FIELD OF THE INVENTION

[001] The present invention relates to bio-fuel pellets and in particularly relates to bio-fuel pellets made of dolochar and a method for making the same.

BACKGROUND OF THE INVENTION

[002] Solid wastes generated by the metallurgical industry contribute significantly towards the enhancement of environmental pollution. The handling, utilization, and safe disposal of these solid wastes are major concerns for the world. Dolochar is such a solid waste generated by the sponge iron industry. It is a combination of Dolomite and Coal dust or Unbumt Coal. Black in colour is irregular in size. Mainly generated in the Direct Reduction of iron (DRI) process from the production of sponge iron. Because of the non-availability of good grade coal, This Industry including and especially in Orissa using very inferior quality coal(Grade-F). If (Grade - B) coal is used, Dolochar is 25T/100T of iron & with infirm coal can go to 40T/100T of iron.

[003] India is the largest producer of sponge iron in the world and second largest producer of raw steel. Over 100 Million Tons of steel and 25 Million Tons of sponge iron. Therefore, the environmental challenge is tremendous. Disposal of such a huge quantity is a major concern. [004] There are expensive processes to recover some of the coal through beneficiation process but is tedious and expensive to add back to coal mix. The separation of unbumt coal is also very difficult. Low load bearing roads this is being tried but generation is so much and handling is severe issue since it has average 45% fixed carbon and needs to be used.

[005] Thus, there is a long felt need for a solution to manage such a huge amount of dolochar through which dolochar can be utilized and converted in a usable format. Such solution should be able to utilize dolochar in a pollution free manner.

OBJECTS OF THE INVENTION

[006] It is an object of the present invention, to provide a bio-fuel pellets using dolochar. [007] It is another object of the present invention, to provide a method for the production of dolochar based bio-fuel pellets.

[008] It is another object of the present invention, to provide bio-fuel pellets that are economic and use the energy (carbon) entrapped in the dolochar.

[009] It is another object of the present invention, to provide a method for conversion of heavy ash, bound dolomite and unburnt coal in the dolochar into a usable residue without segregation. [0010] It is another object of the present invention to provide a method to use the industrial waste, dolochar and to manufacture an easily usable and marketable product, without any segregation or further processing. [0011] It is yet another object of the present invention, to provide bio-fuel pellets that can be used for combustion and as a carbon sequestered soil conditioner to replenish the lost carbon in the soil as well as agri nutrients.

SUMMARY OF THE INVENTION [0012] The present invention provides for bio-fuel pellets and a method for the production of the same. The bio-fuel pellets include biomass and dolochar. The biomass material forms the majority of total mass of the fuel product. The proportion of biomass may vary from 75%-55% depending upon the properties of dolochar, type of biomass used and application of the pellets and dolochar content of the total mass of the fuel pellet may vary from 25% to 45%. Biomass blends well with the dolochar and embodies carbon content. The present invention is a unique product made using the unburnt coal waste into a homogenous pellet agglomerated with biomass. [0013] The present invention provides for a method to convert a highly ash positive and non-disposable dolochar into a proprietary bio-fuel pellet product without toxic emissions or further segregation. The present method provides a cost effective means of using dolochar in its original form because the carbon content of the waste dolochar is used to enhance the energy of the final product.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] For a better understanding of the embodiments of the systems and methods described herein, and to show more clearly how they may be carried into effect, references will now be made, by way of example, to the accompanying drawings, wherein like reference numerals represent like elements/components throughout and wherein:

[0015] FIG. 1 illustrates dolochar based pellets, according to an embodiment of the present invention;

[0016]FIG.2 illustrates different steps of the process of preparing bio-fuel pellets, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0017] The embodiments of the invention will now be described herein, with reference to the accompanying examples and drawings. It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive.

[0018] The present invention provides bio-fuel pellets and manufacturing method for the same. The bio-fuel pellets (100) include dolochar and biomass. These bio fuel pellets are free of any toxic emissions. [0019] According to an embodiment of the present invention, Figure 2 illustrates a method 200 for preparing bio-fuel pellets. The method 200 begins at step 202, wherein grinding of biomass material is done using a grinder to obtain ground particulate form of biomass. At step 204, drying of ground biomass material is performed to provide dried biomass for the step 206. At step 206, the ground and dried biomass is mixed with dolochar. At step 208, blending of the mixture of biomass and dolochar is performed to obtain fine mixture for pellet formation. Further at step 210, pelleting of the mixture of biomass and dolochar is performed using pellet press to obtain bio-fuel pellets.

[0020] The bio-fuel pellets allow the un-usable industrial waste to be utilized in a cost efficient manner as the carbon content of the waste dolochar is used to enhance the energy of the final product or bio-fuel pellets. Also, this provides a means where the waste is being utilized by the industry that generated the said waste. After utilizing this waste as bio-fuel pellets the residual ash left comprises a very small fraction of the original waste.

[0021] According to an embodiment of the present invention, the bio-fuel pellets have high ash fusion temperature and therefore can be used without clinker formation. The bio-fuel pellets of the present invention have <0.04% by weight of nitrogen, 0.23% sulphur and nearly 50% carbon content. Also, the said bio-fuel pellets have good finish and durability. The various parameters of bio-fuel pellets as tested in a laboratory are tabulated below:

---- END of test report -

[0022] Further, the residual ash left after utilizing the bio-fuel pellets is powdery in nature amounting to only about 7% of the original waste. This residual ash is a

— Endof Test Report— combination of organic biomass and coal residue, can be further utilized for carbon sequestration as a soil conditioner and has value as a free soil conditioner enhancement. Thus the complete product in terms of pellets as well as the residual ash finds its use. An independent laboratory report depicting the chemical composition of ash is tabulated below:

The major components of ash i.e. (Si02), (A1203), (Fe203), (CaO), (MgO), (K20) etc. are the beneficial components for the agriculture purpose and help in rapid growth of the plants. These components provide proper nutrients to the plants induced in soil conditioned soil.

[0023] According to an embodiment of the present invention, the biomass material may comprise 75% to 55 % of the total mass of the fuel product pellets, depending upon the water content of dolochar, type of biomass used and application of the pellets and dolochar content of the total mass of the fuel pellet may vary from 25% to 45%. The biomass may include all forms of renewable energy that are derived from plant materials based on either cellulose or lignin for example but not limited to wood waste, agricultural crop waste etc.

[0024] Various concentration combinations of biomass material and dolochar were tested in order to obtain dolochar based fuel pellets (Table 1): [0025] It will be apparent to those skilled in the art that various modifications and variations can be made in the products and methods of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. Additionally, the foregoing examples are appended for the purpose of illustrating the claimed invention, and should not be construed so as to limit the scope of the claimed invention.