US20100018113A1 - Engineered fuel feed stock - Google Patents

Engineered fuel feed stock Download PDF

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Publication number
US20100018113A1
US20100018113A1 US12/492,096 US49209609A US2010018113A1 US 20100018113 A1 US20100018113 A1 US 20100018113A1 US 49209609 A US49209609 A US 49209609A US 2010018113 A1 US2010018113 A1 US 2010018113A1
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US
United States
Prior art keywords
feed stock
vol
engineered fuel
content
btu
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/492,096
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English (en)
Inventor
James W. Bohlig
Dingrong Bai
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Repower Ip LLC
Original Assignee
Casella Waste Systems Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Priority to US12/492,096 priority Critical patent/US20100018113A1/en
Application filed by Casella Waste Systems Inc filed Critical Casella Waste Systems Inc
Assigned to WILMINGTON TRUST COMPANY, AS COLLATERAL AGENT reassignment WILMINGTON TRUST COMPANY, AS COLLATERAL AGENT 2ND LIEN PATENT SECURITY AGREEMENT Assignors: CASELLA WASTE SYSTEMS, INC., A DELAWARE CORPORATION
Priority to US12/644,974 priority patent/US8444721B2/en
Publication of US20100018113A1 publication Critical patent/US20100018113A1/en
Assigned to CASELLA WASTE SYSTEMS, INC. reassignment CASELLA WASTE SYSTEMS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BAI, DINGRONG, BOHLIG, JAMES W.
Assigned to FCR, LLC reassignment FCR, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CASELLA WASTE SYSTEMS, INC.
Assigned to CASELLA WASTE SYSTEMS, INC. reassignment CASELLA WASTE SYSTEMS, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: WILMINGTON TRUST COMPANY, AS COLLATERAL AGENT
Assigned to ARES CAPITAL CORPORATION, AS COLLATERAL AGENT reassignment ARES CAPITAL CORPORATION, AS COLLATERAL AGENT PATENT SECURITY AGREEMENT Assignors: FCR, LLC
Priority to US13/080,351 priority patent/US8192512B2/en
Priority to US13/087,117 priority patent/US8157874B2/en
Priority to US13/087,115 priority patent/US20110209397A1/en
Priority to US13/087,120 priority patent/US8157875B2/en
Priority to US13/087,108 priority patent/US8906119B2/en
Priority to US13/087,126 priority patent/US8192513B2/en
Priority to US13/087,111 priority patent/US8382863B2/en
Assigned to RE COMMUNITY HOLDINGS II, INC. reassignment RE COMMUNITY HOLDINGS II, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FCR, LLC
Assigned to FCR, LLC reassignment FCR, LLC RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: ARES CAPITAL CORPORATION
Assigned to RE COMMUNITY ENERGRY, LLC reassignment RE COMMUNITY ENERGRY, LLC TRANSFER AGREEMENT Assignors: RE COMMUNITY HOLDINGS II, INC.
Assigned to RE COMMUNITY ENERGY, LLC reassignment RE COMMUNITY ENERGY, LLC CORRECTIVE ASSIGNMENT TO CORRECT THE ASSIGNEE FROM --RE COMMUNITY ENERGY, LLC" PREVIOUSLY RECORDED ON REEL 027747 FRAME 0451. ASSIGNOR(S) HEREBY CONFIRMS THE TRANSFER AGREEMENT. Assignors: RE COMMUNITY HOLDINGS II, INC.
Priority to US13/488,074 priority patent/US8523962B2/en
Priority to US13/708,532 priority patent/US8852302B2/en
Assigned to MPH ENERGY LLC reassignment MPH ENERGY LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: RE COMMUNITY ENERGY, LLC
Assigned to KEENELAND CAPITAL, LLC reassignment KEENELAND CAPITAL, LLC SECURITY INTEREST Assignors: ACCORDANT ENERGY, LLC
Assigned to KEENELAND CAPITAL, LLC reassignment KEENELAND CAPITAL, LLC CORRECTIVE ASSIGNMENT TO CORRECT THE PATENT NO. LISTED AS 8,745,599 TO 8,746,599 PREVIOUSLY RECORDED ON REEL 033245 FRAME 0964. ASSIGNOR(S) HEREBY CONFIRMS THE SECURITY AGREEMENT. Assignors: ACCORDANT ENERGY, LLC
Priority to US14/478,129 priority patent/US9062268B2/en
Assigned to SGP LAND, LLC reassignment SGP LAND, LLC SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ACCORDANT ENERGY, LLC
Priority to US14/555,063 priority patent/US9688931B2/en
Assigned to ACCORDANT ENERGY, LLC reassignment ACCORDANT ENERGY, LLC RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: SGP LAND, LLC
Assigned to ACCORDANT ENERGY, LLC reassignment ACCORDANT ENERGY, LLC RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: KEENELAND CAPITAL, LLC
Priority to US14/715,384 priority patent/US9523051B2/en
Assigned to ACCORDANT ENERGY, LLC reassignment ACCORDANT ENERGY, LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: MPH ENERGY LLC
Priority to US15/282,589 priority patent/US10329501B2/en
Priority to US15/333,987 priority patent/US10611974B2/en
Assigned to REPOWER IP, LLC reassignment REPOWER IP, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ACCORDANT ENERGY, LLC
Abandoned legal-status Critical Current

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    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/46—Gasification of granular or pulverulent flues in suspension
    • C10J3/463—Gasification of granular or pulverulent flues in suspension in stationary fluidised beds
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    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
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    • C10L5/00—Solid fuels
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    • C10L5/44—Solid fuels essentially based on materials of non-mineral origin on vegetable substances
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    • C10L2290/30—Pressing, compressing or compacting
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    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/16—Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
    • Y02E20/18—Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/10—Biofuels, e.g. bio-diesel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/141—Feedstock
    • Y02P20/145—Feedstock the feedstock being materials of biological origin

Definitions

  • the present invention relates to alternative fuels.
  • the invention relates to engineering engineered fuel feed stock suited for specific applications including as a fossil fuel substitute for combustion, as well as feed stock for gasification to produce high quality synthesis gas.
  • Feed stock can be engineered to control air emission profiles upon combustion or gasification (such as dioxins, sulfur emitted, as well as others pollutants) as well as to avoid slagging.
  • the feed stock described herein comprises at least one component of processed municipal solid waste, and optionally other components.
  • Sources of fossil fuels useful for heating, transportation, and the production of chemicals as well as petrochemicals are becoming increasingly more scarce and costly.
  • Industries such as those producing energy and petrochemicals are actively searching for cost effective engineered fuel feed stock alternatives for use in generating those products and many others.
  • transportation costs for moving engineered fuel feed stocks for production of energy and petrochemicals is rapidly escalating.
  • Gasification also takes place in a reactor, although in the absence of air, or in the presence of substoichiometric amounts of oxygen.
  • the thermochemical reactions that take place in the absence of oxygen or under substoichiometric amounts of oxygen do not result in the formation of nitrogen oxides or sulfur oxides. Therefore, gasification can eliminate much of the pollutants formed during the firing of fuel.
  • Gasification generates a gaseous, fuel rich product known as synthesis gas (syngas).
  • synthesis gas gas
  • two processes take place that convert the fuel source into a useable fuel gas.
  • pyrolysis releases the volatile components of the fuel at temperatures below 600° C. (1112° F.), a process known as devolatization.
  • the pyrolysis also produces char that consists mainly of carbon or charcoal and ash.
  • the carbon remaining after pyrolysis is either reacted with steam, hydrogen, or pure oxygen. Gasification with pure oxygen results in a high quality mixture of carbon monoxide and hydrogen due to no dilution of nitrogen from air.
  • gasifier types have been developed. They can be grouped into four major classifications: fixed-bed updraft, fixed-bed downdraft, bubbling fluidized-bed and circulating fluidized bed. Differentiation is based on the means of supporting the fuel source in the reactor vessel, the direction of flow of both the fuel and oxidant, and the way heat is supplied to the reactor.
  • the advantages and disadvantages of these gasifier designs have been well documented in literature, for example, Rezaiyan, J. and Nicholas P. Cheremisinoff, Gasification Technology A Primer for Engineers and Engineers . Boca Raton: CRC Press, 2005, the contents of which are hereby incorporated by reference.
  • the updraft gasifier also known as counterflow gasification, is the oldest and simplest form of gasifier; it is still used for coal gasification.
  • the fuel is introduced at the top of the reactor, and a grate at the bottom of the reactor supports the reacting bed.
  • the oxidant in the form of air or oxygen and/or steam are introduced below the grate and flow up through the bed of fuel and char. Complete combustion of char takes place at the bottom of the bed, liberating CO 2 and H 2 O.
  • These hot gases ( ⁇ 1000° C.) pass through the bed above, where they are reduced to H 2 and CO and cooled to about 750° C.
  • updraft gasification is a simple, low cost process that is able to handle fuel with a high moisture and high inorganic content.
  • the primary disadvantage of updraft gasification is that the synthesis gas contains 10-20% tar by weight, requiring extensive syngas cleanup before engine, turbine or synthesis applications.
  • Downdraft gasification also known as concurrent-flow gasification, has the same mechanical configuration as the updraft gasifier except that the oxidant and product gases flow down the reactor, in the same direction as the fuel, and can combust up to 99.9% of the tars formed.
  • Low moisture fuel ( ⁇ 20%) and air or oxygen are ignited in the reaction zone at the top of the reactor, generating pyrolysis gas/vapor, which burns intensely leaving 5 to 15% char and hot combustion gas.
  • These gases flow downward and react with the char at 800 to 1200° C., generating more CO and H 2 while being cooled to below 800° C.
  • unconverted char and ash pass through the bottom of the grate and are sent to disposal.
  • downdraft gasification The advantages of downdraft gasification are that up to 99.9% of the tar formed is consumed, requiring minimal or no tar cleanup. Minerals remain with the char/ash, reducing the need for a cyclone.
  • the disadvantages of downdraft gasification are that it requires feed drying to a low moisture content ( ⁇ 20%). The syngas exiting the reactor is at high temperature, requiring a secondary heat recovery system; and 4-7% of the carbon remains unconverted.
  • the bubbling fluidized bed consists of fine, inert particles of sand or alumina, which have been selected for size, density, and thermal characteristics.
  • gas oxygen, air or steam
  • a point is reached when the frictional force between the particles and the gas counterbalances the weight of the solids.
  • gas velocity minimum fluidization
  • the solid particles become suspended, and bubbling and channeling of gas through the media may occur, such that the particles remain in the reactor and appear to be in a “boiling state”.
  • the minimum fluidization velocity is not equal to the minimum bubbling velocity and channeling velocity. For coarse particles, the minimum bubbling velocity and channeling velocity are close or almost equal, but the channeling velocity may be quite different, due to the gas distribution problem.
  • the fluidized particles tend to break up the fuel fed to the bed and ensure good heat transfer throughout the reactor.
  • the advantages of bubbling fluidized-bed gasification are that it yields a uniform product gas and exhibits a nearly uniform temperature distribution throughout the reactor. It is also able to accept a wide range of fuel particle sizes, including fines; provides high rates of heat transfer between inert material, fuel and gas.
  • the circulating fluidized bed gasifiers operate at gas velocities higher than the so-called transport velocity or onset velocity of circulating fluidization at which the entrainment of the bed particles dramatically increases so that continuous feeding or recycling back the entrained particles to the bed is required to maintain a stable gas-solid system in the bed.
  • the circulating fluidized-bed gasification is suitable for rapid reactions offering high heat transport rates due to high heat capacity of the bed material. High conversion rates are possible with low tar and unconverted carbon.
  • these gasifiers use a homogeneous source of fuel.
  • a constant unchanging fuel source allows the gasifier to be calibrated to consistently form the desired product.
  • Each type of gasifier will operate satisfactorily with respect to stability, gas quality, efficiency and pressure losses only within certain ranges of the fuel properties.
  • Some of the properties of fuel to consider are energy content, moisture content, volatile matter, ash content and ash chemical composition, reactivity, size and size distribution, bulk density, and charring properties.
  • Waste such as municipal solid waste (MSW)
  • MSW Municipal solid waste
  • the drawbacks accompanying combustion have been described above, and include the production of pollutants such as nitrogen oxides, sulfur oxide, particulates and products of chlorine that damage the environment.
  • GHGs pollutants and greenhouse gases
  • fuels such as carbon dioxide, methane, nitrous oxide, water vapor, carbon monoxide, nitrogen oxide, nitrogen dioxide, and ozone
  • GHGs in the atmosphere result in the trapping of absorbed heat and warming of the earth's surface.
  • GHG emissions come mostly from energy use driven largely by economic growth, fuel used for electricity generation, and weather patterns affecting heating and cooling needs.
  • Waste landfills are also significant sources of GHG emissions, mostly because of methane released during decomposition of waste, such as, for example, MSW. Compared with carbon dioxide, methane is twenty-times stronger than carbon dioxide as a GHG, and landfills are responsible for about 4% of the anthropogenic emissions. Considerable reductions in methane emissions can be achieved by combustion of waste and by collecting methane from landfills. The methane collected from the landfill can either be used directly in energy production or flared off, i.e., eliminated through combustion without energy production ( Combustion Of Waste May Reduce Greenhouse Gas Emissions , ScienceDaily, Dec. 8, 2007).
  • CO 2 carbon dioxide
  • the carbon footprint can be seen as the total amount of carbon dioxide and other GHGs emitted over the full life cycle of a product or service.
  • a carbon footprint is usually expressed as a CO 2 equivalent (usually in kilograms or tons), which accounts for the same global warming effects of different GHGs.
  • Carbon footprints can be calculated using a Life Cycle Assessment method, or can be restricted to the immediately attributable emissions from energy use of fossil fuels.
  • Carbon footprint is the total amount of CO 2 attributable to the actions of an individual (mainly through their energy use) over a period of one year. This definition underlies the personal carbon calculators. The term owes its origins to the idea that a footprint is what has been left behind as a result of the individual's activities. Carbon footprints can either consider only direct emissions (typically from energy used in the home and in transport, including travel by cars, airplanes, rail and other public transport), or can also include indirect emissions which include CO 2 emissions as a result of goods and services consumed, along with the concomitant waste produced.
  • the carbon footprint can be efficiently and effectively reduced by applying the following steps: (i) life cycle assessment to accurately determine the current carbon footprint; (ii) identification of hot-spots in terms of energy consumption and associated CO 2 -emissions; (iii) optimization of energy efficiency and, thus, reduction of CO 2 -emissions and reduction of other GHG emissions contributed from production processes; and (iv) identification of solutions to neutralize the CO 2 emissions that cannot be eliminated by energy saving measures.
  • the last step includes carbon offsetting, and investment in projects that aim at the reducing CO 2 emissions.
  • carbon offsets are another way to reduce a carbon footprint.
  • One carbon offset represents the reduction of one ton of CO 2 -eq.
  • Companies that sell carbon offsets invest in projects such as renewable energy research, agricultural and landfill gas capture, and tree-planting.
  • Emissions trading schemes provide a financial incentive for organizations and corporations to reduce their carbon footprint. Such schemes exist under cap-and-trade systems, where the total carbon emissions for a particular country, region, or sector are capped at a certain value, and organizations are issued permits to emit a fraction of the total emissions. Organizations that emit less carbon than their emission target can then sell their “excess” carbon emissions.
  • the disposed materials represent what is left over after a long series of steps including: (i) extraction and processing of raw materials; (ii) manufacture of products; (iii) transportation of materials and products to markets; (iv) use by consumers; and (v) waste management.
  • GHG greenhouse gas
  • Waste management affects GHGs by affecting energy consumption (specifically, combustion of fossil fuels) associated with making, transporting, using, and disposing the product or material that becomes a waste and emissions from the waste in landfills where the waste is disposed.
  • Incineration typically reduces the volume of the MSW by about 90% with the remaining 10% of the volume of the original MSW still needing to be landfilled. This incineration process produces large quantities of the GHG CO 2 . Typically, the amount of energy produced per equivalents CO 2 expelled during incineration are very low, thus making incineration of MSW for energy production one of the worst offenders in producing GHG released into the atmosphere. Therefore, if GHGs are to be avoided, new solutions for the disposal of wastes, such as MSW, other than landfilling and incineration, are needed.
  • Each material disposed of as waste has a different GHG impact depending on how it is made and disposed.
  • the most important GHGs for waste management options are carbon dioxide, methane, nitrous oxide, and perfluorocarbons.
  • carbon dioxide CO 2
  • CO 2 carbon dioxide
  • Most carbon dioxide emissions result from energy use, particularly fossil fuel combustion.
  • Carbon dioxide is the reference gas for measurement of the heat-trapping potential (also known as global warming potential or GWP).
  • GWP heat-trapping potential
  • Methane has a GWP of 21, meaning that one kg of methane has the same heat-trapping potential as 21 kg of CO 2 .
  • Nitrous oxide has a GWP of 310.
  • Perfluorocarbons are the most potent GHGs with GWPs of 6,500 for CF 4 and 9,200 for C 2 F 6 . Emissions of carbon dioxide, methane, nitrous oxide, and perfluorocarbons are usually expressed in “carbon equivalents.” Because CO 2 is 12/44 carbon by weight, one metric ton of CO 2 is equal to 12/44 or 0.27 metric tons of carbon equivalent (MTCE). The MTCE value for one metric ton of each of the other gases is determined by multiplying its GWP by a factor of 12/44 (The Intergovernmental Panel on climate Change (IPCC), climate Change 1995: The Science of climate Change, 1996, p. 121). Methane (CH 4 ), a more potent GHG, is produced when organic waste decomposes in an oxygen free (anaerobic) environment, such as a landfill. Methane from landfills is the largest source of methane in the US.
  • the greater GHG emission reductions are usually obtained when recycled waste materials are processed and used to replace fossil fuels. If the replaced material is biogenic (material derived from living organisms), it is not always possible to obtain reductions of emissions. Even other factors, such as the treatment of the waste material and the fate of the products after the use, affect the emissions balance. For example, the recycling of oil-absorbing sheets made of recycled textiles lead to emission reductions compared with the use of virgin plastic. In another example, the use of recycled plastic as raw material for construction material was found to be better than the use of impregnated wood. This is because the combustion of plastic causes more emissions than impregnated wood for reducing emissions. If the replaced material had been fossil fuel-based, or concrete, or steel, the result would probably have been more favorable to the recycling of plastic.
  • RGGI Regional Greenhouse Gas Initiative
  • RGGI is a market-based program designed to reduce global warming pollution from electric power plants in the Northeast.
  • Other such initiatives are being considered in different sections of the U.S. and on the federal level.
  • RGGI is a government mandated GHG trading system in the Northeastern U.S. This program will require, for example, that coal-fired power plants aggressively reduce their GHG emissions by on average 2.5% per year.
  • One way to do this is by changing the fuel source used or scrubbing the emissions to remove the pollutants.
  • An alternative is to purchase carbon credits generated by others which can offset their emissions into the atmosphere.
  • sulfur emissions as well as chlorine emissions.
  • Fuels and waste containing significant amounts of sulfur or chlorine should be avoided for combustion and gasification reactions. Significant amounts are defined as an amount that when added to a final fuel feed stock causes the final feed stock to have more than 2% sulfur or more than 1% of chlorine. Materials such as coal, used tires, carpet, and rubber, when combusted, release unacceptable amounts of harmful sulfur- and chlorine-based gases.
  • EF engineered fuel feed stock
  • the engineered fuel feed stock is useful for many purposes including, but not limited to, production of synthesis gas.
  • Synthesis gas is useful for a variety of purposes including for production of liquid fuels by Fischer-Tropsch technology.
  • the present disclosure describes an engineered fuel feed stock comprising at least one component derived from a processed MSW waste stream, the feed stock possessing a range of chemical molecular characteristics which make it useful for a variety of combustion and gasification purposes. Purposes such as generating energy when used as a substitute for coal or as a supplement to coal is described, as well as a source feed stock for use in gasification and production of synthesis gas.
  • the feed stock can be in the form of loose material, densified cubes, briquettes, pellets, or other suitable shapes and forms.
  • a process of producing engineered fuel feed stock which comprises the process in which a plurality of waste streams, including solid and liquid wastes, are processed and, where necessary, separated in a materials recovery center so as to inventory the components which comprise the waste streams.
  • the materials comprising the waste stream in the materials recovery facility are inventoried for chemical molecular characteristics, without separation, and this inventoried material can be stored for subsequent use when producing a desired engineered fuel feed stock having a particular chemical molecular profile.
  • the materials comprising the waste stream entering the materials recovery facility are separated according to their chemical molecular characteristics and inventoried separately for use in producing an engineered fuel feed stock.
  • These materials comprising the waste stream entering the materials recovery facility, when undergoing separation, can be positively or negatively selected for, based on, for example, BTU fuel content, carbon content, hydrogen content, ash content, chlorine content, or any other suitable characteristics, for gasification or combustion.
  • Methods for making the engineered fuel feed stock described herein are also described.
  • HHV fuels can be designed, for example, to have the highest possible heat content with a tolerable ash content in order to prevent slagging. These fuels have comparable energy density (BTU/lb) to coal, but without the problems of slagging, fusion and sulfur pollution, and can serve as a substitute for coal or a supplement to coal. Also, engineered fuel feed stocks can be designed, for example, to produce high quality syngas by optimizing the content of C, H, and O in the feed stock prior to gasification.
  • engineered fuel feed stocks produce high quality syngas in terms of HHV if the syngas is to be used for power generation applications or H 2 /CO ratios, amounts of CO and H 2 present in the product syngas in the event that the syngas is to be used in chemical synthetic applications.
  • engineered fuel feed stocks can be engineered so as to minimize harmful emissions, for example, engineered feed stocks comprising less than 2% sulfur content.
  • waste stream components including recyclable materials and recycling residue, can be used to produce the desired engineered fuel feed stock. Although at any given time during the life cycle of the waste entering the materials recovery facility, it may be determined that the highest and best use for some or all of the components of the waste streams is for them to be recycled.
  • the present invention provides an engineered fuel feed stock, comprising a component derived from a processed MSW waste stream, the feed stock having a carbon content of between about 30% and about 80%, a hydrogen content of between about 3% and about 10%, an ash content of less than about 10%, a sulfur content of less than 2%, and a chlorine content of less than about 1%.
  • the feed stock has a HHV of between about 3,000 BTU/lb and about 15,000 BTU/lb.
  • the feed stock has a volatile matter content of about 40% to about 80%.
  • the feed stock has a moisture content of less than about 30%.
  • the feed stock has a moisture content of between about 10% and about 30%.
  • the feed stock has a moisture content of between about 10% and about 20%. In still further embodiments, the feed stock has a moisture content of about 1% and about 10%.
  • the engineered fuel feed stock contains substantially no glass, metal, grit and noncombustibles (other than those necessary to cause the engineered fuel feed stock to be inert).
  • the feed stock has a carbon content of between about 40% and about 70%. In some embodiments, the feed stock has a carbon content of between about 50% and about 60%. In some embodiments, the feed stock has a carbon content of between about 30% and about 40%. In some embodiments, the feed stock has a carbon content of between about 40% and about 50%. In some embodiments, the feed stock has a carbon content of between about 60% and about 70%. In some embodiments, the feed stock has a carbon content of between about 70% and about 80%. In some embodiments, the feed stock has a carbon content of about 35%. In some embodiments, the feed stock has a carbon content of about 45%. In some embodiments, the feed stock has a carbon content of about 55%. In some embodiments, the feed stock has a carbon content of about 65%. In some embodiments, the feed stock has a carbon content of about 75%.
  • the feed stock has a hydrogen content of between about 4% and about 9%. In some embodiments, the feed stock has a hydrogen content of between about 5% and about 8%. In some embodiments, the feed stock has a hydrogen content of between about 6% and about 7%.
  • the feed stock has a moisture content of between about 12% and about 28%. In some embodiments, the feed stock has a moisture content of between about 14% and about 24%. In some embodiments, the feed stock has a moisture content of between about 16% and about 22%. In some embodiments, the feed stock has a moisture content of between about 18% and about 20%.
  • the feed stock has an ash content of less than about 10%. In some embodiments, the feed stock has an ash content of less than about 9%. In some embodiments, the feed stock has an ash content of less than about 8%. In some embodiments, the feed stock has an ash content of less than about 7%. In some embodiments, the feed stock has an ash content of less than about 6%. In some embodiments, the feed stock has an ash content of less than about 5%. In some embodiments, the feed stock has an ash content of less than about 4%. In some embodiments, the feed stock has an ash content of less than about 3%.
  • the feed stock has a HHV of between about 3,000 BTU/lb and about 15,000 BTU/lb. In some embodiments, the feed stock has a HHV of between about 4,000 BTU/lb and about 14,000 BTU/lb. In some embodiments, the feed stock has a HHV of between about 5,000 BTU/lb and about 13,000 BTU/lb. In some embodiments, the feed stock has a HHV of between about 6,000 BTU/lb and about 12,000 BTU/lb. In some embodiments, the feed stock has a HHV of between about 7,000 BTU/lb and about 11,000 BTU/lb. In some embodiments, the feed stock has a HHV of between about 8,000 BTU/lb and about 10,000 BTU/lb. In some embodiments, the feed stock has a HHV of about 9,000 BTU/lb.
  • the feed stock has a volatile matter content of about 50% to about 70%. In some embodiments, the feed stock has a volatile matter content of about 60%.
  • the engineered fuel feed stock has a ratio of H/C from about 0.025 to about 0.20. In some embodiments, the engineered fuel feed stock has a ratio of H/C from about 0.05 to about 0.18. In some embodiments, the engineered fuel feed stock has a ratio of H/C from about 0.07 to about 0.16. In some embodiments, the engineered fuel feed stock has a ratio of H/C from about 0.09 to about 0.14. In some embodiments, the engineered fuel feed stock has a ratio of H/C from about 0.10 to about 0.13. In some embodiments, the engineered fuel feed stock has a ratio of H/C from about 0.11 to about 0.12. In some embodiments, the engineered fuel feed stock has a ratio of H/C of about 0.13. In some embodiments, the engineered fuel feed stock has a ratio of H/C of about 0.08.
  • the engineered fuel feed stock has an O/C ratio from about 0.01 to about 1.0. In some embodiments, the engineered fuel feed stock has an O/C ratio from about 0.1 to about 0.8. In some embodiments, the engineered fuel feed stock has an O/C ratio from about 0.2 to about 0.7. In some embodiments, the engineered fuel feed stock has an O/C ratio from about 0.3 to about 0.6. In some embodiments, the engineered fuel feed stock has an O/C ratio from about 0.4 to about 0.5. In some embodiments, the engineered fuel feed stock has an O/C ratio of about 0.9. In some embodiments, the engineered fuel feed stock has an O/C ratio of about 0.01.
  • the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas comprising H 2 in an amount from about 6 vol. % to about 30 vol. %; CO in an amount from about 14 vol. % to about 25 vol. %, CH 4 in an amount from about 0.3 vol. % to about 6.5 vol. %, CO 2 in an amount from about 6.5 vol. % to about 13.5% vol. %; and N 2 in an amount from about 44 vol. % to about 68 vol. %.
  • the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio from about 0.3 to about 2.0. In some embodiments, the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio from about 0.5 to about 1.5. In some embodiments, the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio from about 0.8 to about 1.2. In some embodiments, the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio of about 1.0.
  • the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having H 2 in an amount of about 20 vol. %; N 2 in an amount of about 46 vol. %; CO in an amount of about 25 vol. %; CH 4 in an amount of about 1 vol. %; CO 2 in an amount of about 8 vol. %; and a BTU/scf of about 160.
  • the engineered fuel feed stock when combusted produces less harmful emissions as compared to the combustion of coal. In some embodiments, the engineered fuel feed stock when combusted produces less sulfur emission as compared to the combustion of coal. In some embodiments, the engineered fuel feed stock when combusted produces less HCl emission as compared to the combustion of coal. In some embodiments, the engineered fuel feed stock when combusted produces less heavy metal emissions such as for example mercury as compared to the combustion of coal. In some embodiments, the engineered fuel feed stock is designed to avoid the emission of particulate matters, NOx, CO, CO2, volatile organic compounds (VOCs), and halogen gases.
  • VOCs volatile organic compounds
  • the engineered fuel feed stock is designed to have reduced emission profiles with respect to GHGs as compared to the GHGs emitted from combusted coal. In some embodiments, the engineered fuel feed stock is designed to have reduced emission profiles with respect to GHGs emitted from the combustion of biomasses such as for example, wood, switch grass and the like.
  • the feed stock is in a loose, non-densified form.
  • the engineered fuel feed stock is in a densified form.
  • the densified form is a cube. In some embodiments, the densified form is rectangular. In other embodiments, the densified form is cylindrical. In some embodiments, the densified form is spherical. In some embodiments, the densified form is a briquette. In other embodiments, the densified form is a pellet.
  • the densified fuel is sliced into sheets of different thickness. In some embodiments, the thickness is between about 3/16 inches to about 3 ⁇ 4 inches.
  • the engineered fuel feed stock further comprises at least one waste material in addition to the component derived from a processed MSW waste stream that enhances the gasification of the fuel pellet. In some embodiments, the engineered fuel feed stock further comprises at least one waste material in addition to the component derived from a processed MSW waste stream that enhances the gasification of the fuel pellet.
  • the enhancement is a reduction in ash. In other embodiments, the enhancement aids in the control of temperature. In still other embodiments, the enhancement is a reduction in the amount of sulfur emissions produced. In still other embodiments, the enhancement is the reduction of chlorine emissions produced. In still other embodiments, the enhancement is the reduction of heavy metal emissions produced.
  • the engineered fuel feed stock is rendered inert.
  • the engineered fuel feed stock comprises at least one additive that renders the feed stock inert.
  • an additive can be blended into the processed MSW waste stream that can render the resulting pellet inert.
  • Some types of wet MSW contain a relatively high number of viable bacterial cells that can generate heat and hydrogen gas during fermentation under wet conditions, for example during prolonged storage or transportation.
  • an additive such as calcium hydroxide can be added to the MSW for the prevention of the rotting of food wastes and for the acceleration of drying of solid wastes.
  • the additive that renders the feed stock inert is CaO.
  • additives are calcium sulfoaluminate and other sulfate compounds, as long as they do not interfere with the downstream processes in which the pellet are used.
  • the MSW can be rendered biologically inert through any known method for inactivating biological material.
  • X-rays can be used to deactivate the MSW before processing, or after processing. Drying can be used to remove the water necessary for organisms such as microbes to grow. Treatment of the MSW with high heat and optionally also high heat under pressure (autoclaving) will also render the MSW biologically inert.
  • autoclaving high heat under pressure
  • the excess heat generated by the reciprocating engines or turbines fueled by the engineered pellets can be redirected through the system and used to render the MSW inert.
  • the feed stock is rendered inert through means such as microwave radiation.
  • the densified form of the engineered fuel feed stock has a diameter of between about 0.25 inches to about 1.5 inches. In some embodiments, the densified form of the engineered fuel feed stock has a length of between about 0.5 inches to about 6 inches. In some embodiments, the densified form of the engineered fuel feed stock has a surface to volume ratio of between about 20:1 to about 3:1. In some embodiments, the densified form of the engineered fuel feed stock has a bulk density of about 10 lb/ft 3 to about 75 lb/ft 3 . In some embodiments, the densified form of the engineered fuel feed stock has a porosity of between about 0.2 and about 0.6.
  • the densified form of the engineered fuel feed stock has an aspect ratio of between about 1 to about 10. In some embodiments, the densified form of the engineered fuel feed stock has a thermal conductivity of between about 0.023 BTU/(ft ⁇ hr ⁇ ° F.) and about 0.578 BTU/(ft ⁇ hr ⁇ ° F.). In some embodiments, the densified form of the engineered fuel feed stock has a specific heat capacity of between about 4.78 ⁇ 10 ⁇ 5 BTU/(lb ⁇ ° F.) to 4.78 ⁇ 10 ⁇ 4 BTU/(lb ⁇ ° F.). In some embodiments, the densified form of the engineered fuel feed stock has a thermal diffusivity of between about 1.08 ⁇ 10 ⁇ 5 ft 2 /s to 2.16 ⁇ 10 ⁇ 5 ft 2 /s.
  • the at least one waste material that enhances the gasification of the fuel pellet is selected from fats, oils and grease (FOG). In some embodiments, the at least one waste material that enhances the gasification of the fuel pellet is sludge.
  • the densified form of the engineered fuel feed stock is substantially encapsulated within the FOG component. In some of the embodiments, the encapsulation layer is scored. In still further embodiments, the scoring of the encapsulated densified form of the engineered fuel feed stock causes the fuel to devolatize more efficiently during gasification process than the fuel without the scoring.
  • an engineered fuel feed stock having a carbon content of between about 30% and about 80%, a hydrogen content of between about 3% and about 10%, a moisture content of between about 10% and about 30%, an ash content of less than about 10%, a sulfur content of less than 2%, and a chlorine content of less than about 1% is described that is produced by a process comprising:
  • an engineered fuel feed stock is described that is produced by a process comprising:
  • the size of the mixture of step e) is reduced to help homogenize the engineered fuel feed stock.
  • a size and shape is determined for a densified form of the mixture of step e) or the size-reduced mixture of step e).
  • the mixture of step e) is densified.
  • the size-reduced mixture of step e) is densified.
  • the engineered fuel feed stock has a HHV of between about 3,000 BTU/lb and about 15,000 BTU/lb.
  • the feed stock has a volatile matter content of about 40% to about 80%.
  • the size of the mixture of step b) or step d) is reduced to help homogenize the engineered fuel feed stock.
  • a size and shape is determined for a densified form of the mixture of step b) or the size-reduced mixtures of steps b) or d).
  • the mixture of step b) is densified.
  • the size-reduced mixture of step e) is densified to a density of about 10 lbs/ft 3 to about 75 lbs/ft 3 .
  • the engineered fuel feed stock has a HHV of between about 3,000 BTU/lb and about 15,000 BTU/lb.
  • the feed stock has a volatile matter content of about 40% to about 80%.
  • a method of producing a engineered fuel feed stock comprising:
  • the engineered fuel feed stock is densified to form a briquette. In other embodiments, the engineered fuel feed stock is densified to form of a pellet.
  • FIG. 1 shows commonly available feed stock materials, such as, for example, coal, FOGs, wood, sludge, black liquor, rubber and MSW streams, positioned in terms of their hydrogen content to carbon content ratio (H/C) (lb/lb) and oxygen content to carbon content (O/C) (lb/lb) ratio.
  • H/C hydrogen content to carbon content ratio
  • O/C oxygen content to carbon content
  • FIG. 2 shows some novel engineered fuel feed stocks produced by selecting known engineered fuel feed stocks within the dotted line and directly mixing the selected feed stocks, and in some cases increasing or decreasing the moisture content.
  • FIG. 3 shows a schematic with direct combustion of feed stock.
  • FIG. 4 shows a schematic with direct combustion of wet feed stock, without reducing its moisture content.
  • FIG. 6 shows the predicted variation of syngas compositions with feed stocks of different moisture contents for a typical wood feed stock at 800° C.
  • FIG. 7 shows the predicted effect of fuel moisture content on carbon conversion, cold gas efficiency and CO+H 2 production rate for a typical coal feed stock at 850° C.
  • FIG. 8 shows the predicted effect of fuel moisture content on carbon conversion, cold gas efficiency and CO+H 2 production rate for pure carbon at 1000° C.
  • FIG. 11 provides a graphical representation of eq. 2 showing the weight fraction of various products as a function of the chain growth parameter ⁇ .
  • FIG. 12 provides predicted C/H and C/O ratios needed in feed stock for the production of syngas with varying H 2 /CO ratios.
  • FIG. 13 provides a graph showing cylindrical diameter plotted against the sphericity, the cylindrical length and specific area.
  • FIG. 14 provides a graph of feed stock containing different carbon and hydrogen contents and their predicted production of CO and H 2 during air gasification.
  • FIG. 15 provides a graph of feed stock containing different carbon and hydrogen contents and their predicted production of CO and H 2 during air/steam gasification.
  • Novel engineered fuel feed stocks comprise at least one waste stream component derived from MSW, such as recycling residue which is the non-recoverable portion of recyclable materials, and which are engineered to have predetermined chemical molecular characteristics.
  • These feed stocks can possess the chemical molecular characteristics of biomass fuels such as, for example, wood and switch grass, and, can also have the positive characteristics of high BTU containing fuels such as, for example, coal, without the negative attributes of coal such as deleterious sulfur emissions.
  • novel engineered fuel feed stocks that comprise chemical molecular characteristics not observed in natural fuels such as, for example, biomass, coal, or petroleum fuels.
  • novel fuels contain, for example, unique ratios of carbon, hydrogen, sulfur, and ash, such that, when compared to known fuels, they provide a different combustion or gasification profile. Since these novel feed stocks have different combustion or gasification profiles, they provide novel fuels for many different types of combustors and gasifiers which, while functioning adequately due to the uniformity of the natural fuel, do not function optimally due to the less than optimized chemical molecular characteristics of natural fuels.
  • Engineered fuel feed stocks such as those useful for the production of thermal energy, power, biofuels, petroleum, and chemicals can be engineered and synthesized according to the methods disclosed herein.
  • Highly variable and heterogeneous streams of waste can now be processed in a controlled manner and a plurality of the resulting components therefrom recombined into an engineered fuel feed stock which behaves as a constant and homogeneous fuel for use in subsequent conversion processes. Included among these processes are pyrolysis, gasification and combustion.
  • the engineered fuel feed stock can be used alone to produce thermal energy, power, biofuels, or chemicals, or it can be used as a supplement along with other fuels for these and other purposes.
  • Methods and processes for engineering homogeneous engineered fuel feed stock from naturally heterogeneous and variable waste streams which possess a variety of optimal physical and chemical characteristics for different conversion processes are described, as well as different feed stocks themselves.
  • Chemical properties can be engineered into the resulting engineered fuel feed stocks based on the type of conversion process for which the fuel will be used.
  • Feed stocks can be engineered for use as fuels including synthetic fuels, high BTU containing fuels (HHV fuels) and fuels useful to produce high quality syngas, among other types of useful fuels.
  • engineered fuels can be designed to have the same or similar chemical molecular compositions as known solid fuels, such as, for example, wood, coal, coke, etc. and function as a substitute for, or supplemental to, fuel for combustion and gasification.
  • Other fuels can be designed and synthesized which have chemical molecular characteristics that are different than naturally occurring fuel.
  • High BTU Fuels can be designed to have the highest possible heat content with a tolerable ash content in order to prevent slagging. These fuels have comparable energy density (such as carbon content, hydrogen content) as coal, but without the problems of slagging, fusion and sulfur pollution (ash content, sulfur content, and chlorine content) and can serve as a substitute for coal, or a supplement to coal. Fuels can be designed to produce high quality syngas by optimizing, for example, the content of C, H, O, moisture, and ash in the engineered fuel feed stock. Such fuels produce high quality syngas in terms of, for example, syngas caloric value, H 2 /CO ratios, and amounts of CO, H 2 , CO 2 , and CH 4 .
  • Thermal conversion devices are described in the art which are designed to suit specific fuels found in the nature and in these cases operational problems often occur or modifications are needed to the devices when fuels other than the designed for fuels are co-fired.
  • the present invention provides for an optimal fuel to be engineered that will best suit known thermal conversion devices and no modifications to the device will be needed.
  • the engineered fuel feed stock described herein provides an efficient way to moderate the operating conditions of thermal conversion devices such as for example by lower the operating temperature, by reducing the need for oxygen supply or steam supply, by allowing for the relaxing of emission controls.
  • the methods described herein provide a powerful means for upgrading low-grade fuels such as sludge, yardwastes, food wastes and the like to be transformed into a high quality fuel.
  • Air equivalence ratio means the ratio of the amount of air supplied to the gasifier divided by the amount of air required for complete fuel combustion. Air equivalence ratio, “ER,” can be represented by the following equation:
  • BTU Blood Thermal Unit
  • carbon boundary means the temperature obtained when exactly enough oxygen is added to achieve complete gasification, or carbon conversion. Above this temperature there is no solid carbon present.
  • carbon content means all carbon contained in the fixed carbon (see definition below) as well as in all the volatile matters in the feed stock.
  • carbon conversion means to convert solid carbon in fuel feed stock into carbon-containing gases, such as CO, CO2 and CH4 in most gasification operations
  • commercial waste means solid waste generated by stores, offices, restaurants, warehouses, and other non-manufacturing, non-processing activities. Commercial waste does not include household, process, industrial or special wastes.
  • construction and demolition debris means uncontaminated solid waste resulting from the construction, remodeling, repair and demolition of utilities, structures and roads; and uncontaminated solid waste resulting from land clearing.
  • waste includes, but is not limited to bricks, concrete and other masonry materials, soil, rock, wood (including painted, treated and coated wood and wood products), land clearing debris, wall coverings, plaster, drywall, plumbing fixtures, nonasbestos insulation, roofing shingles and other roof coverings, asphaltic pavement, glass, plastics that are not sealed in a manner that conceals other wastes, empty buckets ten gallons or less in size and having no more than one inch of residue remaining on the bottom, electrical wiring and components containing no hazardous liquids, and pipe and metals that are incidental to any of the above.
  • Solid waste that is not C&D debris includes, but is not limited to asbestos waste, garbage, corrugated container board, electrical fixtures containing hazardous liquids such as fluorescent light ballasts or transformers, fluorescent lights, carpeting, furniture, appliances, tires, drums, containers greater than ten gallons in size, any containers having more than one inch of residue remaining on the bottom and fuel tanks.
  • hazardous liquids such as fluorescent light ballasts or transformers, fluorescent lights, carpeting, furniture, appliances, tires, drums, containers greater than ten gallons in size, any containers having more than one inch of residue remaining on the bottom and fuel tanks.
  • solid waste including what otherwise would be construction and demolition debris
  • any processing technique that renders individual waste components unrecognizable, such as pulverizing or shredding.
  • devolatization means a process that removes the volatile material in a engineered fuel feed stock thus increasing the relative amount of carbon in the engineered fuel feed stock.
  • fixed carbon is the balance of material after moisture, ash, volatile mater determined by proximate analysis.
  • Garbage means putrescible solid waste including animal and vegetable waste resulting from the handling, storage, sale, preparation, cooking or serving of foods. Garbage originates primarily in home kitchens, stores, markets, restaurants and other places where food is stored, prepared or served.
  • gasification means a technology that uses a noncombustion thermal process to convert solid waste to a clean burning fuel for the purpose of generating for example, electricity, liquid fuels, and diesel distillates.
  • Noncombustion means the use of no air or oxygen or substoichiometric amounts of oxygen in the thermal process.
  • hazardous waste means solid waste that exhibits one of the four characteristics of a hazardous waste (reactivity, corrosivity, ignitability, and/or toxicity) or is specifically designated as such by the Environmental Protection Agency (EPA) as specified in 40 CFR part 262 .
  • EPA Environmental Protection Agency
  • Heating Value is defined as the amount of energy released when a fuel is burned completely in a steady-flow process and the products are returned to the state of the reactants.
  • the heating value is dependent on the phase of water in the combustion products. If H 2 O is in liquid form, heating value is called HHV (Higher Heating Value). When H 2 O is in vapor form, heating value is called LHV (Lower Heating Value).
  • HHV higher heating value
  • HHV Fuel 146.58C+568.78H+29.4S ⁇ 6.58A ⁇ 51.53(O+N).
  • C, H, S, A, O and N are carbon content, hydrogen content, sulfur content, ash content, oxygen content and nitrogen content, respectively, all in weight percentage.
  • MSW munal solid waste
  • Municipal solid waste means solid waste generated at residences, commercial or industrial establishments, and institutions, and includes all processable wastes along with all components of construction and demolition debris that are processable, but excluding hazardous waste, automobile scrap and other motor vehicle waste, infectious waste, asbestos waste, contaminated soil and other absorbent media and ash other than ash from household stoves. Used tires are excluded from the definition of MSW.
  • Components of municipal solid waste include without limitation plastics, fibers, paper, yard waste, rubber, leather, wood, and also recycling residue, a residual component containing the non-recoverable portion of recyclable materials remaining after municipal solid waste has been processed with a plurality of components being sorted from the municipal solid waste.
  • nonprocessable waste means waste that does not readily gasify in gasification systems and does not give off any meaningful contribution of carbon or hydrogen into the synthesis gas generated during gasification.
  • Nonprocessable wastes include but are not limited to: batteries, such as dry cell batteries, mercury batteries and vehicle batteries; refrigerators; stoves; freezers; washers; dryers; bedsprings; vehicle frame parts; crankcases; transmissions; engines; lawn mowers; snow blowers; bicycles; file cabinets; air conditioners; hot water heaters; water storage tanks; water softeners; furnaces; oil storage tanks; metal furniture; propane tanks; and yard waste.
  • processed MSW waste stream means that MSW has been processed at, for example, a materials recovery facility, by having been sorted according to types of MSW components.
  • Types of MSW components include, but are not limited to, plastics, fibers, paper, yard waste, rubber, leather, wood, and also recycling residue, a residual component containing the non-recoverable portion of recyclable materials remaining after municipal solid waste has been processed with a plurality of components being sorted from the municipal solid waste.
  • Processed MSW contains substantially no glass, metals, grit, or non-combustibles.
  • Grit includes dirt, dust, granular wastes such as coffee grounds and sand, and as such the processed MSW contains substantially no coffee grounds.
  • Processable waste means wastes that readily gasify in gasification systems and give off meaningful contribution of carbon or hydrogen into the synthesis gas generated during gasification.
  • Processable waste includes, but is not limited to, newspaper, junk mail, corrugated cardboard, office paper, magazines, books, paperboard, other paper, rubber, textiles, and leather from residential, commercial, and institutional sources only, wood, food wastes, and other combustible portions of the MSW stream.
  • pyrolysis means a process using applied heat in an oxygen-deficient or oxygen-free environment for chemical decomposition of solid waste.
  • recycling residue means the residue remaining after a recycling facility has processed its recyclables from incoming waste which no longer contains economic value from a recycling point of view.
  • sludge means any solid, semisolid, or liquid generated from a municipal, commercial, or industrial wastewater treatment plant or process, water supply treatment plant, air pollution control facility or any other such waste having similar characteristics and effects.
  • solid waste means unwanted or discarded solid material with insufficient liquid content to be free flowing, including but not limited to rubbish, garbage, scrap materials, junk, refuse, inert fill material, and landscape refuse, but does not include hazardous waste, biomedical waste, septic tank sludge, or agricultural wastes, but does not include animal manure and absorbent bedding used for soil enrichment or solid or dissolved materials in industrial discharges.
  • a solid waste, or constituent of the waste may have value, be beneficially used, have other use, or be sold or exchanged, does not exclude it from this definition.
  • steam/carbon ratio means the ratio of total moles of steam injected into the gasifier/combustor divided by the total moles of carbon feed stock.
  • the steam/carbon ratio, “S/C,” can be represented by the following equation:
  • thermal efficiency also known as cold gas efficiency
  • thermal efficacy means the ratio of the total HHV contained in the resulting product gas divided by the total HHV that was contained in the fuel input.
  • Thermal efficacy, “Eff,” can be represented by the following equation:
  • volatile materials also known as volatile organic compounds
  • volatile materials means the organic chemical compounds that have high enough vapor pressures under normal conditions to significantly vaporize and enter the atmosphere.
  • volatile materials include aldehydes, ketones, methane, and other light hydrocarbons.
  • novel engineered fuel feed stocks comprising MSW, the feed stocks having any of a number of desired chemical molecular characteristics, including but not limited to carbon content, hydrogen content, oxygen content, nitrogen content, ash content, sulfur content, moisture content, chlorine content, and HHV content.
  • This feed stock is useful for a variety of chemical conversion processes. Also described are processes for producing an engineered fuel feed stock and methods of making same.
  • MSW One abundant source of engineered fuel feed stock is MSW.
  • MSW is solid waste generated at residences, commercial or industrial establishments, and institutions, and includes all processable wastes along with all components of construction and demolition debris that are processable, but excluding hazardous waste, automobile scrap and other motor vehicle waste, infectious waste, asbestos waste, contaminated soil and other absorbent media and ash other than ash from household stoves. It does include garbage, refuse, and other discarded materials that result from residential, commercial, industrial, and community activities.
  • the composition of MSW varies widely depending on time of collection, season of the year of collection, the types of customers from which the MSW is collected on any given day, etc. MSW may contain a very wide variety of waste or discarded material.
  • the waste may include biodegradable waste, non-biodegradable waste, ferrous materials, non-ferrous metals, paper or cardboard in a wide variety of forms, a wide range of plastics (some of which may contain traces of toxic metals used as catalysts, stabilizers or other additives), paints, varnishes and solvents, fabrics, wood products, glass, chemicals including medicines, pesticides and the like, solid waste of various types and a wide range of other materials.
  • the waste includes household waste and industrial waste. Industrial waste contemplated for use herein is low in toxic or hazardous materials. However, MSW is processed in order to remove non-processable components prior to engineering the engineered fuel feed stocks described herein.
  • Processed MSW has been sorted or inventoried according to types of MSW components.
  • Types of MSW components include, but are not limited to, plastics, fibers, paper, yard waste, rubber, leather, wood, and also recycling residue, a residual component containing the non-recoverable portion of recyclable materials remaining after municipal solid waste has been processed with a plurality of components being sorted from the municipal solid waste.
  • Processed MSW contains substantially no glass, metals, grit, or non-combustibles.
  • Grit includes dirt, dust, granular wastes such as coffee grounds and sand, and as such the processed MSW contains substantially no coffee grounds.
  • substantially no as used herein means that no more than 0.01% of the material is present in the MSW components.
  • FOGs Another fuel source for use in an engineered fuel feed stock is FOGs.
  • FOGs are commonly found in such things as meats, sauces, gravy, dressings, deep-fried foods, baked goods, cheeses, butter and the like.
  • Many different businesses generate FOG wastes by processing or serving food, including; eating and drinking establishments, caterers, hospitals, nursing homes, day care centers, schools and grocery stores.
  • FOGs have been a major problem for municipalities. Studies have concluded that FOGs are one of the primary causes of sanitary sewer blockages which result in sanitary sewer system overflows (SSOs) from sewer collection systems. These SSOs have caused numerous problems in some municipalities including overflow out of the sewage lines out of maintenance (manhole) holes and into storm drains.
  • SSOs sanitary sewer system overflows
  • oils and greases useful in the present invention are petroleum waste products.
  • Nonlimiting examples of petroleum waste products include discarded engine oil.
  • biomass waste also known as biogenic waste.
  • Biomass refers to living and recently dead biological material that can be used as fuel or for industrial production. Most commonly, biomass refers to plant matter grown for use as biofuel, but it also includes plant or animal matter used for production of fibers, chemicals or heat. Biomass may also include biodegradable wastes that can be burnt as fuel. It excludes organic material which has been transformed by geological processes into substances such as coal or petroleum.
  • Nonlimiting types of biomass waste include woods, yard wastes, plants, including miscanthus, switchgrass, hemp, corn, poplar, willow, sugarcane and oil palm (palm oil), coconut shells, and shells of nuts.
  • Sludge is a mixture of solid wastes and bacteria removed from the wastewater at various stages of the treatment process. It can be categorized as “primary sludge” and “secondary sludge”.
  • Primary sludge is about 4% solids and 96% water. It consists of the material which settles out of wastewater in the primary sedimentation tanks, before bacterial digestion takes place. Secondary or activated sludge is much more liquid—about 1% solids and 99% water.
  • Secondary sludge consists of bacteria and organic materials on which the bacteria feed. About 30% of the secondary sludge produced is returned to the aeration tanks to assist with the biological process of sewage treatment. The remaining 70% must be disposed of.
  • the sludge contemplated for use in the present invention is municipal sludge a.k.a. biosolids. Municipal sludge does not include papermill or other industrial/agricultural sludge.
  • the key determinants of the caloric or BTU value of a sludge are its dryness expressed as Total Solids on a wet weight basis (or inversely as water content) and its volatile solids content (Total Volatile Solids or TVS expressed on a dry weight basis).
  • sludge There are two distinct types of sludge—1) raw sludge (sludge treated only with primary and secondary aerobic clarifiers) and 2) digested sludge (add anaerobic digestion to number 1).
  • Anaerobic sludge is typically 60% TVS and raw sludge is typically 75-80% TVS.
  • the TS of sludge cake (dewatered sludge) varies depending on the method used by the treatment plant to dewater the sludge, and ranges from 10% to 97+%.
  • One pound of Volatile Solids has about 10,000-12,000 BTU, e.g., it requires 1,200 BTU to drive off 1 lb of water as steam.
  • animal wastes such as manures, animal biomass (meat and bone tissue), poultry litter, fossil fuels such as coal, coal by products, petroleum coke, black liquor, and carbon black.
  • Chemical compositions of fuel are known to affect reactor performance, whether for combustion or gasification, and therefore the production of, and quality of, syngas.
  • Most gasifiers are constructed so as to be able to efficiently burn one type of fuel—a homogeneous fuel, such as wood pellets or coal, for example.
  • a homogeneous fuel such as wood pellets or coal, for example.
  • the natural fuels such as wood or coal are homogeneous and provide the reactor with a constant supply of predictable fuel, these fuels do not allow the reactors to function optimally due to their suboptimal chemical molecular characteristics.
  • syngas which results from the gasification process, can be used to produce, for example, diesel distillates and liquid fuels.
  • Syngas useful in the production of such products should contain at least a certain amount energy expressed usually in BTU/ft 3 in order to be used efficiently in liquid fuel production, while other syngas requirements for this process may also include an appropriate ratio of hydrogen to carbon monoxide (H 2 /CO), as well as syngas purity.
  • Engineered fuel feed stock is described herein which comprises at least one component derived from a processed MSW waste stream and embodies predetermined chemical molecular characteristics that cause the fuel to perform optimally for a particular thermal conversion process.
  • waste components from MSW so as to remove contaminating wastes that do not contribute to the gasification process or create hazardous emissions (such as dioxins, mercury, sulfur and chlorine, etc.), and optionally adding other materials that enhance the gasification or combustion process, material useful for production of engineered fuel feed stock with the appropriate chemical molecular characteristics is achieved.
  • FIG. 1 shows commonly available feed stock materials, such as, for example, coal, FOGs, wood, sludge, black liquor, rubber and MSW streams, positioned in terms of their hydrogen content to carbon content ratio (H/C) (lb/lb) and oxygen content to carbon content (O/C) (lb/lb) ratio.
  • H/C hydrogen content to carbon content ratio
  • O/C oxygen content to carbon content
  • FIG. 1 also plotted the carbon boundary temperature against the O/C ratio, with variations with H/C indicated by a slashed area.
  • the carbon boundary temperature is the temperature obtained when exactly enough oxygen is added to achieve complete carbon conversion. For biomass gasification the typical temperature is about 850° C.
  • the O/C ratio in feed stock should be about 0.55 to 0.6.
  • over-oxidizing or increased oxidation may occur at this temperature, and thus a higher CO 2 in the syngas would be expected. Therefore, it is an advantage of the engineered feed stock that fuel O/C and H/C ratios can be adjusted to allow for optimal gasification operation and performance to be achieved.
  • FIG. 1 it can also be observed that H 2 /CO production will vary according to H/C content, but only slightly with increasing O/C content. Also, FIG. 1 shows that Heating Value and H 2 +CO production rate both increase with increasing H/C ratios and with decreasing O/C ratios.
  • FIG. 2 shows some novel engineered fuel feed stocks produced by selecting known engineered fuel feed stocks within the dotted line and directly mixing the selected feed stocks, and in some cases increasing or decreasing the moisture content. These novel feed stocks populate areas within the solid lined area within the carbon temperature boundary.
  • Engineered fuel feed stock can be designed by selecting types of feed stock characteristics identified within the carbon boundary of the graph based on, for example, H 2 /CO content in the product syngas, H 2 +CO production rate and Heating Value of the syngas, which would indicate the H/C ratio and O/C ratio required for a particular engineered fuel that should be best suited for a particular application.
  • H 2 /CO content in the product syngas H 2 +CO production rate and Heating Value of the syngas
  • H/C ratio and O/C ratio required for a particular engineered fuel that should be best suited for a particular application.
  • gasification for energy production gasification for Fischer-Tropsch fuel production, pyrolysis, and combustion different HHV contents
  • CO+H2 production rates or H 2 /CO ratios may be required.
  • the combustion and gasification processes use fuel containing sufficient energy that upon firing the fuel releases the stored chemical energy.
  • This energy stored in the fuel can be expressed in terms of percent carbon, hydrogen, oxygen, along with the effects of other components such as sulfur, chlorine, nitrogen, and of course moisture in the form of H 2 O.
  • MSW can be characterized by its chemical molecular make up, such as, for example, the amount of carbon, hydrogen, oxygen, and ash present.
  • MSW normally consists of a variety of components that can individually or collectively be characterized themselves for fuel purposes by a variety of parameters including, without limitation, carbon content, hydrogen content, moisture content, ash content, sulfur content, chlorine content, and HHV content.
  • carbon content, hydrogen content, moisture content, ash content, sulfur content, chlorine content, and HHV content Although heterogeneic in nature, the many components of MSW can serve as raw materials for engineering various engineered fuel feed stocks useful for a variety of different thermal conversion processes.
  • Such materials can be engineered to create engineered fuel feed stocks that embody the chemical characteristics of known fuels, for example, wood and coal, while other feed stocks can be engineered to create fuels that are not observed in nature and provide unique combustion and gasification profiles.
  • the carbon and hydrogen content of most biomasses such as wood is given in Table 1. From Table 1 it can be readily observed that the range of carbon in biomass such as wood varies only slightly, as does the hydrogen content.
  • the carbon and hydrogen content When used as a fuel source, for example, in gasification, the carbon and hydrogen content have a significant effect on the chemical characteristics of the syngas.
  • the process of gasification must be varied so that the chemical characteristics of the syngas can be varied.
  • the present invention allows engineered fuel feed stocks to be engineered that not only contain the carbon content of wood or coal, but also amounts of carbon and hydrogen not contained in biomasses such as wood or in fuels such as coal, thereby providing new fuels for gasification and combustion reactions.
  • the present invention provides for engineered fuel feed stocks to be engineered to contain a variety of carbon and hydrogen amounts beyond what is contained in naturally occurring fuels.
  • FIG. 4 shows a schematic with direct combustion of wet feed stock, without reducing its moisture content.
  • the available heat utilization is Q 3 .
  • HYSYS AspenTech, Inc., Burlington Mass.
  • Feed stock with a moisture content of either 30 wt % or 40 wt % was dried at a rate of one tone per hour to a moisture content of 10 wt %, i.e. 445 lbs/hr or 667 lbs/hr of water removed (vaporized by heating to about 250° F. This requires an input of energy of approximately 0.64 mmBTU/hr or 0.873 mmBTU/hr, respectively.
  • the feed stock at a moisture content of 10 wt % is then combusted in a boiler assuming the heating load is adjusted to control the flue gas temperature to a predetermined temperature.
  • this predetermined temperature could be higher (non-condensation, 150° F.) or lower (condensation, 100° F.) than the temperature of water in flue gas.
  • the radiation heat transfer between flue gas and heat transfer surface may also be increased due to increased emissivity.
  • Moisture can effect gasification in a variety of ways. For example, if moisture is removed from the feed stock prior to being gasified, gasification performance may, or may not, be improved, depending upon which parameter of gasification is observed. In terms of energy utilization efficiency, drying may not improve the overall efficiency of gasification, unlike the effect of drying the feed stock upon combustion applications as discussed above.
  • oxidants such as air, pure oxygen or steam can be used.
  • oxygen large scale coal gasification which operates at temperatures of typically 1500° C.
  • the challenge in this case is operating the gasification with a minimum amount of gasifying feed stock required because this reduces the amount of oxygen per unit product gas.
  • This reduction is oxygen translates into a larger savings during the gasification.
  • more steam is then necessary. Since more moisture is necessary, it can either be introduced into the gasification unit or as in the present invention the necessary moisture is present in the feed stock. This increase in moisture in the feed stock, both reduces the amount of oxygen needed during gasification as well as allows more control of the gasification temperature, which increases carbon conversion, and thus improves the overall gasification performance.
  • thermodynamics and kinetics of the gasification reaction are effected by the amount of moisture during the gasification reaction. Two reactions that occur during the gasification reaction are given below:
  • reaction (b) allows every carbon that is gasified via steam yields two molecules of synthesis gas per atom of carbon with steam, which is less extensive in comparison with only one carbon in reaction (a) via oxygen, which is much more expensive.
  • reaction (b) to predominate during gasification the presence of sufficient moisture is important.
  • syngas production rate and composition can be enhanced in order to favor or disfavor one particular application.
  • the effect of moisture can have on gasifier performance and syngas properties also varies according to the characteristics of the feed stock. For example, the chemically bonded moisture and carbon content are two parameters that can influence of moisture on the feed stock during gasification.
  • gasification feed stock like steam injection into gasifiers
  • gasification moderator which can achieve at least one of the following:
  • ER air equivalence
  • FIG. 6 shows the predicted variation of syngas compositions with feed stocks of different moisture contents for a typical wood feed stock at 800° C.
  • FIG. 7 shows the predicted effect of fuel moisture content on carbon conversion, cold gas efficiency and CO+H 2 production rate for a typical coal feed stock at 850° C.
  • FIG. 8 shows the predicted effect of fuel moisture content on carbon conversion, cold gas efficiency and CO+H 2 production rate for pure carbon at 1000° C.
  • Moisture in feed stock can replace the external steam supply in case steam is used as oxidant, which is often the case when external heat is available, and/or saving oxygen is desired.
  • By replacing air or oxygen as the oxidant by water from feed stock, a high BTU syngas can be produced due to reduced dilution of nitrogen, and increased water-gas reaction (b).
  • the H 2 +CO production rate and cold gas efficiency will be slightly increased with increasing moisture when operating at a constant gasification temperature and air-equivalence ratio ( FIG. 8 ).
  • engineered fuel feed stocks can be engineered for a specified use.
  • Table 5 lists some common components found in MSW, along with their C, H, O, N, S, ash, and HHV content, as well as the ER required for complete combustion.
  • the components can be sorted into any different number of classes, according to, for example, their carbon content.
  • MSW can be sorted into two, three, four, five or even more classes.
  • Table 5a lists four separate classes: class #1 has a carbon content of about 45%, class #2 has a carbon content of about 55%, class #3 has a carbon content of about 60%, and class #4 has a carbon content of about 75%.
  • equation 1 can be used to select from, and assign the amounts from, the four classes listed in Table 5a.
  • an engineered fuel feed stock made from MSW can be designed to have the same chemical composition as natural woodchips.
  • Natural woodchips have the chemical composition listed in Table 6.
  • the precise amounts of the different classes of sorted MSW listed in Table 5 needed for engineering a synthetic fuel of the same chemical composition as natural woodchips were determined according to eq. 1 to be 88.1% from class #1 and 11.9% from class # 2 . No components from classes #3 and #4 were required for this particular synthetic engineered fuel feed stock.
  • Gasification tests were performed at a laboratory scale stratified downdraft gasifier.
  • the gasifier has an inside diameter of 4 inches and a height of 24 inches above a perforated grate.
  • the real-time temperatures are recorded by a data logger thermometer (OMEGA, HH309A).
  • a syngas sampling train consisting of two water scrubbers, and a vacuum pump is used for taking syngas samples, which is analyzed by a HP5890A gas chromotograph to obtain volumetric fractions of H2, N2, CO, CO2 and CH4.
  • a dry gas test meter is installed in the air entrance to measure the air intake rate. The tests with two wood and simulated wood were conducted with air as oxidant at similar operating conditions. The results are listed in Table 8.
  • feed stock #2 has an energy content of 13,991 BTU/lb
  • feed stock # 7 has an energy content of 14,405 BTU/lb, a difference of about 3%.
  • the chemical molecular characteristics of the two feed stocks are listed in Table 9. The moisture content, carbon content, hydrogen content, oxygen content, and ratios of H/C and O/C are very different compared to each other.
  • the feed stocks were gasified using the following procedure. Gasification tests were performed at a laboratory scale stratified downdraft gasifier.
  • the gasifier has an inside diameter of 4 inches and a height of 24 inches above a perforated grate.
  • the real-time temperatures are recorded by a data logger thermometer (OMEGA, HH309A).
  • a syngas sampling train consisting of two water scrubbers, and a vacuum pump is used for taking syngas samples, which is analyzed by a HP5890A gas chromotograph to obtain volumetric fractions of H 2 , N 2 , CO, CO 2 and CH 4 .
  • a dry gas test meter is installed in the air entrance to measure the air intake rate.
  • the tests with two wood and simulated wood were conducted with air as oxidant at similar operating conditions.
  • the results are listed in the following table. It can be seen that syngas composition, H 2 /CO ratio and syngas HHV are fairly close between the two engineered fuel feed stocks.
  • the results of the gasification of feed stocks FS#2 and FS#7 are listed in Table 10.
  • slagging occurs depends on the ash content of the fuel, the melting characteristics of the ash, and the temperature pattern in the gasifier. Local high temperatures in voids in the fuel bed in the oxidation zone, caused by bridging in the bed and maldistribution of gaseous and solids flows, may cause slagging even using fuels with a high ash melting temperature. In general, no slagging is observed with fuels having ash contents below 5-6 percent. Severe slagging can be expected for fuels having ash contents of 12 percent and above.
  • Equation 2 gives the relationship between the energy content of the fuel (HHV) and the amount of ash contained in the engineered fuel feed stock.
  • an engineered fuel feed stock with a HHV of about 10,000 BTU/lb can be designed whereby the ash is held to a minimum amount, for example, less than about 5% ash, or less than about 4% ash.
  • the components of MSW used to engineer the fuels of about 10,000 BTU/lb were selected from the four classes of MSW components derived from MSW listed in Table 5.
  • Table 13 lists the amounts of the components of MSW used for engineering these fuels and their corresponding carbon, hydrogen, sulfur, and ash contents as well as the HHV value for the engineered fuel.
  • the amount of other materials that enhance the gasification process may be increased during the process thereby bringing the chemical molecular characteristics of the densified form of the engineered fuel feed stock within the desired fuel specification.
  • other materials that enhance the gasification process may be added before or during the compression to adjust the chemical molecular characteristics of the resulting densified form of the engineered fuel feed stock.
  • the other material added to the feed stock is a FOG. Table 16 lists the heat content of certain FOGs and their carbon and hydrogen contents.
  • sludge Another type of material that can be added to the feed stock is sludge.
  • Table 17 gives the carbon and hydrogen content of sludge.
  • Fischer-Tropsch The best-known technology for producing hydrocarbons from synthesis gas is the Fischer-Tropsch synthesis. This technology was first demonstrated in Germany in 1902 by Sabatier and Senderens when they hydrogenated carbon monoxide (CO) to methane, using a nickel catalyst. In 1926 Fischer and Tropsch were awarded a patent for the discovery of a catalytic technique to convert synthesis gas to liquid hydrocarbons similar to petroleum.
  • M represents a catalytic metal atom
  • Equation 3 describes the production of hydrocarbons, commonly referred to as the Anderson-Schulz-Flory equation.
  • W n weight fraction of products with carbon number n
  • ⁇ chain growth probability, i.e., the probability that a carbon chain on the catalyst surface will grow by adding another carbon atom rather than terminating.
  • a is dependent on concentrations or partial pressures of CO and H2, temperature, pressure, and catalyst composition but independent of chain length. As a increases, the average carbon number of the product also increases. When ⁇ equals 0, only methane is formed. As a approaches 1, the product becomes predominantly wax.
  • FIG. 11 provides a graphical representation of eq. 2 showing the weight fraction of various products as a function of the chain growth parameter ⁇ .
  • FIG. 11 shows that there is a particular ⁇ that will maximize the yield of a desired product, such as gasoline or diesel fuel.
  • the weight fraction of material between carbon numbers m and n, inclusive, is given by equation 4:
  • ⁇ opt ( m 2 ⁇ m n 2 + n ) 1 n - m + 1 ( eq . ⁇ 5 )
  • Additional gasoline and diesel fuel can be produced through further refining, such as hydrocracking or catalytic cracking of the wax product.
  • H 2 /CO ratio For each of the targeted products derived from syngas the corresponding appropriate H 2 /CO ratio is needed.
  • One way to produce such H 2 /CO ratio is to control the amount of C, H, and O in the feed stock used to produce the syngas.
  • FIG. 12 shows the predicted C/H and C/O ratios needed in the feed stock in order to produce a syngas of the requisite H 2 /CO ratio.
  • the proper ratio of H/C and O/C in the composition of the engineered feed stock can be determined, along with the proper amount of moisture and ash content. Once these ratios have been determined then the proper MSW components can be selected and combined together to form feed stocks that upon gasification will yield a syngas with the desired H 2 /CO ratio.
  • Up and downdraft gasifiers are limited in the range of fuel size acceptable in the feed stock. Fine grained and/or fluffy feed stock may cause flow problems in the bunker section of the gasifier as well as an inadmissible pressure drop over the reduction zone and a high proportion of dust in the gas. Large pressure drops will lead to reduction of the gas load of downdraft equipment, resulting in low temperatures and tar production. Excessively large sizes of particles or pieces give rise to reduced reactivity of the fuel, resulting in startup problems and poor gas quality, and to transport problems through the equipment. A large range in size distribution of the feed stock will generally aggravate the above phenomena. Too large particle sizes can cause gas channeling problems, especially in updraft gasifiers. Acceptable fuel sizes fox gasification systems depend to a certain extent on the design of the units.
  • Particle size distribution in fuel influences aspects of combustor and gasifier operations including the rate at which fuel reacts with oxygen and other gases. Smaller particles of fuel tend to be consumed faster than bigger ones. Particle size is based on area-volume average (d pv ) (eq. 6). The distribution of particle sizes in a population of particles is given by d pv (eq. 7):
  • the shape of the engineered fuel feed stock particles and the densified form of the engineered fuel feed stock also strongly influence the rates of gas-solid reactions and momentum transfers between the particles and the gas stream that carries them.
  • One parameter used to describe the shape of a particle is sphericity, which affects the fluidity of the particles during the gasification/combustion process. Fluidity is important in avoiding channeling and bridging by the particles in the gasifier, thereby reducing the efficiency of the conversion process.
  • Sphericity can be defined by the following formula:
  • ⁇ ⁇ ⁇ p Surface ⁇ ⁇ area ⁇ ⁇ of ⁇ ⁇ spherical ⁇ ⁇ particle Surface ⁇ ⁇ area ⁇ ⁇ of ⁇ ⁇ particle ⁇ ⁇ with same ⁇ ⁇ volume ⁇ ⁇ of ⁇ ⁇ the ⁇ ⁇ spherical ⁇ ⁇ one ⁇
  • Equations 8 and 9 describe the volume of a sphere and cylinder, respectively.
  • Table 15 lists different cylinders and a sphere that all have the same volume (0.524 in 3 ), yet possessing different surface areas (in 2 ) and specific surface areas (in 2 /in 3 ).
  • spheres For shapes with the same volume such as cylinders and spheres, spheres have the lowest specific surface area. As the sphericity of a cylinder approaches 1 it behaves more like a sphere in the gasification/combustion process. However, the surface area for the corresponding volume is not maximized in the shape of a sphere which means the conversion process will not be optimally efficient. There is a minimum specific surface area and highest sphericity for a cylindrical shape depending on its diameter and length. This shape when determined for the engineered fuel is optimal for the conversion process for which the fuel is used. FIG. 13 shows that when the cylindrical diameter is plotted against the sphericity and the cylindrical length and specific area, the optimal size of the pellet can be determined.
  • the engineered feed stock should provide maximum surface area for the same volume in order to favor gas-solid reactions which is determined by maximization of up in eq. 10.
  • the maximization of up for a particular feed stock provides better hydrodynamic performance during the conversion process and cost effectiveness in preparation (size reduction and pelletizing) of the engineered fuel as compared to other natural fuels.
  • the size and shape, and in some embodiments, the sphericity, of the engineered fuel feed stock can be determined.
  • the sphericity of natural woodchips provides a natural starting point. Natural woodchips have a sphericity ( ⁇ p ) of about 0.2.
  • An engineered fuel particle was designed with a sphericity of 0.25, a slightly better sphericity than natural woodchips yet containing the same HHV. Equation 11 describes the size of the engineered fuel particle and Table 18 lists the possible dimensions for such an engineered particle:
  • ⁇ p ⁇ ⁇ ( 6 ⁇ V p / ⁇ ) S p ⁇ a ⁇ ⁇ predetermined ⁇ ⁇ value ⁇ ⁇ ⁇ p ⁇ d pv ⁇ a ⁇ ⁇ predetermined ⁇ ⁇ value ( eq . ⁇ 11 )
  • the smallest particle actually has the greatest specific surface area (72 ft 2 /ft 3 versus 48 ft 2 /ft 3 and 36 ft 2 /ft 3 , respectively).
  • the rate of gasification of the fuel pellets can be positively effected by a number of elements which act as catalysts, such as small quantities of potassium, sodium or zinc.
  • Bulk density is defined as the weight per unit volume of loosely tipped fuel. Fuels with high bulk density are advantageous because they represent a high energy-for-volume value. Low bulk density fuels sometimes give rise to insufficient flow under gravity, resulting in low gas heating values and ultimately in burning of the char in the reduction zone. Average bulk densities of solid fuels such as wood, coal and peat ranges from about 10 lb/ft 3 to about 30 lb/ft 3 . If bulk densities for some components used for the pellets of the invention are too low, the over all bulk density can be improved through pelletization. The bulk density varies significantly with moisture content and particle size of the fuel.
  • Exemplary ranges for specifications of a waste feed for a gasification system can include, but are not limited to: a diameter of between about 0.25 inches to about 1.5 inches; a length of between about 0.5 inch to about 6 inches; a surface to volume ratio of between about 20:1 to about 3:1; a bulk density of about 10 lb/ft 3 to about 75 lb/ft 3 ; a porosity of between about 0.2 and about 0.6; an aspect ratio of between about 1 to about 10; a thermal conductivity of between about 0.023 BTU/(ft ⁇ hr ⁇ ° F.) and about 0.578 BTU/(ft ⁇ hr ⁇ ° F.); a specific heat capacity of between about 4.78 ⁇ 10 ⁇ 5 to 4.78 ⁇ 10 ⁇ 4 BTU/(lb ⁇ ° F.); a thermal diffusivity of between about 1.08 ⁇ 10 ⁇ 5 ft 2 /s to 2.16 ⁇ 10 ⁇ 5 ft 2 /s; a HHV of between about 3,000 BTU/lb
  • MSW feed stock can be classified according to its carbon content and thus its potential for producing the amount of CO and H 2 in the resulting syngas upon thermal conversion.
  • Table 19 shows one classification of types of fuels based on carbon content: low heat fuels (less than 45 wt % carbon); moderate heat fuels (45-60 wt % carbon); and high heat fuels (>60 wt % carbon).
  • the low heat fuels can be characterized as producing syngas containing CO and H 2 at less than about 10 scf/lbs and an HHV of less than about 120 BTU/scf. Because the gasifier requires an air equivalence ratio of more than 0.35 because of the low amount of carbon, the gasifier temperature will not rise above about 850° C. causing incomplete conversion of carbon and the formation of methane and tars. These fuels can be used for production of syngas for all purposes, co-gasification with other fuels including moderate and high heat fuels, as well as LFG.
  • the moderate heat fuels can be characterized as producing syngas containing CO and H 2 at about 10 to about 20 scf/lbs and an HHV of about 120 to about 200 BTU/scf. Because the gasifier requires an air equivalence ratio of about 0.1 to about 0.35 with a carbon content of about 45 wt % to about 60 wt %, the gasifier maintains a temperature of about 850° C. to about 900° C. causing complete conversion of carbon, minimal formation of methane and tars, and low risk of slagging. These fuels can be used for production of syngas for all applications, liquid fuels, and chemicals applications.
  • the high heat fuels can be characterized as producing syngas containing CO and H 2 at greater than about 20 scf/lbs and an HHV of greater than 200 BTU/scf. Because the gasifier requires an air equivalence ratio of only less than about 0.1 with a carbon content of greater than about 60 wt %, the gasifier's temperature is generally greater than about 900° C. causing complete conversion of carbon, no formation of methane and tars, but a high risk of slagging. These fuels can be used for production of syngas for all applications, liquid fuels, and chemicals applications.
  • engineered fuel feed stocks of different carbon content can be selected and fuels can be engineered and synthesized for a particular end use. Such selection allows the fine tuning of the engineered fuels produced from differing heterogeneous feed stocks such as MSW, FOGS, sludges, etc.
  • the engineered fuels can be used for producing syngas containing the desired CO and H 2 content.
  • the MSW can be processed by any method that allows for identification and separation of the component parts according to material type, such as by plastics, fibers, textiles, paper in all its forms, cardboard, rubber, yard waste, food waste, and leather.
  • material type such as by plastics, fibers, textiles, paper in all its forms, cardboard, rubber, yard waste, food waste, and leather.
  • Methods of separation such as those disclosed in U.S. Pat. No. 7,431,156, US 2006/0254957, US 2008/0290006, US 2008/0237093, the disclosures of which are hereby incorporated in their entirety, can be used for separating the components of waste.
  • the component or components of the engineered feed stock are mixed.
  • the mixed components are reduced in size using known techniques such as shredding, grinding, crumbling and the like. Methods for the reduction in size of MSW components is well known and for example are described in U.S. Pat. No. 5,888,256, the disclosure of which is incorporated by reference in its entirety.
  • the individual components are first reduced in size prior to mixing with other components.
  • the mixed components of the engineered fuel feed stock are densified using known densification methods such as, for example, those described in U.S. Pat. No. 5,916,826, the disclosure of which is incorporated by reference in its entirety.
  • the densification forms pellets by the use of a pelletizer, such as a Pasadena hand press, capable of exerting up to 40,000 force-pounds.
  • the FOGS component is added directly to the mixing tank. In other embodiments, the FOGS component is added after mixing just before the waste is placed into a pelletizing die.
  • pellets are produced having a range of dimensions.
  • the pellets should have a diameter of at least about 0.25 inch, and especially in the range of about 0.25 inches to about 1.5 inches.
  • the pellets should have a length of at least about 0.5 inch, and especially in the range of about 0.5 inches to about 6 inches.
  • the pellets become scored on the surface of the encapsulation. This scoring may act as an identifying mark. The scoring can also affect the devolatization process such that the scored pellets volatize at a more efficient rate than the unscored pellets.
  • the engineered fuel feed stock described herein is biologically, chemically and toxicologically inert.
  • biologically inert, chemically inert, and toxicologically inert means that the engineered fuel feed stock described herein does not exceed the EPA's limits for acceptable limits on biological, chemical and toxicological agents contained within the engineered fuel feed stock.
  • the terms also include the meaning that the engineered fuel feed stock does not release toxic products after production or upon prolonged storage.
  • the engineered fuel feed stock does not contain, for example pathogens or live organisms, nor contain the conditions that would promote the growth of organisms after production or upon prolonged storage.
  • the engineered fuel feed stock in any form described herein can be designed so as to have a moisture content sufficient so as not to promote growth of organisms.
  • the engineered fuel feed stock can be designed to be anti-absorbent, meaning it will not absorb water to any appreciable amount after production and upon prolonged storage.
  • the engineered fuel feed stock is also air stable, meaning it will not decompose in the presence of air to give off appreciable amounts of volatile organic compounds.
  • the engineered fuel feed stock described herein may be tested according to known methods in order to determine whether they meet the limits allowed for the definition of inert. For example, 40 CFR Parts 239 through 259 promulgated under Title 40—Protection of the Environment, contains all of the EPA's regulations governing the regulations for solid waste.
  • components for the engineered feed stock were selected they were shredded in a low speed shredder and then mixed mechanically. Afterwards the mixture was densified using a pelletizer. If the moisture content needed to be increased, water was added during the mixing step. A small sample of the feed stock was taken and dried in an temperature controlled and vented oven to confirm the moisture content. The mixed engineered feed stock was then subjected to gasification as described above.
  • Feed Stock #1 Feed stock #1 (FS#1) 82% Newsprints, 18% Plastics AR MF Moisture 3.25 Ash 4.51 4.66 Volatile 86.43 89.33 Fixed Carbon 5.81 6.01 S 0 0.01 H 7.57 7.82 C 51.88 53.62 N 0.06 0.06 O 32.65 33.75 Cl C/H 6.9 6.9 C/O 1.6 1.6 HHV (BTU/lb) 9,552 9,873 HHV (BTU/lb), Calculated 10,696 Density (lb/cu. ft) 20.3
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US12/644,974 US8444721B2 (en) 2008-06-26 2009-12-22 Engineered fuel feed stock
US13/080,351 US8192512B2 (en) 2008-06-26 2011-04-05 Engineered fuel feed stock
US13/087,117 US8157874B2 (en) 2008-06-26 2011-04-14 Engineered fuel feed stock
US13/087,111 US8382863B2 (en) 2008-06-26 2011-04-14 Engineered fuel feed stock
US13/087,126 US8192513B2 (en) 2008-06-26 2011-04-14 Engineered fuel feed stock
US13/087,108 US8906119B2 (en) 2008-06-26 2011-04-14 Engineered fuel feed stock
US13/087,120 US8157875B2 (en) 2008-06-26 2011-04-14 Engineered fuel feed stock
US13/087,115 US20110209397A1 (en) 2008-06-26 2011-04-14 Engineered fuel feed stock
US13/488,074 US8523962B2 (en) 2008-06-26 2012-06-04 Engineered fuel feed stock
US13/708,532 US8852302B2 (en) 2008-06-26 2012-12-07 Engineered fuel feed stock
US14/478,129 US9062268B2 (en) 2008-06-26 2014-09-05 Engineered fuel feed stock
US14/555,063 US9688931B2 (en) 2008-06-26 2014-11-26 Engineered fuel feed stock
US14/715,384 US9523051B2 (en) 2008-06-26 2015-05-18 Engineered fuel feed stock
US15/282,589 US10329501B2 (en) 2008-06-26 2016-09-30 Engineered fuel feed stock
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