RELATED APPLICATIONS The present invention is related to co-pending U.S. patent applications Ser. No. 12/610331, filed Nov. 1, 2009 (01-NOV-2009); Ser. No. 12/649215 filed Dec. 29, 2009 (29-DEC-2009); and Ser. No. 12/649230 filed Dec. 29, 2009 (29-DEC-2009), incorporated by reference through the operation of the closing paragraph of the specification.
BACKGROUND OF THE INVENTION 1. Field of the Invention
Embodiments of the present invention relate to methods for making coated burnable fuels from source materials, to systems for converting the source materials into coated burnable fuels, to coated burnable fuels derived therefrom and to methods and systems for using the coated burnable fuels.
More particularly, embodiments of the present invention relate to burnable fuels from source materials, methods for making coated burnable fuels from source materials, systems for converting source materials into coated burnable fuels, where the burnable fuels include a coated particulate burnable fuel, a shaped particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated particulate burnable fuels, and/or a coated shaped burnable fuel including uncoated and/or coated particulate burnable fuels. The methods include providing one or a plurality of source materials to form an input material. The methods optionally include coating the source materials and/or the input material. The methods also include sizing the input material to form a particulate burnable fuel. The methods can also include coating the particulate burnable fuel during and/or after sizing. The methods can also include shaping a particulate material including coated and uncoated particulate burnable fuels. The method can also include coating a shaped burnable fuel during and/or after shaping to form a coated, shaped burnable fuel, where the shaped burnable fuel includes coated and/or uncoated particulate burnable fuels.
2. Description of the Related Art
Many used or waste materials are currently being recycled, especially in today's climate of environmentalism. However, many used or waste materials include bio-hazardous materials or other materials that are a challenge for bulk recycling. Labeling requirements for bio-hazardous used or waste materials may require these materials to be handled in a different manner than many other waste materials.
Moreover, most used or waste materials constitute complex mixtures of components including pulp materials, fabric materials, plastic or polymer materials, metals or metal containing materials, ceramic materials, ceramic containing materials, bio-hazardous materials, etc. Many conventional waste material recycling methodologies require a separation of the material into separated components, especially metals and metal containing materials, before the material can then be post processed.
Thus, there is a need in the art for methods and systems that can readily convert waste materials directly into coated burnable fuels, where coating process reduces dust, alters improves fuel integrity, and alters fuel properties.
SUMMARY OF THE INVENTION Embodiments of this invention provide methods for converting one or a plurality of source materials, where the source materials can be virgin materials, unused materials, used materials, waste materials, fuels, or mixtures thereof into a burnable fuel, with or without the need for exhaustive component separation, where some or all of the materials are complex mixtures of components including pulp materials, fiber materials, fabric materials, wood materials (e.g., saw dust), plastic or polymer materials, metals or metal containing materials, ceramic or ceramic containing materials, bio-hazardous materials, ash materials, etc. and/or other waste materials. The burnable fuel can also optionally include a solid fuel and/or liquid fuel, that may be added into the source materials at any point in the processing. The burnable fuel can also optionally include virgin pulp materials, virgin fiber materials, virgin polymer materials, virgin ceramic materials and/or other virgin materials or mixtures or combinations thereof. The burnable fuel can also optionally include unused pulp materials, unused fiber materials, unused polymer materials, unused ceramic materials and/or other unused materials or mixtures or combinations thereof. The methods also include sizing the burnable fuel into a particulate burnable fuel. The methods can also include coating the particulate burnable fuel during and/or after sizing to form a coated burnable fuel, where the extent of the coating can be as described herein. The methods can also include shaping an uncoated particulate burnable fuel, a coated burnable fuel or a mixture of the uncoated particulate burnable fuel and the coated particulate burnable fuel to form a shaped particulate burnable fuel. The methods can also include coating the shaped burnable fuel during and/or after shaping, to form a coated, shaped burnable fuel, where the extent of coating is as described herein. The methods can also include one or more pre-processing or pre-treating steps prior to and/or after sizing of the materials. The methods can also include combusting a burnable fuel of this invention in a combustion subsystem and converting a portion of the resulting thermal energy into a useable form of energy and/or into a useful product. The methods can also include packaging a burnable fuel of this invention in a packaging subsystems, where the burnable fuels of this invention include a coated and/or uncoated particulate burnable fuel, and/or a coated and/or coated, shaped burnable fuel.
Embodiments of this invention provide systems for converting one or a plurality of source materials directly into a burnable fuel, without the need for exhaustive component separation, where each source material can include a complex mixture of components including pulp materials, fiber materials, fabric materials, plastic or polymer materials, metals or metal containing materials, ceramic or ceramic containing materials, bio-hazardous materials, ash materials, electronic or electronic containing materials, and/or other waste materials. The burnable fuel can also optionally include a solid fuel and/or liquid fuel. The burnable fuel can also optionally include virgin pulp materials, virgin fiber materials, virgin polymer materials, virgin ceramic materials and/or other virgin materials or mixtures or combinations thereof. The burnable fuel can also optionally include unused pulp materials, unused fiber materials, unused polymer materials, unused ceramic materials and/or other unused materials or mixtures or combinations thereof. The burnable flue can also optionally include unused and/or experimental pharmaceuticals, nutraceuticals, other similar materials or mixtures or combinations thereof. The systems can also include a sizing subsystem for sizing the burnable fuel into a particulate burnable fuel. The systems can also include a particulate fuel coating subsystem for coating the burnable fuel during and/or after sizing to form a coated particulate burnable fuel. The systems can also include a shaping subsystem for converting the particulate burnable fuel (coated, uncoated or mixed) to from a shaped burnable fuel. The systems can also include a shaped fuel coating subsystem for coating the shaped burnable fuel during and/or after shaping to form a coated, shaped burnable fuel. The system can also include one or more pre-processing or pre-treating subsystems for pre-processing or pre-treating the burnable fuel prior to and/or after sizing and/or prior to and/or after shaping. The systems can also include a combustion subsystem for combusting the burnable fuel and converting a portion of the resulting thermal energy into a useable form of energy and/or into a useful product. The systems can also include packaging subsystems for packing a fuel of this invention, where the burnable fuel of this invention includes a coated particulate burnable fuel, and/or a shaped burnable fuel and/or the coated, shaped burnable fuel.
Embodiments of this invention provide burnable fuels derived from methods and systems of this invention: a coated particulate burnable fuel, a shaped burnable fuel including coated particulate burnable fuel, and/or a coated, shaped burnable fuel including uncoated and/or coated particulate burnable fuel.
BRIEF DESCRIPTION OF THE DRAWINGS The invention can be better understood with reference to the following detailed description together with the appended illustrative drawings in which like elements are numbered the same:
Methods with Coating Particles
FIG. 1A depicts an embodiment of conceptual flow diagram of a method of this invention.
FIG. 1B depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 1C depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 1D depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 1E depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 1F depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 1G depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 1H depicts another embodiment of conceptual flow diagram of a method of this invention.
Methods with Coating Shapes
FIG. 2A depicts an embodiment of conceptual flow diagram of a method of this invention.
FIG. 2B depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 2C depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 2D depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 2E depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 2F depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 2G depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 2H depicts another embodiment of conceptual flow diagram of a method of this invention.
Method with Pre-Processing, Coating Shapes and Coating Particles and Shapes
FIG. 3A depicts an embodiment of conceptual flow diagram of a method of this invention.
FIG. 3B depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 3C depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 3D depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 3E depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 3F depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 3G depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 3H depicts another embodiment of conceptual flow diagram of a method of this invention.
Method with Two Source Material, Coating Shapes and Coating Particles and Shapes
FIG. 4A depicts an embodiment of conceptual flow diagram of a method of this invention.
FIG. 4B depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 4C depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 4D depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 4E depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 4F depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 4G depicts another embodiment of conceptual flow diagram of a method of this invention.
FIG. 4H depicts another embodiment of conceptual flow diagram of a method of this invention.
Systems for Coating Particles FIG. 5A depicts an embodiment of a system of this invention.
FIG. 5B depicts another embodiment of a system of this invention.
FIG. 5C depicts another embodiment of a system of this invention.
FIG. 5D depicts another embodiment of a system of this invention.
FIG. 5E depicts another embodiment of a system of this invention.
FIG. 5F depicts another embodiment of a system of this invention.
FIG. 5G depicts another embodiment of a system of this invention.
FIG. 5H depicts another embodiment of a system of this invention.
Systems for Coating Shapes FIG. 6A depicts another embodiment of a system of this invention.
FIG. 6B depicts another embodiment of a system of this invention.
FIG. 6C depicts another embodiment of a system of this invention.
FIG. 6D depicts another embodiment of a system of this invention.
FIG. 6E depicts another embodiment of a system of this invention.
FIG. 6F depicts another embodiment of a system of this invention.
FIG. 6G depicts another embodiment of a system of this invention.
FIG. 6H depicts another embodiment of a system of this invention.
Systems for Coating Particles and Shapes FIG. 7A depicts another embodiment of a system of this invention.
FIG. 7B depicts another embodiment of a system of this invention.
FIG. 7C depicts another embodiment of a system of this invention.
FIG. 7D depicts another embodiment of a system of this invention.
FIG. 7E depicts another embodiment of a system of this invention.
FIG. 7F depicts another embodiment of a system of this invention.
FIG. 7G depicts another embodiment of a system of this invention.
FIG. 7H depicts another embodiment of a system of this invention.
Systems with Two Sources and Coating Particles and Shapes
FIG. 8A depicts another embodiment of a system of this invention.
FIG. 8B depicts another embodiment of a system of this invention.
FIG. 8C depicts another embodiment of a system of this invention.
FIG. 8D depicts another embodiment of a system of this invention.
FIG. 8E depicts another embodiment of a system of this invention.
FIG. 8F depicts another embodiment of a system of this invention.
FIG. 8G depicts another embodiment of a system of this invention.
FIG. 8H depicts another embodiment of a system of this invention.
Particulate Burnable Fuel FIG. 9 depicts an image of a particulate burnable fuel of this invention.
Shaped Burnable Fuel FIG. 10 depicts an image of a shaped burnable fuel of this invention.
Coated Shaped Burnable Fuels FIG. 11 depicts an image of a shaped burnable fuel of this invention coated with a non-flammable, colored sealant coating.
FIG. 12 depicts an image of a shaped burnable fuel of this invention coated with an oil coating.
FIG. 13 depicts an image of a shaped burnable fuel of this invention coated with a waterproof coating.
FIG. 14 depicts an image of a shaped burnable fuel of this invention coated with a flammable, colored sealant coating.
Coating of Shaped Fuels FIGS. 15A-C depict a longitudinal cross-sectional view of a rounded cylindrical shaped burnable fuel with three different coating thicknesses.
FIGS. 16A-C depict a longitudinal cross-sectional view of a cylindrical shaped burnable fuel with three different coating thicknesses.
FIGS. 17A-C depict a cross-sectional view of a spherical shaped burnable fuel with three different coating thicknesses.
FIGS. 18A-C depict a longitudinal cross-sectional view of a ellipsoidal solid shaped burnable fuel with three different coating thicknesses.
FIGS. 19A-C depict a lateral cross-sectional view of a solid cross shaped burnable fuel with three different coating thicknesses.
FIGS. 20A-C depict a lateral cross-sectional view of a solid star shaped burnable fuel with three different coating thicknesses.
DETAILED DESCRIPTION OF THE INVENTION The inventors have found that methods can be implemented for making a burnable fuel from one or a plurality source materials, where the burnable fuels can include coated source materials, coated particulate fuels derived from the source materials, shaped fuels derived from uncoated and coated source materials and/or uncoated and coated particulate fuels, or coated shaped fuels derived from the coated and/or uncoated particulate fuels of this invention. Each source material can include a complex mixture of components, with or without the need for exhaustive component separation, where the components can include pulp materials, fiber materials, fabric materials, polymer materials, metal materials, ceramic materials, industrial waste material, electronic materials, ash materials, and/or other waste materials and/or any other source material that is burnable or can alter an ash composition of the fuel. The resulting burnable fuels can be formulated for use as suitable fuels in a number of different industries including cement plants, power plants, municipal incinerators for steam generation, or any other facility that burns fuels and converts heat derived from the burning of the fuels into a usable form of energy such as electrical energy, mechanical energy, chemical energy, etc. or uses the heat and ash to make a desired end product such as cement. The coating aspects of this invention are designed, but not limited to reduce or suppress dust during source material processing, waterproofing particulate or shaped fuels of this invention, and reduce or elimination worker exposure issues from the source materials or intermediated materials during processing, especially exposure to fine particulate materials or materials may cause health problems. The waterproofing is designed to reduce water absorption and potential leeching of compounds into surface and/or ground water.
Methods for Making Coated Particulate Burnable Fuels Embodiments of this invention relate to methods for receiving and converting one or a plurality source materials into an input material or directly into a burnable fuel, with or without the need for exhaustive component separation. Each sourcee material can include a complex mixture of components as set forth herein. The input material can be formulated to have a desired distribution of components. The methods can optionally include pre-treating or pre-processing the source materials and/or the input material or adjusting the component makeup of the input material. The methods can also include coating the source material and/or the input material. The methods also include sizing or sizing and homogenizing the source materials and/or input material to form a particulate burnable fuel. The methods also include coating the particulate burnable fuel during and/or after sizing to form a coated particulate burnable fuel, where the particles of the coated particulate burnable fuel are coated to a desired surface covering and to a desired coating thickness. In certain embodiments, the desired surface covering means that greater than 5% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 15% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 25% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 50% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 75% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 90% of the surface area of the particles in bul, are coated with at coating material. The desired coating thickness can range from about 100 nm to about 5 mm. In certain embodiments, the thickness can range from about 1 μm to 2.5 mm. In certain embodiments, the thickness can range from about 1 μm to 1 mm. The methods can optionally include pre-treating or pre-processing the particulate burnable fuel during and/or after sizing. The methods can also include shaping a particulate burnable fuel including a coated particulate burnable fuel or a mixture of uncoated and coated particulate burnable fuels into a compact shape to form a shaped burnable fuel. Coating of the particulate burnable fuel is designed to suppress dust by increasing an agglomerating, conglomerating, aggregating, and/or consolidating propensity of the particles in the particulate burnable fuel so that the smaller particles tend to adhere together or adhere to larger particles.
Methods for Making Coated Shaped Burnable Fuels Embodiments of this invention relate to methods for receiving and converting one or a plurality source materials into an input material or directly into a burnable fuel, with or without the need for exhaustive component separation. Each material can include a complex mixture of components as set forth herein. The input material can be formulated to have a desired distribution of components. The methods can optionally include pre-treating or pre-processing the source materials and/or the input material or adjusting the component makeup of the input material. The methods also include sizing or sizing and partially or completely homogenizing the input material to form a particulate burnable fuel. The methods may also include coating the particulate burnable fuel during and/or after sizing to form a coated particulate burnable fuel, where the particles of the coated particulate burnable fuel are coated to a desired surface covering and to a desired coating thickness. In certain embodiments, the desired surface covering means that greater than 5% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 15% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 25% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 50% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 75% of the surface area of the particles in bulk are coated with a coating material. In other embodiments, the desired surface covering means that greater than 90% of the surface area of the particles in bul, are coated with at coating material. The desired coating thickness can range from about 100 nm to about 5 mm. In certain embodiments, the thickness can range from about 1 μm to 2.5 mm. In certain embodiments, the thickness can range from about 1 μm to 1 mm. The methods can optionally include pre-treating or pre-processing the particulate burnable fuel during and/or after sizing. The methods also include shaping a particulate burnable fuel including uncoated and/or coated particulate burnable fuels to form a shaped burnable fuel. The methods also include coating the shaped burnable fuel during and/or after shaping to form a coated, shaped burnable fuel, where the shapes of the shaped burnable fuel are coated to a desired surface covering and to a desired coating thickness. In certain embodiments, the desired surface covering means that greater than 50% of the surface area of the shapes of the shaped burnable fuel are coated with a coating material. In other embodiments, the desired surface covering means that greater than 70% of the surface area of the shapes of the shaped burnable fuel are coated with a coating material. In other embodiments, the desired surface covering means that greater than 80% of the surface area of the shapes of the shaped burnable fuel are coated with a coating material. In other embodiments, the desired surface covering means that greater than 90% of the surface area of the shapes of the shaped burnable fuel are coated with a coating material. Coating of the particulate burnable fuel or the shaped burnable fuels is designed, without limitation, to suppress dust by increasing an agglomerating, conglomerating, aggregating, and/or consolidating propensity of the particles so that they are more easily incorporated into the shaped either before, during and/or after shaping.
Methods for Making Packaged Burnable Fuels Embodiments of this invention relate to methods packaging coated particulate burnable fuels, packaging mixtures of uncoated and coated particulate burnable fuels, packaging of shaped burnable fuels including coated particulate burnable fuels, and/or packaging of coated, shaped burnable fuels.
System for Making Coated Particulate Burnable Fuel Embodiments of this invention relate to systems for converting one or a plurality of source materials into a burnable fuel. Each source material can include a complex mixture of components as set forth below. The systems include an input material subsystem for forming an input material having a desired distribution of source materials. The systems can also include a pre-processing and/or pre-treating subsystem for subjecting the input material or source materials to one or more pre-processing and/or pre-treating steps or for adjusting a making up of the input material. The system may also include a source or input material coating subsystem, where source materials and/or the input material is coated with a first coating material. The systems also include a sizing subsystem for sizing or sizing and partially or completely homogenizing the input material (pre-processed, coated or not) to form a particulate burnable fuel. The sizing subsystem can include one or more shredding units, chopping units, milling units, and/or any other unit that reduces the size of the input material to form the particulate burnable fuel having a desired particle size distribution. The systems also include a particulate coating subsystem for coating the particles of the particulate burnable fuel with a second coating material during and/or after sizing to form a coated, particulate burnable fuel. The systems can also include a particulate burnable fuel packaging subsystem for packaging the coated, particulate burnable fuel or a mixture of uncoated and coated particulate burnable fuels to form packaged or containerized particulate burnable fuels including a coated particulate burnable fuel for ease of transport and use. The system can also include one or more pre-treating or pre-processing and/or post-treating or post processing units for pre and/or post-treating or pre- and/or post-processing all or some of the coated, particulate burnable fuel.
Systems of Making Coated, Shaped Burnable Fuel {Look Through to Change Materials to Steps Re Coating} Embodiments of this invention relate to systems for converting one or a plurality of source materials into a burnable fuel. The systems include sources of source materials. Each source material can include a complex mixture of components as set forth herein. The systems include an input material subsystem for forming an input material having a desired distribution of source materials. The systems can also include a pre-processing and/or pre-treating subsystem for subjecting the input material and/or source materials to one or more pre-processing and/or pre-treating steps or for adjusting a making up of the input material. The system may also include a source or input material coating subsystem, where source materials and/or the input material is coated in an input material coating step, where the source or input materials can be coated with a first coating material or a plurality of first coating materials. The systems also include a sizing subsystem for sizing or sizing and partially or completely homogenizing the input material (pre-processed or not) to form a particulate burnable fuel. The sizing subsystem can include one or more shredding units, chopping units, milling units, and/or any other unit that reduces the size of the input material to form the particulate burnable fuel having a desired particle size distribution. The systems also include a particulate coating subsystem for coating the particles of the particulate burnable fuel in a particulate coating step, where the particulate burnable fuel is coated with a second coating material or a plurality of second coating materials during and/or after sizing to form a coated, particulate burnable fuel. The system can also include one or more pre- and/or post-treating or pre- and/or post-processing units for pre- and/or post-treating or pre- and/or post-processing all or some of the coated, particulate burnable fuel. The particulate burnable fuel can include uncoated and/or coated particulate burnable fuel. The systems also include a coating shaped fuel subsystem for coating shaped burnable fuels in a shape coating step, where the shaped burnable fuel is be coated with a third coating material or a plurality of third coating materials during and/or after shaping to form a coated, shaped burnable fuel. The systems can also include a shaped burnable fuel packaging subsystem for packaging the coated, shaped burnable fuel or as a mixture of uncoated and coated shaped burnable fuels to form packaged or containerized shaped burnable fuels comprising a coated shaped burnable fuel for ease of transport and use. The three coating steps can be the same or different and are designed to: (1) reduce dust, increase an agglomerating, conglomerating, aggregating, and/or consolidating propensity of the particles so that they are more easily incorporated into the shaped either before, during and/or after shaping; (2) alter burn properties of the particulate or shaped burnable fuels; (3) alter water-proofing or water-resistant properties or particulate or shaped burnable fuel; (4) alter shape integrity; and/or (5) alters other particle properties and/or other shape properties. Each coating steps can apply a single coating or multiple coatings to the materials and/or fuels, where the coatings can be the same or different. For example, the coating steps may first coat the materials and/or fuels with a water-proofing coating and a pro-oxidant coating. But, basically, each coating step can coat either the materials and/or the fuels with any number of coating and coating compositions to impart any desired property or combination of properties to the materials and/or fuels.
Coated Particulate Burnable Fuels Embodiments of this invention provide a particulate burnable fuel including 1% to 100% of a coated particulate burnable fuel and 99% to 0% an uncoated particulate burnable fuel, where the can be either volume or weight percent.
Shaped Coated Particulate Burnable Fuels Embodiments of this invention provide a shaped burnable fuel including 1% to 100% of a coated particulate burnable fuel and 99% to 0% an uncoated particulate burnable fuel, where the % can be either volume or weight percent.
Coated Shaped Particulate Burnable Fuels Embodiments of this invention provide a coated shaped burnable fuel, where the coated shaped burnable fuel can include 0% to 100% of a uncoated particulate burnable fuel and 100% to 0% an coated particulate burnable fuel, where the % can be either volume or weight percent.
Suitable Reagents and Equipment of the Invention Suitable source materials include, without limitation, any virgin material, unused material, experimental material, used material, and/or waste material. Exemplary examples of source materials include, without limitation, virgin, unused, experimental, used or waste industrial materials, virgin, unused, experimental, used or waste municipal materials, virgin, unused, experimental, used or waste healthcare materials, virgin, unused, experimental, used or waste medical materials, virgin, unused, experimental, used or waste agricultural materials, virgin, unused, experimental, used or waste biomass materials, virgin, unused, experimental, used or waste electronic materials, virgin, unused, experimental, used or waste metal materials, virgin, unused experimental, used or waste pharmaceutical materials, nutraceutical materials, other virgin, unused, experimental, used or waste materials produced by the pharmaceutical or nutraceutical industries, other virgin, unused, experimental, used or waste materials or mixtures or combinations thereof. Virgin, unused, experimental, used or waste healthcare and virgin, unused, experimental, used or waste medical materials can include medical waste materials, generated by people, doctors, doctor offices, clinics, emergency clinics, hospitals, dentists, dentistry clinics and hospitals, veterinarians, veterinary clinics and hospitals, farms, farmer, ranches, ranchers, or producers of used or waste material and/or other facilities that produce used or waste material. Many of the source materials are complex mixtures of components including, without limitation, pulp materials, fiber materials, fabric materials, polymer materials, metal materials, ceramic materials, ash materials, other materials and/or mixtures or combinations thereof.
Pulp materials suitable for use herein include, without limitation, wood, wood chips, sawdust, paper, cardboard, and/or mixtures or combinations thereof.
Industrial materials suitable for use herein include, without limitation, {complete list}.
Electronic materials suitable for use herein include, without limitation, {complete list}
Ash material suitable for use herein include, without limitation, any partially or completely combusted materials, any slag materials, any coal ash materials, any other material that is produced in a process as a partially oxidized waste or by-product materials, or mixtures or combinations thereof.
Fiber materials suitable for use herein include, without limitation, natural fibers, synthetic fibers, or the like and mixtures or combinations thereof. Exemplary fibers include, without limitation, inorganic fibers, carbon fibers, boron-nitride fibers, organic fibers, ceramic fibers, glass fibers, any other fibrous material and mixtures or combinations thereof.
Fabric materials suitable for use herein include, without limitation, any natural or synthetic fabric and mixtures or combinations thereof. Exemplary examples include, without limitation, cotton, wool and other fabrics made from animals or plants, RAYON, DACRON, fabric made of polyamides, or any other fabric or mixtures or combinations thereof.
Metal or metallic materials include, without limitation, any metal or metal alloy including a metal from the periodic table of elements. Exemplary examples include, alkali metals (Group 1 metals), alkaline earth metals (Group 2 metals), transition metals (Group 3-12 metals), Lanthanide metals, Actinide metals, post-transition metals, metalloids, or mixtures or combinations thereof. Certain metals and metalloids may be removed prior to use depending on the use to which the burnable fuels is put. The metals can be in any form including fibers, pieces, devices including metals, etc. and mixtures or combinations thereof. Exemplary examples include waste electronic devices. Of course, it should be recognized to one of ordinary skill in the art, that certain metals and metal alloys either pose a health or environmental concerns or issue or process concern or issues. Exemplary examples of such metals or metal alloys would include mercury, cadmium, lead, and thallium and radioactive elements and/or isotopes.
Ceramic materials suitable for use herein include, without limitation, any ceramic material or ceramic containing material or mixtures or combinations thereof. Exemplary examples include, without limitation, electronic substrates, glass, dishes, clay pots, any other object that contains a ceramic material, and mixtures or combinations thereof.
The polymer materials suitable for use herein include, without limitation, plastics, thermoplastics, elastomers, thermoplastic elastomers, resins, and other polymer or polymeric materials and/or mixtures or combinations thereof.
Agricultural materials suitable for use herein include, without limitation, any agricultural waste, any agricultural packaging material and mixtures or combinations thereof.
Biomass materials suitable for use herein include, without limitation, any plant matter that is left over after processing to produce an end product such as sugar cane and sugar beet processing, and mixtures or combination thereof.
Other materials can include, without limitation, chemicals, ash, pharmaceuticals (e.g., unused pharmaceuticals, expired pharmaceuticals, or any other pharmaceutical compositions), ceramics, binding agents, composites materials of one or more of the components set forth above, any other materials and/or mixtures or combinations thereof. The inventors have also found that ash and/or slags derived from incinerating certain used or waste materials, where the ash still has material or fuel value can be added to the material to change or augment a compositional makeup of the fuel.
In all of the mixtures, polymer materials from other sources of waste, unused and/or virgin polymer materials can be added as binding agents to the material before burning or before forming the material into a desired compact shape followed by combustion of the fuel. The inventors believe that polymer materials act as binders in the shaping process, e.g., pelletizing, and help to increase the combustible nature of the resulting fuel. {make coating and binding agents interchangeable}
The used or waste material can include any mixture or combination of any of the above identified materials.
Suitable virgin and/or unused materials can be any material that has not been used and is added to the input material to change a property of the resulting fuel including altering a fuel value of the material, altering an ash composition of the material, expired pharmaceuticals, altering a fluidity of the material, altering a bulk density of the material, altering the cohesiveness of the material, altering the wettability of the material, adsorption, absorption, inflammability, non-flammability, or altering other properties or two or more properties of the material or mixtures or combinations thereof.
Suitable coating materials include, without limitation, oils (synthetic oils or natural animal or plant oils), medium to high melting point hydrocarbons, waxes, oligomers, low molecular weight polymers, high molecular weight polymers, resins, thermosetting resins, thermoplastics, elastomers, photocurable monomers, thermally curable monomers, curable monomers, polymerizable monomers, photocurable oligomers, thermally curable oligomers, polymerizable oligomers, photocurable polymers, thermally curable polymers, polymerizable polymers, metal deposition, metallization, metal foils, flame retards, pro-oxidants, flame accelerators, other materials that can form a desired coating or particle coating on the particulate fuels of this invention or mixture or combinations thereof. The coatings are designed to augment, adjust, change or alter one or more characteristics of the particulate fuel or shaped fuel such as, particle aggregation, agglomeration, conglomeration, and/or consolidation propensity to suppress dust, waterproofing, water-resistance, burn rate, fuel value, resulting ash composition, appearance, handleability, particle integrity, shape integrity, ignition temperature, volatility, etc. and mixtures or combinations of altered properties. Coating materials can be used as is or can be used as a solution in a suitable solvent (e.g., polystyrene in acetone), an emulsion, a dispersion, a suspension, other mixture or combination thereof.
Suitable solvents include, without limitation, hydrocarbon solvents (linear or branched, saturated or unsaturated aliphatic solvents, aromatic solvents, naphthenic solvents, etc.), alcohol solvents, ether solvents, cyclic ether solvents, ketone solvents, ester solvents, any other solvent or mixtures or combinations thereof.
Suitable container or packaging include, without limitation, boxes, barrels, sacks, other containers, or mixtures or combinations thereof.
Suitable disinfecting and/or partially or completely sterilizing equipment include, without limitation, any equipment that can disinfect, and/or partially or completely sterilize used or waste material such as autoclaves including those manufactured by OnSite Sterilization, LLC of Pottstown, Pa., chemical treatments, thermal treatments, radiant treatments, radiological treatments, or any combination thereof.
Suitable pre-treating, pre-processing, post-processing and/or post-treating equipment includes, without limitation, heating units, vaporizing units, pyrolyzing units, washing units (water or solvent), cracking units, cooling units, magnetic separation units, electrolysis units, air floatation units, screening units, segregating units, filtering units, sedimentation units, fracturing units, shredding units, ultrasonic units, disinfecting units, sterilizing units, chemical treating units, neutralizing units, quality control units, cryogenic units, condensing units, polymerizing units, injection units or mixtures or combinations. Some of these pre- and post-treatments can add components to the materials or fuels to augment or alter desirable properties of the materials or fuels.
Suitable sizing and homogenizing equipment includes, without limitation, shredders, grinders, choppers, hammer mills, ball mills, or any other equipment used to reduce the physical size of a complex material or any combination of these equipment in series, parallel or a combination thereof. Shedders including those manufactured by SSI Shredding Systems, Inc. of Wilsonville, Oreg.
Suitable shaping equipment includes, without limitation, pelletizes such as those manufactured by Roskamp Champion of Waterloo, Iowa or California Pellet Mill Co. of Crawfordsville, Ind., extruders, other compressing forming equipment or any combination thereof.
Suitable incinerator equipment include, without limitation, any incinerator equipment, pyrolysis treatments, plasma treatments, or other treatments that can burn or combust a used or waste material to an ash, having a given un-used fuel value from 0 to some finite value. Exemplary examples include CONSUMAT® Incinerators manufactured by Consutech Systems, LLC (CONSUMAT is a registered trademark of Consutech Systems, LLC).
Suitable coating equipments include, without limitation: gas, aerosol, liquid, emulsion, dispersion, suspension, slurry, semi-solid and/or solid injection equipments, gas; aerosol, liquid, emulsion, dispersion, suspension, slurry, semi-solid and/or solid spraying equipment; gas, aerosol, liquid, emulsion, dispersion, suspension, slurry, semi-solid and/or solid electrostatic coating equipment; any other gas, aerosol, liquid, emulsion, dispersion, suspension, slurry, semi-solid and/or solid equipment capable of coating (partially or completely) a particulate or shaped material, emersion units, dipping units, other units that bring particles or shapes in contact with a fluid coating material (liquid, emulsion, dispersion, suspension, slurry, etc.) or mixtures or combinations thereof.
Suitable fuel utilization equipment include, without limitation, cement plants, lime plants, brick plants, power plants, municipal incinerators for steam generation, or any other facility that burn fuels and converts heat derived from the burning of the fuel into a usable form of energy or for use of the heat and ash to make an end product or any combination thereof.
For embodiments of the fuels derived from the present invention that are designed to be formed or shaped into a consolidated structure such as a pellet, the particulate material compositions can include an effective amount of binding agents, sufficient to permit the shaping to maintain its final shape. The binding agents are selected from the group consisting of polymer materials or other materials that have a melting or softening temperature between about 40° C. and about 150° C. In certain embodiments, the binding agents are polymer components in used or waste material having a melting or softening temperature between about 40° C. and about 150° C. Exemplary examples of such polymeric materials include, without limitation, modified cellulose, fabrics, plastics, thermoplastics, thermoplastic elastomers, elastomers, fiber enforced resins, metalized or metal coated plastics or polymers, or other polymeric materials and mixtures or combinations thereof. Exemplary plastics and thermoplastics include, without limitation, polyolefins, fluorinated polyolefins, chlorinated polyolefins, polyurethanes, polyalkyleneoxides, polyethers, polyesters, polyamides, polyimides, polycarbonates, epoxy resins, phenolic resins, alkylide resins, polyacrylates, polylactic acid, polyglycolic acid, other biocompatible polymers, and mixtures or combinations thereof. In other embodiments, the bonding agents can include ash alone or in combination with other binding agents. In other embodiments, binding agents can be added to the material to enhance or improve consolidation, to change or alter final ash composition, to reduce or increase metal content, to change or alter consolidated particle properties, to modify or change final particle appearance, or to enhance, improve, alter or change any other final property of the consolidated products of this invention. In specific, materials can be added to the burnable fuel as is, before or after sizing or sizing and shaping to adjust a heat content and/or ash composition of the burnable fuel regardless of its nature or shape.
Source Material Compositions Useful in the Invention Embodiments of this invention include a broad distributions of one or a plurality of source materials including virgin, unused, experimental, used or waste industrial materials, virgin, unused, experimental, used or waste municipal materials, used or waste healthcare materials, used or waste medical materials, used or waste agricultural materials, virgin, unused, experimental, used or waste biomass materials, virgin, unused, experimental, used or waste electronic materials, virgin, unused, experimental, used or waste metal material, virgin, unused experimental, used or waste pharmaceutical materials, nutraceutical materials, other virgin, unused, experimental, used or waste materials produced by the pharmaceutical or nutraceutical industries, other virgin, unused, experimental, used or waste materials, virgin, unused, experimental, used or waste oils (synthetic or natural), USDA AIPHIS waste or mixtures or combinations thereof. Each of these materials can include combustible materials and non-combustible materials. Exemplary examples of both combustible and non-combustible materials include, without limitation, pulp materials, fiber materials, fabric materials, polymer materials, metal materials, ceramic materials, ash materials, and/or other waste materials. Depending on their use, the compositions of this invention can be tailored to meet any desired need. By controlling the relative amount of combustible materials and non-combustible material in the input material, properties of the fuel can be adjusted to a desired value. Such input material properties include, without, limitation, a fuel value, a burn rate, a flow rate, an ash composition, an ash weight, by-product compositions and types, metal concentrations, chlorine and/or bromine concentrations, or any mixture or combination ofproperties. Other included materials can be used to tailor a composition of the ash being produced as the fuel is being burned. The fuel value can be adjusted up or down by changing the mix of combustible materials present and can be augmented further by adding a conventional fuel to the input material or treated material before or simultaneous with burning of the burnable fuels of this invention.
In certain embodiments of this invention, the input material has a composition including from about 20 wt. % to about 100 wt. % of combustible material, from about 0 wt. % to about 50 wt. % of non-combustible materials including metal materials, from about 0 wt. % to about 50 wt. % of binding agents, and from about 0 wt. % to about 50 wt. % of conventional fuels. In other embodiments, the input material has a composition including from about 50 wt. % to about 100 wt. % of combustible material, from about 0 wt. % to about 20 wt. % of non-combustible materials including metal materials, from about 0 wt. % to about 50 wt. % of binding agents, and from about 0 wt. % to about 50 wt. % of conventional fuels. Lesser and greater amount of each component can be included depending on the intended use of the burnable fuel of this invention.
In certain embodiments, the combustible materials can include from about 0 wt. % to about 100 wt. % of pulp materials, from about 0 wt. % to about 100 wt. % of fiber materials, from about 0 wt. % to about 100 wt. % of fabric materials, from about 0 wt. % to about 100 wt. % polymer materials, from about 0 wt. % to about 100 wt. % of other combustible materials, from about 0 wt. % to about 50 wt. % of binding agents, from about 0 wt. % to about 50 wt. % of conventional fuels, and from about 0 wt. % to about 100 wt. % of ash materials having anon-zero fuel value. The non-combustible materials can be added in any amount to alter one or more properties of the resulting burnable fuel.
In other embodiments, the combustible materials can include from about 0 wt. % to about 100 wt. % of pulp materials, from about 0 wt. % to about 100 wt. % of fiber materials, from about 0 wt. % to about 100 wt. % of fabric materials, from about 20 wt. % to about 100 wt. % polymer materials, from about 0 wt. % to about 100 wt. % of other combustible materials, from about 0 wt. % to about 50 wt. % of binding agents, from about 0 wt. % to about 50 wt. % of conventional fuels, and from about 0 wt. % to about 100 wt. % of ash materials having a non-zero fuel value. The non-combustible materials can be added in any amount to alter one or more properties of the resulting burnable fuel.
In other embodiments, the combustible materials can include from about 10 wt. % to about 100 wt. % of pulp materials, from about 10 wt. % to about 100 wt. % of fiber materials, from about 10 wt. % to about 100 wt. % of fabric materials, from about 30 wt. % to about 100 wt. % polymer materials, from about 10 wt. % to about 100 wt. % of other combustible materials, from about 0 wt. % to about 50 wt. % of binding agents, from about 0 wt. % to about 50 wt. % of conventional fuels, and from about 10 wt. % to about 100wt. % of ash materials having a non-zero fuel value. The non-combustible materials can be added in any amount to alter one or more properties of the resulting burnable fuel.
In other embodiments, the combustible materials can include from about 20 wt. % to about 100 wt. % of pulp materials, from about 20 wt. % to about 100 wt. % of fiber materials, from about 20 wt. % to about 100 wt. % of fabric materials, from about 50 wt. % to about 100 wt. % polymer materials, from about 20 wt. % to about 100 wt. % of other combustible materials, from about 0 wt. % to about 50 wt. % of binding agents, from about 0 wt. % to about 50 wt. % of conventional fuels, and from about 20 wt. % to about 100wt. % of ash materials having a non-zero fuel value. The non-combustible materials can be added in any amount to alter one or more properties of the resulting burnable fuel.
In these formulations, the weight percentages are not confined to add up to 100%, but are relative amounts on a weight basis of the final composition.
To determine the actual percentage in final composition, all of the weight percentages would be added up to give the overall formulation weight, then simple percentages can be determined.
It should be recognized that these ranges are simply a set of component break downs and any other component make up can be used provided that if the composition is to be shaped, there is sufficient polymer material in the material to allow the compressed material to hold its shape under normal handling condition. In certain embodiments, the shaping can be performed with added heat, pressure, irradiation (e.g., electromagnetic radiation, acoustic radiation, ultrasonic radiation, etc.), chemical additives and/or chemical treatments, etc., to increase shape integrity and improve crush strength of the shaped material.
Pre-Treatments In certain embodiments, some or all of the input material or a material to be included in the input material is pre-treated to augment, change or remove components of a source material. Such pre-treatments can include quality control testing, heating to remove volatile components, washing to remove water soluble components, solvent washing or extraction to remove solvent extractible components, pre-screening to remove materials having a certain size or construction for separate processing, partial pyrolysis to alter properties of the source material, drying to remove water, crushing of large objects into smaller objects for subsequent processing, any other pretreatment designed to condition a particular source material for use as a component in the input material used to produce the burnable fuels of this invention and any combination of these pre-treatments. Such pre-treating or pre-processing includes those set forth above.
Disinfecting Pre-Treatments In certain embodiments and for certain materials, some or all of the input material or materials that will ultimately be included in the input material is disinfected and/or partially or completely sterilized using any methodology known to render a disinfected material, substantially free of any harmful pathogens. In certain embodiments of this invention, disinfecting and/or partial or complete sterilization is performed via autoclave sterilization. The source material is placed in an autoclave at a temperature and pressure and for a time sufficient to render a disinfected material, free or substantially free of any harmful pathogens. The temperature is generally greater than at least 121° C., at a pressure of at least 15 psig and for a time of at least 30 minutes. In certain embodiments, the temperature is between about 121° C. and about 150° C., the pressure is between about 15 psig and about 50 psig and for a time between about 30 minutes and 60 minutes. In certain embodiments, the temperature is between about 121° C. and about 125 ° C., the pressure is between about 15 psig and about 25 psig and for a time between about 30 minutes and 60 minutes. In certain embodiments, the temperature is between about 121° C. and about 123 ° C., the pressure is between about 15 psig and about 20 psig and for a time between about 30 minutes and 40 minutes. Although specific embodiments have been set forth on temperature, pressure and time, higher temperatures and/or pressures can be used as well as shorter or longer times depending on a desired outcome or property of the disinfected material. For USDA AIPHIS waste, the disinfecting step can be carried out at a reduced temperature of about 100° C., at the same pressure ranges listed above.
Particle Distribution The source materials and input material, regardless of their make up, is sized or sized and partially or completely homogenized or otherwise processed to reduce the particle size of the material and to form a particulate material having a certain particle size distribution and a certain degree of homogeny. The exact particle size distribution depends on the nature of the sizing or sizing and partially or completely homogenizing equipment used and on the screens or other size exclusion means used to control the particle size of the exiting particulate material and end use needs. The distribution of the present invention includes particles having a smallest dimension of between about 0.1 μm and about 1000 mm. In certain embodiments, the particles have a smallest dimension of between about 1 μm and about 500 mm. In certain embodiments, the particles have a smallest dimension between about 10 μm and about 500 mm. In other embodiments, the particles have a smallest dimension between about 100 μm and about 500 mm. In other embodiments, the particles have a smallest dimension between about 1 mm and about 500 mm. In other embodiments, the particles have a smallest dimension between about 1 mm and about 250 mm. In other embodiments, the particles have a smallest dimension between about 1 mm and about 100 mm. In other embodiments, the particles have a smallest dimension between about 1 mm and about 50 mm. In other embodiments, the particles have a smallest dimension between about 10 mm and about 50 mm. The smallest dimension means that the particles are capable of passing through a screen of a desired screen size. The screen size range between openings of about 12.7 mm to about 50.8 mm. In other embodiments, the screen opening ranges between about 19.05 mm and about 44.45 mm. In other embodiments, the screen opening ranges between about 19.05 and about 38.1 mm.
The term partially homogenized in the context of the present invention means that the particulate material, although being composed of many different material components, has been mixed sufficiently that the bulk composition of components is within about 30% the same throughout the entire particulate material. In certain, embodiments, the partial homogeneity is within 20% or lower. The term completely homogenized in the context of the present invention means that the particulate material, although being composed of many different material components, has been mixed sufficiently that the bulk composition of components is within about 10% the same throughout the entire particulate material. In certain, embodiments, the partial homogeneity is within 5%.
Compressed Shapes Optionally, the particulate material from the sizing process is then pressed, extruded or similarly processed into a shape to increase the bulk density of the material. The shape can be any shape including a cylindrical shape, a cubical shape, a rectangular solid shape, a spherical shape, an ellipsoidal shape, a tablet shape or any other compact 3D shape. The dimension of these shapes can range between about 0.5 cm and about 20 cm. In certain embodiments, the shape is substantially elongate shape having a diameter less than or equal to its length. The shape can be of a cylindrical type having sharp cut ends, jagged ends and/or rounded ends depending on the method used to make the elongate shape. Generally, the elongate shapes have a diameter between about 5 mm and about 20 mm and length of about 2 cm to about 10 cm. In certain embodiments, the elongate shape is cylindrical or substantially cylindrical. In other embodiments, the elongate shape has a diameter between about 10 mm and about 20 mm and a length between 3 cm and about 5 cm. In other embodiments, the elongate shape has a diameter between about 10 mm and about 15 mm and a length between 3 cm and about 5 cm. However, the shapes can be larger or smaller depending on end use. In other embodiment, the shape can have a diameter between about 0.5 cm and 20 cm. In other embodiment, the shape can have a diameter between about 0.5 cm and 20 cm and a length between about 0.5 cm and about 20 cm. In other embodiment, the shape can have a length, a width and a height between about 0.5 cm and 20 cm.
Coating Particulate Fuels The particulate burnable fuels of this invention can be coated with a coating designed to coat the particles of the particulate burnable fuel of this invention with a coating designed to augment combustion properties and/or chemical properties and/or physical properties of the particulate burnable fuel, where the extent of coating is as set forth herein. The coating can also be used to agglomerate particles of the particulate burnable fuel to reduce dust. The coating can be a hydrocarbon coating, an oligomeric coating, a polymeric coating, an electrostatic coating, and/or other type of coatings.
Coating Shaped Fuels The shaped burnable fuels of this invention can be coated with a coating designed to coat the compact shapes of the shaped burnable fuel of this invention with a coating designed to augment combustion properties and/or chemical properties and/or physical properties of the shaped burnable fuel, where the extent of coating is as set forth herein. The coating can also be used to agglomerate particles of the particulate burnable fuel to reduce dust during and/or after shaping of the particulate burnable fuel. The coating can be a hydrocarbon coating, an oligomeric coating, a polymeric coating, an electrostatic coating, and/or any other type of coating.
DETAILED DESCRIPTION OF THE DRAWINGS Methods Coated Particulate Burnable Fuels Referring now to FIG. 1A, an embodiment of the present method, generally 100, is shown to include a providing step 102, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 104, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 106, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 104 with a coating material to form a coated particulate burnable fuel.
Referring now to FIG. 1B, an embodiment of the present method, generally 100, is shown to include a providing step 102, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 104, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 106, where the particulate burnable fuel is partially and/or completely coated with a coating material to form a coated particulate burnable fuel. The method also includes a burning step 108, where a particulate burnable fuel including a coated particulate burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 1C, an embodiment of the present method, generally 100, is shown to include a providing step 102, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 104, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 106, where the particulate burnable fuel is partially and/or completely coated during and/or after the sizing step 104 with a coating material to form a coated particulate burnable fuel. The method also includes a packaging step 110, where a particulate burnable fuel including the coated particulate burnable fuel is packaged for shipment or transportation to form a packaged or containerized coated particulate burnable fuel. Besides the coated particulate burnable fuel, uncoated particulate burnable fuel can also be packaged simultaneously with the coated particulate burnable fuel.
Referring now to FIG. 1D, an embodiment of the present method, generally 100, is shown to include a providing step 102, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 104, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 106 where the particulate burnable fuel is partially and/or completely coated during and/or after the sizing step 104 with a coating material to form a coated particulate burnable fuel. The method also includes a packaging step 110, where the coated particulate burnable fuel is packaged for shipment or transportation to form a packaged or containerized coated particulate burnable fuel. Besides the coated particulate burnable fuel, uncoated particulate burnable fuel can also be packaged simultaneously with the coated particulate burnable fuel. The method also includes a burning step 108, where a packaged particulate burnable fuel including a coated particulate burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 1E, an embodiment of the present method, generally 100, is shown to include a providing step 102, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 104, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 106, where the particulate burnable fuel is partially and/or completely coated with a coating material to form a coated particulate fuel. The method also includes a shaping step 112, where a particulate burnable fuel including the coated particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. Besides the coated burnable fuel, uncoated particulate burnable fuel can also be shaped simultaneously with the coated particulate burnable fuel.
Referring now to FIG. 1F, an embodiment of the present method, generally 100, is shown to include a providing step 102, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 104, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 106, where the particulate burnable fuel is partially and/or completely coated with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 112, where a particulate burnable fuel including the coated particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. Besides the coated burnable fuel, uncoated particulate burnable fuel can also be shaped simultaneously with the coated particulate burnable fuel. The method also includes a burning step 108, where a shaped burnable fuel including a coated particulate burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 1G, an embodiment of the present method, generally 100, is shown to include a providing step 102, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 104, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 106, where the particulate burnable fuel is partially and/or completely coated with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 112, where a particulate burnable fuel including the coated particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. Besides the coated burnable fuel, uncoated particulate burnable fuel can also be shaped simultaneously with the coated particulate burnable fuel. The method also includes a packaging step 110, where the shaped burnable fuel including the coated particulate burnable fuel is packaged for shipment or transportation to form a packaged or containerized shaped burnable fuel. Besides the shaped burnable fuel including a coated particulate burnable fuel, the shaped burnable fuels can include, uncoated particulate burnable fuels can also be packaged simultaneously with the shaped burnable fuels including a coated particulate burnable fuel.
Referring now to FIG. 1H, an embodiment of the present method, generally 100, is shown to include a providing step 102, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 104, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 106, where the particulate burnable fuel is partially and/or completely coated with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 112, where a particulate burnable fuel including the coated particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. Besides the coated burnable fuel, uncoated particulate burnable fuel can also be shaped simultaneously with the coated particulate burnable fuel. The method also includes a packaging step 110, where the shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized shaped burnable fuel. Besides the shaped burnable fuel including a coated particulate burnable fuel, shaped burnable fuels including, uncoated particulate burnable fuels can also be packaged simultaneously with the shaped burnable fuels including a coated particulate burnable fuel. The method also includes a burning step 108, where a packaged, shaped burnable fuel including a coated particulate burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Coated Shaped Burnable Fuel Referring now to FIG. 2A, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a shaping step 206, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel.
Referring now to FIG. 2B, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a shaping step 206, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a burning step 210, where the coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 2C, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a shaping step 206, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a packaging step 212, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized coated shaped burnable fuel.
Referring now to FIG. 2D, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a shaping step 206, where the particulate burnable fuel is formed into a burnable compact shape. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape to form a shaped burnable fuel. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a packaging step 212, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel. The method also includes a burning step 210, where the packaged or containerized, coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 2E, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 214, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 214 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 206, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel.
Referring now to FIG. 2F, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 214, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 214 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 206, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a burning step 210, where the packaged or containerized, coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 2G, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 214, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 214 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 206, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a packaging step 212, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel.
Referring now to FIG. 2H, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 214, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 214 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 206, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a packaging step 212, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel. The method also includes a burning step 210, where the packaged or containerized, coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 2I, an embodiment of the present method, generally 200, is shown to include a providing step 202, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes an input material coating step 216, which the input material and/or one or more of the source material are coated with an input coating material. The coating can be as stated herein for the coating coverage of the particulate fuels. The method also includes a sizing step 204, where the input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 214, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 214 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 206, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The shaping step can be a pelletizing step, producing burnable fuel pellets, an extruding step, producing burnable extrudates, or any other step that forms the particulate burnable fuel into a compact shape. The method also includes a shape coating step 208, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a packaging step 212, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel. The method also includes a burning step 210, where the packaged or containerized, coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
One Source Material with Pre-Processing
Referring now to FIG. 3A, an embodiment of the present method, generally 300, is shown to include a providing step 302, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes one or a plurality of input material pre-processing steps 304, where the input material is pre-processed to form a pre-processed input material. The method also includes a sizing step 306, where the pre-processed input material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method may also include one or a plurality of particulate burnable fuel pre-processing steps 308, where the particulate burnable fuel is pre-processed or pre-treated. The method also includes a shaping step 310, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 312, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel.
Referring now to FIG. 3B, an embodiment of the present method, generally 300, is shown to include a providing step 302, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes one or a plurality of input material pre-processing steps 304, where the input material is pre-processed to form a pre-processed material. The method also includes a sizing step 306, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method may also include one or a plurality of particulate burnable fuel pre-processing steps 308, where the particulate burnable fuel is pre-processed or pre-treated. The method also includes a shaping step 310, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 312, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a burning step 314, where the coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 3C, an embodiment of the present method, generally 300, is shown to include a providing step 302, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes one or a plurality of input material pre-processing steps 304, where the input material is pre-processed to form a pre-processed material. The method also includes a sizing step 306, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method may also include one or a plurality of particulate burnable fuel pre-processing steps 308, where the particulate burnable fuel is pre-processed or pre-treated. The method also includes a shaping step 310, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 312, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method can also include a packaging step 316, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel.
Referring now to FIG. 3D, an embodiment of the present method, generally 300, is shown to include a providing step 302, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes one or a plurality of input material pre-processing steps 304, where the input material is pre-processed to form a pre-processed material. The method also includes a sizing step 306, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method may also include one or a plurality of particulate burnable fuel pre-processing steps 308, where the particulate burnable fuel is pre-processed or pre-treated. The method also includes a shaping step 310, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 312, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method can also include a packaging step 316, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel. The method also includes a burning step 314, where the coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 3E, an embodiment of the present method, generally 300, is shown to include a providing step 302, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes one or a plurality of input material pre-processing steps 304, where the input material is pre-processed to form a pre-processed material. The method also includes a sizing step 306, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method may also include one or a plurality of particulate burnable fuel pre-processing steps 308, where the particulate burnable fuel is pre-processed or pre-treated. The method also includes a particle coating step 318, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 318 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 310, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 312, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel.
Referring now to FIG. 3F, an embodiment of the present method, generally 300, is shown to include a providing step 302, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes one or a plurality of input material pre-processing steps 304, where the input material is pre-processed to form a pre-processed material. The method also includes a sizing step 306, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method may also include one or a plurality of particulate burnable fuel pre-processing steps 308, where the particulate burnable fuel is pre-processed or pre-treated. The method also includes a particle coating step 318, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 318 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 310, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 312, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a burning step 314, where thecoated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Referring now to FIG. 3G, an embodiment of the present method, generally 300, is shown to include a providing step 302, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes one or a plurality of input material pre-processing steps 304, where the input material is pre-processed to form a pre-processed material. The method also includes a sizing step 306, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method may also include one or a plurality of particulate burnable fuel pre-processing steps 308, where the particulate burnable fuel is pre-processed or pre-treated. The method also includes a particle coating step 318, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 318 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 310, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 312, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method can also include a packaging step 316, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel.
Referring now to FIG. 3H, an embodiment of the present method, generally 300, is shown to include a providing step 302, where one or a plurality of source materials are mixed to form an input material having a desired compositions of components. The method also includes one or a plurality of input material pre-processing steps 304, where the input material is pre-processed to form a pre-processed material. The method also includes a sizing step 306, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method may also include one or a plurality of particulate burnable fuel pre-processing steps 308, where the particulate burnable fuel is pre-processed or pre-treated. The method also includes a particle coating step 318, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 318 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 310, where the coated particulate burnable fuel or a mixture of uncoated fuel and coated particulate fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 312, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method can also include a packaging step 316, where the coated shaped burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel. The method also includes a burning step 314, where the packaged or containerized, coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom.
Two Source Material, One Pre-Processed Referring now to FIG. 4A, an embodiment of the present method, generally 400, is shown to include a first providing step 402 for providing a first source material. The method also includes a second providing step 404 for providing a second source material. The method also includes one or more pre-processing steps 406 for pre-processing the second source material to form a pre-processed material. The method also includes a mixing step 408, where the first source material and the pre-processed material are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 410, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The term “source material” refers to any waste or other material, without limitation, which contains fuel and/or material value suitable for the end use. The method also includes a shaping step 412, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 414, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel.
Referring now to FIG. 4B, an embodiment of the present method, generally 400, is shown to include a first providing step 402 for providing a first source material. The method also includes a second providing step 404 for providing a second source material. The method also includes one or more pre-processing steps 406 for pre-processing the second source material to form a pre-processed material. The method also includes a mixing step 408, where the first source material and the pre-processed material are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 410, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a shaping step 412, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 414, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a burning step 416, where the coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom. The method can also include one or more pre-processing step for the first source material. These pre-processing steps may be the same or different from the pre-processing steps used to pre-treat the second source material.
Referring now to FIG. 4C, an embodiment of the present method, generally 400, is shown to include a first providing step 402 for providing a first source material. The method also includes a second providing step 404 for providing a second source material. The method also includes one or more pre-processing steps 406 for pre-processing the second source material to form a pre-processed material. The method also includes a mixing step 408, where the first source material and the pre-processed material are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 410, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a shaping step 412, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 414, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method can also include a packaging step 418, where the burnable fuel is packaged for shipment or transportation to form a packaged or containerized, particulate burnable fuel. The method can also include one or more pre-processing step for the first source material. These pre-processing steps may be the same or different from the pre-processing steps used to pre-treat the second source material.
Referring now to FIG. 4D, an embodiment of the present method, generally 400, is shown to include a first providing step 402 for providing a first source material. The method also includes a second providing step 404 for providing a second source material. The method also includes one or more pre-processing steps 406 for pre-processing the second source material to form a pre-processed material. The method also includes a mixing step 408, where the first source material and the pre-processed material are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 410, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a shaping step 412, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 414, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method can also include a packaging step 418, where the burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel. The method also includes a burning step 416, where the packaged or containerized, coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom. The method can also include one or more pre-processing step for the first source material. These pre-processing steps may be the same or different from the pre-processing steps used to pre-treat the second source material.
Referring now to FIG. 4E, an embodiment of the present method, generally 400, is shown to include a first providing step 402 for providing a first source material. The method also includes a second providing step 404 for providing a second source material. The method also includes one or more pre-processing steps 406 for pre-processing the second source material to form a pre-processed material. The method also includes a mixing step 408, where the first source material and the pre-processed material are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 410, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 420, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 420 with a coating material to form a coated particulate burnable fuel. The term “source material” refers to any waste or other material, without limitation, which contains fuel and/or material value suitable for the end use. The method also includes a shaping step 412, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 414, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel.
Referring now to FIG. 4F, an embodiment of the present method, generally 400, is shown to include a first providing step 402 for providing a first source material. The method also includes a second providing step 404 for providing a second source material. The method also includes one or more pre-processing steps 406 for pre-processing the second source material to form a pre-processed material. The method also includes a mixing step 408, where the first source material and the pre-processed material are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 410, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 420, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 420 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 412, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 414, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method also includes a burning step 416, where the coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom. The method can also include one or more pre-processing step for the first source material. These pre-processing steps may be the same or different from the pre-processing steps used to pre-treat the second source material.
Referring now to FIG. 4G, an embodiment of the present method, generally 400, is shown to include a first providing step 402 for providing a first source material. The method also includes a second providing step 404 for providing a second source material. The method also includes one or more pre-processing steps 406 for pre-processing the second source material to form a pre-processed material. The method also includes a mixing step 408, where the first source material and the pre-processed material are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 410, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 420, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 420 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 412, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 414, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method can also include a packaging step 418, where the burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel. The method can also include one or more pre-processing step for the first source material. These pre-processing steps may be the same or different from the pre-processing steps used to pre-treat the second source material.
Referring now to FIG. 4H, an embodiment of the present method, generally 400, is shown to include a first providing step 402 for providing a first source material. The method also includes a second providing step 404 for providing a second source material. The method also includes one or more pre-processing steps 406 for pre-processing the second source material to form a pre-processed material. The method also includes a mixing step 408, where the first source material and the pre-processed material are mixed to form an input material having a desired compositions of components. The method also includes a sizing step 410, where the pre-processed material is sized or sized and partially or completely homogenized to form a particulate burnable fuel. The method also includes a particle coating step 420, where the particles of the particulate burnable fuel are partially and/or completely coated during and/or after the sizing step 420 with a coating material to form a coated particulate burnable fuel. The method also includes a shaping step 412, where the particulate burnable fuel is formed into a burnable compact shape to form a shaped burnable fuel. The method also includes a shape coating step 414, where the shaped burnable fuel is partially and/or completely coated with a coating material to form a coated shaped burnable fuel. The method can also include a packaging step 418, where the burnable fuel is packaged for shipment or transportation to form a packaged or containerized, coated shaped burnable fuel. The method also includes a burning step 416, where the packaged or containerized, coated shaped burnable fuel is burned to produce a useable form of energy, to produce a useable product, or to otherwise use the heat derived therefrom. The method can also include one or more pre-processing step for the first source material. These pre-processing steps may be the same or different from the pre-processing steps used to pre-treat the second source material.
In each of the above methods, the particulate burnable fuel can be pre-processed or pre-treated in one or a plurality of pre-processing or pre-treating steps as shown in FIG. 4A-H.
Systems Particle Coating Referring now to FIG. 5A, an embodiment of the present system, generally 500, is shown to include a material supply subsystem 502, where one or a plurality of source materials 504 are collected or supplied to form an input material 506 for subsequent system processing. The input material 506 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 506 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 508. The SHC subsystem 508 includes a sizing/homogenizing unit 508a and a coating unit 508b, where the coating unit 508b is connected with the exit of the sizing/homogenizing unit 508a. In the sizing/homogenizing unit 508a, the input material 506 is shredded, chopped, shattered, or broken to produce a particulate material 510 (not shown here as it passes directly into the coating unit 508b) having a desired particle size distribution. The particulate material 510 is then coated in the coating unit 508b with the particulate coating material to form a coated particulate burnable fuel 512, where the extent of coating is as described herein. The coating unit 508b can include injectors, sprayers, nebulizers, atomizers, ionizers or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 508b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 512 is then forwarded to a combustion subsystem 514, where a portion of the heat generated by combustion of the coated particulate burnable fuel 512 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 5B, an embodiment of the present system, generally 500, is shown to include a material supply subsystem 502, where one or a plurality of source materials 504 are collected or supplied to form an input material 506 for subsequent system processing. The input material 506 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 506 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 508. The SHC subsystem 508 includes a sizing/homogenizing unit 508a and a coating unit 508b. In the sizing/homogenizing unit 508a, the input material 506 is shredded, chopped, shattered, or broken to produce a particulate material 510 having a desired particle size distribution. The particulate material 510 is then forwarded to the coating unit 508b, where particles of the particulate material 510 are coated with a particulate coating material to form a coated particulate burnable fuel 512, where the extent of coating is as described herein. The coating unit 508b can include injectors, sprayers, nebulizers, atomizers, ionizers or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 508b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 512 is then forwarded to a combustion subsystem 514, where a portion of the heat generated by combustion of the coated particulate burnable fuel 512 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 5C, an embodiment of the present system, generally 500, is shown to include a material supply subsystem 502, where one or a plurality of source materials 504 are collected or supplied to form an input material 506 for subsequent system processing. The input material 506 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 506 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 508. The SHC subsystem 508 includes a sizing/homogenizing unit 508a and a coating unit 508b, where the coating unit 508b is connected with the exit of the sizing/homogenizing unit 508a. In the sizing/homogenizing unit 508a, the input material 506 is shredded, chopped, shattered, or broken to produce a particulate material 510 (not shown here as it passes directly into the coating unit 508b) having a desired particle size distribution. The particulate material 510 is then coated in the coating unit 508b with the particulate coating material to form a coated particulate burnable fuel 512, where the extent of coating is as described herein. The coating unit 508b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mixing the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 508b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 512 is then forwarded to a storage subsystem 516, where the coated particulate burnable fuel 512 is stored for subsequent use as a fuel or fuel component. The coated particulate burnable fuel 512 is then forwarded from the storage subsystem 516 to a combustion subsystem 514, where a portion of the heat generated by combustion of the coated particulate burnable fuel 512 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 5D, an embodiment of the present system, generally 500, is shown to include a material supply subsystem 502, where one or a plurality of source materials 504 are collected or supplied to form an input material 506 for subsequent system processing. The input material 506 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 506 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 508. The SHC subsystem 508 includes a sizing/homogenizing unit 508a and a coating unit 508b. In the sizing/homogenizing unit 508a, the input material 506 is shredded, chopped, shattered, or broken to produce a particulate material 510 having a desired particle size distribution. The particulate material 510 is then forwarded to the coating unit 508b, where particles of the particulate material 510 are coated with a particulate coating material to form a coated particulate burnable fuel 512, where the extent of coating is as described herein. The coating unit 508b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mixing the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 508b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 512 is then forwarded to a storage subsystem 516, where the coated particulate burnable fuel 512 is stored for subsequent use as a fuel or fuel component. The coated particulate burnable fuel 512 is then forwarded from the storage subsystem 516 to a combustion subsystem 514, where a portion of the heat generated by combustion of the coated particulate burnable fuel 512 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 5E, an embodiment of the present system, generally 500, is shown to include a material supply subsystem 502, where one or a plurality of source materials 504 are collected or supplied to form an input material 506 for subsequent system processing. The input material 506 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 506 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 508. The SHC subsystem 508 includes a sizing/homogenizing unit 508a and a coating unit 508b, where the coating unit 508b is connected with the exit of the sizing/homogenizing unit 508a. In the sizing/homogenizing unit 508a, the input material 506 is shredded, chopped, shattered, or broken to produce a particulate material 510 (not shown here as it passes directly into the coating unit 508b) having a desired particle size distribution. The particulate material 510 is then coated in the coating unit 508b with the particulate coating material to form a coated particulate burnable fuel 512, where the extent of coating is as described herein. The coating unit 508b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mixing the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 508b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 512 is then forwarded to a packaging subsystem 518, where the coated particulate burnable fuel 512 is placed in containers to produce a containerized coated particulate burnable fuel 520. The containerized coated particulate burnable fuel 520 is then forwarded to a combustion subsystem 514, where a portion of the heat generated by combustion of the containerized coated particulate burnable fuel 520 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 5F, an embodiment of the present system, generally 500, is shown to include a material supply subsystem 502, where one or a plurality of source materials 504 are collected or supplied to form an input material 506 for subsequent system processing. The input material 506 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 506 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 508. The SHC subsystem 508 includes a sizing/homogenizing unit 508a and a coating unit 508b. In the sizing/homogenizing unit 508a, the input material 506 is shredded, chopped, shattered, or broken to produce a particulate material 510 having a desired particle size distribution. The particulate material 510 is then forwarded to the coating unit 508b, where particles of the particulate material 510 are partially or completely coated with a particulate coating material to form a coated particulate burnable fuel 512, where the extent of coating is as described herein. The coating unit 508b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mixing the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 508b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 512 is then forwarded to a packaging subsystem 518, where the coated particulate burnable fuel 512 is placed in containers to produce a containerized coated particulate burnable fuel 520. The containerized coated particulate burnable fuel 520 is then forwarded to a combustion subsystem 514, where a portion of the heat generated by combustion of the containerized coated particulate burnable fuel 520 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 5G, an embodiment of the present system, generally 500, is shown to include a material supply subsystem 502, where one or a plurality of source materials 504 are collected or supplied to form an input material 506 for subsequent system processing. The input material 506 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 506 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 508. The SHC subsystem 508 includes a sizing/homogenizing unit 508a and a coating unit 508b, where the coating unit 508b is connected with the exit of the sizing/homogenizing unit 508a. In the sizing/homogenizing unit 508a, the input material 506 is shredded, chopped, shattered, or broken to produce a particulate material 510 (not shown here as it passes directly into the coating unit 508b) having a desired particle size distribution. The particulate material 510 is then partially or completely coated in the coating unit 508b with the particulate coating material to form a coated particulate burnable fuel 512, where the extent of coating is as described herein. The coating unit 508b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mixing the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 508b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated burnable fuel 512 is then forwarded to a packaging subsystem 518, where the coated particulate burnable fuel 512 is placed in containers to produce a containerized coated particulate burnable fuel 520. The containerized coated particulate burnable fuel 520 is then forwarded to a storage subsystem 516, where the containerized particulate burnable fuel 520 is stored for subsequent use as a fuel or fuel component. The containerized coated particulate burnable fuel 520 is then forwarded from the storage subsystem 516 to a combustion subsystem 514, where a portion of the heat generated by combustion of the containerized coated particulate burnable fuel 520 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 5H, an embodiment of the present system, generally 500, is shown to include a material supply subsystem 502, where one or a plurality of source materials 504 are collected or supplied to form an input material 506 for subsequent system processing. The input material 506 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 506 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 508. The SHC subsystem 508 includes a sizing/homogenizing unit 508a and a coating unit 508b. In the sizing/homogenizing unit 508a, the input material 506 is shredded, chopped, shattered, or broken to produce a particulate material 510 having a desired particle size distribution. The particulate material 510 is then forwarded to the coating unit 508b, where particles of the particulate material 510 are coated with the particulate coating material to form a coated particulate burnable fuel 512, where the extent of coating is as described herein. The coating unit 508b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mixing the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 508b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated burnable fuel 512 is then forwarded to a packaging subsystem 518, where the coated particulate burnable fuel 512 is placed in containers to produce a containerized coated particulate burnable fuel 520. The containerized coated particulate burnable fuel 520 is then forwarded to a storage subsystem 516, where the containerized particulate burnable fuel 520 is stored for subsequent use as a fuel or fuel component. The containerized coated particulate burnable fuel 520 is then forwarded from the storage subsystem 516 to a combustion subsystem 514, where a portion of the heat generated by combustion of the containerized coated particulate burnable fuel 520 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
In each of the above systems, the source materials and the particulate material can be pre-processed or pre-treated in a pre-processing or pre-treating subsystem (not shown).
Shape Coating Referring now to FIG. 6A, an embodiment of the present system, generally 600, is shown to include a material supply subsystem 602, where one or a plurality of source materials 604 are collected or supplied to form an input material 606 for subsequent system processing. The input material 606 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 606 is then forwarded to a sizing/homogenizing subsystem 608, where the input material 606 is shredded, chopped, shattered, or broken to produce a particulate burnable fuel 610 having a desired particle size distribution. The particulate burnable fuel 610 is then forwarded to a shaping/coating subsystem 612. The shaping/coating subsystem 612 includes a shaping unit 612a and a coating unit 612b, where the coating unit 612b is connected with the exit of the shaping unit 612a. In the shaping unit 612a, the particulate burnable fuel 610 is shaped into a compact shape to form a shaped material 614 (not shown here as it passes directly into the coating unit 612b). The shaped material 614 is thencoated in the coating unit 612b with a shape coating material to form a coated shaped burnable fuel 616, where the extent of coating is as described herein. The coating unit 612b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The coating unit 612b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 616 is then forwarded to a combustion subsystem 618, where a portion of the heat generated by combustion of the coated shaped burnable fuel 616 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 6B, an embodiment of the present system, generally 600, is shown to include a material supply subsystem 602, where one or a plurality of source materials 604 are collected or supplied to form an input material 606 for subsequent system processing. The input material 606 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 606 is then forwarded to a sizing/homogenizing subsystem 608, where the input material 606 is shredded, chopped, shattered, or broken to produce a particulate burnable fuel 610 having a desired particle size distribution. The particulate burnable fuel 610 is then forwarded to a shaping/coating subsystem 612. The shaping/coating subsystem 612 includes a shaping unit 612a and a coating unit 612b. In the shaping unit 612a, the particulate burnable fuel 610 shaped into a compact form to form a shaped material 614. The shaped material 614 is then coated in the coating unit 612b with a shape coating material to form a coated shaped burnable fuel 616, where the extent of coating is as described herein. The coating unit 612b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The coating unit 612b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 616 is then forwarded to a combustion subsystem 618, where a portion of the heat generated by combustion of the coated shaped burnable fuel 616 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 6C, an embodiment of the present system, generally 600, is shown to include a material supply subsystem 602, where one or a plurality of source materials 604 are collected or supplied to form an input material 606 for subsequent system processing. The input material 606 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 606 is then forwarded to a sizing/homogenizing subsystem 608, where the input material 606 is shredded, chopped, shattered, or broken to produce a particulate burnable fuel 610 having a desired particle size distribution. The particulate burnable fuel 610 is then forwarded to a shaping/coating subsystem 612. The shaping/coating subsystem 612 includes a shaping unit 612a and a coating unit 612b, where the coating unit 612b is connected with the exit of the shaping unit 612a. In the shaping unit 612a, the particulate burnable fuel 610 is shaped into a compact shape to form a shaped material 614 (not shown here as it passes directly into the coating unit 612b). The shaped material 614 is then coated in the coating unit 612b with a shape coating material to form a coated shaped burnable fuel 616, where the extent of coating is as described herein. The coating unit 612b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The coating unit 612b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 616 is then forwarded to a storage subsystem 620, where the coated shaped burnable fuel 616 is stored for subsequent use as a fuel or fuel component. The coated shaped burnable fuel 616 is then forwarded to a combustion subsystem 618, where a portion of the heat generated by combustion of the coated shaped burnable fuel 616 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 6D, an embodiment of the present system, generally 600, is shown to include a material supply subsystem 602, where one or a plurality of source materials 604 are collected or supplied to form an input material 606 for subsequent system processing. The input material 606 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 606 is then forwarded to a sizing/homogenizing subsystem 608, where the input material 606 is shredded, chopped, shattered, or broken to produce a particulate burnable fuel 610 having a desired particle size distribution. The particulate burnable fuel 610 is then forwarded to a shaping/coating subsystem 612. The shaping/coating subsystem 612 includes a shaping unit 612a and a coating unit 612b. In the shaping unit 612a, the particulate burnable fuel 610 shaped into a compact form to form a shaped material 614. The shaped material 614 is then coated in the coating unit 612b with a shape coating material to form a coated shaped burnable fuel 616, where the extent of coating is as described herein. The coating unit 612b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The coating unit 612b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 616 is then forwarded to a storage subsystem 620, where the coated shaped burnable fuel 616 is stored for subsequent use as a fuel or fuel component. The coated shaped burnable fuel 616 is then forwarded to a combustion subsystem 618, where a portion of the heat generated by combustion of the coated shaped burnable fuel 616 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 6E, an embodiment of the present system, generally 600, is shown to include a material supply subsystem 602, where one or a plurality of source materials 604 are collected or supplied to form an input material 606 for subsequent system processing. The input material 606 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 606 is then forwarded to a sizing/homogenizing subsystem 608, where the input material 606 is shredded, chopped, shattered, or broken to produce a particulate burnable fuel 610 having a desired particle size distribution. The particulate burnable fuel 610 is then forwarded to a shaping/coating subsystem 612. The shaping/coating subsystem 612 includes a shaping unit 612a and a coating unit 612b, where the coating unit 612b is connected with the exit of the shaping unit 612a. In the shaping unit 612a, the particulate burnable fuel 610 is shaped into a compact shape to form a shaped material 614 (not shown here as it passes directly into the coating unit 612b). The shaped material 614 is then coated in the coating unit 612b with a shape coating material to form a coated shaped burnable fuel 616, where the extent of coating is as described herein. The coating unit 612b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The coating unit 612b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 614 is then forwarded to a packaging subsystem 622, where the coated shaped burnable fuel 616 is containerized to form a containerized coated shaped burnable fuel 624. The containerized coated shaped burnable fuel 624 is then forwarded to a combustion subsystem 618, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 624 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 6F, an embodiment of the present system, generally 600, is shown to include a material supply subsystem 602, where one or a plurality of source materials 604 are collected or supplied to form an input material 606 for subsequent system processing. The input material 606 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 606 is then forwarded to a sizing/homogenizing subsystem 608, where the input material 606 is shredded, chopped, shattered, or broken to produce a particulate burnable fuel 610 having a desired particle size distribution. The particulate burnable fuel 610 is then forwarded to a shaping/coating subsystem 612. The shaping/coating subsystem 612 includes a shaping unit 612a and a coating unit 612b. In the shaping unit 612a, the particulate burnable fuel 610 shaped into a compact form to form a shaped material 614. The shaped material 614 is then coated in the coating unit 612b with a shape coating material to form a coated shaped burnable fuel 616, where the extent of coating is as described herein. The coating unit 612b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The coating unit 612b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 614 is then forwarded to a packaging subsystem 622, where the coated shaped burnable fuel 616 is containerized to form a containerized coated shaped burnable fuel 624. The containerized coated shaped burnable fuel 624 is then forwarded to a combustion subsystem 618, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 624 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 6G, an embodiment of the present system, generally 600, is shown to include a material supply subsystem 602, where one or a plurality of source materials 604 are collected or supplied to form an input material 606 for subsequent system processing. The input material 606 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 606 is then forwarded to a sizing/homogenizing subsystem 608, where the input material 606 is shredded, chopped, shattered, or broken to produce a particulate burnable fuel 610 having a desired particle size distribution. The particulate burnable fuel 610 is then forwarded to a shaping/coating subsystem 612. The shaping/coating subsystem 612 includes a shaping unit 612a and a coating unit 612b, where the coating unit 612b is connected with the exit of the shaping unit 612a. In the shaping unit 612a, the particulate burnable fuel 610 is shaped into a compact shape to form a shaped material 614 (not shown here as it passes directly into the coating unit 612b). The shaped material 614 is then coated in the coating unit 612b with a shape coating material to form a coated shaped burnable fuel 616, where the extent of coating is as described herein. The coating unit 612b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The coating unit 612b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 614 is then forwarded to a packaging subsystem 622, where the coated shaped burnable fuel 616 is containerized to form a containerized coated shaped burnable fuel 624. The containerized coated shaped burnable fuel 624 is then forwarded to a storage subsystem 620, where the containerized coated shaped burnable fuel 624 is stored for subsequent use as a fuel or fuel component. The containerized coated shaped burnable fuel 624 is then forwarded to a combustion subsystem 618, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 624 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 6H, an embodiment of the present system, generally 600, is shown to include a material supply subsystem 602, where one or a plurality of source materials 604 are collected or supplied to form an input material 606 for subsequent system processing. The input material 606 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 606 is then forwarded to a sizing/homogenizing subsystem 608, where the input material 606 is shredded, chopped, shattered, or broken to produce a particulate burnable fuel 610 having a desired particle size distribution. The particulate burnable fuel 610 is then forwarded to a shaping/coating subsystem 612. The shaping/coating subsystem 612 includes a shaping unit 612a and a coating unit 612b. In the shaping unit 612a, the particulate burnable fuel 610 shaped into a compact form to form a shaped material 614. The shaped material 614 is then coated in the coating unit 612b with a shape coating material to form a coated shaped burnable fuel 616, where the extent of coating is as described herein. The coating unit 612b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The coating unit 612b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 614 is then forwarded to a packaging subsystem 622, where the coated shaped burnable fuel 616 is containerized to form a containerized coated shaped burnable fuel 624. The containerized coated shaped burnable fuel 624 is then forwarded to a storage subsystem 620, where the containerized coated shaped burnable fuel 624 is stored for subsequent use as a fuel or fuel component. The containerized coated shaped burnable fuel 624 is then forwarded to a combustion subsystem 618, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 624 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Particle and Shape Coating Referring now to FIG. 7A, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 706 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b, where the particle coating unit 708b is connected with the exit of the sizing/homogenizing unit 708a. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 (not shown here as it passes directly into the particle coating unit 708b) having a desired particle size distribution. The particulate material 710 is then coated in the particle coating unit 708b with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The particle coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The particle coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b, where the shape coating unit 714b is connected with the exit of the shaping unit 714a. In the shaping unit 714a, the particulate burnable fuel 710 is shaped into a compact shape to form a shaped material 716 (not shown here as it passes directly into the shape coating unit 714b). The shaped material 714 is thencoated in the shape coating unit 714b with a shaping coating material to form a coated shaped burnable fuel 718, where the extent of coating is as set forth herein. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the coated shaped burnable fuel 718 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 7B, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 706 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 having a desired particle size distribution. The particulate material 710 is then forwarded to the coating unit 708b, where particles of the particulate material 710 are coated with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b, where the shape coating unit 714b is connected with the exit of the shaping unit 714a. In the shaping unit 714a, the coated particulate burnable fuel 712 is shaped into a compact shape to form a shaped material 714 (not shown here as it passes directly into the shape coating unit 714b). The shaped material 714 is then coated in the shape coating unit 714b with a shape coating material to form a coated shaped burnable fuel 718, where the extent of coating is as set forth herein. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the coated shaped burnable fuel 718 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 7C, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 706 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b, where the particle coating unit 708b is connected with the exit of the sizing/homogenizing unit 708a. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 (not shown here as it passes directly into the particle coating unit 708b) having a desired particle size distribution. The particulate material 710 is then coated in the particle coating unit 708b with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The particle coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The particle coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b, where the shape coating unit 714b is connected with the exit of the shaping unit 714a. In the shaping unit 714a, the coated particulate burnable fuel 712 is shaped into a compact shape to form a shaped material 716 (not shown here as it passes directly into the shape coating unit 714b). The shaped material 716 is then coated in the shape coating unit 714b with a shape coating material to form a coated shaped burnable fuel 718, where the extend of coating is as set forth herein. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the coated shaped burnable fuel 718 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 7D, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 706 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 having a desired particle size distribution. The particulate material 710 is then forwarded to the coating unit 708b, where particles of the particulate material 710 are coated with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b. In the shaping unit 714a, the particulate burnable fuel 710 shaped into a compact form to form a shaped material 716. The shaped material 716 is then coated in the shape coating unit 714b to form a coated shaped burnable fuel 718. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the coated shaped burnable fuel 718 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 7E, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 706 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b, where the particle coating unit 708b is connected with the exit of the sizing/homogenizing unit 708a. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 (not shown here as it passes directly into the particle coating unit 708b) having a desired particle size distribution. The particulate material 710 is then coated in the particle coating unit 708b with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The particle coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The particle coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b, where the shape coating unit 714b is connected with the exit of the shaping unit 714a. In the shaping unit 714a, the coated particulate burnable fuel 712 is shaped into a compact shape to form a shaped material 716 (not shown here as it passes directly into the shape coating unit 714b). The shaped material 714 is then coated in the shape coating unit 714b with a shape coating material to form a coated shaped burnable fuel 718, where the extent of coating is as described herein. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a packaging subsystem 722, where the coated shaped burnable fuel 718 is containerized to form a containerized coated shaped burnable fuel 724. The containerized coated shaped burnable fuel 724 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 724 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 7F, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 706 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 having a desired particle size distribution. The particulate material 710 is then forwarded to the coating unit 708b, where particles of the particulate material 710 are coated with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b, where the shape coating unit 714b is connected with the exit of the shaping unit 714a. In the shaping unit 714a, the particulate burnable fuel 710 is shaped into a compact shape to form a shaped material 714 (not shown here as it passes directly into the shape coating unit 714b). The shaped material 714 is then coated in the shape coating unit 714b with a shape coating material to form a coated shaped burnable fuel 718, where the extent of coating is as described herein. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a packaging subsystem 722, where the coated shaped burnable fuel 718 is containerized to form a containerized coated shaped burnable fuel 724. The containerized coated shaped burnable fuel 724 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 724 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 7G, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 706 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b, where the particle coating unit 708b is connected with the exit of the sizing/homogenizing unit 708a. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 (not shown here as it passes directly into the particle coating unit 708b) having a desired particle size distribution. The particulate material 710 is then coated in the particle coating unit 708b with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The particle coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The particle coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b, where the shape coating unit 714b is connected with the exit of the shaping unit 714a. In the shaping unit 714a, the particulate burnable fuel 710 is shaped into a compact shape to form a shaped material 716 (not shown here as it passes directly into the shape coating unit 714b). The shaped material 716 is then coated in the shape coating unit 714b with a shape coating material to form a coated shaped burnable fuel 718, where the extent of coating is as described herein. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a packaging subsystem 722, where the coated shaped burnable fuel 718 is containerized to form a containerized coated shaped burnable fuel 724. The containerized coated shaped burnable fuel 724 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 724 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 7H, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The input material 706 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 having a desired particle size distribution. The particulate material 710 is then forwarded to the coating unit 708b, where particles of the particulate material 710 are coated with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b. In the shaping unit 714a, the particulate burnable fuel 710 shaped into a compact form to form a shaped material 716. The shaped material 716 is then coated in the shape coating unit 714b with a shape coating material to form a coated shaped burnable fuel 718, where the extent of coating is as described herein. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a packaging subsystem 722, where the coated shaped burnable fuel 718 is containerized to form a containerized coated shaped burnable fuel 724. The containerized coated shaped burnable fuel 724 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 724 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 7I, an embodiment of the present system, generally 700, is shown to include a material supply subsystem 702, where one or a plurality of source materials 704 are collected or supplied to form an input material 706 for subsequent system processing. The input material 706 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The method also includes an input material coating step 726, which the input material and/or one or more of the source material are coated with an input coating material to form a coated input material 728. The coated input material 728 is then sized or sized and partially or completely homogenized and coated by a particulate coating material in a sizing/homogenizing/coating (SHC) subsystem 708. The SHC subsystem 708 includes a sizing/homogenizing unit 708a and a particle coating unit 708b. In the sizing/homogenizing unit 708a, the input material 706 is shredded, chopped, shattered, or broken to produce a particulate material 710 having a desired particle size distribution. The particulate material 710 is then forwarded to the coating unit 708b, where particles of the particulate material 710 are coated with the particulate coating material to form a coated particulate burnable fuel 712, where the extent of coating is as described herein. The coating unit 708b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The coating unit 708b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 712 is then forwarded to a shaping/coating subsystem 714. The shaping/coating subsystem 714 includes a shaping unit 714a and a shape coating unit 714b. In the shaping unit 714a, the particulate burnable fuel 710 shaped into a compact form to form a shaped material 716. The shaped material 716 is then coated in the shape coating unit 714b with a shape coating material to form a coated shaped burnable fuel 718, where the extent of coating is as described herein. The shape coating unit 714b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 714b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 718 is then forwarded to a packaging subsystem 722, where the coated shaped burnable fuel 718 is containerized to form a containerized coated shaped burnable fuel 724. The containerized coated shaped burnable fuel 724 is then forwarded to a combustion subsystem 720, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 724 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
In the embodiments of FIGS. 7A-H, the systems can also include one or more pre-processing, pre-treating, post-processing, and/or post-treating subsystems for pre-processing or pre-treating the source materials, the input material, the particulate material, the particulate burnable fuel, the coated particulate burnable fuel, the shaped burnable fuel, the coated shaped burnable fuel, the containerized particulate burnable fuel (uncoated and/or uncoated) and/or the containerized shaped burnable fuel (uncoated and/or uncoated), where the pre-processes, pre-treatments, post-processes, and/or post-treatments can be any of the pre-processing, pre-treating, post-processing, and/or post-treating disclosed herein.
Two Sources, Particle and Shape Coating Referring now to FIG. 8A, an embodiment of the present system, generally 800, is shown to include a first material supply subsystem 802, where one or a plurality of first source materials 804 are collected or supplied to form a first input material 806. The system 800 also includes a second material supply subsystem 808, where one or a plurality of second source materials 810 are collected or supplied to form a second input material 812. The first and second input materials 806 and 812 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The second input material 812 is then forwarded to a pre-processing subsystem 814, where the second input material 812 is pre-processed in one or a plurality of pre-processing steps to form a pre-processed material 816. The first input material 806 and the pre-processed material 816 are then combined and forwarded to a sizing or sizing and homogenizing subsystem 818, where the materials 806 and 816 are shredded, chopped, shattered, or broken to produce a particulate burnable fuel 820 having a desired particle size distribution. The particulate burnable fuel 820 is then forwarded to a shaping/coating subsystem 822. The shaping/coating subsystem 822 includes a shaping unit 822a and a shape coating unit 822b, where the shape coating unit 822b is connected with the exit of the shaping unit 822a. In the shaping unit 822a, the particulate burnable fuel 820 is shaped into a compact shape to form a shaped material 824 (not shown here as it passes directly into the shape coating unit 822b). The shaped material 824 is then coated in the shape coating unit 822b with a shape coating material to form a coated shaped burnable fuel 826, where the extent of coating is as described above. The shape coating unit 822b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 822b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 826 is then forwarded to a combustion subsystem 828, where a portion of the heat generated by combustion of the coated shaped burnable fuel 826 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 8B, an embodiment of the present system, generally 800, is shown to include a first material supply subsystem 802, where one or a plurality of first source materials 804 are collected or supplied to form a first input material 806. The system 800 also includes a second material supply subsystem 808, where one or a plurality of second source materials 810 are collected or supplied to form a second input material 812. The first and second input materials 806 and 812 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The second input material 812 is then pre-processed in a pre-processing subsystem 814, where the second input material 806 is pre-processed in one or a plurality of pre-processing steps to form a pre-processed material 816. The first input material 806 and the pre-processed material 816 are then combined and forwarded to a sizing or sizing and homogenizing subsystem 818, where the materials 806 and 816 are shredded, chopped, shattered, or broken to produce a particulate burnable fuel 820 having a desired particle size distribution. The particulate burnable fuel 820 is then forwarded to a shaping/coating subsystem 822. The shaping/coating subsystem 822 includes a shaping unit 822a and a shape coating unit 822b. In the shaping unit 822a, the particulate burnable fuel 820 is shaped into a compact form to form a shaped material 824. The shaped material 824 is then coated in the shape coating unit 822b with a shape coating material to form a coated shaped burnable fuel 826, where the extent of coating is as described above. The shape coating unit 822b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 822b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 826 is then forwarded to a combustion subsystem 828, where a portion of the heat generated by combustion of the coated shaped burnable fuel 826 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 8C, an embodiment of the present system, generally 800, is shown to include a first material supply subsystem 802, where one or a plurality of first source materials 804 are collected or supplied to form a first input material 806. The system 800 also includes a second material supply subsystem 808, where one or a plurality of second source materials 810 are collected or supplied to form a second input material 812. The first and second input materials 806 and 812 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The second input material 812 is then pre-processed in a pre-processing subsystem 814, where the second input material 806 is pre-processed in one or a plurality of pre-processing steps to form a pre-processed material 816. The first input material 806 and the pre-processed material 816 are then combined and forwarded to a sizing/homogenizing/coating (SHC) subsystem 818, where the first input material 806 and the pre-processed material 816 are sized or sized and partially or completely homogenized and coated with a particulate coating material. The SHC subsystem 818 includes a sizing/homogenizing unit 818a and a particle coating unit 818b, where the particle coating unit 818b is connected with the exit of the sizing/homogenizing unit 818a. In the sizing/homogenizing unit 818a, the first input material 806 and the pre-processed material 816 are shredded, chopped, shattered, or broken to produce a particulate material 830 (not shown here as it passes directly into the particle coating unit 818b) having a desired particle size distribution. The particulate material 830 is then coated in the particle coating unit 818b with the particulate coating material to form a coated particulate burnable fuel 832, where the extent of coating is as described above. The particle coating unit 818b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into the particulate material 830. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The particle coating unit 818b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 832 is then forwarded to a shaping/coating subsystem 822. The shaping/coating subsystem 822 includes a shaping unit 822a and a shape coating unit 822b, where the shape coating unit 822b is connected with the exit of the shaping unit 822a. In the shaping unit 822a, the coated particulate burnable fuel 832 is shaped into a compact shape to form a shaped material 824 (not shown here as it passes directly into the shape coating unit 822b). The shaped material 824 is thencoated in the shape coating unit 822b with a shape coating material to form a coated shaped burnable fuel 826, where the extent of coating is as described above. The shape coating unit 822b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 822b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 826 is then forwarded to a packaging subsystem 834, where the coated shaped burnable fuel 826 is placed in containers to produce a containerized shaped burnable fuel 836. The containerized shaped burnable fuel 836 is then forwarded to a combustion subsystem 828, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 836 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 8D, an embodiment of the present system, generally 800, is shown to include a first material supply subsystem 802, where one or a plurality of first source materials 804 are collected or supplied to form a first input material 806. The system 800 also includes a second material supply subsystem 808, where one or a plurality of second source materials 810 are collected or supplied to form a second input material 812. The first and second input materials 806 and 812 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The second input material 812 is then pre-processed in a pre-processing subsystem 814, where the second input material 806 is pre-processed in one or a plurality of pre-processing steps to form a pre-processed material 816. The first input material 806 and the pre-processed material 816 are then combined and forwarded to a sizing/homogenizing/coating (SHC) subsystem 818, where the first input material 806 and the pre-processed material 816 are sized or sized and partially or completely homogenized and coated with a particulate coating material. The SHC subsystem 818 includes a sizing/homogenizing unit 818a and a particle coating unit 818b. In the sizing/homogenizing unit 818a, the first input material 806 and the pre-processed material 816 are shredded, chopped, shattered, or broken to produce a particulate material 830 having a desired particle size distribution. The particulate material 830 is then coated in the particle coating unit 818b with the particulate coating material to form a coated particulate burnable fuel 832, where the extent of coating is as described above. The particle coating unit 818b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into the particulate material 830. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The particle coating unit 818b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 832 is then forwarded to a shaping/coating subsystem 822. The shaping/coating subsystem 822 includes a shaping unit 822a and a shape coating unit 822b, where the shape coating unit 822b is connected with the exit of the shaping unit 822a. In the shaping unit 822a, the coated particulate burnable fuel 832 is shaped into a compact shape to form a shaped material 824 (not shown here as it passes directly into the shape coating unit 822b). The shaped material 824 is then coated in the shape coating unit 822b with a shape coating material to form a coated shaped burnable fuel 826, where the extent of coating is as described above. The shape coating unit 822b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 822b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 826 is then forwarded to a packaging subsystem 834, where the coated shaped burnable fuel 826 is placed in containers to produce a containerized shaped burnable fuel 836. The containerized shaped burnable fuel 836 is then forwarded to a combustion subsystem 828, where a portion of the heat generated by combustion of the containerized coated shaped burnable fuel 836 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 8E, an embodiment of the present system, generally 800, is shown to include a first material supply subsystem 802, where one or a plurality of first source materials 804 are collected or supplied to form a first input material 806. The system 800 also includes a second material supply subsystem 808, where one or a plurality of second source materials 810 are collected or supplied to form a second input material 812. The first and second input materials 806 and 812 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The second input material 812 is then pre-processed in a pre-processing subsystem 814, where the second input material 806 is pre-processed in one or a plurality of pre-processing steps to form a pre-processed material 816. The first input material 806 and the pre-processed material 816 are then combined and forwarded to a sizing/homogenizing/coating (SHC) subsystem 818, where the first input material 806 and the pre-processed material 816 are sized or sized and partially or completely homogenized and coated with a particulate coating material. The SHC subsystem 818 includes a sizing/homogenizing unit 818a and a particle coating unit 818b, where the particle coating unit 818b is connected with the exit of the sizing/homogenizing unit 818a. In the sizing/homogenizing unit 818a, the first input material 806 and the pre-processed material 816 are shredded, chopped, shattered, or broken to produce a particulate material 830 (not shown here as it passes directly into the particle coating unit 818b) having a desired particle size distribution. The particulate material 830 is then coated in the particle coating unit 818b with the particulate coating material to form a coated particulate burnable fuel 832, where the extent of coating is as described above. The particle coating unit 818b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into the particulate material 830. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The particle coating unit 818b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 832 is then forwarded to a shaping/coating subsystem 822. The shaping/coating subsystem 822 includes a shaping unit 822a and a shape coating unit 822b. In the shaping unit 822a, the particulate burnable fuel 820 is shaped into a compact form to form a shaped material 824. The shaped material 824 is then coated in the shape coating unit 822b with a shape coating material to form a coated shaped burnable fuel 826, where the extent of coating is as described above. The shape coating unit 822b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 822b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 826 is then forwarded to a combustion subsystem 828, where a portion of the heat generated by combustion of the coated shaped burnable fuel 826 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
Referring now to FIG. 8F, an embodiment of the present system, generally 800, is shown to include a first material supply subsystem 802, where one or a plurality of first source materials 804 are collected or supplied to form a first input material 806. The system 800 also includes a second material supply subsystem 808, where one or a plurality of second source materials 810 are collected or supplied to form a second input material 812. The first and second input materials 806 and 812 can include a variety of components as described above and can be adjusted to achieve a desired compositional makeup of components. The second input material 812 is then pre-processed in a pre-processing subsystem 814, where the second input material 806 is pre-processed in one or a plurality of pre-processing steps to form a pre-processed material 816. The first input material 806 and the pre-processed material 816 are then combined and forwarded to a sizing/homogenizing/coating (SHC) subsystem 818, where the first input material 806 and the pre-processed material 816 are sized or sized and partially or completely homogenized and coated with a particulate coating material. The SHC subsystem 818 includes a sizing/homogenizing unit 818a and a particle coating unit 818b. In the sizing/homogenizing unit 818a, the first input material 806 and the pre-processed material 816 are shredded, chopped, shattered, or broken to produce a particulate material 830 having a desired particle size distribution. The particulate material 830 is then coated in the particle coating unit 818b with the particulate coating material to form a coated particulate burnable fuel 832, where the extent of coating is as described above. The particle coating unit 818b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into the particulate material 830. The equipment can include separate gas injectors to fluidize and mix the particles of the particulate material and the coating material to improve distribution of the coating material throughout the particulate material. The particle coating unit 818b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated particulate burnable fuel 832 is then forwarded to a shaping/coating subsystem 822. The shaping/coating subsystem 822 includes a shaping unit 822a and a shape coating unit 822b. In the shaping unit 822a, the particulate burnable fuel 820 is shaped into a compact form to form a shaped material 824. The shaped material 824 is then coated in the shape coating unit 822b with a shape coating material to form a coated shaped burnable fuel 826, where the extent of coating is as described above. The shape coating unit 822b can include injectors, sprayers, nebulizers, atomizers, ionizers, or similar equipment for introducing a liquid coating material or a liquid gas mixture containing a coating material into particulate material. The equipment can include separate gas injectors to fluidize and mix the shape material and the coating material to improve distribution of the coating material throughout the shaped material. The shape coating unit 822b can also include baffles and other devices for improving coating material coverage of the particles of the particulate fuel. The coated shaped burnable fuel 826 is then forwarded to a combustion subsystem 828, where a portion of the heat generated by combustion of the coated shaped burnable fuel 826 is converted into a useable form of energy, into heat and a useable product or into heat for subsequent use.
In each of the above systems, the particulate burnable fuel can be pre-processed or pre-treated in a second pre-processing or pre-treating subsystem as shown in FIG. 8A-F. The embodiments of FIGS. 5A-H, 6A-H, 7A-H and 8A-F can all include an input coating step, where the input material and one or more of the source materials can be coated by an input material coating. This coating can be used for any purpose including those set forth for the particulate coatings and/or the shaped coatings.
EXPERIMENTS OF THE INVENTION EXAMPLE 1 The following data was obtained from a pilot plant facility, where source material was disinfected and shredded to form the particulate burnable fuel of the present invention.
Source material was analyzed based on component makeup. The analysis revealed the component ranges set forth in Table I.
TABLE I
Constituent List and Ranges
% Range
Constituent Low High % Typical
Plastic 50 100 70
Cardboard 15 100 29
Stainless Steel 0 5 1
EXAMPLE 2 The following data was obtained from a pilot plant facility, where source material was disinfected and shredded to form a burnable fuel and an ash obtained from burning of other source material were burned and the resulting ash analyzed.
Samples were received in 2.5 gallon buckets and were non-homogeneous. Samples were shredded for particle size reduction. Coarsely milled and finely milled sample splits were returned and showed some inhomogeneity. The more finely milled sample split was utilized for all analyses.
Due to sample inhomogeneity, all analyses were performed multiple times (duplicate minimum) and values reported as represent “best value” averages. All data were reported on a finely milled sample weight basis.
Samples were stage ashed to 750° C. and held at temperature for 8 hours for ash percentage determination. After weighing, ash residues were fused with lithium metaborate for ash component analyses.
Metals except for mercury were determined by ICP-AES and ICP-MS after total sample decomposition with mixed acids including hydrofluoric acid or by high temperature fusion of sample ash with lithium metaborate. Mercury was determined by combustion/amalgamation cold vapor atomic absorption.
Bromide, chloride, nitrate, sulfate, and ortho-phosphate were measured by ion chromatography on washings from oxygen bomb combustion, and do not necessarily represent elements in these oxidation states prior to combustion.
Higher heating value is the gross calorific content and has not been corrected for possible sulfur content according to ASTM D5865.
The incinerated ash had a heat content of 5321 BTU/lb (12,377 MJ/kg) and a 49 wt. % residue after burning at 750° C. The resulting ash had an elemental analysis tabulated in TABLE II.
TABLE II
Element Analysis of Ash in μg/g
Br− Cl− NO3− SO42− o-PO43− Ag Al As Ba Be Cd Ca
60 1730 440 2840 <20 26 36500 3.6 6000 0.7 1.5 23600
Co Cr Cu Fe Pb Mg Mn Hg Ni K Si Na
24 1060 450 12100 162 7800 340 0.12 500 5370 119000 16700
Tl Ti Zn
0.04 5560 4390
The particulate burnable fuel had heat content of 16,400 BTU/lb (38,150 MJ/kg) and a 5.6 wt. % residue after burning at 750° C. The resulting ash had an elemental analysis tabulated in TABLE III.
TABLE III
Element Analysis of Ash in μg/g
Br− Cl− NO3− SO42− o-PO43− Ag Al As Ba Be Cd Ca
<20 240 71000 1400 <20 78 2420 1.6 710 0.1 0.1 1950
Co Cr Cu Fe Pb Mg Mn Hg Ni K Si Na
33 4700 110 33400 24 210 580 0.06 2870 560 5610 1280
Tl Ti Zn
<0.01 1520 330
EXAMPLE 3 A source material was obtained, disinfected, shredded and pelletized.
Referring to FIG. 9, a photograph of the particulate burnable fuel is shown comprising particles between about 19.05 mm and about 38.1 mm. The particulate burnable fuel had a bulk density between about 12 lb/ft3 (0.19 g/cm3) and about 15 lb/ft3 (0.24 g/cm3). The particulate burnable fuel can have a greater or lower density depending on composition and/or processing.
Referring to FIG. 10, the burnable fuel of FIG. 9 was pelletized to form shaped substantially cylindrical shapes. The shapes have a diameter between about 10 mm and about 15 mm and a length between 3 cm and about 5 cm. The shapes are shown here to be cracked with jagged ends. The shaped burnable fuel has a bulk density of between about 20 lb/ft3 (0.32 g/cm3) and about 30 lb/ft3 (0.48 g/cm3). The shaped burnable fuel can have a greater or lower density depending on composition and/or processing.
Non-Flammable Colored Sealant Coating EXAMPLE 4 This example illustrates the coating of the shaped fuel of FIG. 10 with a non-flammable sealant colored with a color to evidence the coating.
The non-flammable colored sealant was applied several times to a shaped fuel of FIG. 10 to achieve an an acceptable percentage of coated shaped fuel pellets. The colored sealant did not dry quickly and did not adhere well. The coating is fire resistant at temperatures up to about 400° F. FIG. 11 shows examples of the non-flammable colored sealant shaped burnable fuel.
Oil Coating EXAMPLE 5 This example illustrates the coating of the shaped fuel of FIG. 10 with oil.
The oil was applied by pouring the oil onto the shaped burnable fuel of FIG. 10. The oil was also applied using a more viscous oil and aerosolized oil. These application procedures produced a shaped burnable fuel having a superior oil coating. FIG. 12 shows examples of the oil coated shaped burnable fuel.
Waterproof Coating EXAMPLE 6 This example illustrates the coating of the shaped fuel of FIG. 10 with a waterproof coating.
The waterproof coating covered the pellets well and was easy to apply to the shaped burnable fuel of FIG. 10. The should boost the flammability of the shaped burnable fuel. The amount used can be adjusted to impart a given flammability of the shaped burnable fuel. FIG. 13 shows examples of the water proofed shaped burnable fuel.
Flammable Colored Sealant Coating EXAMPLE 7 This example illustrates the coating of the shaped fuel of FIG. 10 with a flammable sealant colored with a color to evidence the coating.
The flammable colored sealant coated the shaped fuel over an acceptable surface area of the pellets, adhered well, dried quickly, and the color came out well to the shaped burnable fuel of FIG. 10. This coating should allow the shaped burnable fuel to combust normally with minimal increase in ignitability. FIG. 14 shows examples of the flammable colored sealant shaped burnable fuel.
DETAILED DESCRIPTION OF DRAWINGS OF COATED SHAPES Referring now to FIG. 15A, an embodiment of a longitudinal cross-sectional view of a rounded cylindrical shaped burnable fuel 1500 having a coating 1502. Looking at FIG. 15A, the coating 1502 is shown to be of low thickness, where thin means the coating is between about 1 mono-layer thick to about 10 μm thick. Looking at FIG. 15B, the coating 1502 is shown to be of medium thickness, where thin means the coating is between about 10 μm thick and about 1 mm thick. Looking at FIG. 15C, the coating 1502 is shown to be high thickness, where thin means the coating is greater than 1 mm thick.
Referring now to FIG. 16A, an embodiment of a longitudinal cross-sectional view of a cylindrical shaped burnable fuel 1600 having a coating 1602. Looking at FIG. 16A, the coating 1502 is shown to be of low thickness, where thin means the coating is between about 1 mono-layer thick to about 10 μm thick. Looking at FIG. 16B, the coating 1602 is shown to be of medium thickness, where thin means the coating is between about 10 μm thick and about 1 mm thick. Looking at FIG. 16C, the coating 1602 is shown to be high thickness, where thin means the coating is greater than 1 mm thick.
Referring now to FIG. 17A, an embodiment of a cross-sectional view of a spherical shaped burnable fuel 1700 having a coating 1702. Looking at FIG. 17A, the coating 1702 is shown to be of low thickness, where thin means the coating is between about 1 mono-layer thick to about 10 μm thick. Looking at FIG. 17B, the coating 1702 is shown to be of medium thickness, where thin means the coating is between about 10 μm thick and about 1 mm thick. Looking at FIG. 17C, the coating 1702 is shown to be high thickness, where thin means the coating is greater than 1 mm thick.
Referring now to FIG. 18A, an embodiment of a longitudinal cross-sectional view of a ellipsoidal solid shaped burnable fuel 1800 having a coating 1802. Looking at FIG. 18A, the coating 1802 is shown to be of low thickness, where thin means the coating is between about 1 mono-layer thick to about 10 μm thick. Looking at FIG. 18B, the coating 1802 is shown to be of medium thickness, where thin means the coating is between about 10 μm thick and about 1 mm thick. Looking at FIG. 18C, the coating 1802 is shown to be high thickness, where thin means the coating is between about 1 mono-layer thick to greater than 1 mm thick.
Referring now to FIG. 19A, an embodiment of a lateral cross-sectional view of a solid cross shaped burnable fuel 1900 having a coating 1902. Looking at FIG. 19A, the coating 1902 is shown to be of low thickness, where thin means the coating is between about 1 mono-layer thick to about 10 μm thick. Looking at FIG. 19B, the coating 1902 is shown to be of medium thickness, where thin means the coating is between about 10 μm thick and about 1 mm thick. Looking at FIG. 19C, the coating 1902 is shown to be high thickness, where thin means the coating is greater than 1 mm thick.
Referring now to FIG. 20A, an embodiment of a lateral cross-sectional view of a solid star shaped burnable fuel 2000 having a coating 2002. Looking at FIG. 20A, the coating 2002 is shown to be of low thickness, where thin means the coating is between about 1 mono-layer thick to about 10 μm thick. Looking at FIG. 20B, the coating 2002 is shown to be of medium thickness, where thin means the coating is between about 10 μm thick and about 1 mm thick. Looking at FIG. 20C, the coating 2002 is shown to be high thickness, where thin means the coating is greater than 1 mm thick.
In all of the above embodiments, the coatings can be a single layer of a single coating materials or a plurality of layers of the same or different coating material depending on the properties that the coating is to impart to the shaped fuel. While no coated particulate materials are shown in separate drawings, it should be recognized that the particles can also be coated in a similar way. In addition, the particles can be coated to increase aggregation propensity so that the particles need to clump to a lesser or greater extent as may be desired to reduce dust or to aid in compaction or containerization or shaping and pelletizing.
All references cited herein are incorporated by reference. Although the invention has been disclosed with reference to its preferred embodiments, from reading this description those of skill in the art may appreciate changes and modification that may be made which do not depart from the scope and spirit of the invention as described above and claimed hereafter.
