Method and device for pelletizing unprocessed cellulosic fibrous material
The present invention relates to a method and a device for pelletizing unprocessed cellulosic fibrous material on an industrial scale, and in particular to the use of said unprocessed cellulosic fibrous material pellets as a combustible fuel product.
This application claims the benefit of U.S. Provisional Application No. 60/721,358, filed Sep. 28, 2005. The subject application also claims priority to European Patent Application No. 05021213.3, filed Sep. 28, 2005.
FIELD OF THE INVENTIONThe present invention relates to a method and a device for pelletizing unprocessed cellulosic fibrous material, in particular sugar-cane bagasse, on an industrial scale, and in particular to the use of said unprocessed cellulosic fibrous material pellets as a combustible fuel product.
BACKGROUND OF THE INVENTIONSince fossil fuel has become a finite energy source, in the last decades many efforts have been put into the production of alternative energy materials. These alternative materials should not only be affordable and readily available, they also should be preferably derived from renewable sources. Among the existing renewable alternatives to fossil fuels, biomass has raised great interest. Wood or wood by-products are prime examples of renewable energy materials when used for the production of fuel briquettes or pellets. The main source of firewood has been found in native forests, mainly the Atlantic rain forests and the cerrados in Brazil. It is simple to imagine that these sources are also finite sources, and that an increase of wood fuel consumption would not only lead to an increase in the price of these raw materials but also to the loss of many forests since a tree needs a long growth period, which decreases the desirability of wood as a renewable energy source.
As an alternative to wood-based products, other agriculture materials, such as sugar-cane, have been investigated. Sugar-cane (Saccharum officinarum) belongs to the family of grasses (Poaceae). It is a tall grass which is native in warm temperate to tropical regions of the world. There are 13 million hectares of sugar-cane plantations worldwide, and Brazil is one of the major growers of sugar-cane. In Brazil, sugar-cane is currently used to produce sugar as well as to provide the alcohol used in making gasohol fuels.
Sugar from freshly harvested sugar-cane is extracted by sugar-cane mills, mostly located in sugar-cane producing regions. In a sugar mill, sugar-cane is washed, chopped and shredded, then the shredded cane is repeatedly mixed with water and crushed between rollers to collect juices containing 10-15% sucrose. The remaining fibrous waste is commonly known as bagasse, and is currently used on-site in sugar mills as a fuel, by feeding the bagasse into the boilers to generate steam and power. In this way, bagasse makes a sugar mill more than self-sufficient in energy. The surplus bagasse can also be used for animal feed, in paper manufacture, or burned to generate electricity for the local power grid.
After extracting sugar from the fibrous residues, the bagasse moisture content can vary considerably, containing up to 50% water. However in this state, the bagasse cannot be transported elsewhere as a fuel due to the low calorific value (8-9 Giga Joules per metric ton), and transporting issues.
Therefore, it would be useful to convert the bagasse into a compact transportable fuel, which can be achieved by drying and pelletizing. In addition, the resulting pellets can be blended with coal in an effort to reduce emissions in coal-fired power stations.
U.S. Pat. No. 4,363,636 (WO 83/01457 A1) (BR 8207930) describes bagasse as a source of energy that is increased by a flexible operation adapted to the power requirements, fuel storage requirements and other variables of a sugar mill operation. Part or all of a primary stream of bagasse from the sugar mill is dried from its initial moisture content, e.g. in the order of 50%, to a lower moisture content of about 25-40% using a portion of the hot flue gases from the boilers which are used to supply power for the sugar mill operation. The resulting drier material is separated to provide an oversize particle stream which may be sent directly to the boiler for burning, to storage in the bagasse house, or to a secondary drying operation, and a secondary stream of fine particle size bagasse components which are most suitable for further processing and densification. This secondary stream, with optional addition of oversize particles from the primary drying operation, is then dried in contact with another portion of hot flue gases to a moisture content suitable for densification, about 6-12% where a pellet mill is employed, and is further subjected to particle size selection, if necessary, and then subjected to densification in a pellet mill or other suitable equipment. The densified material is then sent to storage, returned to the boilers for part or all of the fuel requirement or transported to other potential users.
MU 6801860 U describes a sugar cane bagasse dryer intended to eliminate the low effectiveness of burning the wet bagasse, as it comes from compression. This arrangement basically comprises a diffuser that holds a carrier mat with the crushed sugar cane bagasse. Such carrier mat is provided with a flow channel to drain the liquid from the bagasse. Such bagasse is inserted in the upper portion of a drying column and leaves dry in the lower portion due to heated air provided by the furnace.
BR 8801542 also describes a dryer for solid bagasse, i.e. sugar cane bagasse, without jeopardizing the necessary thermal power used as direct heat source, cut cane straw and/or foliage in general.
BR 8100104 describes a cyclone, a dryer operative under the simultaneous principle of pneumatic heat and mass, a separator cyclone and pelletizer, and using the fluid from solid fuel burn called “BIOCOM” as drying agent, generating vapour to cook the product, which is rich in nutritive substances. Similarly, BR 8100102 describes a process for obtaining a dry and solid fuel with high heat power from sugar cane bagasse and its plant which includes a bagasse dryer operating under the heat transference principle and pneumatic mass, followed by a separator cyclone and a agglomerated and continuous presser, working as dryer agent, the fluid being originated from the burning of fuel obtained in a furnace, the final product being dry and compact, such product being able to be economically stored and carried, without the difficulties of the original product.
BR 8102291 describes a process to increase the apparent specific heat power of sugar cane bagasse and its available energy, inside or outside the sugar factory. This process makes use of the wasted heat or the heat wrongly used in sugar cane and alcohol factories by drying or dehydrating the bagasse, increasing its lower heat power (Kcal/Kg). This causes a great excess of bagasse, which will be packaged in the adequate grain measure and compacted to obtain a greater heat concentration, in order to facilitate its transport or storage to be used as alternative energy and/or animal food and similar.
U.S. Pat. No. 4,326,470 describes an individual bagasse drier that realizes a system of utilization of the chimney gases to decrease the moisture of the bagasse left from the mill in 10 or 15 points, increasing the steam production between 13.5% to 15.45% respectively. It consists of a drier for each furnace, and consumes 54% of the power installed per ton of dry bagasse, in relation to the existing systems in the market.
U.S. Pat. No. 4,613,339 describes a method for preparing and using a combustible fuel product using sweet sorghum. A sorghum variety high in sugar, high in biomass, and low in nitrogen is first processed to remove a majority of sugars therefrom. The remaining ligno-cellulosic residue, commonly known as bagasse, is converted into combustible pellets or alternatively stored for future pelletization. Storage is accomplished by first piling the bagasse on a hard surface. The bagasse is then compressed to form a compacted mass. Compression frees trapped air in the pile, hindering oxidative degradation by bacteria and other microorganisms. U.S. Pat. No. 4,613,339 further discloses that sugarcane is not preferred for the method, since it requires temperate, humid growing conditions that are not found in the US. U.S. Pat. No. 4,613,339 discusses about spontaneous combustion, a feature that appears to be inherent to pelletization. U.S. Pat. No. 4,613,339 proposes to use low-nitrogen sorghum in order to address this problem. Thus, this method can only be used for the pelletization of some materials.
U.S. Pat. No. 4,015,951 discloses pellets adapted to be burned in industrial applications that are prepared by adjusting the particle size of organic fibrous material to not more than about 85% of the minimum dimension of the pellets to be produced, adjusting the moisture content of the fibrous particles to about 16% to about 28% by weight, pelletizing the particles into substantially symmetrical pellets having a maximum dimension of about one-half inch at a pressure whereby constituents of the particles exude and form a coating of wax-like material on the surface of the pellets, and adjusting the moisture of the pellets to a content which is in equilibrium with the atmosphere. U.S. Pat. No. 4,015,951 further discloses a method of making fuel pellets of organic fibrous material. The method includes providing and feeding a raw material of random particle size, conveying the material to a hammer mill, while foreign particles are removed, adjusting the particle size to a maximum dimension of 85% of the pellet (or less), transporting the particles to a rotary drum type dryer, adjusting the moisture content to about 16-28 wt % “free moisture” (regarded as important step), conveying the material to a pelletizer, compression of the material at about 325 to 350° F., and adjusting the temperature and moisture content by a fan to about 7 to 8% equilibrium moisture. The size of the pellets shall be one-eighth to one-half inch, the density is about 65 pounds per cubic foot. The organic fibres are described as agricultural or wood waste materials. U.S. Pat. No. 4,015,951 requires to adjust the moisture in equilibrium with the atmosphere, and that the moisture content should be uniform before storing, since the pellets in the pile will have a different moisture, compared to the surface pellets (apparently in order to reach uniform burning).
U.S. Pat. No. 5,643,342 discloses a fuel pellet and a method of manufacturing a fuel pellet capable of burning in either a stoker or pulver furnace. The pellet is formed by an extrusion process and method for drying a combustible cellulosic fibrous material, wherein said method comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material contains particles. The pellet is about ¾ to about 3 inches in length (i.e. larger than the pellets as claimed herein). The pellet is always composed of several components to be extruded. The screening as described by U.S. Pat. No. 5,643,342 appears to be suitable only to exclude material that is present as excess particles (i.e. smaller than 80 mesh).
So far, the operation technology of pelletization machinery and similar equipment, such as briquetters, are generally known to the person of skill in the art. However, their use with unprocessed sugar-cane bagasse had never been performed on an industrial scale without the use of the hot flue gases from the boilers. While the literature mentions the production of pellets from unprocessed sugar-cane bagasse, the manner in which this method is described is not feasible to solve the particular problems and needs that derive from the secure industrial production perspective.
Some basic studies involving pelletization in a lab environment have been carried out in Australia, showing that long-lasting pellets can be produced with 10% humidity, 60-100° C., and eight-second compression time in the pelletization equipment at pressures of 80 to 320 kgf/cm2, all of which led to a final product density between 450 kg to 600 kg of dry material per cubic meter. However, in all these tests production was way below the pelletizers' nominal capacity.
In regard to the phase involving the unprocessed sugar-cane bagasse, which is a key step to ensure sound method performance, it is essential to mention some experiments, wherein the unprocessed sugar-cane bagasse using the boiler exhaust gases in a counter-flow with the bagasse in suspension.
The pellet-production facilities Centro de Tecnologia Canavieira developed had a first model applied on an industrial scale next to a sugar mill. This model operated on-and-off during the 1982 crop and it basically produced hydrolyzed sugar-cane bagasse pellets for animal-feed applications. Another aspect analyzed was the high bagasse drying temperature, which rendered operations unsafe because of the fire risk. This technology also faced operational difficulties in relation to the air-bagasse counter-flow, mainly frequent clogging of the system.
It should be noted, that the pelletization method is basically the compressing of unprocessed sugar-cane bagasse, which has variable density and humidity. The raw material used in producing the pellets is unprocessed sugar-cane bagasse with following characteristics:
For comparison the average calorific content of some types of firewood are shown:
As already mentioned, bagasse has been used as a fiel and pelletized. However, for its use as nationally registered biofuel and to freight the pellets overseas the final pellets should have similar calorific content as the above mentioned firewood and a certain moisture.
Thus, among the existing renewable alternatives to fossil fuels, the biomass has raised the greatest interest. Since firewood found in native forests is a finite energy source, it is essential to replace the firewood biomass for unprocessed bagasse pellets. This invention refers to a secure continuous pelletization method on an industrial scale compressing unprocessed sugar-cane bagasse, using steam to dry during the spinning dryer. In addition, this method is environmentally clean and reuses all industrial rejects.
Moreover, this product will have the following additional advantages:
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- The product is from 100% recycled origin and is environmentally friendly because it reduces deforestation.
- The product has a calorific charge similar to firewood.
- The product requires reduced storage capacity, thus enabling emergency and buffer stocks.
- It is a clean product without the drawbacks of firewood.
- The product's low humidity raises temperature quickly and the product releases less smoke, ashes and soot when compared to firewood.
- It has a more homogeneous calorific charge than firewood.
- It has a higher flame temperature.
- It causes less pollution because it is a renewable fuel.
- The present invention addresses the issue of problems arising with combustion and fire in an industrial environment during the drying step(s). The state of the art is silent about the use of special security measures when processing sugar cane bagasse.
- The state of the art furthermore does not discuss the energy consumption required when producing the sugar cane bagasse.
It is an object of the present invention to provide a method and a device on an industrial scale for pelletizing unprocessed sugar-cane bagasse in order to obtain pellets having the following preferable characteristics: Upper calorific content: about 4,500 to about 5,500 kcal/kg; lower calorific content: about 3,500 to about 4,500 kcal/kg; density: about 500 to about 600 kg dry matter/m3; and humidity: about 10% to about 15%.
Another object of this invention is to provide a method and a device for the production of unprocessed sugar-cane pellets, correcting the operational difficulties faced by the previous mentioned attempts on an industrial scale, e.g. the high bagasse drying temperature and therefore the high fire risk. One further object of this invention is to provide unprocessed sugar-cane bagasse pellets to be used in place of fossil fuels for steam-generation processes, hot-gas generators, and equipment that generates thermal energy. In line with this it is another object of this invention to provide unprocessed sugar-cane bagasse pellets transportable to regions, such as Europe or Japan with shortages of biomass of high calorific value, as a cleaner fuel with all the necessary specification, consistency and price requirements.
These and other objects and advantages of the present invention will become more readily apparent from the following detailed description.
DESCRIPTION OF EMBODIMENTS OF THE INVENTIONThe present invention involves a method and a device on an industrial scale for pelletizing unprocessed sugar-cane bagasse in order to obtain pellets.
In a first aspect of the present invention, the object thereof is solved by providing a method for drying a combustible cellulosic fibrous material, wherein said method comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material.
Preferred is a method according to the invention, wherein said drying unit is a rotary dryer, in particular a spinning tube dryer (8). Such dryers are known to the person of skill and are commercially available (for example as manufactured by the Masiero Industrial S/A, Brazil), and can be readily adjusted by the person of skill for performing the inventive method in an industrial scale. One preferred example of a rotary dryer, in form of a spinning tube dryer with a bundled tube arrangement, is shown in
Preferred is a method according to the invention, wherein said heat source comprises a system of tubes, in particular bundled tubes, conveying the heat source. More preferably, said heat source is saturated steam.
Further preferred is a method according to the invention, wherein the heat source is applied at a temperature ranging from about 170 to about 185° C. inside the tubes, resulting in temperatures ranging from about 135 to about 140° C. on the external surfaces of the tubes in the drying unit (i.e. the steam inside the pipes dry without contact with the bagasse, whilst the steam flow heating the internal surface of the pipes and bagasse has contact with the external surface of the pipes). This results in the temperatures ranging from about 135 to about 140° C. Preferably, said sugar-cane bagasse starts to dry as soon as it gets in contact with the bundle of tubes.
Preferred is a method according to the invention, wherein the heat source is applied at a pressure of about 8.34 bar to about 9.81 bar (8.5 to 10 kgf/cm2) inside the tubes.
In another preferred embodiment of the method of the present invention, said spinning tube dryer is fitted with deflectors positioned at an angle of about 45° attached to the tube bundles, in order to increase efficiency in the transportation and drying of bagasse inside the dryer.
In a second aspect of the present invention, the object thereof is solved by providing a method for pelletizing combustible cellulosic fibrous material, comprising:
- (a) providing and feeding of unprocessed combustible cellulosic fibrous material into said method,
- (b) cleaning of said unprocessed combustible cellulosic fibrous material,
- (c) drying of said cleaned unprocessed combustible cellulosic fibrous material,
- (d) pelletization of said dried combustible cellulosic fibrous material, and
- (e) sorting and drying of said pelletized combustible cellulosic fibrous material, wherein the drying in step (c) comprises a method according to the invention as described above.
Preferably, the dried combustible cellulosic fibrous material pellets are suitably stored in an additional step (f).
Preferably, in step (a) of the method of the present invention, unprocessed combustible cellulosic fibrous material is continuously fed into the method while the bagasse is loosened and flattened.
In one embodiment of the method according to the present invention, unprocessed combustible cellulosic fibrous material is fed in step (a) through a feed box (2) and loosened and flattened by a sprayer (3).
In a preferred embodiment of the method of the present invention said feed box can hold a 15-minute supply in relation to the plant output capacity.
In another preferred embodiment of the method of the present invention, said feed box has a cleated or similar type conveyor belt to transport the unprocessed combustible cellulosic fibrous material.
In a particular preferred embodiment of the method of the present invention, said feed box comprises a rectangular flat-wall and a flat-bottom.
In one embodiment of the method of the present invention, in step (b) ferrous material and impurities of the unprocessed combustible cellulosic fibrous material are removed. More preferably, said ferrous material is removed by an electromagnet (5), and any other impurities are removed by a di-stone (6).
In another preferred embodiment of the method according to the present invention, subsequently a fiber remover and a separator of coarse impurities are used.
In another preferred embodiment of the method of the present invention, said feeding conveyor belt is fitted with the said electromagnet (5) having a minimum magnetic capacity of about 1,500 gauss. This electromagnet is placed far enough above the conveyor belt so that it can remove ferrous material and does not halt the method and the pelletizer. This electromagnet is cleaned frequently to have removed any ferrous material attracted thereto.
In another particular preferred embodiment, said electromagnet is installed in the passage between conveyor belts, an area where the combustible cellulosic fibrous material is moved considerably.
In a further particular preferred embodiment said di-stone (6) is a rotating machine consisting of 5 to 8 perpendicular axes with star-shaped knives that counter rotate.
In one embodiment of the method of the present invention, said unprocessed combustible cellulosic fibrous material is dried using saturated steam in step (c).
In a preferred embodiment of the method according to the present invention, the cleaned unprocessed combustible cellulosic fibrous material is transported by a cleated or similar type conveyor belt (7) to the spinning tube dryer (8) using a system of bundled tubes conveying saturated steam at about 8.34 bar to about 9.81 bar (8.5 to 10 kgf/cm2), at a temperature ranging from about 170 to about 185° C. inside the tube, providing indirect contact with the product in the tube's external wall (i.e. the steam inside the pipes dry without contact with the combustible cellulosic fibrous material, whilst the steam flow heating the internal surface of the pipes and combustible cellulosic fibrous material has contact with the external surface of the pipes). This results in temperatures ranging from about 135 to about 140° C. Preferably, said combustible cellulosic fibrous material starts to dry as soon as it gets in contact with the bundle of tubes.
In another preferred embodiment of the method of the present invention, said combustible cellulosic fibrous material is dried from a moisture in the range of about 44 to about 55% to about 13 to about 20% in a drying step. Then, in one embodiment of the method according to the present invention, the dried combustible cellulosic fibrous material having a humidity varying between about 13 to about 20% is taken to the pelletizers by a cleated or similar type conveyor belt.
In another preferred embodiment of the method of the present invention, said spinning tube dryer is fitted with deflectors positioned at an angle of about 45° attached to the tube bundles, in order to increase efficiency in the transportation and drying of combustible cellulosic fibrous material inside the dryer.
In a further embodiment of the method of the present invention, the minimum spacing between the tubes is about 75 mm, helping to prevent any combustible cellulosic fibrous material accumulation inside the dryer, which eventually might lead to combustion.
In another preferred embodiment of the method of the present invention, in step (c) said unprocessed combustible cellulosic fibrous material remains inside the spinning tube dryer for about 12 minutes, at about 4 rpm using about 2 to about 3 metric tons of steam per hour.
In a particular preferred embodiment of the method according to the present invention, after the combustible cellulosic fibrous material leaves the tubular bundles, it is insufflated with hot air by a duct coming from a heat radiator (9) fed by saturated steam (VS). This operation heats the gases in counter flow with the combustible cellulosic fibrous material, thus helping the drying method and preventing any accumulation of solid residues (powder) inside the dryer.
In another preferred embodiment of the method of the present invention, the hot and humid gases in step (c) are removed on the opposite side of the entrance of the dryer by a duct with forced exhaust (10), and sent to a cyclone, or similar equipment, where the solid particles (powder) are separated and sent to be burned by the boiler.
In one embodiment of the method according to the present invention, the dried combustible cellulosic fibrous material having a humidity varying between about 13 to about 20% is taken to the pelletizers by a cleated or similar type conveyor belt.
In one embodiment of the method according to the present invention, in step (d) the said dried combustible cellulosic fibrous material is fed continuously to the pelletizer by spouts to the conditioner of the pelletizer (12).
In a preferred embodiment of the method of the present invention, said spouts in step (d) are sloping spouts with adjustable gates and magnetic plates that withhold any ferrous impurities that have not been collected before in order to prevent any damage to the pelletizers.
In a more preferred embodiment of the method of the present invention, the combustible cellulosic fibrous material is fed by the spout to the conditioner of the pelletizer (12), which is a spinning cylindral metal box with about 450 mm diameter, fitted with wings and which loosens the combustible cellulosic fibrous material and feeds the pelletizer. This machine is driven by a 5 hp motor. In said conditioner, the combustible cellulosic fibrous material receives an injection of saturated steam (VS) which helps pelletization and adjusts humidity to levels as above.
In one embodiment of the method according to the present invention, the combustible cellulosic fibrous material enters the pelletizer's pressing system in step (d).
In a preferred embodiment of the method of the present invention, said pelletizer's pressing system is driven by a motor of about 125 hp at about 1750 rpm.
In another preferred embodiment of the method of the present invention, said pelletizer's pressing system has a mold rotating at about 360 rpm, and two pressing rollers and regulators.
In a more preferred embodiment of the method of the present invention, said pelletizer comprises a cast-steel case, holding the primary shafts, the hollow mold shafts, the compacting rollers and the motor itself, whereas the main shaft fixes the two compacting rollers and the scrapers.
In a particular preferred embodiment of the method of the present invention said mold is affixed to the hollow rotating shaft, driven by gears and an electric motor with power varying from about 100 hp to about 400 hp, at about 220 rpm to about 420 rpm, depending on the type of raw material the pelletizer is processing.
In another preferred embodiment of the method of the present invention said mold comprises a mold diameter of about 520 to about 820 mm, a diameter of the mold holes of about 4.76 mm to about 19.05 mm ( 3/16″ to ¾″), a width of the track of the molds used of about 100 to about 220 mm, and a number of holes in the molds used of about 860 to about 4600 holes.
In a further preferred embodiment of the method of the present invention said compacting rollers having a diameter ranging from about 140 mm to about 220 mm, an eccentric shaft, and a metal shield pressing. They also feature a device with adjusting regulators that enable greater roller pressure on the mold and thus increase the pressure on the unprocessed combustible cellulosic fibrous material, which ensures more consisting compacting of the pellets and consequently greater density.
In a particular preferred embodiment of the method of the present invention said metal pressing shield of the compacting roller has thickness ranging from about 15 mm to about 40 mm and grooves about 2 to about 5 mm deep and about 2 to about 5 mm wide, spaced apart about 8 to about 12 mm. In contact with the unprocessed combustible cellulosic fibrous material, these grooves ensure better traction and improve pressing against the mold.
In another particular preferred embodiment of the method of the present invention, said mold is a metal ring with a flange for fixing on the hollow shaft and a surface with various holes, whereas these holes can be of various sizes, as demanded by the method.
In a further preferred embodiment of the method of the present invention, the unprocessed combustible cellulosic fibrous material is pelletized, by using a 650 mm diameter mold with 890 9.525 mm (⅜″) holes. Said mold is 125 mm wide and has an actual thickness of 30 mm and an additional thickness of 30 mm for relief. In the relief thickness, the diameter is 1-2 mm larger than the hole in the actual thickness. This mold system is called a relief mold, because it has a compacting chamber in the diameter desirable and the remaining thickness of the mold has a larger diameter, in which the compacted pellets are released from the actual pressing chamber, without the pressure of the hole walls, thus ensuring greater flow in the mold.
In one embodiment of the method according to the present invention, following step (d) the combustible cellulosic fibrous material pellets are removed from the pelletizers.
In a preferred embodiment of the method of the present invention the combustible cellulosic fibrous material pellets are removed by a variable-speed cleated or similar type conveyor belt after step (d).
In another embodiment of the method according to the present invention, in step (e) the combustible cellulosic fibrous material pellets are sorted according to their size.
In a preferred embodiment of the method of the present invention the combustible cellulosic fibrous material pellets are sorted by a vibrating sifter (14) in step (e).
In a more preferred embodiment of the method of the present invention any material that is rejected in the sifter in step (e), together with any excess dried combustible cellulosic fibrous material from the feeding conveyor belt (11) is returned to the feed box to be reused in the method.
In a particular preferred embodiment of the method of the present invention, in step (e) the combustible cellulosic fibrous material pellets are cooled down to room temperature of about 20 to about 40° C., preferably 30 to about 40° C.
In a more particular preferred embodiment of the method of the present invention said the combustible cellulosic fibrous material pellets after the pellets are sorted, go to the cleated conveyor belt cooler (16) with a perforated screen and an exhaust system featuring a powder retention cyclone or similar device (17). This removes any solid material, which goes back to the pelletization method.
In another preferred embodiment of the method of the present invention said cooler consists of two cleated conveyor belts with a perforated screen. Above it there is an exhaust system that aspires all solid particles (dust) from the air and cools the pellets to room temperature of between 20 to 40° C.
In one embodiment of the method according to the present invention the final combustible cellulosic fibrous material, with a humidity ranging from about 9 to about 13% and a density between about 0.55 to about 0.60 g/cm3 are taken to a storage system in step (f) by a conveyor belt (18).
In a preferred embodiment of the method of the present invention, in step (f) said final combustible cellulosic fibrous material pellets are stored in big bags or silos (19 and 20).
In another preferred embodiment of the method of the present invention said storage system requires airtight facilities to prevent environmental damage from the dust formed during handling and storage.
In a preferred embodiment of the method of the present invention, said combustible cellulosic fibrous material is selected from at least one of paper mill sludge, wood chips, paper fiber, cherry pits, olive pits, sugar-cane bagasse, sweet sorghum bagasse, grass clippings, and fur trees, and combinations thereof. Most preferred is unprocessed sugar-cane bagasse.
In one additional preferred embodiment, the method according to the present invention is selected from fully automated and/or contiguous processes.
The other object of the invention is solved by providing a device for converting unprocessed combustible cellulosic fibrous material into combustible compressed cellulosic fibrous material pellets by a method according to the invention as above, wherein said device comprises a drying unit for drying of said combustible cellulosic fibrous material, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material.
Yet another object of the invention is solved by providing a device for converting unprocessed combustible cellulosic fibrous material into combustible compressed cellulosic fibrous material pellets by a method according to the invention as above, wherein said device comprises:
- (a) a continuous feeding unit,
- (b) a cleaning unit,
- (c) a drying unit,
- (d) a pelletization unit, and
- (e) a sorting and second drying unit, and, optionally
- (f) a storing unit
In preferred embodiments of the devices according to the present invention, said unit (a) comprises a cleated or similar type conveyor belt (1), a feedbox (2), and a sprayer (3).
In preferred embodiments of the devices according to the present invention, said feed box can hold a 15-minute supply and has a cleated or similar type conveyor belt.
In particular preferred embodiments of the devices of the present invention, said feed box is a rectangular flat-wall and flat bottom feedbox.
In embodiments of the devices according to the present invention said unit (b) comprises a cleated or similar type conveyor belt (4), an electromagnet (5), and a di-stone (6).
In preferred embodiments of the devices of the present invention, said electromagnet has a minimum magnetic capacity of about 1500 gauss.
In particular preferred embodiments of the devices of the present invention, said di-stone is a rotating machine consisting of about 5 to 8 perpendicular axes with star-shaped knives that counter rotate.
In embodiments of the devices according to the present invention, said unit (c) comprises a cleated or similar type conveyor belt (7), a spinning tube dryer (8), an insufflating system (9), and an exhaust system featuring cyclones (10).
In a preferred embodiments of the devices of the present invention, said spinning tube dryer is fitted with deflectors positioned at an angle of about 45° attached to the tube bundles, whereas the minimum spacing between the tubes is about 75 mm.
In embodiments of the devices according to the present invention, said unit (d) comprises a cleated or similar type conveyor belt (11), sloping spouts, conditioner of the pelletizer, the pelletizers (12), and a variable-speed cleated or similar type conveyor belt (13).
In preferred embodiments of the devices of the present invention, said sloping spouts have adjustable gates and magnetic plates.
In other preferred embodiments of the devices of the present invention, said conditioner is a spinning cylindrical metal box with a diameter of about 450 mm, fitted with wings and driven by a motor of about 5 hp.
In yet other preferred embodiments of the devices of the present invention, said pelletizer comprises a pressing system, a cast-steel case, holding the primary shafts, the hollow mold shafts, the compacting rollers and the motor itself, whereas the main shaft fixes the two compacting rollers and the scrapers.
In particularly preferred embodiments of the devices of the present invention, said pelletizer's pressing system has a mold rotating at about 360 rpm and two pressing rollers and regulators and is driven by a motor of about 125 hp at about 1750 rpm.
In other particularly preferred embodiments of the devices of the present invention, said mold is fixed at the hollow rotating shaft, driven by gears and an electric motor with power varying from about 100 hp to 400 hp, at about 220 rpm to 420 rpm depending on the type of raw material the pelletizer is processing.
In further particularly preferred embodiments of the devices of the present invention, said mold is a metal ring with a flange for fixing on the hollow shaft and a surface with various holes, whereas these holes can be of various sizes, as demanded by the method.
In other particularly preferred embodiments of the devices of the present invention, said mold comprises a mold diameter of about 520 to about 820 mm, a diameter of the mold holes of about 4.76 mm to about 19.05 mm ( 3/16″ to ¾″), a width of the track of the molds used of about 100 to about 220 mm, and a number of holes in the molds used of about 860 to about 4600 holes.
In other particularly preferred embodiments of the devices of the present invention, said compacting rollers having a diameter ranging from about 140 mm to about 220 mm, an eccentric shaft, a metal shield pressing, and a device with adjusting regulators.
In other particularly preferred embodiments of the devices of the present invention said metal pressing shield of the compacting roller has thickness ranging from about15 mm to about 40 mm and grooves about 2 to about 5 mm deep and about 2 to about 5 mm wide, spaced about 8 to about 12 mm apart.
In embodiments of the devices according to the present invention, said unit (e) comprises a variable-speed cleated or similar type conveyor belt (13), a vibrating sifter (14), a cooler (16) with a pleated conveyor belt with a perforated screen, and an exhaust system with a cyclone (17).
In embodiments of the devices according to the present invention, said unit (f) comprises a cleated or similar type conveyor belt (18), big bag packing system (19) or silos (20).
In preferred embodiments of the devices according to the present invention, said unit (d) and (e) are connected to unit (b) via a cleated or similar type conveyor belt (15).
In preferred embodiments of the devices according to the present invention, said units are integrated into one system.
In another preferred aspect thereof, the present invention relates to pelletized combustible cellulosic fibrous material, obtainable according to a method as above according to the present invention.
Most preferred is a pelletized combustible cellulosic fibrous material according to the present invention, wherein said bagasse has an upper calorific content of about 4,500 to about 5,500 kcal/kg, a lower calorific content of about 3,500 to about 4,500 kcal/kg, a density of about 500 to about 600 kg dry matter/m3, and a humidity of about 10% to about 15%. Further preferred is a pelletized combustible cellulosic fibrous material according to the present invention, wherein said pelletized combustible cellulosic fibrous material is further blended with coal. This will even further improve the combustion properties of the inventive pellets.
In one embodiment of the present invention, the combustible cellulosic fibrous material pellets obtained by the method according to the present invention are used as renewable biomass to generate energy.
In a further embodiment of the present invention, the combustible cellulosic fibrous material pellets are used as biofuel in the power generation sector.
In one embodiment of the present invention, the unprocessed combustible cellulosic fibrous material pellets are blended with coal.
In a further preferred embodiment of the present invention, said pelletized combustible cellulosic fibrous material is selected from pellets of at least one of paper mill sludge, wood chips, paper fiber, cherry pits, olive pits, sugar-cane bagasse, sweet sorghum bagasse, grass clippings, and fur trees, and combinations thereof. Preferred is sugar-cane bagasse.
Another aspect of the present invention relates to the use of combustible cellulosic fibrous material pellets according to the present invention as a renewable biomass to generate energy and/or as biofuel in the power generation sector.
Preferred is the use of a device according to the present invention for producing a pelletized combustible cellulosic fibrous material.
Further preferred is a use according to the present invention, wherein said pelletized combustible cellulosic fibrous material is selected from pellets of at least one of paper mill sludge, wood chips, paper fiber, cherry pits, olive pits, sugar-cane bagasse, sweet sorghum bagasse, grass clippings, and fur trees and combinations thereof. Preferred is sugar-cane bagasse.
It should be noted, that the term “about” in this description means±10%, if not indicated otherwise.
It should be understood that the features of the invention as disclosed and described herein can be used not only in the respective combination as indicated, but also in a singular fashion without departing from the intended scope of the present invention. For the purposes of the present invention, all references and patents or patent applications as cited herein are incorporated by reference in their entireties.
The invention will now be described in more detail by reference to the following Figures, and the Examples. The following examples are provided for illustrative purposes only and are not intended to limit the invention.
The method and the setup of the device as claimed in the present application has been achieved through tests at our pilot pelletization plant, using the following equipment:
One carbon steel grain hopper to receive and store raw material, with 9 m3 capacity.
One screw transporter, with a 10-12 metric ton/hour capacity, driven by a 5 hp at 1,750 rpm motor, to feed the vibrating sifter.
One vibrating sifter, with a 10-12 metric ton/hour capacity, driven by a 5 hp at 1,750 rpm motor, to separate the unprocessed sugar-cane bagasse.
One screw transporter, with a 10-12 metric ton/hour capacity, driven by a 5 hp at 1,750 rpm motor, to feed the dryer.
One spinning tube dryer, with a 10-12 metric ton/hour capacity, driven by a 7.5 hp at 1,750 rpm motor.
One hot-gas exhaust, with a 1,000 m3/hour capacity, driven by a 25 hp at 1,750 rpm motor.
One cyclone to separate dust, with a 5 metric ton/hour capacity.
One fan to insufflate hot air, with a 650 m3/hour capacity, driven by a 7.5 hp at 1,750 rpm motor.
One steam radiator, with a 50,000 kcal/hour capacity.
One internal dryer screw transporter, with a 10-12 metric ton/hour capacity, driven by a 0.75 hp at 1,750 rpm motor.
One dryer outlet screw transporter, with a 10-12 metric ton/hour capacity, driven by a 5 hp at 1,750 rpm motor.
One pelletizer feeder screw transporter, with a 10-12 metric ton/hour capacity, driven by a 5 hp at 1,750 rpm motor.
Three pelletizers, with a 1.5 metric ton/hour capacity each, driven by 125 hp at 1,750 rpm motors.
One pelletizer, with a 5 metric ton/hour capacity, driven by a 250 hp at 1,750 rpm motor.
Four pelletizer conditioners, with a 3 metric ton/hour capacity each, driven by 5 hp at 1,750 rpm motors.
One pellet conveyor belt, with a 10-12 metric ton/hour capacity, driven by a 5 hp at 1750 rpm motor.
One vibrating sifter, with a 2.5 metric ton/hour capacity, driven by a 3 hp at 1,750 rpm motor.
One screw transporter for vibrating-sifter rejects, with a 1 metric ton/hour capacity, driven by a 0.75 hp at 1,750 rpm motor.
Two pellet coolers, with a 2.5 metric ton/hour capacity, driven by 1 hp at 1750 rpm motors.
Two cooler drivers with 3 hp at 1,750 rpm motors.
One pellet conveyor belt, with a 5 metric ton/hour capacity, driven by a 3 hp at 1750 rpm motor.
One big bag loading system.
One set of carbon steel tubes used to feed steam to the dryer and removed condensed matter which is send to the boiler thermal air remover.
Working Example With reference to
Then, the unprocessed sugar-cane bagasse is dried in a spinning tube dryer (8) using a system of bundled tubes conveying saturated steam at 9 kgf/cm2, at a temperature of about 175° C. inside the tube, providing indirect contact with the product in the tube's external wall (i.e. the steam inside the pipes dry without contact with the bagasse, whilst the steam flow heating the internal surface of the pipes and bagasse has contact with the external surface of the pipes). This results in a temperature of about 138° C. The spinning tube dryer is fitted with deflectors positioned at about 45° attached to the tube bundles. The unprocessed sugar-cane bagasse is then cooled down to approximately room temperature.
The unprocessed sugar-cane bagasse now remains inside the spinning tube dryer for 12 minutes, at 4 rpm using approx. 2 to 3 metric tons of steam per hour. After leaving the tubular bundles, the bagasse is insufflated with hot air by a duct coming from a heat radiator (9) fed by saturated steam (VS). This operation heats the gases in counter flow with the bagasse, thus helping the drying method and preventing any accumulation of solid residues (powder) inside the dryer. The hot and humid gases are removed on the opposite side of the entrance of the dryer by a duct with forced exhaust (10), and sent to a cyclone, or similar equipment, where the solid particles (powder) are separated and sent to be burned by the boiler.
The now dried sugar-cane bagasse with a humidity varying between 13 to 20% is then taken to the pelletizers by a cleated type conveyor belt and fed continuously to the pelletizer by spouts to the conditioner of the pelletizer (12). The spouts are sloping spouts with adjustable gates and magnetic plates that withhold any ferrous impurities that have not been collected before to prevent any damage to the pelletizer.
The conditioner of the pelletizer (12), which is a spinning cylindral metal box with 450 mm diameter, is fitted with wings and now loosens the bagasse and feeds it to the pelletizer. The machine is driven by a 5 hp motor. In this conditioner, the bagasse receives an injection of saturated steam (VS) which helps pelletization and adjusts humidity.
Then, the sugar-cane bagasse enters the pelletizer's pressing system which is driven by a motor of 125 hp at about 1750 rpm. Said pelletizer's pressing system has a mold rotating at about 360 rpm and two pressing rollers and regulators, whereas the pelletizer comprises a cast-steel, holding the primary shafts, the hollow mold shafts, the compacting rollers and the motor itself, whereas the main shaft fixes the two compacting rollers and the scrapers. The mold is fixed at the hollow rotating shaft, driven by gears and an electric motor with power varying from 100 hp to 400 hp, at 220 rpm to 420 rpm, depending on the type of raw material the pelletizer is processing. Furthermore, the mold comprises a mold diameter of 650 mm, with a diameter of the mold holes of about 9.53 mm (⅜″). and a width of the track of the molds of 125 mm, and a number of holes in the molds used of 890.
The compacting rollers have a diameter of 125 mm, an eccentric shaft, a metal shield pressing, and a device with adjusting regulators. The adjusting regulators enable greater roller pressure on the mold and thus increase the pressure on the unprocessed sugar-cane bagasse, which ensures more consisting compacting of the pellets and consequently greater density. The metal pressing shield of the compacting roller has thickness of 30 mm and grooves 3 mm deep and 3 mm wide, spaced 10 mm apart. In contact with the unprocessed sugar-cane bagasse, these grooves ensure better traction and improve pressing against the mold.
Then, the sugar-cane bagasse pellets are removed from the pelletizers by a variable-speed cleated type conveyor belt and subsequently sorted by size by a vibrating sifter. Any material rejected at the sifter, together with any excess dried sugar-cane bagasse from the feeding conveyor belt (11) is returned back to the feed box to be reused in the process.
The sugar-cane bagasse pellets are then cooled down to room temperature of approx. 30° C. After the pellets are sorted they are transported by a cleated conveyor belt cooler (16) having a perforated screen and an exhaust system featuring a powder retention cyclone device (17). This removes any solid material, which goes back to the pelletization method. Above the system, there is an exhaust system that aspires all solid particles (dust) from the air and cools the pellets to room temperature, i.e. approx. 30° C.
The final sugar-cane bagasse pellets, having a humidity ranging from about 9 to about 13% and a density between about 0.55 to about 0.60 g/cm3 are taken to a storage system by a conveyor belt (18). The final sugar-cane bagasse pellets are then suitably stored in big bags before further transport thereof.
Claims
1. A method for drying a combustible cellulosic fibrous material, wherein said method comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material.
2. The method according to claim 1, wherein said drying unit is a rotary dryer, in particular a spinning tube dryer (8).
3. The method according to claim 2, wherein said heat source comprises a system of tubes, in particular bundled tubes, conveying the heat source.
4. The method according to claim 3, wherein said heat source is saturated steam.
5. The method according to claim 2, wherein the heat source is applied at a temperature ranging from about 170 to about 185° C. inside the tubes, resulting in temperatures ranging from about 135 to about 140° C. on the external surfaces of the tubes in the drying unit.
6. The method according to any of claim 2, wherein the heat source is applied at a pressure of about 8.34 bar to about 9.81 bar (8.5 to 10 kgf/cm2) inside the tubes.
7. A method for pelletizing combustible cellulosic fibrous material, wherein said method comprises the following steps:
- (a) providing and feeding of unprocessed combustible cellulosic fibrous material into said method,
- (b) cleaning of said unprocessed combustible cellulosic fibrous material,
- (c) drying of said cleaned unprocessed combustible cellulosic fibrous material,
- (d) pelletization of said dried combustible cellulosic fibrous material, and
- (e) sorting and drying of said pelletized combustible cellulosic fibrous material,
- wherein the drying in step (c) comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material.
8. The method according to claim 7, wherein in step (a) unprocessed combustible cellulosic fibrous material is continuously fed into the method while said material is loosened and flattened.
9. The method according to claim 7, wherein in step (b) ferrous material and impurities are removed from the unprocessed combustible cellulosic fibrous material.
10. The method according to claim 7, wherein in step (c) said drying step comprises applying a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material, wherein said heat source optionally comprises a system of tubes, in particular bundled tubes, conveying the heat source.
11. The method according to claim 10, wherein the heat source is applied at a temperature ranging from about 170 to about 185° C. inside the tubes, resulting in temperatures ranging from about 135 to about 140° C. on the external surfaces of the tubes in the drying unit.
12. The method according to claim 10, wherein the heat source is applied at a pressure of about 8.34 bar to about 9.81 bar (8.5 to 10 kgf/cm2) inside the tubes.
13. The method according to claim 10, wherein said combustible cellulosic fibrous material remains inside the tube dryer for about 12 minutes, at about 4 rpm using about 2 to about 3 metric tons of steam per hour.
14. The method according to claim 7, wherein in step (c) after the combustible cellulosic fibrous material leaves the tubular bundles, it is insufflated in counter flow with hot air by a duct coming from a heat radiator fed by saturated steam (VS).
15. The method according to claim 14, wherein in step (c) the hot and humid gases are removed on the opposite side of the entrance of the dryer by a duct with forced exhaust, and sent to a cyclone, or similar equipment, where the solid particles (powder) are separated and sent to be burned by the boiler.
16. The method according to claim 7, wherein in step (d) the dried combustible cellulosic fibrous material, with a humidity varying between about 13 to about 20% is continuously fed to the pelletizers, where the combustible cellulosic fibrous material receives an injection of saturated steam, and then enters the pelletizer's pressing system.
17. The method according to claim 7, wherein after step (d) the combustible cellulosic fibrous material pellets are removed from the pelletizers, in particular by a variable-speed cleated or similar type conveyor belt.
18. The method according to claim 7, wherein in step (e) the combustible cellulosic fibrous material pellets are sorted according to their size, and/or in step (e) any rejected material at the sifter, together with any excess with excess dried combustible cellulosic fibrous material from the feeding conveyor belt is returned to the feed box to be reused in said method.
19. The method according to claim 7, wherein in step (e) the combustible cellulosic fibrous material pellets are cooled down to room temperature of about 20 to about 40° C.
20. The method according to claim 7, wherein in step (f) the final combustible cellulosic fibrous material pellets, having a humidity ranging from about 9 to about 13% and a density between about 0.55 to about 0.60 g/cm3 are advanced to a storage system.
21. The method according to claims 7, further comprising storing of the dried combustible cellulosic fibrous material pellets in step (f).
22. The method according to claim 7, wherein said method is a fully automated and/or continuous method.
23. The method according to claim 7, wherein said combustible cellulosic fibrous material is selected from at least one of paper mill sludge, wood chips, paper fiber, cherry pits, olive pits, sugar-cane bagasse, sweet sorghum bagasse, grass clippings, and fur trees, and combinations thereof.
24. A device for converting unprocessed combustible cellulosic fibrous material into combustible compressed cellulosic fibrous material pellets by a method for pelletizing combustible cellulosic fibrous material, wherein said method comprises the following steps:
- (a) providing and feeding of unprocessed combustible cellulosic fibrous material into said method,
- (b) cleaning of said unprocessed combustible cellulosic fibrous material,
- (c) drying of said cleaned unprocessed combustible cellulosic fibrous material,
- (d) pelletization of said dried combustible cellulosic fibrous material, and
- (e) sorting and drying of said pelletized combustible cellulosic fibrous material,
- wherein the drying in step (c) comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material,
- wherein said device comprises a drying unit for drying of said combustible cellulosic fibrous material, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material.
25. A device for converting unprocessed combustible cellulosic fibrous material into combustible compressed cellulosic fibrous material pellets by a method for pelletizing combustible cellulosic fibrous material, wherein said method comprises the following steps:
- (a) providing and feeding of unprocessed combustible cellulosic fibrous material into said method,
- (b) cleaning of said unprocessed combustible cellulosic fibrous material,
- (c) drying of said cleaned unprocessed combustible cellulosic fibrous material,
- (d) pelletization of said dried combustible cellulosic fibrous material, and
- (e) sorting and drying of said pelletized combustible cellulosic fibrous material,
- wherein the drying in step (c) comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material,
- wherein said device comprises:
- (a) a continuous feeding unit,
- (b) a cleaning unit,
- (c) a drying unit,
- (d) a pelletization unit, and
- (e) a sorting and second drying unit, and, optionally
- (f) a storing unit.
26. The device according to claim 25, wherein unit (a) comprises a cleated or similar type conveyor belt, a feed box, and a sprayer.
27. The device according to claim 25, wherein said feed box can hold a 15-minute supply and has a rectangular flat-wall, a flat-bottom, and a cleated or similar type conveyor belt.
28. The device according to any of claim 25, wherein unit (b) comprises a cleated or similar type conveyor belt, an electromagnet, and a di-stone.
29. The device according to claim 28, wherein said electromagnet has a minimum magnetic capacity of about 1500 gauss, and said di-stone is a rotating machine consisting of about 5 to 8 perpendicular axes with star-shaped knives that counter-rotate.
30. The device according to claim 25, wherein unit (c) comprises a cleated or similar type conveyor belt, a spinning tube dryer, an insufflating system, and an exhaust system featuring cyclones.
31. The device according to claim 30, wherein said spinning tube dryer is fitted with deflectors positioned at about 45° attached to the tube bundles, and the minimum spacing between the tubes is about 75 mm.
32. The device according to claim 25, wherein unit (d) comprises a cleated or similar type conveyor belt, sloping spouts, conditioner of the pelletizer, the pelletizers, and a variable-speed cleated or similar type conveyor belt (13).
33. The device according to claim 32, wherein said sloping spouts have adjustable gates and magnetic plates, said conditioner is a spinning cylindrical metal box with a diameter of about 450 mm, fitted with wings and driven by a motor of about 5 hp, and said pelletizer comprises a pressing system, a cast-steel case, holding the primary shafts, the hollow mold shafts, the compacting rollers and the motor itself, whereas the main shaft fixes the two compacting rollers and the scarpers.
34. The device according to claim 33, wherein said compacting roller having a diameter ranging from about 140 mm to about 220 mm, an eccentric shaft, a device with adjusting regulators and a metal shield pressing, having a thickness ranging from about 15 mm to about 40 mm and grooves about 2 to about 5 mm deep and about 2 to about 5 mm wide, and spaced about 8 to about 12 mm apart.
35. The device according to claim 34, wherein said pelletizer's pressing system has a mold rotating at about 360 rpm, two pressing rollers, regulators and is driven by a motor of about 125 hp at about 1750 rpm.
36. The device according to claim 35, wherein said mold is fixed at the hollow rotating shaft, driven by gears and an electric motor with power varying from about 100 hp to 400 hp, at about 220 rpm to 420 rpm, is a metal ring with a flange for fixing on the hollow shaft and a surface with various holes, wheraes these holes can be of various sizes, and comprises a mold diameter of about 520 to 820 mm, a diameter of the mold holes of about 4.76 mm to about 19.05 mm ( 3/16″ to ¾″), a width of the track of the molds of about 100 to 220 mm, and a number of holes in the molds of about 860-4600 holes.
37. The device according to claim 25, wherein unit (e) comprises a variable-speed cleated or similar type conveyor belt, a vibrating sifter, a cooler with a cleated conveyor belt with a perforated screen, and an exhaust system with a cyclone.
38. The device according to claim 25, further comprising a storing unit (f)
39. The device according to claim 38, wherein unit (f) comprises a cleated or similar type conveyor belt, big bags or silos.
40. The device according to claim 25, wherein unit (d) and unit (e) are connected to unit (b) via a cleated or similar type conveyor belt.
41. The device according to claim 25, wherein said units are integrated into one system.
42. A pelletized combustible cellulosic fibrous material, obtainable by a method for pelletizing combustible cellulosic fibrous material, wherein said method comprises the following steps:
- (a) providing and feeding of unprocessed combustible cellulosic fibrous material into said method,
- (b) cleaning of said unprocessed combustible cellulosic fibrous material,
- (c) drying of said cleaned unprocessed combustible cellulosic fibrous material,
- (d) pelletization of said dried combustible cellulosic fibrous material, and
- (e) sorting and drying of said pelletized combustible cellulosic fibrous material,
- wherein the drying in step (c) comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material.
43. The pelletized combustible cellulosic fibrous material according to claim 42, wherein said material has an upper calorific content of about 4,500 to about 5,500 kcal/kg, a lower calorific content of about 3,500 to about 4,500 kcal/kg, a density of about 500 to about 600 kg dry matter/m3, and a humidity of about 10% to about 15%.
44. The pelletized combustible cellulosic fibrous material according to claim 42, wherein said material is further blended with coal.
45. The pelletized combustible cellulosic fibrous material according to claim 42, wherein said pelletized combustible cellulosic fibrous material is selected from pellets of at least one of paper mill sludge, wood chips, paper fiber, cherry pits, olive pits, sugar-cane bagasse, sweet sorghum bagasse, grass clippings, and fur trees, and combinations thereof.
46. A method for generating energy and/or biofuel, comprising the use of a pelletized combustible cellulosic fibrous material, obtainable by a method for pelletizing combustible cellulosic fibrous material, wherein said method comprises the following steps:
- (a) providing and feeding of unprocessed combustible cellulosic fibrous material into said method,
- (b) cleaning of said unprocessed combustible cellulosic fibrous material,
- (c) drying of said cleaned unprocessed combustible cellulosic fibrous material,
- (d) pelletization of said dried combustible cellulosic fibrous material, and
- (e) sorting and drying of said pelletized combustible cellulosic fibrous material,
- wherein the drying in step (c) comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material as a renewable biomass.
47. A method for producing a pelletized combustible cellulosic fibrous material comprising the use of a device for converting unprocessed combustible cellulosic fibrous material into combustible compressed cellulosic fibrous material pellets by a method for pelletizing combustible cellulosic fibrous material, wherein said method comprises the following steps:
- (a) providing and feeding of unprocessed combustible cellulosic fibrous material into said method,
- (b) cleaning of said unprocessed combustible cellulosic fibrous material,
- (c) drying of said cleaned unprocessed combustible cellulosic fibrous material,
- (d) pelletization of said dried combustible cellulosic fibrous material, and
- (e) sorting and drying of said pelletized combustible cellulosic fibrous material,
- wherein the drying in step (c) comprises the step of drying of said combustible cellulosic fibrous material in a drying unit, wherein said drying unit comprises a heat source that indirectly provides heat to said combustible cellulosic fibrous material when drying said combustible cellulosic fibrous material,
- wherein said device comprises:
- (a) a continuous feeding unit,
- (b) a cleaning unit,
- (c) a drying unit,
- (d) a pelletization unit, and
- (e) a sorting and second drying unit, and, optionally
- (f) a storing unit.
Type: Application
Filed: Sep 28, 2006
Publication Date: Apr 19, 2007
Inventors: Pedro Lana (Sao Paulo), Michael Curran (Yvoire)
Application Number: 11/540,875
International Classification: F23G 5/02 (20060101); C10L 5/00 (20060101);
