Flax Based Fuel Pellet and Method of Manufacture

• US 20100146850A1
• Filed: 12/28/2007
• Published: 06/17/2010
• Est. Priority Date: 12/29/2006
• Status: Abandoned Application

• Current Assignee: Jayson A. Bexell
• Original Assignee: Jayson A. Bexell
• Inventors: Bexell, Jayson A.
• Application Number:
  US12/521,646
• Publication Number:
  US 20100146850A1
• Time in Patent Office: Days
• US Class Current: 44/589
• CPC Class Codes: C10L 5/363 Pellets or granulates
• CPC Class Codes: C10L 5/44 on vegetable substances
• 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

A fuel pellet made substantially of flax stem fiber. The fuel pellet is made from waste material available at minimal cost that produces pellets that burn at a high temperature, generate little smoke and less than about 4% ash residue, and can be stored for long periods without deteriorating. Preferred fuel pellets include at least about 60% flax stem fiber; wherein at least about 60% of the particles are less than about a quarter of an inch in length. The fuel pellet is processed by first selecting or processing the flax stem fiber so that it has a moisture content of from about 5 to about 12%. The bulk flax stem fiber material is then processed in a hammermill or the like to reduce the size of the fiber particles. The processed flax is then extruded through a commercial pelletizing machine. The pellets are then cut and then dried.

Claims

1. A fuel pellet comprising:

at least about 60% flax stem fiber material;

wherein the flax stem fiber material includes particles of different sizes;

wherein at least about 60% of the particles are less than about a quarter of an inch in length;

wherein the fuel pellet, when burned, produces less than about 4% ash residue.

2. The fuel pellet of claim 1, further comprising a lubricant material, wherein the lubricant material is selected from the group consisting of vegetable oil, oilseed, and a combination thereof.

3. The fuel pellet of claim 2, wherein fuel pellet further comprises from about 0.002% to about 5% by wt. lubricant material.

4. The fuel pellet of claim 1, wherein the fuel pellet comprises at least 90% flax stem fiber material;

wherein at least about 80% of the particles are less than about a half of an inch in length.

5. The fuel pellet of claim 4, wherein the fuel pellet has a bulk density of at least about 40 lb/ft³.

6. The fuel pellet of claim 1, wherein the fuel pellet has a moisture content of from about 4% to about 14%.

7. The fuel pellet of claim 1, wherein the fuel pellet, when burned, produces no creosote.

8. The fuel pellet of claim 2, wherein the lubricant material is at least partially derived from a plant selected from the group consisting of flaxseed, canola, soybeans, corn, sunflower, safflower, crambe and a combination thereof.

9. A method of making a fuel pellet, the method comprising the steps of:

providing flax stem fiber material;

providing a binder;

providing water to modify the flax stem fiber while it is being processed;

processing the flax stem fiber material with the binder material and water to form a processed flax mixture;

extruding the processed flax mixture to form an extruded flax mixture; and

cutting the extruded flax mixture to form pellets.

10. The method of claim 9, wherein the step of providing includes providing enough flax stem fiber material such that the pellets include at least 90% by wt. flax stern fiber material and wherein the flax stem fiber material includes particles of different sizes;

wherein about 60% of the particles are less than about a quarter of an inch in length.

11. The method of making a fuel pellet of claim 9, wherein the flax stem fiber material and binder material are processed with a processor selected from the group consisting of a hammermill and a hay grinder.

12. The method of making a fuel pellet of claim 9, wherein the water is in the form of steam.

13. The method of making a fuel pellet of claim 9, wherein the extruded flax mixture is cut into pellets each sized about ¼

to about 5/16 inches long.

14. The method of making a fuel pellet of claim 9, further including the step of drying the pellets.

15. The method of making a fuel pellet of claim 9, further comprising the step of providing a lubricant material and processing the flax stem fiber material with the lubricant material.

16. The method of making a fuel pellet of claim 15, wherein the lubricant material is derived from a plant selected from the group consisting of flaxseed, canola, soybeans, corn, sunflower, safflower, crambe and a combination thereof.

17. The method of making a fuel pellet of claim 9, wherein the flax stem fiber material is in a form selected from the group consisting of smaller straw fibers, stern portions, a powder consistency and a combination thereof.

18. The method of making a fuel pellet of claim 9, wherein the flax stem fiber material is of a powder consistency;

the method further comprising the step of mixing the powdered stem fiber with a binder.

19. The method of making a fuel pellet of claim 16, wherein the binder includes particulate cereal grain flour byproducts.

20. The method of making a fuel pellet of claim 16, wherein the binder agent is preferably mixed with the powdered stem fiber in concentrations of from about 0.002 to about 5% by wt.

21. The method of making a fuel pellet of claim 9, wherein the step of providing flax stem fiber material includes providing flax stem fiber material having a moisture content of from about 5 to about 12%.

22. The method of making a fuel pellet of claim 9, further comprising the step of cooling the pellets in an industrial cooler.

23. The method of making a fuel pellet of claim 9, further comprising the step of drying the pellets to a moisture content of from about 4 to about 14%.

24. A fuel pellet made by the process of claim 9.

25. The fuel pellet of claim 24, the fuel pellet comprising at least 60% by wt. flax stem fiber material.

26. The fuel pellet made by the process of claim 25, the fuel pellet comprising at least 90% by wt. flax stem fiber material;

wherein about 80% of the particles are less than about a half of an inch in length.