WO2010120286A1 - Procédés de liaison de solides particulaires et compositions solides particulaires - Google Patents

Procédés de liaison de solides particulaires et compositions solides particulaires Download PDF

Info

Publication number
WO2010120286A1
WO2010120286A1 PCT/US2009/040614 US2009040614W WO2010120286A1 WO 2010120286 A1 WO2010120286 A1 WO 2010120286A1 US 2009040614 W US2009040614 W US 2009040614W WO 2010120286 A1 WO2010120286 A1 WO 2010120286A1
Authority
WO
WIPO (PCT)
Prior art keywords
composition
component comprises
component
biomass
coal
Prior art date
Application number
PCT/US2009/040614
Other languages
English (en)
Inventor
Thomas K. Flanery
Lorence M. Moot
Lawrence W. Umstadter
Original Assignee
Kela Energy, Llc.
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.)
Filing date
Publication date
Application filed by Kela Energy, Llc. filed Critical Kela Energy, Llc.
Priority to PCT/US2009/040614 priority Critical patent/WO2010120286A1/fr
Publication of WO2010120286A1 publication Critical patent/WO2010120286A1/fr

Links

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
    • C10L5/40—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
    • 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
    • C10L5/06—Methods of shaping, e.g. pelletizing or briquetting
    • C10L5/10—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders
    • 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
    • C10L5/46—Solid fuels essentially based on materials of non-mineral origin on sewage, house, or town refuse
    • 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

  • particulate materials such as coal fines, coke breeze, saw dust, and other biomass wastes
  • metal oxides from blast furnaces, basic oxygen furnaces and electric arc furnaces have routinely been discarded, in large quantities, creating a source of pollution and presenting an environmental hazard, which continues for decades.
  • composite waste products including post-consumer and post-industrial carpet waste, are routinely discarded into waste storage facilities, such as landfills.
  • the slow rate of decomposition results in an unfavorable environmental impact that continues for decades.
  • Fine coal particulates collected during coal processing and washing operations have been found to be high in moisture and thus lower in heating value and/or less usable for fuel or non-fuel applications.
  • the coal fines were either discarded into permanent impounds or were all or in part blended into steam coal products for sale.
  • the addition of the high moisture fines reduced the quality and BTU value of the coal products, driving down the value, and making them less desirable as a fuel or for metallurgical grade coal use in the production of iron or steel.
  • Embodiments of the present disclosure include methods of binding particulate solids as well as compositions resulting therefrom.
  • compositions comprising: a particulate solid component, where the particulate solid component comprises about 50% to 85% of the composition; and an additional component, where the additional component is selected from the group consisting of: a biomass component, a polymer component, and a composite waste product component.
  • FIG. 1 is a block diagram illustrating an embodiment of the methods disclosed herein.
  • FIG. 2 is a block diagram illustrating an exemplary process under the methodsdisclosed herein.
  • FIG. 3 is a block diagram illustrating an exemplary process under the methods disclosed herein.
  • FIG. 4 is a block diagram illustrating a non-limiting example of elements in a composite waste product.
  • FIG. 5 is a block diagram illustrating an exemplary process under the methods disclosed herein.
  • FIG. 6 is a block diagram illustrating an exemplary process under the methods disclosed herein.
  • FIG. 7 is a block diagram illustrating components of an exemplary production plant for practicing the methods disclosed herein.
  • FIG. 8 illustrates the sulfur emissions reduction in pounds per year for an embodiment of the present disclosure versus stoker coal.
  • FIG. 9 illustrates the yield increase shown to be about 134% based on an example of sample pellets formed from embodiments of the present disclosure.
  • the yield increase is calculated comparing the amount of product produced (coal fine plus binder, 2,689 lbs.) compared to the amount of coal fines fed into the process (2,000 lbs.).
  • FIG. 10 is a graph that illustrates the water pick-up and drying characteristics of five pellets. The comparison is between pellet weight in grams and time. Total time is two hours. At time represented by 1-2 (30 mins), the pellets are being soaked in water.
  • FIG. 11 is a graph that illustrates %WPU (percent water pick up) of an embodiment of the present disclosure. The pellets were soaked from time zero to time 0.5 hours and air dried after 0.5 hours.
  • FIG. 12 is a graph that illustrates water soak data in grams vs. time.
  • FIG. 13 is a graph that illustrates carbon reduction in ash based on the first stoker test burn. The lower amount of carbon in the ash (material left in the bottom of the boiler after burning) indicates a more complete burn (carbon is the material burned).
  • FIG. 1 is a block diagram illustrating an embodiment of the methods disclosed herein.
  • the method 100 includes reducing a composite waste product 110 through, for example, a shredding, densifying, or pelletizing process.
  • An exemplary composite waste product in an embodiment herein includes waste carpet.
  • Waste carpet can be, for example, consumer recycled carpet or industrial waste carpet.
  • the methods disclosed herein thus allow for an advantageous reduction of both post consumer and post industrial nylon or other types of carpet and waste stream polyolefin or other suitable polymeric material that would have otherwise gone into municipal land fills.
  • the reducing function can be performed as a separate step prior to the other steps of the methods described herein or, alternatively, as an integrated step.
  • an exemplary composite waste product includes carpet.
  • Carpet can include, but is not limited to, industrial carpet processing waste and cuttings, post industrial waste carpet, consumer installation waste, post consumer carpet, separated carpet fibers, densified whole carpet, and densified carpet fibers.
  • composite waste products can include, but are not limited to, industrial, post industrial, or post consumer nylon (polyamide) waste fiber or other materials; industrial, post industrial, or post consumer nylon (polyamide) waste fiber or other materials with mixed or added components of plastic, inorganic fillers, minerals, and/or biomass; industrial, post industrial, or post consumer fiberous materials, including but not limited to, fiberglass, other mineral fibers, polymeric fibers, organic fibers, and natural fibers; and industrial, post industrial, or post consumer polymers or other materials that will melt during processing.
  • These composite waste products may be used alone or in a mixture with carpet.
  • virgin e.g., non-waste
  • particulate solids are added to the composite waste product 120.
  • the particulate solids may be fuel solids including, but not limited to, coke breeze, coke fines, coal fines, and wood wastes.
  • the particulate solids may be non-fuel particulate waste including, but not limited to, particulate radiation contaminates, metal wastes, toxic waste particulates, and metal oxides.
  • the adding step 120 may be performed in a batch operation, where all of the particulate solids for a process batch are added at one time. Alternatively, the adding step 120 may be performed in a continuous process where the particulate solids are added in a continuous stream.
  • the composite waste product generally includes, for example, a polypropylene or other polymeric binder element and a nylon fiber element.
  • the temperature of the mixture is increased to fluidize all or parts of the binder element 140 through, for example, a combination of heat generated by the mixing process and heat provided to the process by external devices 140.
  • the fluid polypropylene binder element captures the fine particulate solids.
  • the nylon carpet fibers become tacky at the temperature at which the binder fluidizes, which causes the nylon carpet fiber to sinter to both the particulate solids and the fluid binder.
  • the process temperatures for fluidizing the polypropylene binder without fluidizing the nylon fibers are about 125 0 C to 250 0 C or about 135 0 C to 235 0 C.
  • the combination of the fluid polypropylene binder and the nylon fiber results in a mechanical capture of the particulate material in a combined polypropylene and nylon fiber polymer matrix.
  • the mixture is then formed into solid formed products, such as, for example, briquettes or pellets, using heat and/or pressure 150.
  • the pellet is extruded into various shapes (e.g., a cylindrical pellet) that can be cut randomly into any size. After the forming process, the resulting solid formed product is structurally stable and does not retrogress into fine particles during storage and handling.
  • the solid formed product When particulate solids are fuel based, the solid formed product is bound reliably together and constitutes a high BTU (e.g., an increase of about 10% to 16%) fuel for industrial, utility, and residential use, which does not materially pollute the air to a degree different from conventional fuels.
  • High BTU includes BTU values of about 12,500 BTU/lb or greater.
  • the solid formed product In the case of non-fuel particulate solids, such as industrial waste, the solid formed product is bound reliably together and constitutes a durable way of recycling in a subsequent industrial process or long term stable storage which does not materially pollute the air, soil, or ground water.
  • Embodiments of the present disclosure include compositions where sulfur in the particulate solid is reduced by about 25% to 40% by dilution, depending on the blend and initial quality of the particulate solid (e.g., a composition comprised of 70% coal/coal fines with 1% sulfur; 10% carpet; 15% plastic; and 5% biomass will produce a composition with 0.7% sulfur, which is a 30% decrease in sulfur based on blending).
  • Embodiments of the present disclosure include compositions including all types of coal (e.g., peat, lignite, sub-bituminous, bituminous, anthracite, and graphite).
  • Embodiments of the present disclosure include a method that significantly reduces sulfur through both dilution and self scrubbing during combustion.
  • FIG. 2 illustrates a block diagram of an exemplary process under the methods disclosed herein.
  • the process 200 combines recycled carpet 210 and particulate solids 220 into a mixture by heating and blending or mixing as indicated in block 230. Additionally, other polymers 250 may be optionally added to achieve specific characteristics relating to mechanical properties, chemical composition, or a combination thereof.
  • polymers can include, but are not limited to, polyolefins, polyolefin blends with other thermoplastics, polyolefin blends with fillers and other inorganic materials, polyolefin blends with biomass and other natural materials, polyamides, polyamides mixed with other thermoplastic polymers, polyamides with inert fillers, thermoplastics, and thermoplastics in mixtures with thermoset plastics.
  • solid formed products are formed in block 240 using, for example, conventional briquette or pellet forming technology. Additionally, one of ordinary skill in the art knows or will know that the mixture may be formed into solid products including extrusions, sheets or other homogeneous or non-homogeneous shapes, as needed.
  • FIG. 3 illustrates a block diagram of an exemplary process under the methods disclosed herein.
  • the process 300 utilizes recycled carpet 310, which is reduced in step 315.
  • the reducing function includes, but is not limited to, shredding, grinding, pelletizing, and other techniques known by one of ordinary skill in the art.
  • particulate solids 320 are processed to achieve a maximum particle size by grinding or crushing.
  • a mixture of the reduced recycled carpet and the ground particulate solids is produced by heating and blending or mixing, as indicated in block 330.
  • recycled plastics may be added to the mixture for supplemental fuel content and/or environmentally beneficial disposal.
  • solid products are formed, as indicated in block 340, using conventional forming technology including, but not limited to, the methods and forms discussed above.
  • FIG. 4 is a block diagram illustrating a non- limiting example of elements in a composite waste product.
  • An embodiment of the composite waste product 400 includes, but is not limited to, a polypropylene backing material 410, nylon carpet fibers 420 and calcium carbonate 430.
  • the polypropylene backing material 410 becomes fluid at a processing temperature allowing it to capture the particulate solids.
  • the nylon carpet fibers 420 become tacky, but not fluid at the processing temperature and, in the process of blending, serve to form a fiber matrix in the mixture.
  • the calcium carbonate element when used in a sulfur containing fuel application and under present combustion methods, may result in a reduction of sulfur dioxide emissions.
  • An embodiment of the process 500 applies recycled baled carpet 510 to a bale breaker 512 for subsequent processing by a shredder/grinder 514.
  • the shredder/grinder 514 is one of a number of reducing techniques known by one of ordinary skill in the art.
  • the reduced carpet is then received by an accumulator 550.
  • An accumulator 550 receives raw or intermediately processed materials from multiple sources. For example, in this case, the accumulator 550 receives reduced carpet and other materials, as discussed below, for subsequent processing.
  • recycled plastic 530 is optionally included in the mixture to facilitate improved fuel content, mechanical properties, or a combination thereof, and to facilitate an environmentally beneficial method of disposal.
  • the recycled plastic 530 is processed through a shredder/grinder 532 and transferred to a mixer 540.
  • additional virgin polymers 536 may be optionally added. Since the virgin polymers 536 are typically purchased in a form ready for processing, such as pellets, the virgin polymers 536 are deposited directly into the mixer 540.
  • cellulose material 534 including but not limited to, wood wastes, may be optionally added to the mixture 540.
  • the blending of cellulose material 534 provides a partial fuel content from a renewable resource, thus extending the life of available fossil fuels, such as the coal, PET coke, or coke fines, with a clean burning alternative synthetic fuel.
  • the synthetic solid fuels can be formed into various shapes and sizes for use in devices including, but not limited to, stoker boilers, pulverized utility boilers, circulating fluidized bed (CFB) boilers, pressurized fluidized bed combustion (PFBC) boilers, coal gasification (IGCC) units, and wood and coal burning furnaces.
  • CFRB circulating fluidized bed
  • PFBC pressurized fluidized bed combustion
  • IGCC coal gasification
  • Coal or coke fines 520 are processed through a crusher or grinder 522 to reduce the particulate solid fuels to a maximum particle size.
  • the crushed coal or coke fines are then transferred to the mixer 540.
  • the contents of the mixer 540 including the processed coal or coke fines 520, recycled plastic 530, cellulose 534 and virgin polymers 536 is mixed and transferred to the accumulator 550.
  • the accumulator 550 which includes the combined contents of the mixer 540 and the recycled carpet from the shredder/ grinder 514, conveys its contents to a pellet mill 560 using a feeder 552.
  • the pellet mill 560 blends the combined contents and uses, for example, a combination of heat, pressure, and forming technology to form solid products, including but not limited to pellets, briquettes, extrusions or sheets, of the mixture, which are then transferred to a cooler 562. After cooling, the solid products are structurally stable and do not retrogress into fine particles during storage and handling. The solid products are then transferred to storage 564 where they remain intact because the solid particulate materials are encapsulated to prevent degradation, leaching or contamination into the environment. The solid products also exhibit resistance to moisture because the moisture is driven out by the process heat and then sealed out by the encapsulating function of the binder element. In an embodiment, the moisture level of the product is about 1 % to 2%. In another embodiment, the product locks out moisture even when immersed in water for several hours.
  • the process 600 includes reducing waste carpet 610 including, but not limited to, shredding, grinding, or pelletizing the waste carpet.
  • Particulate solids which may have a fuel content are added 620 and the particulate solids are mixed with the waste carpet 630.
  • the mixture is heated using, for example, a combination of heat generated by the process plus any supplemental heat necessary to fluidize the binder element of the waste carpet 640.
  • supplemental heat may be provided by any number of methods including, but not limited to, electric resistive and inductive devices, combustion causing devices, electromagnetic wave devices, and recaptured heat from other processes.
  • the mixture is formed into solid products by pressure, heat, or extrusion 650, for example.
  • the methods use a single machine to mix and heat the mixture to flux temperatures (e.g., about 125 0 C to 25O 0 C) using process heat, shear heat, and friction to heat the materials.
  • the same machine blends in filler materials (e.g., biomass or other particulates) and forms pellets using a die mechanism.
  • the pellets are then cut at the die using a cutter (e.g., a rotary cutter) and cooled.
  • the pellets may be cooled by, including but not limited to, using water bath, water spray, or blending the hot pellets with wet fine particulates.
  • the processing takes about 1 to 3 minutes and generally does not need any form of curing time.
  • waste carpet is presented in an embodiment described herein, one of ordinary skill in the art knows, or will know that any composite waste product having binder and fiber elements may be used.
  • polymer impregnated cloth used in some industrial processes may also be a suitable composite waste product.
  • the components are added at ambient temperature and rapidly heated using process heaters, friction, and shear heat to activate or flux the binder.
  • the application of vacuum to the processing unit can be used to efficiently remove water vapor and other volatiles.
  • the methods described herein allow for a reduction of coal fines wasted into long term impounds as refuse as well as an environmentally preferable pelletized product that is cleaner than coal while retaining similar properties as a fuel or as a carbon source for other applications.
  • the methods described herein further allow for the reclamation of older coal fines impounds that results in an improved product that has useful applications where coal is specified.
  • the methods described herein allow for a means to introduce biomass in various amounts into coal fired boilers and other coal applications without the need for boiler modification or separate fuel handling systems.
  • FIG. 7 is a block diagram illustrating components of an exemplary production plant for practicing the methods disclosed herein.
  • the plant 700 includes a composite waste reducer 710, which, for example, shreds, grinds, or pelletizes waste carpet.
  • a solid particulate delivery device 720 provides solid particulates to the reduced composite waste at, for example, a combining device 730.
  • the combining device 730 combines the reduced composite waste product with particulate solids to create a mixture.
  • heat generation/regulation equipment 740 provides sufficient supplemental heat to the mixture to fluidize one element of the composite waste product.
  • the heated mixture is then provided to a solid product forming device 750, configured to produce solid formed products.
  • the solid formed products include but are not limited to pellets, briquettes, extrusions and sheets, among others. As discussed above, the solid formed products may be produced for subsequent consumption wherein the solid particulates have a useful fuel content or other desirable recycle value. Alternatively, the solid formed product may provide a safe and effective method of storing and handling useful or potentially harmful solid particulate materials.
  • the plant 700 also includes sufficient process control equipment 760 such that the production steps are integrated into a continuous process. In the alternative, the process control equipment 760 is configured, for example, to perform production steps in independent stages.
  • composition e.g., product
  • stoker coal fuel for industrial steam and heating purposes, utility grade steam coal fuel for power generation and other purposes, or metallurgical grade coal (MET) for iron and steel production as well as specialty applications.
  • MET metallurgical grade coal
  • Some product pellets include biomass of various sources to both further reduce sulfur, ash, and other HAP's as well as extend the fossil material resource by the inclusion of a renewable component.
  • the inclusion of both the binder materials comprised of recycled nylon carpet and other polymer reclaim material and the optional biomass component result in an increased yield of total fuel production when compared to the wet coal fines alone.
  • the yield increase is dependant upon the starting moisture content and the specific blend used, but is usually in a range from about 20% to 35%.
  • final moisture content of the composition may be reduced to about 2% due to the heat and pressure generated by the binding process. This has added benefits in that the biomass material (when included) is broken down into a form that is better suited for boiler fuel.
  • Embodiments of the present disclosure can include compositions with the following characteristics: lower product moisture content compared to washed coal fines; higher heating value in coal fuel pellets; lower sulfur and HAP's content when compared to coal fines used to make the compositions; improved and more complete combustion properties (e.g., about 2% unburned carbon); lower SOx emissions (e.g., SOx emissions reduced by about 35%); lower NOx emissions (based on the type of boiler) (e.g., nitrogen dioxide reduction of about 18.8%); higher hydrogen content (e.g., about 33%); and increased total yield of coal pellet product (e.g., about 12% to 30% increase).
  • SOx emissions e.g., SOx emissions reduced by about 35%
  • lower NOx emissions based on the type of boiler
  • higher hydrogen content e.g., about 33%)
  • increased total yield of coal pellet product e.g., about 12% to 30% increase.
  • NOx includes any possible combinations of nitrogen and oxygen (e.g., NO, NO 2 ).
  • the total yield is increased because waste coal fines are used in the composition (e.g., pellet), thus increasing the overall yield because yield at the mine compares the amount of salable coal based on the amount of mined coal, and for every ton of material not sent to waste, the yield increases.
  • Embodiments of the present disclosure include compositions that may be blended to meet MET coal specifications using coal fines of suitable grade. These compositions can be consumed in MET coal applications for production of iron, steel, and coke, alone or as a blend with other coals.
  • the addition of other desirable particulates such as iron ore, iron oxides, and fluxing agents e.g., calcium carbonate, limestone, or dolomite
  • fluxing agents e.g., calcium carbonate, limestone, or dolomite
  • Embodiments of this type are advantageous because they provide for self fluxing for production of iron without coke or with less coke.
  • Embodiments of the present disclosure include a composition comprising: a particulate solid component, where the particulate solid component comprises about 50% to 85% of the composition, and an additional component, where the additional component is selected from the group consisting of: a biomass component, a polymer component, a composite waste product component, and a combination thereof.
  • the particulate solid component can include, but is not limited to, coke breeze, coke fines, coal fines, and wood wastes.
  • the polymer component can include, but is not limited to plastics (e.g., recycled plastics), polyolefins, polyolefin blends with other thermoplastics, polyolefin blends with fillers and other inorganic materials, polyolefin blends with biomass and other natural materials, polyamides, polyamides mixed with other thermoplastic polymers, polyamides with inert fillers, thermoplastics, and thermoplastics in mixtures with thermoset plastics.
  • the composite waste product component can include, but is not limited to, carpet.
  • Carpet can include, but is not limited to, industrial carpet processing waste and cuttings, post industrial waste carpet, consumer installation waste, post consumer carpet, separated carpet fibers, densified whole carpet, and densified carpet fibers.
  • composite waste products can include, but are not limited to, industrial, post industrial, or post consumer nylon (polyamide) waste fiber or other materials; industrial, post industrial, or post consumer nylon (polyamide) waste fiber or other materials with mixed or added components of plastic, inorganic fillers, minerals, and/or biomass; industrial, post industrial, or post consumer fiberous materials, including but not limited to, fiberglass, other mineral fibers, polymeric fibers, organic fibers, and natural fibers; and industrial, post industrial, or post consumer polymers or other materials that will melt during processing.
  • These composite waste products may be used alone or in a mixture with carpet.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a polymer component.
  • the biomass component comprises about 0.01% to 20% of the composition
  • the polymer component comprises about 0.01% to 20% of the composition.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a composite waste product component.
  • the biomass component comprises about 0.01% to
  • the composite waste product component comprises about 0.01% to 20% of the composition.
  • Embodiments of the present disclosure include compositions where the additional component comprises a polymer component and a composite waste product component.
  • the polymer component comprises about 0.01% to 20% of the composition
  • the composite waste product component comprises about 0.01% to 20% of the composition.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component, a polymer component, and a composite waste product component.
  • the particulate solid component comprises about 50% to 85% of the composition
  • the biomass component comprises about 0.01% to 20% of the composition
  • the polymer component comprises about 0.01% to 20% of the composition
  • the composite waste product comprises about 0.01% to 20% of the composition.
  • the particulate solid component comprises about 70% of the composition
  • the biomass component comprises about 5% of the composition
  • the polymer component comprises about 15% of the composition
  • the composite waste product component comprises about 10% of the composition.
  • Embodiments of the present disclosure include compositions used as industrial stoker grade fuel coal pellets.
  • Stoker grade pellets are those pellets engineered and manufactured for use in boilers requiring stoker fuel. Stoker boilers and combustion units burn chunk coal on a stationary or moving grate. Boilers of this type are typically used in industrial manufacturing locations and institutional facilities to manufacture steam and other forms of high temperature fluids.
  • the fuel is delivered to the boiler in "chunks" and pieces nominally about 3/8" x 3/8" to 3/4" x 3/4". This fuel will typically have low sulfur content (less than about 1 %), low ash (non-combustibles, less than about 10%), and low concentrations of HAP's.
  • Embodiments of the present disclosure include compositions that have a very high BTU (e.g., BTU values of about 12,500 BTU/lb or greater) and are very low in sulfur content (e.g., less than about 1%).
  • a very high BTU e.g., BTU values of about 12,500 BTU/lb or greater
  • very low in sulfur content e.g., less than about 1%
  • Embodiments of the present disclosure include compositions comprising a cleaner burning product (e.g., emissions compared to coal are lower, less carbon in ash, less smoke at start-up), that is lower in moisture and fines, and enables coal fired boilers and furnaces to operate with less emissions of SOx, NOx, and HAP's.
  • a cleaner burning product e.g., emissions compared to coal are lower, less carbon in ash, less smoke at start-up
  • Embodiments of the present disclosure include compositions comprising products that enable better Environmental Protection Agency (EPA) emissions compliance without additional flue gas treatment.
  • Embodiments of the present disclosure include compositions that ignite rapidly
  • compositions include a rough surface (e.g., more surface area) that ignites faster.
  • Embodiments of the present disclosure include a composition comprising: a particulate solid component, where the particulate solid component comprises about 60% to 85% of the composition, and an additional component, where the additional component is selected from the group consisting of: a biomass component, a polymer component, and a composite waste product component.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a polymer component.
  • the biomass component comprises about 0.01 % to 25% of the composition
  • the polymer component comprises about 0.01% to 15% of the composition.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a composite waste product component.
  • the biomass component comprises about 0.01% to
  • the composite waste product component comprises about
  • Embodiments of the present disclosure include compositions where the additional component comprises a polymer component and a composite waste product component.
  • the polymer component comprises about 0.01 % to 15% of the composition
  • the composite waste product comprises about 0.01 % to 10% of the composition.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component, a polymer component, and a composite waste product component.
  • the particulate solid component comprises about 60% to 85% of the composition
  • the biomass component comprises about 0.01% to 25% of the composition
  • the polymer component comprises about 0.01% to 15% of the composition
  • the composite waste product component comprises about 0.01% to 10% of the composition.
  • the particulate solid component comprises about 80% of the composition
  • the biomass component comprises about 5% of the composition
  • the polymer component comprises about 10% of the composition
  • the composite waste product component comprises about 5% of the composition.
  • Embodiments of the present disclosure include compositions used as a utility steam coal fuel pellet (e.g., fuel to be used in a utility boiler to generate steam/electricity).
  • Embodiments of the present disclosure include a composition comprising: a particulate solid component, where the particulate solid component comprises about 65% to 85% of the composition; and an additional component, where the additional component is selected from the group consisting of: a biomass component, a polymer component, and a composite waste product component.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a polymer component.
  • the biomass component comprises about 0.01% to 20% of the composition
  • the polymer component comprises about 8% to 20% of the composition.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a composite waste product component.
  • the biomass component comprises about 0.01% to
  • the composite waste product comprises about 0.01% to
  • Embodiments of the present disclosure include compositions where the additional component comprises a polymer component and a composite waste product component.
  • the polymer component comprises about 8% to 20% of the composition
  • the composite waste product component comprises about 0.01% to 10% of the composition.
  • Embodiments of the present disclosure include compositions where the additional component comprises a biomass component, a polymer component, and a composite waste product component.
  • the particulate solid component comprises about 65% to 85% of the composition
  • the biomass component comprises about 0.01% to 20% of the composition
  • the polymer component comprises about 8% to 20% of the composition
  • the composite waste product component comprises about 0.01% to 10% of the composition.
  • the particulate solid component comprises about 80% of the composition, wherein the polymer component comprises about 15% of the composition, and wherein the composite waste product component comprises about 5% of the composition.
  • Embodiments of the present disclosure include compositions used as a metallurgical MET coal pellet.
  • the particulate solid component is coal fines that are of a low volatility, higher in fixed carbon, and posses the type of petrography properties needed in the metals industry for either coke production or direct injection applications.
  • MET coal is not burned, but is used during the steel and metal making process to add carbon to the material.
  • direct injection the MET material is added directly to the steel making vats.
  • Embodiments of the present disclosure include compositions with an additive component where the additive component is selected from the group consisting of: coke breeze, carbon black, PET coke, and a combination thereof.
  • the particular additive components are selected for their high concentrations of carbon and/or low concentrations of volatiles.
  • the composition is capable of oversees transport and outdoor storage without degradation and moisture absorption.
  • Example 1 As illustrated in Table 1 below, Example 1 is based on combustion testing emission data and data on the make-up of an embodiment of the present disclosure burned during a trial.
  • the top portion of Table 1 shows the basic properties of a standard coal that is burned in a boiler.
  • the lower portion of Table 1 depicts the reduction in sulfur emissions based on blending of materials in a composition of the present disclosure, Btu increase (sulfur emissions are reduced by the higher Btu value of an embodiment of the present disclosure because less fuel needs to be burned to provide the same amount of energy, thus generating less emissions), and the effect of SO 2 scrubbing by the calcium carbonate contained in the recycled carpet.
  • Table 1 illustrates Table 1 as illustrated in Table 1 below, Example 1 is based on combustion testing emission data and data on the make-up of an embodiment of the present disclosure burned during a trial.
  • the top portion of Table 1 shows the basic properties of a standard coal that is burned in a boiler.
  • the lower portion of Table 1 depicts the reduction in sulfur emissions based on blending of materials
  • Example 2 illustrates sulfur reduction in an embodiment of the present disclosure including a pellet based on coal fines blending with the binder materials. This data is pre-combustion and is illustrated in Table 2 below. Table 2.
  • composition 015-B 2.89 35.5%
  • Composition 016-A 0.57 25.0%
  • composition 016-B 0.62 18.4%
  • composition 019-A 1.09 27.3%
  • composition 019-B 1.12 25.3%
  • Example 3 illustrates moisture reduction in produced pellets compared to the starting coal in an embodiment of the present disclosure including a pellet based on coal fines blending with the binder materials.
  • coal fine at 19.2% moisture are processed into pellets which have a total moisture content of 0.93%. This data is illustrated in Table 3 below. Table 3.
  • composition 019-A 1.74
  • Example 4 illustrates heating value increase in an embodiment of the present disclosure including a pellet based on coal fines blending with the binder materials.
  • pelletizing coal with a heating value of 8,897 Btu/lb produces a pellet with a heating value of 12,160 Btu/lb (an increase of 36.7%). This data is illustrated in Table 4 below. Table 4.
  • Tables 5 and 6 illustrates that embodiments of the present disclosure pick up very low amounts of water when soaked (e.g., less than about 2%) and pellets formed from compositions of the present disclosure dry very rapidly. Thus, the pellets are not adversely affected by water, nor do they fall apart when soaked in water.
  • all weight is in grams; "initial” includes the weight of a pellet prior to water soak; “removal” is the weight after water soak of thirty (30) minutes with immediate dry; and %WPU is percent wet pick up.
  • Table 6 includes %WPU of water during soak and the loss of water over time. Table 5.
  • Tables 7 and 8 illustrate properties for another embodiment of the present disclosure.
  • the data contained in Tables 7 and 8 illustrates that embodiments of the present disclosure pick up very low amounts of water when soaked (e.g., less than about 2%) and pellets formed from compositions of the present disclosure dry very rapidly. Thus, the pellets are not adversely affected by water nor do they fall apart when soaked in water.
  • all weight is in grams; "initial” includes the weight of a pellet prior to water soak; “removal” is the weight after water soak of thirty (30) minutes with immediate dry; and %WPU is percent wet pick up. Table 7.
  • Example 7 is a comparison of typical HAP values to data collected during a test burn of an embodiment of the present disclosure. In all cases, the values for an embodiment of the present disclosure are within the established range of values or below the established range (lower values are advantageous). Table 9.
  • ratios, concentrations, amounts, and other numerical data may be expressed herein in a range format. It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited.
  • a concentration range of "about 0.1% to about 5%” should be interpreted to include not only the explicitly recited concentration of about 0.1 wt% to about 5 wt%, but also include individual concentrations (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the indicated range.
  • the term "about” can include ⁇ 1%, ⁇ 2%, ⁇ 3%, ⁇ 4%, ⁇ 5%, ⁇ 6%, ⁇ 7%, ⁇ 8%, ⁇ 9%, or ⁇ 10%, or more of the numerical value(s) being modified.
  • the term “about” can include ⁇ 1%, ⁇ 2%, ⁇ 3%, ⁇ 4%, ⁇ 5%, ⁇ 6%, ⁇ 7%, ⁇ 8%, ⁇ 9%, ⁇ 10%, or more of 0.00001 to 1.
  • the phrase “about 'x' to 'y'” includes “about 'x' to about 'y'”.

Abstract

Des modes de réalisation de la présente invention comprennent des procédés de liaison de solides particulaires ainsi que des compositions qui en résultent.
PCT/US2009/040614 2009-04-15 2009-04-15 Procédés de liaison de solides particulaires et compositions solides particulaires WO2010120286A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2009/040614 WO2010120286A1 (fr) 2009-04-15 2009-04-15 Procédés de liaison de solides particulaires et compositions solides particulaires

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2009/040614 WO2010120286A1 (fr) 2009-04-15 2009-04-15 Procédés de liaison de solides particulaires et compositions solides particulaires

Publications (1)

Publication Number Publication Date
WO2010120286A1 true WO2010120286A1 (fr) 2010-10-21

Family

ID=42982746

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2009/040614 WO2010120286A1 (fr) 2009-04-15 2009-04-15 Procédés de liaison de solides particulaires et compositions solides particulaires

Country Status (1)

Country Link
WO (1) WO2010120286A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5916826A (en) * 1997-12-05 1999-06-29 Waste Technology Transfer, Inc. Pelletizing and briquetting of coal fines using binders produced by liquefaction of biomass
US20050132643A1 (en) * 2003-12-17 2005-06-23 Kele Energy, Llc Methods for binding particulate solids

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5916826A (en) * 1997-12-05 1999-06-29 Waste Technology Transfer, Inc. Pelletizing and briquetting of coal fines using binders produced by liquefaction of biomass
US20050132643A1 (en) * 2003-12-17 2005-06-23 Kele Energy, Llc Methods for binding particulate solids

Similar Documents

Publication Publication Date Title
US20090235577A1 (en) Methods For Binding Particulate Solids And Particulate Solid Compositions
US10626340B2 (en) Systems and methods for producing engineered fuel feed stocks from waste material
US8062390B2 (en) Methods for binding particulate solids
US8999014B2 (en) Systems and methods for producing engineered fuel feedstocks with reduced chlorine content
JP5492556B2 (ja) 焙焼による固体燃料の調製方法、およびそのようにして得られた固体燃料、およびそれらの燃料の使用
US10240091B2 (en) Process for devolatizing a feedstock
WO2010075306A1 (fr) Briquettes de particules de charbon dont le liant est la lignine et procédés et systèmes pour les préparer
WO2010120286A1 (fr) Procédés de liaison de solides particulaires et compositions solides particulaires
AU2006202328B2 (en) Methods for binding particulate solids
Harding Cofiring tire-derived fuel with coal
CA2550497A1 (fr) Methodes de liaison de particules solides

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 09843443

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 09843443

Country of ref document: EP

Kind code of ref document: A1