Sorbent containing engineered fuel feed stock

• US 10,563,144 B2
• Filed: 08/04/2017
• Issued: 02/18/2020
• Est. Priority Date: 12/22/2009
• Status: Active Grant

• Current Assignee: Repower IP LLC
• Original Assignee: Accordant Energy, LLC
• Inventors: Bohlig, James W., Bai, Dingrong, Calabrese, Paula A.
• Primary Examiner(s): Weiss, Pamela H
• Application Number:
  US15/669,797
• Publication Number:
  US 20180086995A1
• Time in Patent Office: 928 Days
• CPC Class Codes: A61P 37/00 Drugs for immunological or allergic disorders
• CPC Class Codes: C10J 2300/0946 Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
• CPC Class Codes: C10J 2300/0983 Additives
• CPC Class Codes: C10J 2300/0996 Calcium-containing inorganic materials, e.g. lime
• CPC Class Codes: C10J 3/72 Other features
• CPC Class Codes: C10L 2200/029 Salts, such as carbonates, oxides, hydroxides, percompounds, e.g. peroxides, perborates, nitrates, nitrites, sulfates, and silicates
• CPC Class Codes: C10L 5/44 on vegetable substances
• CPC Class Codes: C10L 5/46 on sewage, house, or town refuse C10L5/403, C10L5/406 take precedence
• CPC Class Codes: F23G 2201/40 Gasification
• CPC Class Codes: F23G 2201/701 with additives
• CPC Class Codes: F23G 2207/60 Additives supply
• CPC Class Codes: F23G 5/0273 using indirect heating
• CPC Class Codes: F23K 1/00 Preparation of lump or pulverulent fuel in readiness for delivery to combustion apparatus
• CPC Class Codes: F23K 2201/505 with additives
• CPC Class Codes: Y02E 20/12 Heat utilisation in combustion or incineration of waste
• CPC Class Codes: Y02E 20/18 Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel

Abstract

Disclosed are novel engineered fuel feed stocks, feed stocks produced by the described processes, methods of making the fuel feed stocks, methods of producing energy from the fuel feed stocks. Components derived from processed MSW waste streams can be used to make such feed stocks which are substantially free of glass, metals, grit and noncombustibles and contain a sorbent. These feed stocks are useful for a variety of purposes including as gasification and combustion fuels. In addition, one or more sorbents can be added to the feed stocks in order to reduce the amount of a variety of pollutants present in traditional fuel and feed stocks, including, but not limited, sulfur and chlorine. Further, these feed stocks with added sorbent can mitigate corrosion, improve fuel conversion, extend power generating plant lifetime, reduce ash slagging, and reduced operating temperature.

Claims

1. A method of producing an engineered fuel feed stock comprising at least one fiber component and at least one plastic component, the method comprising:

a) selecting a plurality of components from a waste stream, the plurality of components including the at least one fiber component and the at least one plastic component, which plurality of components in combination have chemical molecular characteristics comprising;

a carbon content of between 30 wt. % and 80 wt. %,

a hydrogen content of between 3 wt. % and 10 wt. %,

a volatile matter content of 40 wt. % to 80 wt. %, and

an ash content of less than 10 wt. %;

b) combining the selected components of a) and a sorbent to form the engineered fuel feed stock, wherein the engineered fuel feed stock contains biodegradable waste and non-biodegradable wastes.

2. The method of claim 1, further comprising:

c) adding additional fuel components to meet the desired chemical molecular characteristics of a).

3. The method of claim 2, wherein the additional fuel components include biomass.

4. The method of claim 3, wherein the biomass is wood.

5. The method of claim 1, further comprising:

d) comminuting the engineered fuel feed stock.

6. The method of claim 1, further comprising:

e) densifying the engineered fuel feed stock.

7. The method of claim 1, wherein the sorbent is selected from the group consisting of sodium sesquicarbonate (Trona), sodium bicarbonate, sodium carbonate, zinc ferrite, zinc copper ferrite, zinc titanate, copper ferrite aluminate, copper aluminate, copper manganese oxide, nickel supported on alumina, zinc oxide, iron oxide, copper, copper (I) oxide, copper (II) oxide, limestone, lime, Fe, FeO, Fe₂O₃, Fe₃O₄, iron filings, CaCO₃, Ca(OH)₂, CaCO₃.MgO, silica, alumina, china clay, kaolinite, bauxite, emathlite, attapulgite, coal ash, egg shells, wood ash, coal ash, and Ca-montmorillonite.

8. The method of claim 7, wherein the sorbent is obtained from a renewable source.

9. The method of claim 7, wherein the sorbent is in an amount of between 0.1% (weight sorbent/weight fuel feed stock (w/w)) and 50% (w/w).

10. The method of claim 9, wherein the sorbent is in the amount of between 1% (w/w) and 20% (w/w).

11. The method of claim 1, wherein the ash content is less than 8 wt. %.

12. The method of claim 11, wherein the ash content is less than 6 wt. %.

13. The method of claim 12, wherein the ash content is less than 5 wt. %.

14. The method of claim 1, wherein the engineered fuel feed stock contains substantially no glass, metals, grit, and noncombustible waste.

15. The method of claim 1, wherein the volatile matter content is between 50 wt. % and 70 wt. %.

16. The method of claim 15, wherein the volatile matter content is about 60 wt. %.

17. The method of claim 1, wherein the engineered fuel feed stock has a HHV of between 3,000 BTU/lb and 18,000 BTU/lb.

18. The method of claim 17, wherein the HHV is between 5,000 BTU/lb and 13,000 BTU/lb.

19. The method of claim 18, wherein the HHV is between 8,000 BTU/lb and 10,000 BTU/lb.

20. The method of claim 1, wherein the engineered fuel feed stock has a moisture content of between 10 wt. % and 30 wt. %.

21. The method of claim 20, wherein the moisture content is between 10 wt. % and 20 wt. %.

22. The method of claim 1, wherein the engineered fuel feed stock has a moisture content of between 1 wt. % and 10 wt. %.

23. The method of claim 1, wherein the engineered fuel feed stock has a sulfur content of less than 0.5 wt. %.

24. The method of claim 1, wherein the engineered fuel feed stock has a chlorine content of less than 1 wt. %.

25. The method of claim 1, wherein the engineered fuel feed stock has an H/C ratio of between 0.025 and 0.20.

26. The method of claim 1, wherein the engineered fuel feed stock has an O/C ratio of between 0.01 and 1.0.

27. The method of claim 1, wherein the carbon content is between 40 wt. % and 60 wt. %.

28. The method of claim 1, wherein the waste stream is a processed MSW waste stream.

29. The method of claim 1, wherein the waste stream is a processed industrial waste stream.

30. The method of claim 1, wherein the engineered fuel feed stock consists essentially of fiber, plastic, and sorbent.

31. A method of producing an engineered fuel feed stock comprising at least one fiber component and at least one plastic component, the method comprising:

a) separating a plurality of MSW streams into a plurality of MSW waste components based on chemical molecular characteristics;

b) selecting the plurality of the MSW waste components, the plurality of components including the at least one fiber component and the at least one plastic component, which plurality of MSW components in combination have chemical molecular characteristics comprising;

a carbon content of between 30 wt. % and 80 wt. %,

a hydrogen content of between 3 wt. % and 10 wt. %,

an ash content of less than 10 wt. %, and

a moisture content of between 10 wt. % and 30 wt. %;

c) combining the selected components of step a) and a sorbent to form the engineered fuel feed stock, wherein the engineered fuel feed stock contains biodegradable waste and non-biodegradable wastes.

32. The method of claim 31, further comprising:

d) adding additional fuel components to meet the desired chemical molecular characteristics of b).

33. The method of claim 32, wherein the additional fuel components include biomass.

34. The method of claim 33, wherein the biomass is wood.

35. The method of claim 31, further comprising:

e) comminuting the engineered fuel feed stock.

36. The method of claim 31, further comprising:

f) densifying the engineered fuel feed stock.

37. The method of claim 31, wherein the sorbent is selected from the group consisting of sodium sesquicarbonate (Trona), sodium bicarbonate, sodium carbonate, zinc ferrite, zinc copper ferrite, zinc titanate, copper ferrite aluminate, copper aluminate, copper manganese oxide, nickel supported on alumina, zinc oxide, iron oxide, copper, copper (I) oxide, copper (II) oxide, limestone, lime, Fe, FeO, Fe₂O₃, Fe₃O₄, iron filings, CaCO₃, Ca(OH)₂, CaCO₃.MgO, silica, alumina, china clay, kaolinite, bauxite, emathlite, attapulgite, coal ash, egg shells, wood ash, coal ash, and Ca-montmorillonite.

38. The method of claim 37, wherein the sorbent is obtained from a renewable source.

39. The method of claim 37, wherein the sorbent is in an amount of between 0.1% (weight sorbent/weight fuel feed stock (w/w)) and 50% (w/w).

40. The method of claim 39, wherein the sorbent is in the amount of between 1% (w/w) and 20% (w/w).

41. The method of claim 31, wherein the ash content is less than 8 wt. %.

42. The method of claim 31, wherein the ash content is less than 6 wt. %.

43. The method of claim 42, wherein the ash content is less than 5 wt. %.

44. The method of claim 31, wherein the engineered fuel feed stock contains substantially no glass, metals, grit, and noncombustible waste.

45. The method of claim 31, wherein the engineered fuel feed stock has a volatile matter content of 40 wt. % to 80 wt. %.

46. The method of claim 45, wherein the volatile matter content is between 50 wt. % and 70 wt. %.

47. The method of claim 31, wherein the engineered fuel feed stock has a HHV of between 3,000 BTU/lb and 18,000 BTU/lb.

48. The method of claim 47, wherein the HHV is between 5,000 BTU/lb and 13,000 BTU/lb.

49. The method of claim 48, wherein the HHV is between 8,000 BTU/lb and 10,000 BTU/lb.

50. The method of claim 31, wherein the moisture content is between 10 wt. % and 20 wt. %.

51. The method of claim 31, wherein the moisture content is between 12 wt. % and 28 wt. %.

52. The method of claim 51, wherein the moisture content is between 14 wt. % and 24 wt. %.

53. The method of claim 31, wherein the engineered fuel feed stock has a sulfur content of less than 0.5 wt. %.

54. The method of claim 31, wherein the engineered fuel feed stock has a chlorine content of less than 1 wt. %.

55. The method of claim 31, wherein the engineered fuel feed stock has an H/C ratio of between 0.025 and 0.20.

56. The method of claim 31, wherein the engineered fuel feed stock has an O/C ratio of between 0.01 and 1.0.

57. The method of claim 31, wherein the carbon content is between 40 wt. % and 60 wt. %.

58. The method of claim 31, wherein the engineered fuel feed stock consists essentially of fiber, plastic, and sorbent.

59. A method of producing an engineered fuel feed stock comprising at least one fiber component and at least one plastic component, the method comprising:

a) separating a plurality of MSW streams into MSW components;

b) selecting a plurality of MSW components, the plurality of MSW components including the at least one fiber component and the at least one plastic component, which plurality of MSW components in combination have chemical molecular characteristics comprising;

a carbon content of between 30 wt. % and 80 wt. %,

a hydrogen content of between 3 wt. % and 10 wt. %,

a volatile matter content of 40 wt. % to 80 wt. %,

an ash content of less than 10 wt. %, and

a moisture content of between 10 wt. % and 30 wt. %;

c) selecting an amount of sorbent;

d) combining the selected components of step b) and the amount of sorbent to form the engineered fuel feed stock, wherein the engineered fuel feed stock contains biodegradable waste and non-biodegradable wastes; and

e) densifying the engineered fuel feed stock.

60. The method of claim 59, further comprising:

f) comparing the resulting chemical molecular characteristics of the engineered fuel feed stock of d) with the chemical molecular characteristics of step b).

61. The method of claim 60, further comprising:

g) adding additional fuel components to the engineered fuel feed stock in d).

62. The method of claim 61, wherein the additional fuel components include biomass.

63. The method of claim 62, wherein the biomass is wood.

64. The method of claim 59, further comprising:

h) comminuting the engineered fuel feed stock.

65. The method of claim 59, wherein the sorbent is selected from the group consisting of sodium sesquicarbonate (Trona), sodium bicarbonate, sodium carbonate, zinc ferrite, zinc copper ferrite, zinc titanate, copper ferrite aluminate, copper aluminate, copper manganese oxide, nickel supported on alumina, zinc oxide, iron oxide, copper, copper (I) oxide, copper (II) oxide, limestone, lime, Fe, FeO, Fe₂O₃, Fe₃O₄, iron filings, CaCO₃, Ca(OH)₂, CaCO₃.MgO, silica, alumina, china clay, kaolinite, bauxite, emathlite, attapulgite, coal ash, egg shells, wood ash, coal ash, and Ca-montmorillonite.

66. The method of claim 59, wherein the sorbent is in the amount of between 0.1% (weight sorbent/weight fuel feed stock (w/w)) and 50% (w/w).

67. The method of claim 66, wherein the sorbent is in the amount of between 1% (w/w) and 20% (w/w).

68. The method of claim 59, wherein the ash content is less than 8 wt. %.

69. The method of claim 68, wherein the ash content is less than 6 wt. %.

70. The method of claim 69, wherein the ash content is less than 5 wt. %.

71. The method of claim 59, wherein the engineered fuel feed stock contains substantially no glass, metals, grit, and noncombustible waste.

72. The method of claim 59, wherein the volatile matter content is between 50 wt. % and 70 wt. %.

73. The method of claim 59, wherein the engineered fuel feed stock has a HHV of between 3,000 BTU/lb and 18,000 BTU/lb.

74. The method of claim 73, wherein the HHV is between 5,000 BTU/lb and 13,000 BTU/lb.

75. The method of claim 74, wherein the HHV is between 8,000 BTU/lb and 10,000 BTU/lb.

76. The method of claim 59, wherein the moisture content is between 10 wt. % and 20 wt. %.

77. The method of claim 59, wherein the engineered fuel feed stock has a sulfur content of less than 0.5 wt. %.

78. The method of claim 59, wherein the engineered fuel feed stock has a chlorine content of less than 1 wt. %.

79. The method of claim 59, wherein the engineered fuel feed stock has an H/C ratio of between 0.025 and 0.20.

80. The method of claim 59, wherein the engineered fuel feed stock has an O/C ratio of between 0.01 and 1.0.

81. The method of claim 59, wherein the carbon content is between 40 wt. % and 60 wt. %.