Synthetic fuel pellet and methods

Abstract

The present invention includes a synthetic fuel pellet, the pellet comprising a compressed agglomeration of: (a) coal fines; (b) a fibrous cellulosic material wherein the fibers of the fibrous cellulosic material have been substantially disintegrated; and (c) at least one binder, the binder adapted to form a pellet of the coal fines and the fibrous cellulosic material.

1 . A synthetic fuel pellet, said pellet comprising a compressed agglomeration of:
 a. coal fines;   b. a fibrous cellulosic material wherein the fibers of said fibrous cellulosic material have been substantially disintegrated; and   c. at least one binder, said binder adapted to form a pellet of said coal fines and said fibrous cellulosic material.   
   
   
       2 . A synthetic fuel pellet according to  claim 1  wherein said at least one binder comprises a plasticized organic material. 
   
   
       3 . A synthetic fuel pellet according to  claim 1  wherein said at least one binder comprises nylon. 
   
   
       4 . A synthetic fuel pellet according to  claim 1  wherein said at least one binder comprises polyvinyl alcohol. 
   
   
       5 . A synthetic fuel pellet according to  claim 4  wherein said polyvinyl alcohol is present in said pellet in the range of from about 0.1% to about 1% of solids. 
   
   
       6 . A synthetic fuel pellet according to  claim 1  wherein at least one binder is substantially free of epoxy resins. 
   
   
       7 . A synthetic fuel pellet according to  claim 1  wherein at least one binder is adapted to make said fibrous cellulosic material substantially waterproof. 
   
   
       8 . A synthetic fuel pellet according to  claim 1  wherein said binder includes a thermoset binder derived from steam treatment of cellulose. 
   
   
       9 . A synthetic fuel pellet according to  claim 1  wherein said binder includes a Maillard reaction resin. 
   
   
       10 . A synthetic fuel pellet according to  claim 1  wherein said at least one binder comprises polyvinyl alcohol, and a binder selected from the group consisting of Maillard reaction resins and thermoset binders derived from steam treatment of cellulose. 
   
   
       11 . A synthetic fuel pellet according to  claim 1  wherein the percent by weight ratio of the coal fines to the fibrous cellulosic material is in the range of from about 10 to 1 to about 2 to 1. 
   
   
       12 . A synthetic fuel pellet according to  claim 1  wherein said coal fines are present in an amount in the range of from about 70 to about 90 percent by weight of said pellet. 
   
   
       13 . A synthetic fuel pellet according to  claim 1  wherein said fibrous cellulosic material is present in an amount in the range of from about 10 to about 30 percent by weight of said pellet. 
   
   
       14 . A synthetic fuel pellet according to  claim 1  wherein said fibrous cellulosic material has an average fiber length in the range of from about 0.5 to about 4.0 millimeters. 
   
   
       15 . A synthetic fuel pellet according to  claim 1  wherein the fibers of said fibrous cellulosic material have been has been subjected to pneumatic or mechanical fibril disintegration prior to being incorporated into said compressed agglomeration. 
   
   
       16 . A synthetic fuel pellet, said pellet comprising a compressed agglomeration of:
 a. coal fines;   b. a fibrous cellulosic material wherein the fibers of said fibrous cellulosic material have been substantially disintegrated; and   c. at least one binder, said binder adapted to render said fibrous cellulosic material substantially waterproof and to form a pellet of said coal fines and said fibrous cellulosic material.   
     Method of Making Synthetic Fuel Pellet 
   
   
       17 . A method of preparing a synthetic fuel pellet, said method comprising the steps of:
 a. bringing into contact a mixture of:
 i. coal fines; 
 ii. a fibrous cellulosic material wherein the fibers of said fibrous cellulosic material have been substantially disintegrated; and 
 iii. at least one binder, said binder adapted to render said fibrous cellulosic material substantially waterproof and to form a pellet of said coal fines and said fibrous cellulosic material; and 
   b. compressing said mixture for sufficient time to form a pellet.   
   
   
       18 . A method according to  claim 18  wherein said compression is at a pressure below about 10,000 pounds per square inch. 
   
   
       19 . A method according to  claim 18  wherein said compression is carried out at a temperature below about 400 degrees Fahrenheit. 
   
   
       20 . A method according to  claim 18  wherein said at least one binder is first admixed with said fibrous cellulosic material prior to forming said mixture by the addition of said coal fines. 
   
   
       21 . A method of preparing a synthetic fuel pellet, said method comprising the steps of:
 a. bringing into contact a mixture of:
 i. coal fines; 
 ii. a fibrous cellulosic material wherein the fibers of said fibrous cellulosic material have been substantially disintegrated by pneumatic or mechanical fibril disintegration;
 wherein said coal fines are present in an amount in the range of from about 70 to about 90 percent by weight of said mixture; and 
 wherein said fibrous cellulosic material is present in an amount in the range of from about 10 to about 30 percent by weight of said mixture; and 
 
 iii. at least one binder, said binder adapted to render said fibrous cellulosic material substantially waterproof and to form a pellet of said coal fines and said fibrous cellulosic material; and 
   b. compressing said mixture for sufficient time to form a pellet.   
     Pelletizable Mixture Precursor 
   
   
       22 . A pelletizable mixture for making a synthetic fuel pellet, said pellet mixture comprising:
 a. coal fines;   b. a fibrous cellulosic material wherein the fibers of said fibrous cellulosic material have been substantially disintegrated; and   
     at least one binder, said binder adapted to form a pellet of said coal fines and said fibrous cellulosic material.