Fuel pellet and method of making the fuel pellet

• US 5,980,595 A
• Filed: 02/02/1998
• Issued: 11/09/1999
• Est. Priority Date: 08/02/1995
• Status: Expired due to Term

• Current Assignee: Pelletshield Engineered Products, LLC
• Original Assignee: Pelletech Fuels, Inc.
• Inventors: Andrews, Michael R.
• Primary Examiner(s): McAvoy, Ellen M.
• Application Number:
  US09/029,029
• Time in Patent Office: 645 Days
• Field of Search: 44/530
• US Class Current: 44/530
• CPC Class Codes: C10L 5/40 essentially based on materials of non-mineral origin
• 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 and a method of manufacturing a fuel pellet capable of burning in either a stoker or pulver furnace, comprising from about 0 to about 80% by weight of cellulosic material, from about 1% to about 50% by weight of densified thermoplastic material, and from about 0 to about 50% by weight of coal. The cellulosic material, densified thermoplastic material and coal are ground from about 80 Mesh to about 200 Mesh, and then blended into a mixture wherein the contents are evenly distributed throughout. Following the blending process, the mixture is forced through a pelletizer. As the pellets are removed from the pelletizer they are immediately cooled so that the densified thermoplastic particles do not melt. The resulting fuel pellets produce from about 10,000 BTU per pound to about 16,000 BTU per pound and leave an ash deposit of about 0 to about 6% by weight, and a sulfur dioxide output of about 0 to about 3% by weight.

Claims

1. A fuel pellet comprising:

from about 0 to about 50% by weight coal;

from about 0 to about 80% by weight of cellulosic material;

from about 1% to about 50% by weight of densified thermoplastic material;

the thermoplastic material being discrete particles throughout the pellet and being at least 80 Mesh;

the cellulosic material having a moisture content from about 2% to about 10% by weight, and the cellulosic material being about 80 Mesh.

2. The fuel pellet of claim 1, wherein the cellulosic material is selected from the group consisting of paper mill sludge, wood and paper fibers, and combinations thereof.

3. The fuel pellet of claim 2, wherein the cellulosic material is selected from the group consisting of cherry pit, olive pits, sugar cane (bagasse), grass clippings, fur trees and other cellulosic materials, and combinations thereof.

4. The fuel pellet of claim 1, wherein the cellulosic material being between 80 and 200 Mesh.

5. The fuel pellet of claim 1, wherein the coal being between 80 and 200 Mesh.

6. The fuel pellet of claim 1, wherein the densified thermoplastic material being between 80 and 200 Mesh.

7. The fuel pellet of claim 1, wherein said pellet having a heat output from about 12,000 BTU per pound to about 16,000 BTU per pound.

8. The fuel pellet of claim 1, wherein said pellet having a sulfur dioxide output from about 0 to about 3% by weight.

9. The fuel pellet of claim 1, wherein said pellet having an ash output from about 0 to about 6% by weight.

10. The fuel pellet of claim 1, wherein said fuel pellet being about 0.50 inches in diameter to about 0.75 inches in diameter, and about 0.75 inches in length to about 3.00 inches in length.

11. A method for manufacturing a fuel pellet, comprising the steps of:

selecting elements of said fuel pellet to manufacture a composition thereof,

from about 0 to about 80% by weight of cellulosic material,

from about 1% to about 50% by weight of densified thermoplastic material,

from about 0 to about 50% by weight of coal,

said composition of said fuel pellet comprising from about 2% to about 10% by weight of moisture,

pulverizing said cellulosic material to at least about 80 Mesh,

reducing the moisture content of the cellulosic material to at about 10% by weight and not less than about 2% by weight,

pulverizing said cellulosic material a second time,

densifying thermoplastic film by an agglomeration process,

granulating said densified thermoplastic film to at least about 80 Mesh,

pulverizing said coal to at least about 80 Mesh,

blending the pulverized and granulated particles to create a composition, and

feeding said composition through a pelletizer to form said fuel pellets.

12. The method of manufacturing said fuel pellet of claim 11, further including the steps of:

cooling said fuel pellets upon exiting the pelletizer,

processing said fuel pellets through a shaker screen for separating the fuel pellets from any discharges; and

feeding said discharges through said pelletizer.

13. The method of manufacturing said fuel pellet of claim 12, wherein said fuel pellet being cooled by means of a cold water wash.

14. The method of manufacturing said fuel pellet of claim 12, wherein said fuel pellet being cooled by means of liquid nitrogen.

15. The method of manufacturing said fuel pellet of claim 11, wherein said fuel pellet having a heat output of at least about 10,000 BTU per pound.

16. The method of manufacturing said fuel pellet of claim 11, wherein said fuel pellet having a heat output of at least about 16,000 BTU per pound.

17. The method of manufacturing said fuel pellet of claim 11, wherein said fuel pellets being about 0.50 inches in diameter to about 0.75 inches in diameter, and about 0.75 inches in length to about 3.00 inches in length.

18. The method of manufacturing said fuel pellet of claim 11, wherein said densified thermoplastic being cooled by a liquid nitrogen means upon exiting the agglomeration process.

19. The method of manufacturing said fuel pellet of claim 13, wherein said densified thermoplastic being cooled by a cold water wash upon exiting the agglomeration process.