System and Method for Obtaining Combinations of Coal and Biomass Solid Fuel Pellets with High Caloric Content

Abstract

The invention is a new solid fuel combining coal and biomass and the process for making such fuel. The coal must be selected and prepared to be the correct sizes and quality, including the moisture content and levels of pollutants. Biomass must be selected and prepared by grinding and through a heating process in order to remove moisture and partially char the biomass. The biomass may be selected based on its percentage volume of carbon and hydrogen. A third material, binder is prepared in volumes to associate with the coal and biomass. The coal, biomass and binder are mixed in appropriate quantities and may be delivered to an extrusion, press pellet or briquetting machine that forms the mixture into an appropriate size and shape for the intended combustion situation. The resultant solid fuel has had desired properties for efficient burning and emission levels in the furnace for which it is designed.

1 . A system for pyrolyzing coal, coal char and biomass to yield high caloric fuel, the system comprising: a crusher comprising open proximal and distal ends, said crusher further comprising an open flange fixedly connected to said distal end of said crusher and further comprising means for shaping coal to specified sizes; a shredder comprising open proximal and distal ends, further comprising an open flange fixedly connected to said distal end, said shredder further comprising means for threshing said biomass into specified sizes; a first and a second kiln wherein said first and second kiln each comprise an open proximal input end and a distal open output end, said kilns further comprising an open flange fixedly connected to said proximal and distal end, said first and second kilns further comprising means for controlling respective temperatures of each of said kilns; a duct comprising an open proximal input and distal output end, said duct further comprising an open flange fixedly connected to said proximal distal end, said duct further comprising means for controlling said duct temperature; a mixer comprising at least one open proximal end and one open distal end, said mixer further comprising an open flange fixedly connected to said each proximal and distal ends, said mixer further comprising means for mixing and joining contents within said mixer; a forming machine comprising an open proximal end, further comprising an open flange fixedly connected to said proximal end, and further comprising at least one die fixedly attached to said distal end of said forming machine, said forming machine further comprising means for casting coal, coal char and biomass entering said forming machine from said mixer into geometrical shapes of specified sizes. 
     
     
         2 . A system as in  claim 1  wherein said proximal end of said crusher receives coal at its proximal end. 
     
     
         3 . A system as in  claim 1  wherein said first kiln receives coal from said crusher said kiln further comprising a moving belt mounted in the interior of said first kiln providing means for moving said coal from the proximal to the distal end of said first kiln. 
     
     
         4 . A system as in  claim 1  wherein the temperature of the proximal end of said first kiln is in the temperature range 150-200 C., said distal end of first kiln is in the range 350-500 C. 
     
     
         5 . A system as in  claim 1  wherein said heated first kiln provides sufficient thermal energy for gases to be driven off from said coal, said gases selected from the group consisting of water vapor, mercury, chlorine, sulfur and hydrocarbons, with the remaining heated solid transformed to coal char. 
     
     
         6 . A system as in  claim 1  wherein said first kiln comprises means for entraining water vapor near its proximal end in a clean up station, further comprising means for entraining high temperature volatile gases at the distal end in a cleanup station, said gases selected from the group consisting of mercury, chlorine and sulfur at the s distal end of said first kiln. 
     
     
         7 . A system as in  claim 1  wherein said duct receives hydrocarbon gases from said first kiln wherein said duct comprises means for maintaining the temperature at the proximal end of said duct in the temperature range 150-200 C. and at the distal end of said duct in the temperature range 250-375 C. said temperatures causing caloric hydrocarbons gases to liquefy. 
     
     
         8 . A system as in  claims 1  and  6  wherein hydrocarbon gases heated in said first kiln are transferred at the distal end of said first kiln to at least one of said proximal openings of said duct and one of said proximal openings of said mixer, wherein said solid heated coal in said first kiln is converted to coal char and wherein said char is transferred to a second opening at the proximal end of said mixer. 
     
     
         9 . A system as in  claim 1  wherein said mixer comprises a set of rotating blades with means for mixing contents transferred to its interior from said first and second kilns and said duct, said mixer further comprising up to 3 proximal input openings, each opening comprising a fixedly attached open flange, said mixer comprising one distal output end with a fixedly attached open flange. 
     
     
         10 . A system as in  claim 1  wherein said forming device receives contents from said mixer, said forming device comprising a rigid duct further comprising a proximal open end and further comprising an interior mounted rotating screw extending the length of said duct, said screw rotation providing means for extruding contents of said forming device through a die mounted at the distal end of said device. 
     
     
         11 . A system as in  claim 10  wherein the extruded output of said forming device is in the shape of at least one of pellets, bricks and briquettes. 
     
     
         12 . A system as in  claim 1  wherein said open flange at distal end of said coal crusher is fixedly attached to said open flange at proximal end of first kiln, and further wherein open flange at distal end of first kiln is rigidly attached to one of an open flange at proximal end of said mixer and one of said open flange at proximal end of duct, and further wherein said open flange at distal end of said duct is fixedly attached to one of said open flanges at proximal end of said mixer, and further wherein said open flange at distal end of said mixer is fixedly attached to said open flange at proximal end of forming machine. 
     
     
         13 . A system as in  claim 1  wherein said biomass is loaded into said shredder, said shredder comprising a proximal and distal end, said shredder further comprising a piston with cutting blades extending into the interior of said shredder and further comprising a motor that drives said piston in an up-down motion causing shredding of said biomass. 
     
     
         14 . A system as in  claim 1  wherein said distal flange of said crusher is fixedly attached to said proximal flange of said second kiln, and further wherein said distal flange of said second kiln is fixedly attached to one of said proximal end flanges of said mixer. 
     
     
         15 . A system as in  claim 1  wherein a second kiln receives said biomass from said shredder, said second kiln further comprising a moving rotary belt mounted within the interior of said kiln, said belt spanning the length of said kiln and wherein said belt transports said shredded biomass from said proximal end to said distal end of said second kiln, said second kiln further comprising a temperature control unit wherein said proximal end of second kiln is maintained at a temperature range 100-150 C. and said distal end of said kiln in the temperature range 200-230 C., 
     
     
         16 . A second kiln as in  claim 14  further comprising means for entraining gases emanating from said heated shredded biomass. 
     
     
         17 . A system as in  claim 1  wherein said distal flange of said crusher is fixedly attached to said proximal flange of said second kiln, and further wherein said distal flange of said second kiln is fixedly attached to one of said proximal end flanges of said mixer. 
     
     
         18 . A method for producing a high caloric coal—biomass fuel, comprising the steps of: loading coal into a first kiln; heating said kiln, passing the heated hydrocarbon gases from said first kiln to a condensation duct; transferring said condensed gases from said duct to a mixer, passing the solid coal char of said first kiln to said mixer; the method further comprising loading biomass into a second heated kiln; directing the heated contents from said second heated kiln into said mixer. 
     
     
         19 . A method as in  claim 18  comprising the mixing of said biomass, hydrocarbons and solid char; removing said mixed contents from said mixer to a briquette forming device wherein said forming device converts the contents of said mixer into at least one of briquettes, bricks and pellets.