die means, said press means mounted within said housing for rotational movement in a horizontal plane with respect to said housing and said die means for pressing said pulverized waste matter into a through said die means, feed means for feeding said pulverized waste matter into the path of said press means, drive means associated with said housing for driving said feed means to feed pulverized waste matter into the path of said press means and for driving said press means to press said pulverized waste matter into said die means, and discharge means associated with said housing for effecting the discharge from said housing of the formed densified fuel cubes.

2. The densification system as set forth in Claim 1 above wherein said receiving means comprises an inlet port positioned vertically above said die means and said press means such that said pulverized waste matter is gravitationally fed through said system.

3. The densification system as set forth in Claim 2 above, wherein said housing is circular in configuration and said plurality of die means comprises a plurality of die blocks mounted circumferentially on said housing and about the periphery thereof.

4. The densification system as set forth in Claim 3 above, wherein said die means each comprises a die block having an interior surface, said interior surface being at least partially uniformly irregular in configuration.

5. The densification system set forth in Claim 4 above, wherein said partially uniformly irregular interior surface of each of said die blocks comprises a plurality of grooves formed in the interior surfaces thereof and extending along the path of travel of said waste matter as the same traverses said die block.

6. The densification system set forth in Claim 4 above, wherein said press means comprises at least one press wheel rotationally mounted for rotational movement within said housing and positioned immediately adjacent to said plurality of die blocks thereby to press waste matter fed into the path of said press means into and through said die blocks.

7. The densification system set forth in Claim 6 above, wherein said feed means comprises an inverted cone member fixedly secured to said drive means and positioned intermediate said inlet port and said press means thereby to receive waste matter from said inlet port and feed the same into the path of said press means.

8. The densification system set forth in Claim 7 above, wherein said feed means further includes feed paddles mounted on said cone member, for distributing said pulverized waste matter throughout the entire circumferential extent of said press means.

9. The densification system set forth in Claim 7 above, wherein said drive means comprises a drive shaft positioned substantially centrally within said housing and extending in a plane vertical with respect to said press means, said drive shaft having a top end and a bottom end, motor means associated with said system having the bottom end of said drive shaft connected thereto to effect the rotational movement of said drive shaft, the top end of said drive shaft being connected to said feed means, and said press means being connected to said drive shaft intermediate the ends thereof, whereby the rotational movement of said drive shaft will effect a simultaneous rotational movement of said feed means and said press means within said housing, said rotational movement of said feed means and said press means being identical one to the other.

10. The densification system set forth in Claim 9 above, wherein said discharge means comprises a first apertured floor positioned within said housing and below said die means, and a second solid floor positioned below said first apertured floor and spaced therefrom, said apertures in said first floor being dimensionally sized smaller than the dimensions of said formed fuel cubes, a discharge opening positioned in said housing and in communication with said apertured first floor, ejection means associated with said apertured first floor thereby to move said formed fuel cubes collected on said apertured first floor from within the confines of said housing to said discharge opening for ejection from said system, and recirculation means associated with said second solid floor for recirculating particled fuel cube matter collected through said apertured first floor to said densification system.

11. A densification system for compressing and densifying waste matter into solid fuel cubes comprising in combination, a first station including pulverizing means for pulverizing waste matter into particles having a particle size of not more than 3/8ths inch, a second station including a housing, feeding means interposed between said first station and said second station for feeding the pulverized waste matter from said pulverizing means to said housing, die means positioned within said housing for receiving said pulverized waste matter and compressing the same into densified fuel cubes, press means positioned within said housing adjacent to said die means for compressing said pulverized waste matter into and through said die means, second feed means positioned within said housing for feeding said pulverized waste matter into the path of said press means, drive means associated with said housing connected with said second feed means and said press means for simultaneously driving said second feed means for feeding pulverized waste matter into the path of said press means, and for driving said press means to compress said pulverized waste matter into and through said die means, and discharge means positioned within said housing and associated with said die means to receive said compressed fuel cubes from said die means and effect the discharge thereof from said second station.

12. The densification system as set forth in Claim 11 above, wherein said system further includes recirculation means associated with said discharge means and adapted to collect any and ail particlized waste matter remaining undensified and to recirculate the same to said first station for further pulverizing and recirculation through said system.

1 3. The densification system as set forth in Claim 1 2 above, wherein said recirculation means comprises a discharge chute associated with said discharge means, an enclosed passageway interconnecting said discharge chute with said first station, and suction means associated with said discharge chute and enclosed passageway for vacuuming any and all particles of waste matter not densified for recirculation through said first station and said system.

14. The densification system as set forth in Claim 11 above, wherein said housing is circular in configuration, and said die means are positioned in a horizontal plane relative to said housing and circumferentially spaced around the entire periphery of said housing, and said press means they are mounted within said housing for rotational movement along a horizontal path immediately adjacent to said die means.

1 5. The densification system set forth in Claim 14 above, wherein said die means comprises a plurality of die blocks, each of said die blocks having an interior surface, said interior surface having at least a portion thereof formed by a uniformly irregular surface.

1 6. The densification system set forth in Claim 1 5 above, wherein each of said die blocks has a rectangular cross-sectional configuration including a top wall, a bottom wall, and opposed side walls, and said top wall and bottom wall each being provided with at least one groove formed therein and extending along the path of travel of the waste matter pressed therethrough.

1 7. A horizontally disposed densification device for compressing and densifying waste matter into fuel cubes, comprising in combination, a housing having an inlet port and a discharge port, an upper support plate horizontally mounted within the confines of said housing, a lower support plate horizontally mounted within the confines of said housing and positioned in space relationship with respect to said upper support plate, a main shaft vertically supported within the confines of said housing and extending through said upper and lower support plate, drive means associated with said housing and having one end of said main shaft rotatingly mounted on said drive means thereby to provide rotational movement to said main shaft, a plurality of die means mounted within said housing and positioned substantially intermediate said upper and lower support plates and along the periphery thereof, press means mounted within said housing intermediate said upper and lower support plates immediately adjacent said plurality of die means and fixedly secured to said main shaft, said press means being mounted on said main shaft in a manner which will effect the rotational movement thereof in a horizontal plane within the confines of said housing and intermediate said upper and lower support plates, said upper support plate provided with a plurality of feed apertures positioned along the periphery thereof, feed means mounted for rotational movement on the opposed end of said main shaft within said housing and positioned above said upper support plate, and discharge means positioned in said housing to effect the discharge of densified fuel cubes therefrom, whereby pulverized waste matter is fed into said housing through said inlet port, fed into the path of said press means by said feed means, said press means the operating to compress said pulverized waste matter into said die means thereby to densify and compress the same as the waste matter passes through said die means, and the discharge means operating to collect and discharge the densified fuel cubes formed therein discharge port.

18. The densification device as set forth in Claim 17 above, wherein each of said die means comprises a die block having an interior surface, said interior surface being substantially uniformly irregular in configuration.

1 9. The densification device as set forth in Claim 1 8 above, wherein each of said die blocks is rectangular in configuration and said interior surface thereof has a top wall, a bottom wall and a pair of opposed side walls, each of said top and bottom walls having at least one groove formed therein, said groove being formed along a path parallel to the path of travel of waste matter through said die block.

20. The densification device as set forth in Claim 1 7 above, wherein said press means comprises of press wheels mounted on a press wheel arm, said press wheel arm being rotationally mounted on said main shaft intermediate said upper and lower support plates, and said press wheels positioned to ride along the interior periphery of said housing immediately adjacent to said die means.

21. The densification device as set forth in Claim 20 above, wherein each of said press wheels is rotationally mounted adjacent the opposed ends of said press wheel arm, such that each of said wheel is rotationally movable relative to said press wheel arm, while said press wheel arm is rotationally movable relative to the rotational movement of said main shaft.

22. The densification device as set forth in Claim 1 7 above, wherein said feed means comprises inverted cone member fixedly secured to said drive means and positioned intermediate to said inlet port and said upper support plate thereby to receive waste matter from said inlet port and feed the same through said upper support plate into the path of travel of said press means.

23. The densification device as set forth in Claim 22 above, wherein said inverted cone member fixedly secured on said main shaft at the upper end thereof such that the rotational movement of said main shaft will cause a concomitant rotational movement of said inverted cone member thereby to cause the pulverized waste matter entering through said inlet port to be distributed by said inverted cone member throughout the entire circumferential extent of said housing.

24. The densification device as set forth in Claim 1 8 above, wherein each of said die blocks is further provided with a removable die sleeve mounted thereon along the interior surface thereof and immediately adjacent to the path of travel of said press means, said die sleeve having a side to side inwardly tapered configuration thereby to function for the purpose of directing pulverized waste matter into the dies, and to provide a tapered die cavity configuration.

25. A method of forming a solid densified fuel cube from a mass of carbonaceous matter comprising the steps of providing a mass of pulverized carbonaceous matter having a particle size not exceeding 3/8ths inch, providing at least one die having an interior surface which is, in part, uniformly irregular, providing press means adjacent to said die, said press means being movably mounted relative to said die, feeding said pulverized matter of carbonaceous matter into the path of said movable press means, compressing said pulverized carbonaceous matter into said die by the movement of said press means relative to said die, and collecting the solidified and densified fuel cubes after passage through said die.

26. The method as set forth in Claim 25 above, wherein said die includes an interior surface having a portion thereof provided with a plurality of formed irregularities, said irregularities extending along the path of travel of said pulverized waste matter traversing therethrough.

27. The method as set forth in Claim 26 above, wherein said die having said interior surface is formed to have a rectangular configuration, including a top wall, a bottom wall and a pair of opposed side walls, and said top wall and bottom wall are each provided with at least one groove formed therein, said groove extending along a path parallel to the path of travel of the pulverized waste matter traversing therethrough.

28. The method as set forth in Claim 25 above, wherein said press means is designed to be rotationally mounted at a point adjacent to said die such that the carbonaceous waste matter imposed between said press member and said die will be compressed and forced by said press means into and through said die thereby to become densified and compressed therein.

29. The method as set forth in Claim 25 above, which further includes the step of providing a liquified petroleum base heat-enhancer thereby to enhance the heat of friction attendant to the carbonaceous waste matter as the same traverses through said die, and thereby improve the densification factor associated with said fuel cube.

30. A formed artificial fuel cube comprising a mass of pulverized carbonaceous matter compressed into a solid mass having a density between 30 and 60 pounds per cubic foot of bulk density, and having a heat value of not less than 8000 btu.

31. The artificial fuel cube as set forth in Claim 30 above, wherein said cube further includes at least a partially uniformly irregular outer surface.

32. The artificial fuel cube as set forth in Claim 31 above, wherein said fuel cube includes at least a pair of opposed outer surfaces having at least one groove formed therein.