Systems and methods for managing and utilizing excess corn residue

Abstract

Systems and methods for managing excess above-ground corn residue are disclosed. Systems and methods for combusting corn residue to produce heat for generating steam are also disclosed. Additionally, methods and systems for harvesting and pre-processing corn residue prior to combustion of the corn residue are disclosed.

What is claimed is: 
     
         1 . A method for harvesting corn stover and for combusting the corn stover to produce heat for generating steam, the method comprising:
 shredding the corn stover to an average length in the range of 5-12 inches and windrowing the shredded corn stover, the corn stover having a moisture content in the range of 10-15 percent;   baling the windrowed corn stover into bales having a density of at least 13 pounds per cubic foot;   transporting the bales to a processing station where the bales are reduced to provide reduced corn stover having an average piece length less than 3 inches with no more than 25 percent by weight of the reduced corn stover being less than 0.25 inches in length;   combusting the reduced corn stover in a furnace to produce heat; and   using the heat from the furnace to generate steam in a boiler.   
     
     
         2 . A method for combusting corn stover to produce heat for generating steam, the method comprising:
 combusting the corn stover in a furnace to produce heat;   using the heat from the combustion in the furnace to generate steam in a boiler;   operating the furnace such that the furnace has an outlet exhaust gas temperature in the range of 1400 degrees F. to 1800 degrees F.;   operating the furnace and the boiler such that the boiler provides a steam pressure in the range of 800-1000 psig at a superheater outlet; and   operating the furnace and the boiler such that the boiler provides a steam temperature in the range of 800-1000 degrees F. at the superheater outlet.