Carbonized component-based fuel pellet

Abstract

With the rapid increase in the price of fossil fuels and growing concerns over climate change, the demand for renewable energy sources continues to increase. Densified biomass fuels are an alternative, renewable energy source that is becoming increasingly popular. A densified biomass with increased and controllable energy density is needed. Various embodiments of densified biomass and process to manufacture are taught herein.

What is claimed is: 
     
         1 . A process for manufacturing a densified biomass having an energy density of greater than 8000 BTU/lb. comprising the steps of:
 a) combining a carbonized component and at least one other component chosen from the group consisting of biomass, lubricant, and binder to form a combined carbonized component; and   b) densifying the combined carbonized mixture to form the densified biomass.   
     
     
         2 . The process according to  claim 1  where the combined carbonized mixture, based on dry weight, is 10-80% carbonized component, 0-80% biomass, 0-30% binder, 0-20% lubricant. 
     
     
         3 . The process according to  claim 1  where the combined carbonized mixture, based on dry weight, is 10-40% carbonized component, 50-80% biomass, and 0-5% binder, and 0-5% lubricant. 
     
     
         4 . The process according to  claim 1  where the carbonized mixture, based on dry weight, is 10-40% carbonized component, 50-80% biomass, and 5% binder, and 5% lubricant. 
     
     
         5 . The process according to  claim 1  where the combined carbonized mixture includes the carbonized component and the biomass. 
     
     
         6 . The process according to  claim 5  where the biomass is comprised of both woody type and non-woody type biomasses. 
     
     
         7 . The process according to  claim 1  where the combined carbonized mixture includes the carbonized component and the binder. 
     
     
         8 . The process according to  claim 7  where the combined carbonized mixture, based on dry weight, is 80-90% carbonized component and 0-20% binder. 
     
     
         9 . The process according to  claim 7  where the binder includes at least one chosen from a bio-polymer or non-bio polymer. 
     
     
         10 . The process according to  claim 9  where the binder includes high density polyethylene. 
     
     
         11 . The process according to  claim 7  where the binder includes a hydrophobic polymer. 
     
     
         12 . The process according to  claim 1  where the combined carbonized component includes the carbonized component and the lubricant, the lubricant is at least one chosen from the group consisting of bio-oils, petro-based oils, and synthetic lubricant. 
     
     
         13 . The process according to  claim 12  where the lubricant includes at least one bio-oil. 
     
     
         14 . The process according to  claim 1  where the lubricant includes a hydrophobic lubricant. 
     
     
         15 . The process according to  claim 1  where the carbonized component includes a carbonized component derived from a second biomass that has a low lignin content. 
     
     
         16 . The process according to  claim 1 , where the combined carbonized component includes the carbonized component and a biomass. 
     
     
         17 . The process according to  claim 16 , where the second biomass is the same type as the biomass. 
     
     
         18 . The process according to  claim 17 , where the second biomass is the same species as the biomass. 
     
     
         19 . The process according to  claim 16  where the biomass is woody type, non-woody type, or a combination thereof. 
     
     
         20 . The process according to  claim 1  where the carbonized component is an organic substance converted into carbon or carbon-containing residue. 
     
     
         21 . The process according to  claim 1  where densifying includes pelletization. 
     
     
         22 . The process according to  claim 1  further comprising drying the combined carbonized mixture prior to densifying. 
     
     
         23 . The process according to  claim 1  further comprising applying a second lubricant to the densified biomass after densification. 
     
     
         24 . The process according to  claim 1  further comprising applying a second binder to the densified biomass after densification. 
     
     
         25 . A densified biomass having an energy density of greater than 8000 BTU/lb. comprising the steps of:
 a) mixing a carbonized component and at least one other component chosen from the group consisting of biomass, lubricant, and binder to form a combined carbonized mixture;
 i) where the carbonized component includes biochar derived from a second biomass of a woody type; 
 ii) where the biomass includes woody biomass; 
 iii) where the lubricant includes bio-oil; 
 iv) where the binder includes high density polyethylene. 
   b) densifying the combined carbonized mixture into the densified biomass;   c) applying a hydrophobic component to the densified biomass.   
     
     
         26 . The densified biomass according to  claim 25  where the combined carbonized mixture, based on dry weight, is 10-80% carbonized component, 0-80% biomass, 0-30% binder, 0-20% lubricant. 
     
     
         27 . The densified biomass according to  claim 25  where the combined carbonized mixture, based on dry weight, is 10-40% carbonized component, 50-80% biomass, and 0-5% binder, and 0-5% lubricant. 
     
     
         28 . The densified biomass according to  claim 25  where the carbonized mixture, based on dry weight, is 10-40% carbonized component, 50-80% biomass, and 5% binder, and 5% lubricant. 
     
     
         29 . The densified biomass according to  claim 25  where the combined carbonized mixture includes the carbonized component and the biomass. 
     
     
         30 . The densified biomass according to  claim 29  where the combined carbonized mixture includes the carbonized component and the binder. 
     
     
         31 . The densified biomass according to  claim 31  where the combined carbonized mixture, based on dry weight, is 80-90% carbonized component and 0-20% binder. 
     
     
         32 . The densified biomass according to  claim 25  where combined carbonized mixture includes the carbonized component, the biomass and the lubricant, the lubricant. 
     
     
         33 . The densified biomass according to  claim 39 , where the second biomass is of the same species as the biomass. 
     
     
         34 . The densified biomass according to  claim 26  where the densifying includes pellitization. 
     
     
         35 . The densified biomass according to  claim 26  further comprising creating a selected moisture content in the combined carbonized mixture prior to densification. 
     
     
         36 . The densified biomass according to  claim 35 , where creating a selected moisture content includes adding moisture to the combined carbonized mixture. 
     
     
         37 . The densified biomass according to  claim 35 , where creating the selected moisture content includes drying the combined carbonized component. 
     
     
         38 . The densified biomass according to  claim 26  where a second lubricant is applied to the densified biomass after densification and includes a polymer. 
     
     
         39 . The densified biomass according to  claim 26  where a second binder is applied to the densified biomass after densification.