Methods For Binding Particulate Solids And Particulate Solid Compositions

Abstract

Embodiments of the present disclosure include methods of binding particulate solids as well as compositions resulting therefrom.

Description

BACKGROUND

In the past, particulate materials, such as coal fines, coke breeze, saw dust, and other biomass wastes, have presented storage, handling, and processing challenges. Additionally, metal oxides from blast furnaces, basic oxygen furnaces and electric arc furnaces have routinely been discarded, in large quantities, creating a source of pollution and presenting an environmental hazard, which continues for decades. Further, composite waste products, including post-consumer and post-industrial carpet waste, are routinely discarded into waste storage facilities, such as landfills. In addition to presenting challenges related to handling the composite waste products, the slow rate of decomposition results in an unfavorable environmental impact that continues for decades.

Prior attempts at disposing of or re-use of coke breeze, coal fines, and other particulate solids by producing solid forms, such as briquettes or pellets, have been largely unsuccessful because the particulate solids do not adequately bind, and the resulting product can be mechanically unstable, disintegrating or degrading back into small, fine particles during storage and handling. Other attempts at producing solid forms from the particulate solids may use costly and/or poor performing binder materials, such as petroleum pitch or water-based latexes, and may use costly and complex processing techniques. Water-based materials will reduce the heating value of fuel based solids and produce a formed material which is unstable during outside storage and transport and may disintegrate causing fugitive dust emissions or ground water contamination. Further, previous attempts have utilized binders, including petroleum-based materials, which become tacky and difficult to transport at ambient and elevated temperatures, and may cause contamination and run-off problems when stored outside.

Fine coal particulates collected during coal processing and washing operations have been found to be high in moisture and thus lower in heating value and/or less usable for fuel or non-fuel applications. The coal fines were either discarded into permanent impounds or were all or in part blended into steam coal products for sale. The addition of the high moisture fines reduced the quality and BTU value of the coal products, driving down the value, and making them less desirable as a fuel or for metallurgical grade coal use in the production of iron or steel.

Most coal consumers limit the total of fine coal in their fuel. This is particularly true of wet coal fines. Thermal driers have been used to dry the wet coal fines, but they are costly and have environmental impacts of their own. Dry coal fines are not immune to rain and moisture when exposed to normal outdoor storage and shipping methods. Those weaknesses make thermal drying a temporary solution. This forces coal processing plants to limit the efficiency of the washing and separation process, and to also limit the collection of fines to avoid the need to dry wet fines or blend them into other products. Previous methods for the pelletization of coal fines to improve their quality and handling have been either not economical or ineffective.

Thus, a heretofore-unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies.

SUMMARY

Embodiments of the present disclosure include methods of binding particulate solids as well as compositions resulting therefrom.

Briefly described, embodiments of the present disclosure include compositions comprising: a particulate solid component, where the particulate solid component comprises about 50% to 85% of the composition; and an additional component, where the additional component is selected from the group consisting of: a biomass component, a polymer component, and a composite waste product component.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

FIG. 1 is a block diagram illustrating an embodiment of the methods disclosed herein.

FIG. 2 is a block diagram illustrating an exemplary process under the methods disclosed herein.

FIG. 3 is a block diagram illustrating an exemplary process under the methods disclosed herein.

FIG. 4 is a block diagram illustrating a non-limiting example of elements in a composite waste product.

FIG. 5 is a block diagram illustrating an exemplary process under the methods disclosed herein.

FIG. 6 is a block diagram illustrating an exemplary process under the methods disclosed herein.

FIG. 7 is a block diagram illustrating components of an exemplary production plant for practicing the methods disclosed herein.

FIG. 8 illustrates the sulfur emissions reduction in pounds per year for an embodiment of the present disclosure versus stoker coal.

FIG. 9 illustrates the yield increase shown to be about 134% based on an example of sample pellets formed from embodiments of the present disclosure. The yield increase is calculated comparing the amount of product produced (coal fine plus binder, 2,689 lbs.) compared to the amount of coal fines fed into the process (2,000 lbs.).

FIG. 10 is a graph that illustrates the water pick-up and drying characteristics of five pellets. The comparison is between pellet weight in grams and time. Total time is two hours. At time represented by 1-2 (30 mins), the pellets are being soaked in water. From times 2-5 the pellets are being air dried. After two hours the pellets are essentially back to their starting weights.

FIG. 11 is a graph that illustrates % WPU (percent water pick up) of an embodiment of the present disclosure. The pellets were soaked from time zero to time 0.5 hours and air dried after 0.5 hours.

FIG. 12 is a graph that illustrates water soak data in grams vs. time.

FIG. 13 is a graph that illustrates carbon reduction in ash based on the first stoker test burn. The lower amount of carbon in the ash (material left in the bottom of the boiler after burning) indicates a more complete burn (carbon is the material burned).

DETAILED DESCRIPTION

Before the present disclosure is described in greater detail, it is to be understood that this disclosure is not limited to particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

Discussion:

Reference is made to FIG. 1, which is a block diagram illustrating an embodiment of the methods disclosed herein. The method 100 includes reducing a composite waste product 110 through, for example, a shredding, densifying, or pelletizing process. An exemplary composite waste product in an embodiment herein includes waste carpet. Waste carpet can be, for example, consumer recycled carpet or industrial waste carpet. The methods disclosed herein thus allow for an advantageous reduction of both post consumer and post industrial nylon or other types of carpet and waste stream polyolefin or other suitable polymeric material that would have otherwise gone into municipal land fills. One of ordinary skill in the art knows or will know that the reducing function can be performed as a separate step prior to the other steps of the methods described herein or, alternatively, as an integrated step.

As stated above, an exemplary composite waste product includes carpet. Carpet can include, but is not limited to, industrial carpet processing waste and cuttings, post industrial waste carpet, consumer installation waste, post consumer carpet, separated carpet fibers, densified whole carpet, and densified carpet fibers. In addition, composite waste products can include, but are not limited to, industrial, post industrial, or post consumer nylon (polyamide) waste fiber or other materials; industrial, post industrial, or post consumer nylon (polyamide) waste fiber or other materials with mixed or added components of plastic, inorganic fillers, minerals, and/or biomass; industrial, post industrial, or post consumer fiberous materials, including but not limited to, fiberglass, other mineral fibers, polymeric fibers, organic fibers, and natural fibers; and industrial, post industrial, or post consumer polymers or other materials that will melt during processing. These composite waste products may be used alone or in a mixture with carpet. One of ordinary skill in the art will appreciate that the methods disclosed herein can also be run using virgin (e.g., non-waste), first quality materials of the same description.

After the composite waste product is reduced, particulate solids are added to the composite waste product 120. The particulate solids may be fuel solids including, but not limited to, coke breeze, coke fines, coal fines, and wood wastes. Alternatively, the particulate solids may be non-fuel particulate waste including, but not limited to, particulate radiation contaminates, metal wastes, toxic waste particulates, and metal oxides. The adding step 120 may be performed in a batch operation, where all of the particulate solids for a process batch are added at one time. Alternatively, the adding step 120 may be performed in a continuous process where the particulate solids are added in a continuous stream.

The particulate solids are blended with the composite waste product to create a mixture of the composite waste product and the particulate solids 130. In the case of recycled carpet, the composite waste product generally includes, for example, a polypropylene or other polymeric binder element and a nylon fiber element. The temperature of the mixture is increased to fluidize all or parts of the binder element 140 through, for example, a combination of heat generated by the mixing process and heat provided to the process by external devices 140. The fluid polypropylene binder element captures the fine particulate solids. Further, the nylon carpet fibers become tacky at the temperature at which the binder fluidizes, which causes the nylon carpet fiber to sinter to both the particulate solids and the fluid binder. In an embodiment, the process temperatures for fluidizing the polypropylene binder without fluidizing the nylon fibers are about 125° C. to 250° C. or about 135° C. to 235° C. The combination of the fluid polypropylene binder and the nylon fiber results in a mechanical capture of the particulate material in a combined polypropylene and nylon fiber polymer matrix.

The mixture is then formed into solid formed products, such as, for example, briquettes or pellets, using heat and/or pressure 150. In an embodiment, the pellet is extruded into various shapes (e.g., a cylindrical pellet) that can be cut randomly into any size. After the forming process, the resulting solid formed product is structurally stable and does not retrogress into fine particles during storage and handling.

When particulate solids are fuel based, the solid formed product is bound reliably together and constitutes a high BTU (e.g., an increase of about 10% to 16%) fuel for industrial, utility, and residential use, which does not materially pollute the air to a degree different from conventional fuels. High BTU includes BTU values of about 12,500 BTU/lb or greater. In the case of non-fuel particulate solids, such as industrial waste, the solid formed product is bound reliably together and constitutes a durable way of recycling in a subsequent industrial process or long term stable storage which does not materially pollute the air, soil, or ground water.

Embodiments of the present disclosure include compositions where sulfur in the particulate solid is reduced by about 25% to 40% by dilution, depending on the blend and initial quality of the particulate solid (e.g., a composition comprised of 70% coal/coal fines with 1% sulfur; 10% carpet; 15% plastic; and 5% biomass will produce a composition with 0.7% sulfur, which is a 30% decrease in sulfur based on blending). Embodiments of the present disclosure include compositions including all types of coal (e.g., peat, lignite, sub-bituminous, bituminous, anthracite, and graphite). Embodiments of the present disclosure include a method that significantly reduces sulfur through both dilution and self scrubbing during combustion.

Reference is now made to FIG. 2, which illustrates a block diagram of an exemplary process under the methods disclosed herein. The process 200 combines recycled carpet 210 and particulate solids 220 into a mixture by heating and blending or mixing as indicated in block 230. Additionally, other polymers 250 may be optionally added to achieve specific characteristics relating to mechanical properties, chemical composition, or a combination thereof. Other polymers can include, but are not limited to, polyolefins, polyolefin blends with other thermoplastics, polyolefin blends with fillers and other inorganic materials, polyolefin blends with biomass and other natural materials, polyamides, polyamides mixed with other thermoplastic polymers, polyamides with inert fillers, thermoplastics, and thermoplastics in mixtures with thermoset plastics. After the heating and blending or mixing is completed, solid formed products are formed in block 240 using, for example, conventional briquette or pellet forming technology. Additionally, one of ordinary skill in the art knows or will know that the mixture may be formed into solid products including extrusions, sheets or other homogeneous or non-homogeneous shapes, as needed.

Reference is now made to FIG. 3, which illustrates a block diagram of an exemplary process under the methods disclosed herein. The process 300 utilizes recycled carpet 310, which is reduced in step 315. The reducing function includes, but is not limited to, shredding, grinding, pelletizing, and other techniques known by one of ordinary skill in the art. Additionally, as indicated in block 325, particulate solids 320 are processed to achieve a maximum particle size by grinding or crushing. A mixture of the reduced recycled carpet and the ground particulate solids is produced by heating and blending or mixing, as indicated in block 330. Additionally and optionally, recycled plastics may be added to the mixture for supplemental fuel content and/or environmentally beneficial disposal. After the heating and blending or mixing is completed, solid products are formed, as indicated in block 340, using conventional forming technology including, but not limited to, the methods and forms discussed above.

Reference is now made to FIG. 4, which is a block diagram illustrating a non-limiting example of elements in a composite waste product. An embodiment of the composite waste product 400 includes, but is not limited to, a polypropylene backing material 410, nylon carpet fibers 420 and calcium carbonate 430. The polypropylene backing material 410 becomes fluid at a processing temperature allowing it to capture the particulate solids. The nylon carpet fibers 420 become tacky, but not fluid at the processing temperature and, in the process of blending, serve to form a fiber matrix in the mixture. The calcium carbonate element, when used in a sulfur containing fuel application and under present combustion methods, may result in a reduction of sulfur dioxide emissions. An additional about 10% reduction in sulfur (SOx) emissions may be found during combustion when sulfur in the particulate solid combines with calcium carbonate found in the binder materials to form calcium sulfate instead of sulfur dioxide. As a result, the calcium sulfate is captured as an inert in the ash and can be safely land-filled as opposed to aerial gaseous emissions of SOx. This reduction is advantageous because it diminishes or eliminates the utility of powdered limestone injection associated with conventional sulfur dioxide emission reduction methods. Additionally, remaining binding ingredients include other polymers (not shown) as normal components of carpet backing material. As used in this disclosure “SOx” includes any possible combinations of sulfur and oxygen (e.g., SO, SO₂, SO₃).

Reference is now made to FIG. 5, which is a block diagram illustrating an exemplary process under the methods disclosed herein. An embodiment of the process 500 applies recycled baled carpet 510 to a bale breaker 512 for subsequent processing by a shredder/grinder 514. The shredder/grinder 514 is one of a number of reducing techniques known by one of ordinary skill in the art. The reduced carpet is then received by an accumulator 550. An accumulator 550 receives raw or intermediately processed materials from multiple sources. For example, in this case, the accumulator 550 receives reduced carpet and other materials, as discussed below, for subsequent processing.

As discussed above, recycled plastic 530 is optionally included in the mixture to facilitate improved fuel content, mechanical properties, or a combination thereof, and to facilitate an environmentally beneficial method of disposal. To aid in processing, the recycled plastic 530 is processed through a shredder/grinder 532 and transferred to a mixer 540. In the case where specific chemical or mechanical properties are desirable, additional virgin polymers 536 may be optionally added. Since the virgin polymers 536 are typically purchased in a form ready for processing, such as pellets, the virgin polymers 536 are deposited directly into the mixer 540.

In addition to the recycled plastic 530 and the virgin polymers 536, cellulose material 534, including but not limited to, wood wastes, may be optionally added to the mixture 540. The blending of cellulose material 534 provides a partial fuel content from a renewable resource, thus extending the life of available fossil fuels, such as the coal, PET coke, or coke fines, with a clean burning alternative synthetic fuel. The synthetic solid fuels can be formed into various shapes and sizes for use in devices including, but not limited to, stoker boilers, pulverized utility boilers, circulating fluidized bed (CFB) boilers, pressurized fluidized bed combustion (PFBC) boilers, coal gasification (IGCC) units, and wood and coal burning furnaces. The addition of biomass allows for a reduction in sulfur, ash, and other hazardous air pollutants (HAP's) as well as allows for a renewable energy in the product and extending the fossil resource.

Coal or coke fines 520 are processed through a crusher or grinder 522 to reduce the particulate solid fuels to a maximum particle size. The crushed coal or coke fines are then transferred to the mixer 540. The contents of the mixer 540 including the processed coal or coke fines 520, recycled plastic 530, cellulose 534 and virgin polymers 536 is mixed and transferred to the accumulator 550. The accumulator 550, which includes the combined contents of the mixer 540 and the recycled carpet from the shredder/grinder 514, conveys its contents to a pellet mill 560 using a feeder 552.

The pellet mill 560 blends the combined contents and uses, for example, a combination of heat, pressure, and forming technology to form solid products, including but not limited to pellets, briquettes, extrusions or sheets, of the mixture, which are then transferred to a cooler 562. After cooling, the solid products are structurally stable and do not retrogress into fine particles during storage and handling. The solid products are then transferred to storage 564 where they remain intact because the solid particulate materials are encapsulated to prevent degradation, leaching or contamination into the environment. The solid products also exhibit resistance to moisture because the moisture is driven out by the process heat and then sealed out by the encapsulating function of the binder element. In an embodiment, the moisture level of the product is about 1% to 2%. In another embodiment, the product locks out moisture even when immersed in water for several hours.

Reference is now made to FIG. 6, which illustrates a block diagram of an exemplary process under the methods disclosed herein. The process 600 includes reducing waste carpet 610 including, but not limited to, shredding, grinding, or pelletizing the waste carpet. Particulate solids, which may have a fuel content are added 620 and the particulate solids are mixed with the waste carpet 630. The mixture is heated using, for example, a combination of heat generated by the process plus any supplemental heat necessary to fluidize the binder element of the waste carpet 640. One of ordinary skill in the art knows or will know that supplemental heat may be provided by any number of methods including, but not limited to, electric resistive and inductive devices, combustion causing devices, electromagnetic wave devices, and recaptured heat from other processes. After the mixing is completed, the mixture is formed into solid products by pressure, heat, or extrusion 650, for example.

In an embodiment of the present disclosure, the methods use a single machine to mix and heat the mixture to flux temperatures (e.g., about 125° C. to 250° C.) using process heat, shear heat, and friction to heat the materials. In another embodiment, the same machine blends in filler materials (e.g., biomass or other particulates) and forms pellets using a die mechanism. The pellets are then cut at the die using a cutter (e.g., a rotary cutter) and cooled. The pellets may be cooled by, including but not limited to, using water bath, water spray, or blending the hot pellets with wet fine particulates. Thus, the processing takes about 1 to 3 minutes and generally does not need any form of curing time.

The methods described herein do not require water, acids or any other chemical or elemental component from the particulate solids to form the bond. As a result, virtually any particulate or blended materials can be reliably pelletized using methods described herein. Although waste carpet is presented in an embodiment described herein, one of ordinary skill in the art knows, or will know that any composite waste product having binder and fiber elements may be used. For example, polymer impregnated cloth used in some industrial processes may also be a suitable composite waste product.

In an embodiment of the methods disclosed herein, the components are added at ambient temperature and rapidly heated using process heaters, friction, and shear heat to activate or flux the binder. In another embodiment, the application of vacuum to the processing unit can be used to efficiently remove water vapor and other volatiles.

The methods described herein allow for a reduction of coal fines wasted into long term impounds as refuse as well as an environmentally preferable pelletized product that is cleaner than coal while retaining similar properties as a fuel or as a carbon source for other applications. The methods described herein further allow for the reclamation of older coal fines impounds that results in an improved product that has useful applications where coal is specified.

The methods described herein allow for a means to introduce biomass in various amounts into coal fired boilers and other coal applications without the need for boiler modification or separate fuel handling systems.

The methods described herein further allow for improving the yield and efficiency of the coal processing and washing operation, which both improves overall average coal quality and quantity, and reduces waste in the mineral recovery process.

Reference is now made to FIG. 7, which is a block diagram illustrating components of an exemplary production plant for practicing the methods disclosed herein. The plant 700 includes a composite waste reducer 710, which, for example, shreds, grinds, or pelletizes waste carpet. A solid particulate delivery device 720 provides solid particulates to the reduced composite waste at, for example, a combining device 730. The combining device 730 combines the reduced composite waste product with particulate solids to create a mixture. Additionally and possibly in combination with the combining device 730, heat generation/regulation equipment 740 provides sufficient supplemental heat to the mixture to fluidize one element of the composite waste product. The heated mixture is then provided to a solid product forming device 750, configured to produce solid formed products. The solid formed products include but are not limited to pellets, briquettes, extrusions and sheets, among others. As discussed above, the solid formed products may be produced for subsequent consumption wherein the solid particulates have a useful fuel content or other desirable recycle value. Alternatively, the solid formed product may provide a safe and effective method of storing and handling useful or potentially harmful solid particulate materials. The plant 700 also includes sufficient process control equipment 760 such that the production steps are integrated into a continuous process. In the alternative, the process control equipment 760 is configured, for example, to perform production steps in independent stages.

Application of the method disclosed herein produces a composition (e.g., product) that may be used, depending upon the blend, for stoker coal fuel for industrial steam and heating purposes, utility grade steam coal fuel for power generation and other purposes, or metallurgical grade coal (MET) for iron and steel production as well as specialty applications. Some product pellets include biomass of various sources to both further reduce sulfur, ash, and other HAP's as well as extend the fossil material resource by the inclusion of a renewable component. The inclusion of both the binder materials comprised of recycled nylon carpet and other polymer reclaim material and the optional biomass component result in an increased yield of total fuel production when compared to the wet coal fines alone. The yield increase is dependant upon the starting moisture content and the specific blend used, but is usually in a range from about 20% to 35%. In an embodiment of the present disclosure, final moisture content of the composition may be reduced to about 2% due to the heat and pressure generated by the binding process. This has added benefits in that the biomass material (when included) is broken down into a form that is better suited for boiler fuel.

Embodiments of the present disclosure can include compositions with the following characteristics: lower product moisture content compared to washed coal fines; higher heating value in coal fuel pellets; lower sulfur and HAP's content when compared to coal fines used to make the compositions; improved and more complete combustion properties (e.g., about 2% unburned carbon); lower SOx emissions (e.g., SOx emissions reduced by about 35%); lower NOx emissions (based on the type of boiler) (e.g., nitrogen dioxide reduction of about 18.8%); higher hydrogen content (e.g., about 33%); and increased total yield of coal pellet product (e.g., about 12% to 30% increase). As used in this disclosure, “NOx” includes any possible combinations of nitrogen and oxygen (e.g., NO, NO₂). In an embodiment of the method disclosed herein, the total yield is increased because waste coal fines are used in the composition (e.g., pellet), thus increasing the overall yield because yield at the mine compares the amount of salable coal based on the amount of mined coal, and for every ton of material not sent to waste, the yield increases.

Embodiments of the present disclosure include compositions that may be blended to meet MET coal specifications using coal fines of suitable grade. These compositions can be consumed in MET coal applications for production of iron, steel, and coke, alone or as a blend with other coals. The addition of other desirable particulates such as iron ore, iron oxides, and fluxing agents (e.g., calcium carbonate, limestone, or dolomite) offers the option of self fluxing iron pellets. Embodiments of this type are advantageous because they provide for self fluxing for production of iron without coke or with less coke.

Embodiments of the present disclosure include a composition comprising: a particulate solid component, where the particulate solid component comprises about 50% to 85% of the composition, and an additional component, where the additional component is selected from the group consisting of: a biomass component, a polymer component, a composite waste product component, and a combination thereof.

The particulate solid component can include, but is not limited to, coke breeze, coke fines, coal fines, and wood wastes.

The polymer component can include, but is not limited to plastics (e.g., recycled plastics), polyolefins, polyolefin blends with other thermoplastics, polyolefin blends with fillers and other inorganic materials, polyolefin blends with biomass and other natural materials, polyamides, polyamides mixed with other thermoplastic polymers, polyamides with inert fillers, thermoplastics, and thermoplastics in mixtures with thermoset plastics.

The composite waste product component can include, but is not limited to, carpet. Carpet can include, but is not limited to, industrial carpet processing waste and cuttings, post industrial waste carpet, consumer installation waste, post consumer carpet, separated carpet fibers, densified whole carpet, and densified carpet fibers. In addition, composite waste products can include, but are not limited to, industrial, post industrial, or post consumer nylon (polyamide) waste fiber or other materials; industrial, post industrial, or post consumer nylon (polyamide) waste fiber or other materials with mixed or added components of plastic, inorganic fillers, minerals, and/or biomass; industrial, post industrial, or post consumer fiberous materials, including but not limited to, fiberglass, other mineral fibers, polymeric fibers, organic fibers, and natural fibers; and industrial, post industrial, or post consumer polymers or other materials that will melt during processing. These composite waste products may be used alone or in a mixture with carpet.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a polymer component. In an embodiment, the biomass component comprises about 0.01% to 20% of the composition, and the polymer component comprises about 0.01% to 20% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a composite waste product component. In an embodiment, the biomass component comprises about 0.01% to 20% of the composition, and the composite waste product component comprises about 0.01% to 20% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a polymer component and a composite waste product component. In an embodiment, the polymer component comprises about 0.01% to 20% of the composition, and the composite waste product component comprises about 0.01% to 20% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component, a polymer component, and a composite waste product component. In an embodiment, the particulate solid component comprises about 50% to 85% of the composition, the biomass component comprises about 0.01% to 20% of the composition, the polymer component comprises about 0.01% to 20% of the composition, and the composite waste product comprises about 0.01% to 20% of the composition. In another embodiment, the particulate solid component comprises about 70% of the composition, the biomass component comprises about 5% of the composition, the polymer component comprises about 15% of the composition, and the composite waste product component comprises about 10% of the composition.

Embodiments of the present disclosure include compositions used as industrial stoker grade fuel coal pellets. Stoker grade pellets are those pellets engineered and manufactured for use in boilers requiring stoker fuel. Stoker boilers and combustion units burn chunk coal on a stationary or moving grate. Boilers of this type are typically used in industrial manufacturing locations and institutional facilities to manufacture steam and other forms of high temperature fluids. The fuel is delivered to the boiler in “chunks” and pieces nominally about ⅜″×⅜″ to ¾″×¾″. This fuel will typically have low sulfur content (less than about 1%), low ash (non-combustibles, less than about 10%), and low concentrations of HAP's.

Embodiments of the present disclosure include compositions that have a very high BTU (e.g., BTU values of about 12,500 BTU/lb or greater) and are very low in sulfur content (e.g., less than about 1%).

Embodiments of the present disclosure include compositions comprising a cleaner burning product (e.g., emissions compared to coal are lower, less carbon in ash, less smoke at start-up), that is lower in moisture and fines, and enables coal fired boilers and furnaces to operate with less emissions of SOx, NOx, and HAP's. Embodiments of the present disclosure include compositions comprising products that enable better Environmental Protection Agency (EPA) emissions compliance without additional flue gas treatment.

Embodiments of the present disclosure include compositions that ignite rapidly (e.g., ignite faster in a stoker boiler environment compared to coal). In an embodiment, the compositions include a rough surface (e.g., more surface area) that ignites faster.

Embodiments of the present disclosure include a composition comprising: a particulate solid component, where the particulate solid component comprises about 60% to 85% of the composition, and an additional component, where the additional component is selected from the group consisting of: a biomass component, a polymer component, and a composite waste product component.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a polymer component. In an embodiment, the biomass component comprises about 0.01% to 25% of the composition, and the polymer component comprises about 0.01% to 15% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a composite waste product component. In an embodiment, the biomass component comprises about 0.01% to 25% of the composition, and the composite waste product component comprises about 0.01% to 10% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a polymer component and a composite waste product component. In an embodiment, the polymer component comprises about 0.01% to 15% of the composition, and the composite waste product comprises about 0.01% to 10% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component, a polymer component, and a composite waste product component. In an embodiment, the particulate solid component comprises about 60% to 85% of the composition, the biomass component comprises about 0.01% to 25% of the composition, the polymer component comprises about 0.01% to 15% of the composition, and the composite waste product component comprises about 0.01% to 10% of the composition. In another embodiment, the particulate solid component comprises about 80% of the composition, the biomass component comprises about 5% of the composition, the polymer component comprises about 10% of the composition, and the composite waste product component comprises about 5% of the composition.

Embodiments of the present disclosure include compositions used as a utility steam coal fuel pellet (e.g., fuel to be used in a utility boiler to generate steam/electricity).

Embodiments of the present disclosure include a composition comprising: a particulate solid component, where the particulate solid component comprises about 65% to 85% of the composition; and an additional component, where the additional component is selected from the group consisting of: a biomass component, a polymer component, and a composite waste product component.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a polymer component. In an embodiment, the biomass component comprises about 0.01% to 20% of the composition, and the polymer component comprises about 8% to 20% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component and a composite waste product component. In an embodiment, the biomass component comprises about 0.01% to 20% of the composition, and the composite waste product comprises about 0.01% to 10% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a polymer component and a composite waste product component. In an embodiment, the polymer component comprises about 8% to 20% of the composition, and the composite waste product component comprises about 0.01% to 10% of the composition.

Embodiments of the present disclosure include compositions where the additional component comprises a biomass component, a polymer component, and a composite waste product component. In an embodiment, the particulate solid component comprises about 65% to 85% of the composition, the biomass component comprises about 0.01% to 20% of the composition, the polymer component comprises about 8% to 20% of the composition, and the composite waste product component comprises about 0.01% to 10% of the composition. In another embodiment, the particulate solid component comprises about 80% of the composition, wherein the polymer component comprises about 15% of the composition, and wherein the composite waste product component comprises about 5% of the composition.

Embodiments of the present disclosure include compositions used as a metallurgical MET coal pellet. In an embodiment, the particulate solid component is coal fines that are of a low volatility, higher in fixed carbon, and posses the type of petrography properties needed in the metals industry for either coke production or direct injection applications. MET coal is not burned, but is used during the steel and metal making process to add carbon to the material. In direct injection, the MET material is added directly to the steel making vats.

Embodiments of the present disclosure include compositions with an additive component where the additive component is selected from the group consisting of: coke breeze, carbon black, PET coke, and a combination thereof. The particular additive components are selected for their high concentrations of carbon and/or low concentrations of volatiles. In an embodiment, the composition is capable of oversees transport and outdoor storage without degradation and moisture absorption.

EXAMPLES

Example 1

As illustrated in Table 1 below, Example 1 is based on combustion testing emission data and data on the make-up of an embodiment of the present disclosure burned during a trial. The top portion of Table 1 shows the basic properties of a standard coal that is burned in a boiler. The lower portion of Table 1 depicts the reduction in sulfur emissions based on blending of materials in a composition of the present disclosure, Btu increase (sulfur emissions are reduced by the higher Btu value of an embodiment of the present disclosure because less fuel needs to be burned to provide the same amount of energy, thus generating less emissions), and the effect of SO₂ scrubbing by the calcium carbonate contained in the recycled carpet.

TABLE 1
Basis - 6,675 tons per year of Stoker
Coal with the following properties:
	1% Sulfur
	12,500 Btu/lb
	253,650 Pounds per year (PPY) SO2 emissions
Reductions using		Sulfur Reduction
an embodiment of	Lower Sulfur by 30%	73,051	PPY
the present	due to blending
disclosure	Increase Btu by 500	10,146	PPY
	Btu/lb
	SO2 scrubbing during	5,848	PPY
	combustion
	Total Reduction	89,045	PPY
Total Sulfur Reduction - 35%

Example 2

Example 2 illustrates sulfur reduction in an embodiment of the present disclosure including a pellet based on coal fines blending with the binder materials. This data is pre-combustion and is illustrated in Table 2 below.

TABLE 2
EXAMPLE #2
	Sulfur %
	Sulfur	%
	%	Dec
	Coal 015	4.48
	Composition 015-A	3.93	12.3%
	Composition 015-B	2.89	35.5%
	Coal 016	0.76
	Composition 016-A	0.57	25.0%
	Composition 016-B	0.62	18.4%
	Coal 019	1.5
	Composition 019-A	1.09	27.3%
	Composition 019-B	1.12	25.3%
	NOTES:
	“A” blends contain biomass, “B” blends do not contain biomass.
	Coal 015 Nothern Appalachan Coal
	Coal 016 East KY Bituminous Coal
	Coal 019 KY Blue Gem Coal
	Based on Short Prox lab testing.

Example 3

Example 3 illustrates moisture reduction in produced pellets compared to the starting coal in an embodiment of the present disclosure including a pellet based on coal fines blending with the binder materials. As an example, coal fine at 19.2% moisture are processed into pellets which have a total moisture content of 0.93%. This data is illustrated in Table 3 below.

TABLE 3
Moisture %
Coal 015          18.2
Composition 015-A 0.93
Composition 015-B 0.96
Coal 016          10.91
Composition 016-A 1.4
Composition 016-B 1.1
Coal 019          16.28
Composition 019-A 1.74
Composition 019-B 1.62
NOTES:
“A” blends contain biomass, “B” blends do not contain biomass.
Coal 015 Nothern Appalachan Coal
Coal 016 East KY Bituminous Coal
Coal 019 KY Blue Gem Coal
Based on Short Prox lab testing.

Example 4

Example 4 illustrates heating value increase in an embodiment of the present disclosure including a pellet based on coal fines blending with the binder materials. As an example, pelletizing coal with a heating value of 8,897 Btu/lb produces a pellet with a heating value of 12,160 Btu/lb (an increase of 36.7%). This data is illustrated in Table 4 below.

	TABLE 4
	Heating Value
	Btu/lb	% Increase
	Coal 015	8,897
	Composition 015-A	12,160	36.7%
	Composition 015-B	12,102	36.0%
	Coal 016	11,231
	Composition 016-A	13,115	16.8%
	Composition 016-B	13,561	20.7%
	Coal 019	11,924
	Composition 019-A	14,412	20.9%
	Composition 019-B	14,436	21.1%
	NOTES:
	“A” blends contain biomass, “B” blends do not contain biomass.
	Coal 015 Nothern Appalachan Coal
	Coal 016 East KY Bituminous Coal
	Coal 019 KY Blue Gem Coal
	Based on Short Prox lab testing.

Example 5

The data contained in Tables 5 and 6 illustrates that embodiments of the present disclosure pick up very low amounts of water when soaked (e.g., less than about 2%) and pellets formed from compositions of the present disclosure dry very rapidly. Thus, the pellets are not adversely affected by water, nor do they fall apart when soaked in water. In the Tables, all weight is in grams; “initial” includes the weight of a pellet prior to water soak; “removal” is the weight after water soak of thirty (30) minutes with immediate dry; and % WPU is percent wet pick up.

Table 6 includes % WPU of water during soak and the loss of water over time.

	TABLE 5
	0	30	60	90	150
	Weight of Pellet in Grams
#	Initial	Removal	30 min	60 min	120 min
Pellet 1	14.98	15.18	15.10	15.04	14.99
Pellet 2	12.72	12.95	12.87	12.82	12.75
Pellet 3	13.09	13.24	13.16	13.13	13.10
Pellet 4	14.62	14.81	14.70	14.65	14.61
Pellet 5	14.59	14.77	14.67	14.62	14.59
Min	12.72	12.95	12.87	12.82	12.75
Max	14.98	15.18	15.10	15.04	14.99
Ave	14.00	14.19	14.10	14.05	14.01
Std Dev	1.01973	1.017472	1.0101238	1.00303	1.009019

	TABLE 6
	% WPU
#	Removal	30 min	60 min	120 min
Pellet 1	1.34	0.80	0.40	0.07
Pellet 2	1.81	1.18	0.79	0.24
Pellet 3	1.15	0.53	0.31	0.08
Pellet 4	1.30	0.55	0.21	−0.07
Pellet 5	1.23	0.55	0.21	0.00
Min	1.15	0.53	0.21	−0.07
Max	1.81	1.18	0.79	0.24
Ave	1.36	0.72	0.38	0.06
Std Dev	0.258268	0.278884	0.240775	0.113249

Example 6

Tables 7 and 8 illustrate properties for another embodiment of the present disclosure. The data contained in Tables 7 and 8 illustrates that embodiments of the present disclosure pick up very low amounts of water when soaked (e.g., less than about 2%) and pellets formed from compositions of the present disclosure dry very rapidly. Thus, the pellets are not adversely affected by water nor do they fall apart when soaked in water. In the Tables, all weight is in grams; “initial” includes the weight of a pellet prior to water soak; “removal” is the weight after water soak of thirty (30) minutes with immediate dry; and % WPU is percent wet pick up.

	TABLE 7
	#	Initial	Removal	30 min	60 min	120 min
	1	10.08	10.36	10.27	10.21	10.13
	2	9.2	9.41	9.34	9.27	9.23
	3	11.46	11.71	11.63	11.56	11.5
	4	11.01	11.23	11.09	11.03	10.99
	5	10.54	10.67	10.6	10.58	10.56

	TABLE 8
	% WPU
#	Removal	30 min	60 min	120 min
1	2.777778	1.884921	1.289683	0.496032
2	2.282609	1.521739	0.76087	0.326087
3	2.181501	1.483421	0.8726	0.34904
4	1.998183	0.726612	0.181653	−0.18165
5	1.233397	0.56926	0.379507	0.189753
Min	1.233397	0.56926	0.181653	−0.18165
Max	2.777778	1.884921	1.289683	0.496032
Ave	2.094693	1.23719	0.696862	0.235852
Std Dev	0.561382	0.563022	0.433754	0.257431

Example 7

Table 9 is a comparison of typical HAP values to data collected during a test burn of an embodiment of the present disclosure. In all cases, the values for an embodiment of the present disclosure are within the established range of values or below the established range (lower values are advantageous).

TABLE 9
EMISSION FACTORS FOR TRACE ELEMENTS, POM, AND HCOH FROM UNCONTROLLED
BITUMINOUS AND SUBBITUMINOUS COAL COMBUSTION
Firing Configuration	Emission Factor, lb/1.0E12 Btu
(SCC)	As	Be	Cd	Cr	Pb b	Mn	Hg	Ni	POM	HCON
Pulverized coal, configuration	ND	ND	ND	1922	ND	ND	ND	ND	ND	112 C
unknown (no SCC)
Pulverized coal, wet bottom	538	81	44-70	1020-1570	507	808-2980	16	840-1290	ND	ND
Pulverized coal, dry bottom	684	81	44.4	1250-1570	507	228-2980	16	1030-1290	2.08	ND
Pulverized coal, dry bottom	ND	ND	ND	ND	ND	ND	ND	ND	2.4	ND
tangental
Cyclone furnace	115	<81	28	212-1502	507	228-1300	16	174-1296	ND	ND
Stoker, configuration unknown	ND	73	ND	19-300	ND	2170	16	775-1290	ND	ND
Spreader stoker	264-542	ND	21-43	942-1570	507	ND	ND	ND	ND	221 d
Overfeed stoker, traveling grate	542-1030	ND	43-82	ND	507	ND	ND	ND	ND	140 a
An embodiment of a composition	87.6	1.2	2.86	204	91.6	73.6	9.74	1120	ND	ND
of the present disclosure
a References 56-61. The emission factors in this table represent the ranges of factors reported in the literature. If only one data point is found it is still reported in this table. To convert from displayed units to pg/J, multiply by 0.43.
SCC = Source Classification Code.
ND = no data.
b Lead emission factors were taken directly from an EPA background document for support of the national Ambient Air Quality Standards.
C Based on two units; 133 E6 Btu/hr and 1550 E5 Btu/hr.
d Based on 1 unit; 59E6 Btu/hr.

It should be noted that ratios, concentrations, amounts, and other numerical data may be expressed herein in a range format. It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a concentration range of “about 0.1% to about 5%” should be interpreted to include not only the explicitly recited concentration of about 0.1 wt % to about 5 wt %, but also include individual concentrations (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the indicated range. The term “about” can include ±1%, ±2%, ±3%, ±4%, ±5%, ±6%, ±7%, ±8%, ±9%, or ±10%, or more of the numerical value(s) being modified. In embodiments where “about” modifies 0 (zero), the term “about” can include ±1%, ±2%, ±3%, ±4%, ±5%, ±6%, ±7%, ±8%, ±9%, ±10%, or more of 0.00001 to 1. In addition, the phrase “about ‘x’ to ‘y’” includes “about ‘x’ to about ‘y’”.

It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations, and are merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Claims

1. A composition comprising: a particulate solid component, wherein the particulate solid component comprises about 50% to 85% of the composition; andan additional component, wherein the additional component is selected from the group consisting of: a biomass component, a polymer component, a composite waste product component, and a combination thereof.

2. The composition of claim 1, wherein the additional component comprises a biomass component and a polymer component.

3. The composition of claim 2, wherein the biomass component comprises about 0.01% to 20% of the composition, and the polymer component comprises about 0.01% to 20% of the composition.

4. The composition of claim 1, wherein the additional component comprises a biomass component and a composite waste product component.

5. The composition of claim 4, wherein the biomass component comprises about 0.01% to 20% of the composition, and the composite waste product component comprises about 0.01% to 20% of the composition.

6. The composition of claim 1, wherein the additional component comprises a polymer component and a composite waste product component.

7. The composition of claim 6, wherein the polymer component comprises about 0.01% to 20% of the composition, and the composite waste product component comprises about 0.01% to 20% of the composition.

8. The composition of claim 1, wherein the additional component comprises a biomass component, a polymer component, and a composite waste product component.

9. The composition of claim 8, wherein the particulate solid component comprises about 50% to 85% of the composition, wherein the biomass component comprises about 0.01% to 20% of the composition, wherein the polymer component comprises about 0.01% to 20% of the composition, and wherein the composite waste product comprises about 0.01% to 20% of the composition.

10. The composition of claim 8, wherein the particulate solid component comprises about 70% of the composition, wherein the biomass component comprises about 5% of the composition, wherein the polymer component comprises about 15% of the composition, and wherein the composite waste product component comprises about 10% of the composition.

11. The composition of claim 10, wherein the composition is an industrial stoker grade fuel coal pellet.

12. The composition of claim 10, wherein the composition has a BTU of about 12,500 BTU/lb or greater.

13. The composition of claim 10, wherein the composition has a sulfur content of less than about 1%.

14. The composition of claim 1, wherein the particulate solid component comprises about 60% to 85% of the composition.

15. The composition of claim 14, wherein the additional component comprises a biomass component and a polymer component.

16. The composition of claim 15, wherein the biomass component comprises about 0.01% to 25% of the composition, and the polymer component comprises about 0.01% to 15% of the composition.

17. The composition of claim 14, wherein the additional component comprises a biomass component and a composite waste product component.

18. The composition of claim 17, wherein the biomass component comprises about 0.01% to 25% of the composition, and the composite waste product component comprises about 0.01% to 10% of the composition.

19. The composition of claim 14, wherein the additional component comprises a polymer component and a composite waste product component.

20. The composition of claim 19, wherein the polymer component comprises about 0.01% to 15% of the composition, and the composite waste product comprises about 0.01% to 10% of the composition.

21. The composition of claim 14, wherein the additional component comprises a biomass component, a polymer component, and a composite waste product component.

22. The composition of claim 21, wherein the particulate solid component comprises about 60% to 85% of the composition, wherein the biomass component comprises about 0.01% to 25% of the composition, wherein the polymer component comprises about 0.01% to 15% of the composition, and wherein the composite waste product component comprises about 0.01% to 10% of the composition.

23. The composition of claim 21, wherein the particulate solid component comprises about 80% of the composition, wherein the biomass component comprises about 5% of the composition, wherein the polymer component comprises about 10% of the composition, and wherein the composite waste product component comprises about 5% of the composition.

24. The composition of claim 23, wherein the composition is a utility steam coal fuel pellet.

25. The composition of claim 23, wherein the composition has a BTU of about 12,500 BTU/lb or greater.

26. The composition of claim 23, wherein the composition has a sulfur content of less than about 1%.

27. The composition of claim 1, wherein the particulate solid component comprises about 65% to 85% of the composition.

28. The composition of claim 27, wherein the additional component comprises a biomass component and a polymer component.

29. The composition of claim 28, wherein the biomass component comprises about 0.01% to 20% of the composition, and the polymer component comprises about 8% to 20% of the composition.

30. The composition of claim 27, wherein the additional component comprises a biomass component and a composite waste product component.

31. The composition of claim 30, wherein the biomass component comprises about 0.01% to 20% of the composition, and the composite waste product comprises about 0.01% to 10% of the composition.

32. The composition of claim 27, wherein the additional component comprises a polymer component and a composite waste product component.

33. The composition of claim 32, wherein the polymer component comprises about 8% to 20% of the composition, and the composite waste product component comprises about 0.01% to 10% of the composition.

34. The composition of claim 27, wherein the additional component comprises a biomass component, a polymer component, and a composite waste product component.

35. The composition of claim 34, wherein the particulate solid component comprises about 65% to 85% of the composition, wherein the biomass component comprises about 0.01% to 20% of the composition, wherein the polymer component comprises about 8% to 20% of the composition, and wherein the composite waste product component comprises about 0.01% to 10% of the composition.

36. The composition of claim 34, wherein the particulate solid component comprises about 80% of the composition, wherein the polymer component comprises about 15% of the composition, and wherein the composite waste product component comprises about 5% of the composition.

37. The composition of claim 36, wherein the composition is a metallurgical MET coal pellet.

38. The composition of claim 32, wherein an additive component is selected from the group consisting of: coke breeze, carbon black, PET coke, and a combination thereof.

39. The composition of claim 38, wherein the composition is capable of oversees transport and outdoor storage without degradation and moisture absorption.