Flax Based Fuel Pellet and Method of Manufacture

Abstract

A fuel pellet made substantially of flax stem fiber. The fuel pellet is made from waste material available at minimal cost that produces pellets that burn at a high temperature, generate little smoke and less than about 4% ash residue, and can be stored for long periods without deteriorating. Preferred fuel pellets include at least about 60% flax stem fiber; wherein at least about 60% of the particles are less than about a quarter of an inch in length. The fuel pellet is processed by first selecting or processing the flax stem fiber so that it has a moisture content of from about 5 to about 12%. The bulk flax stem fiber material is then processed in a hammermill or the like to reduce the size of the fiber particles. The processed flax is then extruded through a commercial pelletizing machine. The pellets are then cut and then dried.

1 . A fuel pellet comprising:
 at least about 60% flax stem fiber material; wherein the flax stem fiber material includes particles of different sizes; wherein at least about 60% of the particles are less than about a quarter of an inch in length; wherein the fuel pellet, when burned, produces less than about 4% ash residue.   
   
   
       2 . The fuel pellet of  claim 1 , further comprising a lubricant material, wherein the lubricant material is selected from the group consisting of vegetable oil, oilseed, and a combination thereof. 
   
   
       3 . The fuel pellet of  claim 2 , wherein fuel pellet further comprises from about 0.002% to about 5% by wt. lubricant material. 
   
   
       4 . The fuel pellet of  claim 1 , wherein the fuel pellet comprises at least 90% flax stem fiber material; wherein at least about 80% of the particles are less than about a half of an inch in length. 
   
   
       5 . The fuel pellet of  claim 4 , wherein the fuel pellet has a bulk density of at least about 40 lb/ft 3 . 
   
   
       6 . The fuel pellet of  claim 1 , wherein the fuel pellet has a moisture content of from about 4% to about 14%. 
   
   
       7 . The fuel pellet of  claim 1 , wherein the fuel pellet, when burned, produces no creosote. 
   
   
       8 . The fuel pellet of  claim 2 , wherein the lubricant material is at least partially derived from a plant selected from the group consisting of flaxseed, canola, soybeans, corn, sunflower, safflower, crambe and a combination thereof. 
   
   
       9 . A method of making a fuel pellet, the method comprising the steps of:
 providing flax stem fiber material;   providing a binder;   providing water to modify the flax stem fiber while it is being processed;   processing the flax stem fiber material with the binder material and water to form a processed flax mixture;   extruding the processed flax mixture to form an extruded flax mixture; and   cutting the extruded flax mixture to form pellets.   
   
   
       10 . The method of  claim 9 , wherein the step of providing includes providing enough flax stem fiber material such that the pellets include at least 90% by wt. flax stern fiber material and wherein the flax stem fiber material includes particles of different sizes; wherein about 60% of the particles are less than about a quarter of an inch in length. 
   
   
       11 . The method of making a fuel pellet of  claim 9 , wherein the flax stem fiber material and binder material are processed with a processor selected from the group consisting of a hammermill and a hay grinder. 
   
   
       12 . The method of making a fuel pellet of  claim 9 , wherein the water is in the form of steam. 
   
   
       13 . The method of making a fuel pellet of  claim 9 , wherein the extruded flax mixture is cut into pellets each sized about ¼ to about 5/16 inches long. 
   
   
       14 . The method of making a fuel pellet of  claim 9 , further including the step of drying the pellets. 
   
   
       15 . The method of making a fuel pellet of  claim 9 , further comprising the step of providing a lubricant material and processing the flax stem fiber material with the lubricant material. 
   
   
       16 . The method of making a fuel pellet of  claim 15 , wherein the lubricant material is derived from a plant selected from the group consisting of flaxseed, canola, soybeans, corn, sunflower, safflower, crambe and a combination thereof. 
   
   
       17 . The method of making a fuel pellet of  claim 9 , wherein the flax stem fiber material is in a form selected from the group consisting of smaller straw fibers, stern portions, a powder consistency and a combination thereof. 
   
   
       18 . The method of making a fuel pellet of  claim 9 , wherein the flax stem fiber material is of a powder consistency; the method further comprising the step of mixing the powdered stem fiber with a binder. 
   
   
       19 . The method of making a fuel pellet of  claim 16 , wherein the binder includes particulate cereal grain flour byproducts. 
   
   
       20 . The method of making a fuel pellet of  claim 16 , wherein the binder agent is preferably mixed with the powdered stem fiber in concentrations of from about 0.002 to about 5% by wt. 
   
   
       21 . The method of making a fuel pellet of  claim 9 , wherein the step of providing flax stem fiber material includes providing flax stem fiber material having a moisture content of from about 5 to about 12%. 
   
   
       22 . The method of making a fuel pellet of  claim 9 , further comprising the step of cooling the pellets in an industrial cooler. 
   
   
       23 . The method of making a fuel pellet of  claim 9 , further comprising the step of drying the pellets to a moisture content of from about 4 to about 14%. 
   
   
       24 . A fuel pellet made by the process of  claim 9 . 
   
   
       25 . The fuel pellet of  claim 24 , the fuel pellet comprising at least 60% by wt. flax stem fiber material. 
   
   
       26 . The fuel pellet made by the process of  claim 25 , the fuel pellet comprising at least 90% by wt. flax stem fiber material; wherein about 80% of the particles are less than about a half of an inch in length.