Classifications

• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L5/00—Solid fuels
  • C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
  • C10L5/34—Other details of the shaped fuels, e.g. briquettes
  • C10L5/36—Shape
  • C10L5/363—Pellets or granulates
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23K—FODDER
  • A23K10/00—Animal feeding-stuffs
  • A23K10/30—Animal feeding-stuffs from material of plant origin, e.g. roots, seeds or hay; from material of fungal origin, e.g. mushrooms
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L5/00—Solid fuels
  • C10L5/40—Solid fuels essentially based on materials of non-mineral origin
  • C10L5/44—Solid fuels essentially based on materials of non-mineral origin on vegetable substances
  • C10L5/442—Wood or forestry waste
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L9/00—Treating solid fuels to improve their combustion
  • C10L9/08—Treating solid fuels to improve their combustion by heat treatments, e.g. calcining
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
  • C10L9/00—Treating solid fuels to improve their combustion
  • C10L9/10—Treating solid fuels to improve their combustion by using additives
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
  • D21C1/00—Pretreatment of the finely-divided materials before digesting
  • D21C1/02—Pretreatment of the finely-divided materials before digesting with water or steam
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
  • D21C3/00—Pulping cellulose-containing materials
  • D21C3/22—Other features of pulping processes
  • D21C3/222—Use of compounds accelerating the pulping processes
• • 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

Definitions

• the present invention relates generally to a method for making fuel pellets, and more particularly, but not by way of limitation, to a method of making molding compounds and extruded parts, including fuel pellets, from lignocellulosic biomass.
• the best established procedures for making fuel pellets involve compressing biomass in a pelletizing mill to make so-called “white”, i.e., light colored pellets, which can be regarded as a more compact energy source than the raw material itself.
• White pellets need to be made from finely divided biomass, meaning that coarser materials need to be ground before pelletizing, an energy intensive step.
• the pellets typically contain about 10% moisture and need to be stored under cover, as they absorb water easily and lose their cohesiveness. They are also liable to create dust during transport and storage and thus, risk causing a dust explosion.
• pelletized biomass is well established as a fuel for small-scale heating purposes
• its shortcomings have made it difficult to use as a straightforward replacement for coal in large-scale installations such as power stations.
• the demand is for a pellet that is easily crushed to a powder and can be stored outdoors.
• the pellets have a high bulk density to minimize storage requirements and a high specific energy content to minimize freight costs per unit of energy produced. The latter translates into low moisture content.
• the “steam explosion” process entails the use of medium pressure steam to break the bonds between the various components in the feed to form substances that can act as binders. Steam explosion has been used in semi-commercial scale to make fuel pellets in a pellet mill from softwood sawdust.
• Torrefaction removes volatiles (which can be burned), and moisture from a feed (which can be a “white” pellet), at the same time converting it to a form that is more easily crushed (although more friable), with a higher energy content per unit weight than the feed upon which it is based.
• this friability means that the process may need to be carried out immediately prior to the pellet being used.
• the present invention relates to a method for producing fuel pellets and a pellet used as a fuel source prepared by a process.
• Lignocellulosic biomass having a moisture content of less than about 30% by weight is introduced into a reactor.
• the moisture content of the lignocellulosic biomass may be less than about 15% by weight.
• Less than about 50 weight % of a carbon source may be added to the biomass.
• the carbon sources is coal dust, coke powder, or unprocessed biomass.
• a vacuum of less than 500 torr, preferably less than 200 torr, is applied to the reactor.
• Steam having a temperature of between about 180° C. and about 235° C. is injected into the reactor.
• the biomass is maintained in the reactor between about 1 and about 12 minutes.
• the treated biomass having a moisture content less than about 30% by weight is removed from the reactor.
• the treated biomass is formed into a pellet or briquette such that forming may be pelletizing, extruding, briquetting,
• a catalyst is introduced into the reactor.
• the catalyst is a fatty acid, ester, or triglyceride.
• the catalyst is introduced prior to or together with the steam into the reactor.
• the present invention is directed to making products from lignocellulosic biomasses by a combination of a steam explosion technique followed by either pelletizing in a mill, briquetting, or by extrusion in a compounding extruder.
• Such products have unique compositions and considerably better properties, in particular, exceptionally high strength and bulk density and very low water absorption than those made by state-of-the-art steam explosion processes. They are also cheaper to manufacture.
• Examples of lignocellulosic biomasses are wood chips, sawdust, annual crop residues, etc.
• the present invention may be used to convert any known lignocellulosic biomass into fiber masses or treated biomass suitable for the manufacture of products and extruded products in accordance with the method of the present invention or variations thereof, as described herein.
• Products made by the present invention are characterized in that at least ten (10) mass percent of the product includes substances, preferably, carbohydrates that are soluble in water at 23° C. and at least fifteen (15) mass of the product includes lignin, pseudo-lignin, esters and/or resins insoluble in water but soluble in 10% NaOH.
• the biomass is chipped hardwood, softwood or corncobs, where at least 95% of the chips have a smallest dimension of more than 5 mm but less than 15 mm, and are dried to a moisture content of below 30% and preferably below 15%.
• the biomass is an annual crop residue such as that from the grass family (Poaceae) or from oilseed crops or shredded waste paper which is preferably compacted as pellets or briquettes and dried to a moisture content of below 30% and preferably below 15%.
• the dried biomass is transported to a preheated pressure reactor which is evacuated to less than 500 torr and preferably less than 200 torr for a period of at least 1 minute, and not more than 12 minutes. Dry, saturated or slightly superheated steam having a temperature of at least 180° C. and not more than 235° C. is introduced into the reactor.
• a catalyst chosen from a group of fatty acids, esters or triglycerides i.e., a vegetable oil such as Jatropha, corn oil, or spent cooking oil
• a catalyst chosen from a group of fatty acids, esters or triglycerides is injected into the evacuated reactor containing the dried biomass immediately prior to or together with the steam in an amount of 1-15% and preferably 2-7% by weight of biomass.
• vacuum pretreatment and the optional use of a hydrophobic oil as a catalyst in the present invention provides advantages, including the acceleration of the steam treatment process, which allows the biomass to be converted at lower thermal loading and with a higher degree of conversion to alkali soluble materials, than is the case for state-of-the-art “steam explosion” processes. This saves energy and reduces the dehydration of hemicellulose sugars to furfural derivatives, which are odorous volatiles (VOC's) typically formed in state-of-the-art steam explosion processes.
• VOC's odorous volatiles
• reaction times for grasses and annual crop residues are from 2 minutes at 220° C. to 12 minutes at 175° C., from 3 minutes at 225° C. to 10 minutes at 190° C., for most hardwood chips; and from 3 minutes at 235° C. to 12 minutes at 195° C., for softwood chips.
• biomass is then ejected from the reactor.
• the degree of saturation of the steam can be adjusted so that the free moisture content of the ejected biomass is below 30% and preferably less than 20%.
• the moisture content is below 12%.
• Biomass suitable for making the products have a total content of material soluble in 10% NaOH of at least 25% and preferably more than 35%. Of this, at least one-fourth (1 ⁇ 4) and not more than three-fifths (3 ⁇ 5) should also be soluble in water at 23° C.
• the biomass can then be transferred, without further drying, to a mill, briquetting machine, or a compounding extruder and pelletized or briquetted, with or without the addition of up to 50% of a finely divided carbon source such as coal, coke dust, or unprocessed biomass, such as sawdust or shredded paper.
• a processing aid such as an oil, preferably a vegetable oil or a fat can be added to improve the flow characteristics of the biomass.
• extrusion is conventionally used to describe any process where pellets are made by forcing biomass through a die.
• extrusion is used to describe pellets manufactured in connection with a pellet mill and not with a compounding extruder such as employed herein. The use of such an extruder is unique to one embodiment of the method of the present invention.
• a conventional extruder meeting the requirements of one embodiment of this invention includes one or two screw conveyors rotating in a barrel equipped with heating elements, one or more compression zones, one or more mixing zones, one or more degassing zones, and a die that can be heated or chilled, having a profile through which the material is extruded.
• the extruder may also be equipped with a metering device for the addition of a hydrophobic processing aid. It should be understood by one of ordinary skill in the art that a variety of extruders may be utilized so long as the extruder functions in accordance with the present invention as described herein.
• Steam-treated biomass is conveyed to a first, heated mixing zone of the extruder where moisture is removed by degassing.
• a processing aid may then be added and the whole conveyed, while heated to at least 125° C., to the first mixing zone, which may also be heated, and then to a compression zone where it is further compacted in a molten or semi-molten state.
• the whole is then conveyed, optionally, via a second mixing zone to a second vacuum degassing zone where volatiles are removed before being conveyed to the die zone and converted into pellets.
• Products made according to this embodiment have extremely high rigidity, durability, density and energy content and very low water content, typically less than 3% after immersion in water at room temperature for 1 hour.
• Products made in accordance with the present invention may optionally contain up to 50% by weight of a finely divided carbon source, such as coal, coke dust, or a biomass such as sawdust that is not steam-treated, as long as the chemical composition of the extruded product falls within the above-mentioned range.
• a finely divided carbon source such as coal, coke dust, or a biomass such as sawdust that is not steam-treated
• Fuel pellets made according to the method of the present invention have much lower water contents than coal, even after extended outdoor storage, and offer a number of practical advantages as a power station fuel compared to coal and other fossil fuels used in power generation such as coke derived from petroleum (petcoke) or coal.
• the flue gas produced by combustion of these pellets is much cleaner than that from coal, coke and heavy fuel oil, being practically free of sulphuric and toxic elements such as arsenic, mercury, vanadium, etc. This means that it does not need to be desulphurized before being released to the environment, a process that typically adds 10% or more to the cost of generating electrical power from fossil fuels as well as creating a product, often regarded as toxic waste, which needs to be dumped accordingly.
• venting in a compounding extruder during extrusion allows odorous volatiles such as furfurals and organic acids that may be produced during steam treatment and extrusion, to be removed prior to the product being formed. It should be noted that these odorous components are most undesirable in products such as construction boards and moldings.
• Fuel pellets made in accordance with the method described here contain biomass that has become embrittled. They are thus easier to grind than white pellets. Compared to the white pellets available in the market, they have much lower moisture contents (typically ⁇ 2% as opposed to ca. 10%) and therefore, a higher energy content per unit weight and a far lower water absorption. They are also resistant to impact and are, therefore, essentially dust-free.
• the pellet or briquette contain less than 5% moisture, at least 8% and preferably between 10 and 15% of substances soluble in water at 23° C. and at least 12%, preferably between 15 and 30%, of substances insoluble in water at 23° C., but soluble in a 10% solution of sodium hydroxide, so that the ratio between the substances soluble only in alkali to those soluble only in water is not less than 1.0 and preferably between 1.3 and 1.7 and the total of both is not less than 20%, preferably at least 25%, of the total dry matter content of the pellet or briquette.
• pellets or briquettes meeting these specifications contain less than 1% of substances such as furfurals that have objectionable odors and are volatile at between 120° C. and 170° C.
• Black” pellets made by the present invention possess considerable advantages compared with similar pellets made in a mill, including lower water content following extended outdoor storage capability, greatly reduced run-off during outdoor storage, considerably higher bulk density and durability and lack of odor.
• Table 1 illustrates the properties of fuel pellets made according to the methods described herein by steam-treating oak wood chips dried to a moisture content of 15% to a vacuum of 250 torr for 2 minutes in a preheated reactor following which dry steam at 210° C. is injected and the whole held at this temperature for 6 minutes before being discharged, dried to 9% moisture and then converted into pellets 6 mm in diameter in a mill die whose die compression length is 8.
• fuel pellets are produced in a screw conveyor compounding extruder such that the fuel pellets have high energy content, low moisture content and improved strength and crushability with the minimum energy requirement and without needing to dry the steam-treated biomass before pelletizing.
• lignocellulosic material whose smallest dimension (thickness) is not more than 15 mm, is introduced into a reactor.
• the reactor is evacuated with the lignocellulosic material in the reactor. Dry, saturated or slightly unsaturated steam is injected into the reactor.
• an oil such as vegetable oil, or fat, is introducted prior to or together with the steam.
• the saturated steam is injected into the reactor at a temperature not less than 170° C. nor higher than 230° C., preferably between 185° C. and 215° C.
• the temperature of the steam depends upon the lignocellulosic material and the total reaction time from introduction of steam to removal of the steam-treated material.
• the lignocellulosic material is maintained in the reactor not more than 15 minutes, nor less than 2 minutes, preferably between 3 and 10 minutes.
• the process of the present invention ensures that the steam-treated product is such that the proportion soluble in 10% NaOH is at least 25%, preferably at least 40%, of which at least two-fifths (2 ⁇ 5) is soluble in water at 23° C.
• the moisture content of the biomass, during steam treatment, is controlled by using a combination of vacuum pretreatment followed by injection of dry or slightly superheated steam such that the steam-treated biomass contains less than 30% by weight and preferably not more than 15% by weight free moisture.
• the biomass is pelletized in an extruder such that the temperature in the extruder is sufficient to plasticize the biomass, by degassing in one and preferably two stages to remove water vapor and organic volatiles (VOC's), respectively.
• the pellets have a bulk density of more than 800 kg/m 3 , a moisture content of 3% or less, absorbing less than 3% water after total immersion for 1 hour and losing less than 2% by weight dry matter after immersion in water for 24 hours.
• extruded products are made using a flat die, in the case of boards with steam-treated materials that can contain as much as 30% or more of thin wood chips, strands or flakes, or in the case of thinner sheets, e.g., for lamination purposes, by the use of steam-treated material containing up to 30% of finely divided biomass that has not been steam-treated.
• any lignocellulosic material whose smallest dimension (thickness) is not more than 15 mm can be converted into fuel pellets in a pellet mill.
• the lignocellulosic material is introduced into a reactor.
• the reactor is evacuated with the lignocellulosic material in the reactor.
• Dry, saturated or slightly unsaturated steam whose temperature is not less than 170° C., nor more than 230° C., preferably between 185° C. and 215° C., depending upon the feed, is injected into the reactor.
• a catalyst may be added to the reactor as discussed herein.
• the total reaction time from introduction of steam to removal of the steam-treated material is not more than 15 minutes, nor less than 2 minutes, and preferably between 3 and 10 minutes.
• the present invention ensures that the steam-treated product is such that the proportion soluble in 10% NaOH is at least 25%, preferably at least 40%, of which at least two-fifths (2 ⁇ 5) is soluble in water at 23° C.
• the moisture content of the biomass is controlled before and during steam treatment using vacuum pretreatment followed by the injection of dry or slightly superheated steam, such that the steam-treated biomass contains less than 15% by weight and preferably not more than 12% by weight free moisture.

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• Oil, Petroleum & Natural Gas (AREA)
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• General Life Sciences & Earth Sciences (AREA)
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• Solid Fuels And Fuel-Associated Substances (AREA)
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• 2011
  • 2011-06-08 EP EP15177364.5A patent/EP2952560A1/fr not_active Withdrawn
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