U.S. patent application number 13/090349 was filed with the patent office on 2011-12-22 for process and system for mixing, binding and stabilizing agents for manufacturing refuse driven solid waste.
Invention is credited to Gerard J. O'Brien, William F. Rhatigan.
Application Number | 20110308147 13/090349 |
Document ID | / |
Family ID | 44834492 |
Filed Date | 2011-12-22 |
United States Patent
Application |
20110308147 |
Kind Code |
A1 |
Rhatigan; William F. ; et
al. |
December 22, 2011 |
Process and System for Mixing, Binding and Stabilizing Agents for
Manufacturing Refuse Driven Solid Waste
Abstract
The present invention generally relates to waste to energy
systems and methods. The instant invention is further directed to
processes and systems for mixing, binding, and stabilizing agents
for manufactured refuse driven solid fuel.
Inventors: |
Rhatigan; William F.;
(Pocasset, MA) ; O'Brien; Gerard J.; (Pocasset,
MA) |
Family ID: |
44834492 |
Appl. No.: |
13/090349 |
Filed: |
April 20, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61325946 |
Apr 20, 2010 |
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Current U.S.
Class: |
44/605 |
Current CPC
Class: |
Y02E 50/10 20130101;
Y02E 50/30 20130101; C10L 5/46 20130101; C10L 5/14 20130101 |
Class at
Publication: |
44/605 |
International
Class: |
C10L 5/48 20060101
C10L005/48 |
Claims
1. A method for manufacturing solid fuel with enhanced efficiency
and throughputs of energy from solid waste comprising the steps of:
determining a desired BTU value for the solid fuel; obtaining solid
waste; determining the BTU value of the solid waste; manipulating
the BTU value of the solid waste to the desired BTU value; and
manufacturing solid fuel from the solid waste.
2. The method of claim 1, further comprising the step of adding a
binding agent to the solid waste.
3. The method of claim 2, wherein the binding agent is organic.
4. The method of claim 2, wherein the binding agent is
inorganic.
5. The method of claim 1, wherein the BTU value of the solid waste
is manipulated by the addition of at least one composition of known
BTU value.
6. The method of claim 1, further comprising the step of adding
additional compounds in order to affect the physical
characteristics of solid fuel.
7. The method of claim 1, wherein the method is a machine
implemented method.
8. The method of claim 1, wherein the solid waste comprises
inorganic waste.
9. The method of claim 1, wherein the solid waste comprises organic
waste.
10. Solid fuel manufactured in accordance with the method of claim
1.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to waste to energy
systems and methods. The instant invention is further directed to
processes and systems for mixing, binding, and stabilizing agents
for manufactured refuse driven solid fuel.
BACKGROUND OF THE INVENTION
[0002] Large quantities of solid waste, construction debris, large
items, and low value hazardous waste are generated daily in urban,
suburban, and rural areas. Additionally, industrial, manufacturing,
and agricultural businesses generate solid waste in vast
quantities. This waste is a problem globally. Typically, land
filling and incineration have been used as common means of waste
disposal. This creates excessive environmental problems, e.g.,
various chemical leaching and air pollution, etc., and contributes
significantly to greenhouse gas concerns.
[0003] Even with recycling efforts and increased awareness, the
majority of waste is being hauled and buried in landfills, which
within itself creates environmental concerns and problems. It is
accordingly desirable to process and manufacture this waste into a
viable and renewable manufactured product, such as solid, usable
fuel.
[0004] Gasification is a proven manufacturing process that converts
hydrocarbons in any organic fuel to a synthesis gas (syngas), which
can be further processed to produce chemicals, fertilizers, liquid
fuels, hydrogen, and electricity. Gasification is a flexible,
commercially proven, and efficient technology. Waste to Energy
(WTE) gasification can help improve air quality by reducing Green
House Gas emissions as well as emissions of several major key air
pollutants, as well as dioxins, depending on which feedstock's are
employed. These emission reductions can provide economic and
environmental benefits by virtually eliminating toxic emissions and
lowering emission-related operating costs, such as allowance permit
costs and emissions-control equipment expenses WTE gasification
achieves the reduction of greenhouse gas emission through three
separate mechanisms: 1) Generating electrical power or
steam,--combustion avoids carbon dioxide (CO2) emissions from
fossil fuel based electrical generation, 2) gasification process
effectively avoids all potential methane emissions from landfills;
thereby avoiding any potential release of methane in the future
and, 3) Recovery of ferrous and nonferrous metals from MSW
(Manufactured Solid Waste) is more energy efficient than production
from raw materials.
[0005] In addition to gasification, the use of coal in power
generation currently is 1 billion tons per year, in the USA alone.
Coal provides an economical method to heat and steam generation.
The inherent problem with coal as a fuel is the emissions creating
greenhouse gases and toxic dioxins. EcoTac.TM. reduces the gases
and toxic dioxins when co-fired with coal, while not impeding the
efficiency or operation.
[0006] The composition of the waste material in its natural state
is also a limiting factor as a result of decomposition, odor,
environmental leachate, and the inability to store or create
inventory. The processes of alternative and traditional power
generation, such as coal, gas, pyrolisis gasification, gasification
and plasma arc gasification, are all benefited from the
stabilization and the method of creating a variable or constant BTU
value and thermal image.
[0007] Currently, the majority of solid or industrial waste is
transported in its "natural form". This provides for not only
environmental issues, but an extremely poor weight to volume ratio.
There are methods of compacting and bailing that will increase the
weight to volume, but neither method environmentally stabilizes the
product. Additionally, these methods provide little ability to
prolong `shelf life". The process and system will not only resolve
these issues, but add the benefit of altering the BTU value and
thermal model positively or negatively.
SUMMARY OF THE INVENTION
[0008] The instant invention provides systems and methods for
making solid fuels from various waste compositions.
[0009] The present invention provides solid fuels that enhance the
efficiency and throughputs of energy generation in the fields of
coal, natural gas, syngas, gasification, plasma arc gasification
pyrolysis, and pyrolysis gasification.
[0010] One embodiment of the present intervention relates generally
to the composition of the compounds used in the system and the
method of mixing or injection of the compounds into the engineered
fuel to bind into a solid form, regardless of shape. Also, embodied
in the process is the ability to increase or decrease BTU value of
the engineered fuel and its base chemical or thermal image.
Additionally, the present invention provides means to act as a
method of stabilization or containment of any type or form of
waste.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a diagram of one embodiment of the present
invention.
[0012] FIG. 2 is a diagram of a system in accordance with the
present invention.
[0013] FIG. 3 is a diagram of a system in accordance with the
present invention.
[0014] FIG. 4 is a chart representing the analysis of a composition
in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] For simplicity and illustrative purposes, the principles of
the present invention are described by referring to various
exemplary embodiments thereof. Although the preferred embodiments
of the invention are particularly disclosed herein, one of ordinary
skill in the art will readily recognize that the same principles
are equally applicable to, and can be implicated in other
compositions and methods, and that any such variation would be
within such modifications that do not part from the scope of the
present invention. Before explaining the disclosed embodiments of
the present invention in detail, it is also to be understood that
the invention is not limited in its application to the details of
any particular embodiment shown, since of course the invention is
capable of other embodiments. The terminology used herein is for
the purpose of description and not of limitation. Further, although
certain methods are described with reference to certain steps that
are presented herein in certain order, in many instances, these
steps may be performed in any order as may be appreciated by one
skilled in the art, and the methods are not limited to the
particular arrangement of steps disclosed herein.
[0016] The system and process of the present invention may be used
with any combination of any solid or liquid refuse driven fuel. The
combination of organic or inorganic compounds may be used in the
process or either may be used singularly to produce the
stabilization and density of the engineered fuel.
[0017] The invention may comprise one or several features as
described herein, and or several combinations of the process of
injection and mixing. The process is comprised of various materials
both organic and inorganic, but considered carbon neutral. The base
process will provide binding of either solid or liquid and can be
used in any combination or ratio of solid to liquid as a percentage
of weight or volume. The system will use the resultant of the
process to create a base product and will inject or insert into the
engineered fuel.
[0018] The system will use a mixer to establish the baseline
product. The system may comprise an additional mixer to enhance or
reduce the viscosity and absorption ratio predicated of the initial
state of the engineered fuel.
[0019] Additional embodiments of the system may comprise automatic
controllers to adjust and limit the exact amount of the additives
to the baseline products. The additives may be either organic or
inorganic and will have the ability to increase or decrease the BTU
value of the base engineered fuel. Further embodiments may comprise
the addition of heat to the system for its drying and ability to
transform the products neutral state.
[0020] The mixture can be based on a single compound, either
organic or inorganic and will establish a baseline BTU value and
thermal model. The single compound can be blended with two or more
alternative compounds that will produce a difficult BTU value and a
set of trace chemical elements. The addition of heat to the final
blend will only be added to affect the viscosity and set time of
the injection into the solid fuel mix.
[0021] Depending on the form and shape of the final enclosed or
encapsulation, the material will be injected under pressure. The
volume and pressure will be a function of density of the solid
fuel, amount of oxygen balance, as well as BTU and thermal
model.
Example 1
[0022] With the establishment of the desired BTU value and chemical
composition for the manufactured solid fuel, the fuel will be
balanced by either stabilization, encasement or solidifying
methods. In either case, the use of binding agents may be used.
[0023] The BTU value of the manufactured solid fuel may be
manipulated by the addition of either a single compound or two or
more compounds.
[0024] The compounds may be either organic or inorganic, or a
combination of either group to increase or decrease the final BTU
value and thermal image of the gaseous compounds of the solid
fuel.
[0025] Ideally, the compounds, either organics or inorganic, will
be derived as a byproduct or substate of the original MSW, but have
been altered in either state or molecular structure.
[0026] Compounds may also be added to increase viscosity of the
additive to the solid fuel. The compounds may be comprised of
variable compositions and can be either Newtonian or non-Newtonian
in composition.
[0027] BTU value and thermal image of the additive may be used to
increase or decrease the base mix of either the binding or
solidifying agent of the solid fuel to effect stability of the
final solid fuel.
[0028] The viscosity of either the single or multiple variable
compositions of the additive to the solid fuel may be used to
effectively increase or decrease the additive of the solid fuel for
shear stress, velocity or gradient of the additive and ultimately
the final solid fuel.
[0029] Dry or liquid organics or inorganics may be used as a
binding agent. The medium may be either neutral in BTU value, or be
combined singularly or with two or more mediums as to increase or
decrease carbon value.
[0030] Organic or Inorganic medium used as a binding agent may be
used singularly or with two or more agents as to not affect BTU
value, but used to change the molecular structure to increase or
decrease gas composition of the thermal image.
[0031] Mixing of the medium used to create the binding agent may be
accomplished by either manual or automatic process. The use of a
singular mixing means and methods will produce a 60% of the
singular agent or the introduction of two or more mediums used as
the base binding agent or the manufactured solid fuel.
[0032] The mixing process will enable a desired level of air and
moisture entrapment in the base binding agent. This process may be
used singuularly or with two or more of the medium used to create
the blended binding agent.
[0033] Entrapment of moisture and air may be adjusted singularly or
in combination and may be mixed as to generate disproportionate
ratios of air and moisture.
[0034] The process of mixing may be accomplished manually or
automatically in any combination that creates the effective binding
agent with the necessary cohesiveness to solidify the manufactured
solid fuel from the transformation point in the manufacturing
process of recombination, but before final packaging.
[0035] The use of automated controllers may be added to the mixing
process. The addition of the controllers may be either hydraulic or
electrical, and/or any combination of the two.
[0036] The controllers may be used to adjust the speed, volume,
temperature and velocity of the medium used in the binding agent
either singularly or in any combination of two or more agents that
are creating the binding agent.
[0037] Controllers used in the mixing may be incorporated to adjust
the process on either the x or y axis to effect moisture, and/or
entrapment of air.
[0038] The controllers may be used in the mixing process to affect
the additives from either a solid to a liquid, or liquid to a
solid, while maintaining the optimum dynamic viscosity.
[0039] Automated controllers used in the mixing process will effect
mixing not only dimensionally on the x and y axis, but also as it
correlates to volume, density, temperature, as well as fugitive
elasticity, not only as a factor of the binding agent, but also the
manufactured solid fuel.
[0040] During mixing of the binding agent should a gas be created
or incorporated as part of the entrapment mixing a defined minimum
and maximum ratio will be used to increase or decrease viscosity
with the increase if temperature of the binding agent.
[0041] The use of a single or multiple controllers as to location,
size, functionality, in the process of establishing the medium(s)
used to develop the base binding agent may be established with the
introduction of computer aided design simulation or CAE to the
process.
[0042] If CAE is used; the simulation will not only be for the
incorporation of the controllers, but may be used to establish
concurrent engineering versus sequentional engineering and material
control.
[0043] Additionally, CAE simulation for the binding agent may be
used to establish process parameter control, encasement design
considerations and cost estimation.
[0044] The binding agent may be incorporated into the solid fuel
process manually or automatically by various forms and techniques
of injection.
[0045] Manual incorporation of the binding agent may use singular
or multiple components in the additive and may be placed in a free
flow manner, with varying degrees or percentages of incorporation
into the manufactured solid fuel.
[0046] Automatic incorporation of the binding agent into the
manufactured solid fuel process may be instituted in single or
multiple steps and area's of the manufacturing process.
[0047] Variables effecting the location and volume of the manual or
automatic incorporation of the binding agent are dependent on the
desired specification of the solid fuel for BTU value and thermal
value.
[0048] Automatic injection of the binding agent will be based on
the thermal properties of the mediums used to create the binding
agent.
[0049] Automatic injection of the binding agent may be incorporated
into the process at a single point or at multiple points of the x
and y axis dependant on shape, volume, density of the encapsulation
and method used to process for shipment.
[0050] The form and type of material used to encapsulate the
manufactured solid fuel may require single or multiple parts of
injection of the binding agent to ensure total solidification of
the binding agent to the manufactured solid fuel.
[0051] Mold flow analysis may be added to the CAE simulation
process to adjust injection pressure and to manipulate thermal
property, variable solidifying rates, flow paths and set time.
[0052] Single gates or two or more gates may be used to ensure
complete integration of the binding into the manufactured solid
fuels.
[0053] A single gate or multiple gates can be incorporated into the
injection controllers to set a uniform rate of psi (pounds per
square inch) or exert a maximum pressure of 20,000 psi.
[0054] Pressure and flow control for injection will also be based
on the thickness of the wall encapsulation material, shape and
compressive strength.
[0055] Dynamic modeling of pressure, flow and gates may be
incorporated to establish the tensile or compressive strength under
full load of the encapsulated manufactured solid fuel.
[0056] Additional pumps may be introduced to create vacuum pressure
for the removal of air within the encasement as the manufactured
solid fuel is added. The addition of one or more binding agents may
be incorporated for desired vacuum pressure prior to full
encapsulation.
[0057] The volume of air removed is a direct ratio of the optimum
fuel design as required by the customer. The quality of entrapped
air may be modified positively or negatively to maintain BTU and
thermal value.
[0058] Controllers used in conjunction with pumps will adjust
excessive transient pressure to prevent molecular degradation of
the material and shape used for encapsulation.
[0059] The introduction of moisture may be found/used in either as
a by product of organic and/or inorganic material used in either
the binding agent or within the manufactured solid fuel.
[0060] Moisture will be adjusted by addition or subtraction by
either pumps or gate valves to prevent dangerous transient
pressures being entrapped as a final component of the manufactured
solid fuel.
Example 2
[0061] A solid fuel was produced using methods in accordance with
the instant invention. The desired analysis of the solid fuel is
outlined in Table 2.
TABLE-US-00001 TABLE 2 FUEL COMPOSITION BTU/RANGE 10,500-14,500
DESIRED ULTIMATE ANALYSIS ON DRY BASIS: ASH <54% C >68% H
8.1% O <16% N 1%% S <1.0% CL <.1% FL <.004% H2O 5.0% HG
<.3 PPM
[0062] Based on an average 5% moisture content
[0063] Examples of the actual analysis of the solid fuel can be
seen in Table 1.
TABLE-US-00002 TABLE 1 SAMPLE IDENTIFICATION MUNICIPAL WASTE DATE
REPORTED: 03/26/10 % MOIS % % VOL % FIXED BTU/ % SUL TURE ASH ATILE
CARBON LBS FUR AS REC'D 0.88 2.14 91.08 5.90 12683 0.07 DRY BASIS
-- 2.16 91.89 5.95 12796 0.07 M-A-FREE 13078 Note: Sample Tested
using ASTM Volume 05.06 for Gaseous Fuels; Coal and Coke ULTIMATE
ANALYSIS (% DRY BASIS) ASH 2.16 HYDROGEN 7.54 CARBON 66.41 NITROGEN
0.61 SULFUR 0.07 OXYGEN 23.21 CHLORINE 0.41
[0064] As shown in Table 1, solid fuel produced in accordance with
the instant invention surpasses desired dry analysis targets.
Example 3
[0065] Additional samples of solid fuel were produced in accordance
with the methods described herein. The analysis of these samples is
shown in Tables 3 and 4.
TABLE-US-00003 TABLE 3 Weight % As Dry As Dry PROXIMATE ANALYSIS
Received Basis ULTIMATE ANALYSIS Received Basis % Moisture D3302
2.17 ***** % Moisture D3302 2.17 ***** % Ash D3174 4.41 4.51 %
Carbon D5373 65.89 67.35 % Volatile D3175 92.28 94.33 % Hydrogen
D5373 8.12 8.30 % Fixed Carbon D3172 1.13 1.16 % Nitrogen D5373
1.91 1.95 BTU D5865 13483 13782 % Chlorine D6721 0.15 0.15 MAF-BTU
D3180 14433 % Sulfur D4239B 0.05 0.05 % Total Sulfur D4239B 0.05
0.05 % Ash D3174 4.41 4.51 SULFUR FORMS % Oxygen (Diff.) D3176
17.30 17.69 % Pyritic D2492 ***** ***** (Chlorine D6721 Dry Basis
ug/g 1471) % Sulfate D2492 ***** ***** MINERAL ANALYSIS D6349 %
Ignited Basis % Organic D2492 ***** ***** Phos. Pentoxide, P2O5
***** % Total Sulfur D4239B 0.05 0.05 Silica, SiO2 ***** WATER
SOLUBLE Ferric Oxide, Fe2O3 ***** % Na2O ASME1974 ***** *****
Alumina, Al2O3 ***** % K2O ASME1974 ***** ***** Titania, TiO2 *****
% Chlorine ASME1974 ***** ***** Lime, CaO ***** Alkalies as Na2O
ASME1974 ***** ***** Magnesia, MgO ***** FUSION TEMP. OF ASH D1857
Reducing Oxidizing Sulfur Trioxide, SO3 ***** I.D. ***** *****
Potassium Oxide, K2O ***** H = W ***** ***** Sodium Oxide, Na2O
***** H = 1/2 W ***** ***** Barium Oxide, BaO ***** Fluid *****
***** Strontium Oxide, SrO ***** GRINDABILITY INDEX D409 ***** @
***** % Moist. Manganese Dioxide, MnO2 ***** GRIND INDEX
UNCONDITIONED ***** @ ***** % Moist. Undetermined ***** FREE
SWELLING INDEX D720 ***** Type of Ash ASME1974 ***** Apparent
Specific Gravity of Coal ModIC7113 ***** Silica Value ASME1974
***** % Equilibrium Moisture D1412 ***** T250 Deg B&W *****
Base/Acid Ratio ASME1974 ***** lb Ash/mm BTU 3.27 lb SO2/mm BTU
0.07 Fouling Index ASME1974 ***** Slagging Index ASME1974 *****
(Mercury D6722 Dry Basis ug/g 0.019)
TABLE-US-00004 TABLE 4 Weight % As Dry As Dry PROXIMATE ANALYSIS
Received Basis ULTIMATE ANALYSIS Received Basis % Moisture D3302
2.12 ***** % Moisture D3302 2.12 ***** % Ash D3174 2.30 2.35 %
Carbon D5373 66.91 68.36 % Volatile D3175 94.15 96.19 % Hydrogen
D5373 8.31 8.49 % Fixed Carbon D3172 1.43 1.46 % Nitrogen D5373
2.30 2.35 BTU D5865 13652 13948 % Chlorine D6721 0.15 0.15 MAF-BTU
D3180 14284 % Sulfur D4239B 0.03 0.03 % Total Sulfur D4239B 0.03
0.03 % Ash D3174 2.30 2.35 SULFUR FORMS % Oxygen (Diff.) D3176
17.88 18.27 % Pyritic D2492 ***** ***** (Chlorine D6721 Dry Basis
ug/g 1486) % Sulfate D2492 ***** ***** MINERAL ANALYSIS D6349 %
Ignited Basis % Organic D2492 ***** ***** Phos. Pentoxide, P2O5
***** % Total Sulfur D4239B 0.03 0.03 Silica, SiO2 ***** WATER
SOLUBLE Ferric Oxide, Fe2O3 ***** % Na2O ASME1974 ***** *****
Alumina, Al2O3 ***** % K2O ASME1974 ***** ***** Titania, TiO2 *****
% Chlorine ASME1974 ***** ***** Lime, CaO ***** Alkalies as Na2O
ASME1974 ***** ***** Magnesia, MgO ***** FUSION TEMP. OF ASH D1857
Reducing Oxidizing Sulfur Trioxide, SO3 ***** I.D. ***** *****
Potassium Oxide, K2O ***** H = W ***** ***** Sodium Oxide, Na2O
***** H = 1/2 W ***** ***** Barium Oxide, BaO ***** Fluid *****
***** Strontium Oxide, SrO ***** GRINDABILITY INDEX D409 ***** @
***** % Moist. Manganese Dioxide, MnO2 ***** GRIND INDEX
UNCONDITIONED ***** @ ***** % Moist. Undetermined ***** FREE
SWELLING INDEX D720 ***** Type of Ash ASME1974 ***** Apparent
Specific Gravity of Coal ModIC7113 ***** Silica Value ASME1974
***** % Equilibrium Moisture D1412 ***** T250 Deg B&W *****
Base/Acid Ratio ASME1974 ***** lb Ash/mm BTU 1.68 lb SO2/mm BTU
0.04 Fouling Index ASME1974 ***** Slagging Index ASME1974 *****
(Mercury D6722 Dry Basis ug/g 0.015)
[0066] While the invention has been described with reference to
certain exemplary embodiments thereof, those skilled in the art may
make various modifications to the described embodiments of the
invention without departing from the scope of the invention. The
terms and descriptions used herein are set forth by way of
illustration only and are not meant as limitations. In particular,
although the present invention has been described by way of
examples, a variety of compositions and methods would practice the
inventive concepts described herein. Although the invention has
been described and disclosed in various terms and certain
embodiments, the scope of the invention is not intended to be, nor
should it be deemed to be, limited thereby and such other
modifications or embodiments as may be suggested by the teachings
herein are particularly reserved, especially as they fall within
the breadth and scope of the claims here appended. Those skilled in
the art will recognize that these and other variations are possible
within the scope of the invention as defined in the following
claims and their equivalents.
* * * * *