Solid fuel product

Abstract

A solid fuel product can include a carbon based solid fuel, a cementitious material, and a plastic material. The carbon based solid fuel can include coal, petroleum coke, wood and/or other carbon products. The cementitious material can include Portland cement, lime, calcium aluminate cement, natural cement, slag cement, blended cement, cement kiln dust, lime kiln dust, and/or fly ash. The plastic material can include a thermoplastic material and/or a thermoset material. The solid fuel product can include about 45% by weight to about 98% by weight of the carbon based solid fuel and about 1% by weight to about 50% by weight of the plastic material.

We claim: 
     
         1 . A solid fuel product, comprising:
 about 45% by weight to about 98% by weight of a carbon based solid fuel;   about 1% by weight to about 50% by weight of a plastic material; and   about 1% by weight to about 5% by weight of a cementitious material,   wherein the cementitious material comprises at least one of Portland cement, lime, calcium aluminate cement, natural cement, slag cement, blended cement, cement kiln dust, lime kiln dust, and fly ash.   
     
     
         2 . The solid fuel product according to  claim 1 , wherein the carbon based solid fuel comprises at least one of coal, petroleum coke, and wood. 
     
     
         3 . The solid fuel product according to  claim 2 , wherein the coal comprises at least one of bituminous coal, anthracite coal, sub-bituminous coal, and lignite coal. 
     
     
         4 . The solid fuel product according to  claim 1 , wherein the plastic material comprises at least one of a high density polyethylene, a low density polyethylene, a polypropylene, a polystyrene, a polyethylene terephthalate, and a polyester. 
     
     
         5 . The solid fuel product according to  claim 1 , wherein the plastic material comprises at least one of a urea formaldehyde, a melamine urea formaldehyde, a phenol formaldehyde, a melamine-urea-phenol-formaldehyde, a polymeric methylene di-isocyanate, and a styrene monomer. 
     
     
         6 . A method for making a solid fuel product, comprising the steps of:
 mixing a cementitious material with a carbon base material to form a homogenous mixture, the carbon base material comprising at least one of coal, petroleum coke, and wood;   mixing a plastic material with the homogenous mixture to form a plastic mixture;   heating the plastic mixture to form a hot plastic mixture; and   injecting the hot plastic mixture into a plastic injection mold machine to provide the solid fuel product.   
     
     
         7 . The method for making a solid fuel product according to  claim 6 , wherein the solid fuel product comprises about 45% to about 98% by weight of the carbon base material. 
     
     
         8 . The method for making a solid fuel product according to  claim 6 , further comprising heating the homogeneous mixture to a temperature of about 190° C. to about 250° C. 
     
     
         9 . The method for making a solid fuel product, according to  claim 6 , wherein the carbon base material is coal and the coal comprises at least one of bituminous coal, anthracite coal, sub-bituminous coal, and lignite coal. 
     
     
         10 . The method for making a solid fuel product, according to  claim 6 , wherein the solid fuel product comprises between about 1% to about 50% by weight of the plastic material. 
     
     
         11 . The method for making a solid fuel product, according to  claim 6 , wherein the plastic material comprises at least one of a high density polyethylene, a low density polyethylene, a polypropylene, a polystyrene, a polyethylene terephthalate, and a polyester. 
     
     
         12 . The method for making a solid fuel product, according to  claim 6 , wherein the plastic material comprises at least one of a urea formaldehyde, a melamine urea formaldehyde, a phenol formaldehyde, a melamine-urea-phenol-formaldehyde, a polymeric methylene di-isocyanate, and a styrene monomer.