CROSS REFERENCE TO RELATED APPLICATION

This application is a conversion of provisional applications US 61/801,618 and US 61/801,693, both filed on March 15, 2013. These applications are herein incorporated by reference.

SUMMARY OF THE INVENTION

The present disclosure is related to methods of converting waste materials into burnable fuel. More specifically, the present disclosure is directed to a method of making a low emission biomass fuel composition from treated waste material.

The present disclosure is directed to a novel method for the production of a biomass composition from waste materials, such as land fill waste, industrial waste, construction waste, municipal garbage, biowaste including switch grass, forest litter, paper waste, peat, cane waste, and other compostable garbage. The method includes the steps of evaluating the waste material for emissions related factors, treating the evaluated waste material to form a low emissions biomass composition and shaping the biomass composition into solid fuel structures. The treating step further comprises the steps of sizing selected waste materials, blending the sized waste materials with an additive formulated specifically for the waste material and forming the blended waste materials into biomass fuel formations. The resulting biomass formations produce lower emissions than typically produced by coal and may be used as a replacement for coal, or as an additive to be combined with coal, in coal burning structures and devices.

Other features and advantages of the present invention will become apparent after study of the specification and claims that follow. All publications and patents mentioned in this application are herein incorporated by reference for any purpose. BRIEF DESCRIPTION OF THE DRAWINGS The following disclosure can be better understood with reference to the following detailed description together with the appended illustrative drawing in which like elements are numbered the same:

Figure 1A is a flow chart illustrating the steps involved in the process of making a low emission biomass composition.

Figure IB is a flow chart illustrating the steps for the treatment of waste materials within the process of making low emission biomass composition.

Figure 2 is a flow chart illustrating the steps involved in the process of making low emission solid fuel formations in more detail. DEFINITIONS

As used herein, "waste material" and "waste materials" are defined as any waste materials, such as land fill waste, industrial waste, construction waste, municipal garbage, biowaste including switch grass, forest litter, paper waste, peat, cane waste, and other compostable garbage. As used herein, "emission" or "emissions" are defined environmentally undesirable gas byproducts of combustion, including greenhouse gases, carbon gases, and actually and potentially toxic or environmentally detrimental gases.

As used herein, "emission sponge" is defined as a material that absorbs spent fuel and re-burns the spent fuel resulting in reduced carbon emissions and reduced actual and potential toxic or environmentally negative emissions from the fuel. Emission sponges include salt, sea salt, baking powder, calcium from sea shells, rice, rice byproduct, their equivalents, and combinations thereof.

As used herein, "filler" is defined as a material that acts as a mechanical bond within the waste material to fill voids left by break down of the waste material. Fillers include natural products that would provide a mechanical bond between the waste material particles. These materials include flour, such as, soy flour, wheat flour, and rice flour, rice, oats, potatoes, their equivalents and combinations thereof. As used herein, "BTU modifier" is defined as a material that can hold or transfer heat. BTU modifiers include, steel slag, coal fines, iron powder, their equivalents, and, combinations thereof.

DETAILED DESCRIPTION OF THE INVENTION The present disclosure provides a novel method for the production of a biomass fuel composition from waste materials. Referring to FIG. 1A, the method for the production of a biomass fuel composition from waste materials includes the steps of evaluating (10) selected waste material for emissions related factors, treating (20) the evaluated waste material to adjust the emission levels of the biomass composition, and forming (30) the biomass composition into solid fuel formations. The solid fuel formations resulting from this method produce lower gas emission than coal alone. The solid fuel formations may be used in place of, or combined with coal, in coal burning structures and devices.

In the evaluation step (10) information regarding certain properties of a selected starting waste material is gathered. These properties include the moisture/water content of the waste material, the gas emission levels released by the untreated waste material when it is burned, and the BTU levels produced by the untreated waste material when it is burned. The emission levels and BTU levels are then compared to the predetermined target levels for each property and used to formulate an additive used to produce a biomass fuel composition that displays target properties.

The moisture/water content of the untreated waste material will vary greatly but is preferably between 12.0% and 25.0% by weight and most preferably between 18.0% and 23.0% by weight. If the water content of the waste material needs to be increased, water will be added to the waste material during the treatment stage. If the water content is determined to be too high, additional waste material may be added to reduce the percentage of water in the waste material. Alternatively, the waste material may be dried until the water content is within the acceptable range.

The gas emission level of the untreated waste material is adjusted to its target level through the addition of an additive during the treatment step. The additive comprising an emission sponge, a filler and an optional BTU modifier. The formulation of a specific additive is determine by modifying batches of the untreated waste material with emission sponge, filler and optionally, BTU modifier until the target levels are achieved. For example, if the waste material is municipal garbage and it produces emissions higher than desired, the specific amount of emission sponge needed to lower the gas emission to the target level is calculated and included in the additive composition formulated for the municipal garbage. Likewise, if a BTU rating of a municipal garage sample is less than a desired amount, a BTU modifier is included in the additive to adjust the BTU rating of the municipal waste. The amount of BTU modifier needed to increase the BTU rating of the garbage is calculated and included in the additive composition formulated for the municipal garbage. Although the particular formulation of the factors in the additive composition will vary depending upon specific target requirements, the amount of emission sponge is preferably between 0.1% to 10.0% by weight, and most preferably between 1.5% to 3.0% by weight, and, the amount of filler is preferably between 0.1% to 6.0% by weight, and most preferably between 1.0% to 3.0% by weight. If the biomass fuel composition will be used as an additive to be combined with coal, a BTU modifier will not be needed in the additive because the coal will serve as a BTU modifier. In this circumstance, the amount of emission sponge included in the additive composition, the may be overloaded to provide emission reduction for the waste material and the coal with which it will be blended. If the biomass fuel composition is not being used as an additive, the amount of BTU modifier present in the additive is preferably between 0.1% to 50.00% by weight, and most preferably between 3.0% to 5.0% by weight.

Referring to FIG. IB, the treating step (20) further comprises sizing (22) selected waste materials and soaking and blending (24) the sized waste materials with the additive composition formulated specifically for the waste material. An additional second sizing (26) step may be necessary depending on the particle size of the biomass composition.

Referring to FIG. 2, after the evaluation step, the waste material must be sized (120) to ensure the diameter of the waste material particles are uniform and not greater than one half inch. If the waste material particles have been pre-sized to fall within these parameters, a first size reduction is not needed. If, however, the waste material is irregular in shape and includes particles greater than one half inch in diameter, the particles are introduced to a hopper (100) and they are fed through a shredder (110) or similar size reduction device (120), to form uniform waste material particles not greater than one half inch in diameter and preferably between one half inch and one quarter inch in diameter. The sized waste material is the treated with the additive formulated for use with that waste material and allowed to soak at a temperature of at least 130 degrees Fahrenheit, but preferably at least 135 degrees Fahrenheit, for at least one minute.

The treated waste composition is then fed (130) into a hammer mill (170) for further size reduction until the size of the waste material particles is not greater than one quarter inch.

The treated biomass composition is then fed (180) into a press (190) and formed into pellets, briquettes, spheres or other desired shapes. Adjustments in the pressure used in the formation of the solid fuel formations may be used to further adjust the BTU ratings. The resulting solid fuel formations may then be added directly to the coal burning device or structure or blended with coal before use.

Although the additive composition may be blended with the waste material at any point in the process prior to the shaping step (190), it is preferably blended into the waste material particulates following the first sizing step (120). The resulting biomass composition comprises between 3.2% to 56.00% by weight additive composition by weight and burns cleaner and more fully than conventional coal or blended biofuels as shown below.

Bioburn Results

Coal/Bio

Blend 3

Pak-dup 8.61 20.07 18.34 8672 7925 10850 0.96 0.88 1.50 2.21

Corn

Stover

Pak 6.04 8.27 7.77 7573 7115 8256 0.07 0.06 0.76 0.18

Corn

Stover

Pak-dup 6.02 7.92 7.44 7524 7071 8171 0.05 0.05 0.80 0.14

Examples

Waste material is selected and evaluated for moisture level, BTU levels and emissions levels. An additive composition comprising sea salt and soy flour is formulated based upon the desired BTU and emissions levels.

Still referring to FIG. 2, the waste material is then deposited into a hopper (100), which feeds the waste material (110) into a shredder, and waste materials pass through a shredder (120) to produce waste material particles having a diameter not greater than one half inch. As an auger or conveyor (130) moves the sized waste material, the additive composition comprising sea salt and soy flour is then added (140) to the waste material particles until they are coated with the additive composition.

The coated waste material particles are then transferred into a vat or other receiving container for further treatment and the moisture content and temperature of the mixture is determined. If the moisture content of the coated particulate matter is less than 12.0% by weight, water is added (150) until the moisture content of the waste material particles is preferably between 18.0 to 23% by weight. The waste material and additive composition are then allowed to soak (160) at temperature and for a time sufficient to destroy most biological agents, typically at a temperature of at least 130 degrees Fahrenheit, but preferably at least 135 degrees Fahrenheit, for at least one minute. This step serves to decontaminate the waste material and break down chemical and mechanical bonds within the waste material. If the temperature of the mixture is less than 130 degrees F, the temperature of the mixture is increased with an external heating device until the mixture reaches a temperature of at least 130 degrees Fahrenheit and allowed to soak for at least one minute. This step kills biological contaminants and accelerates breakdown of the mechanical bonds within the waste materials. In an alternative embodiment, the waste material particles are coated with a corresponding additive composition formulation following the first size reduction then transferred into a vat or similar container. The water content and temperature of the waste material particles is measured and adjusted so that the water content is at least 12% by weight and the temperature is at least 130 degrees Fahrenheit, but preferably at least 135 degrees Fahrenheit.

If needed, the size of the waste material particles is then reduced a second time by passing the soaked particulates through a hammer mill (170) or similar size reduction device until the diameter of the waste material particulates is not greater than one half inch, but preferably not greater than one quarter inch. The milled waste material particulate and additive composition mixture is then move (180) and pressed (190) into desired solid fuel formations such as pellets, briquettes, spheres. The resulting fuel formations may then be coated with starch for product stabilization.

The scope of the invention is not limited to the specific embodiments described herein. Rather, the claim should be looked to in order to judge the full scope of the invention.