Preparation method of non-carbon hydrogen fuel with inorganic solid waste coupled high-temperature trigger chain polymerization reaction sustained release energy

Abstract

The application discloses a non-carbon hydrogen fuel with inorganic solid waste coupling high-temperature trigger chain type polymerization reaction continuous energy release, the fuel is composed of inorganic industrial solid waste, through multilevel, chain type, cross solid phase combination reaction between raw material components, the reaction continuously releases heat, and no carbon dioxide is generated in the reaction process, the solid phase combination reaction constitutes a high-temperature trigger chain type polymerization energy release reaction system, and the application relates to the technical field of solid waste resource utilization, the fuel uses inorganic industrial solid waste as all raw materials, through optimization of the proportion of calcium, aluminum, silicon, iron, magnesium and sulfur elements, a multilevel solid phase heat release system which can be excited at high temperature and continuously carried out is formed, the application realizes bulk consumption and high-value energy utilization of intractable inorganic solid waste, provides a brand-new zero-carbon clean heat source, and can be widely applied to industrial kiln heating, solid waste collaborative treatment and other fields.

Description

Technical Field

[0001] This invention relates to the fields of solid waste resource utilization and clean energy technology, specifically a method for preparing non-hydrogen fuels that continuously release energy through an inorganic solid waste coupled with a high-temperature triggered chain polymerization reaction. Background Technology

[0002] With the advancement of the "dual carbon" goals, the replacement of traditional fossil fuels and the large-scale disposal of industrial solid waste have become urgent issues. Currently, industrial solid waste such as aluminum tailings (red mud), aluminum ash slag, desulfurization gypsum, and calcium carbide sludge are stockpiled in large quantities, posing high environmental risks. Their resource utilization is mostly concentrated in the building materials sector (such as cement and bricks), with low added value and unable to solve the carbon emission problem.

[0003] Existing technologies include some research on fuel production from solid waste, but most rely on residual carbon or organic matter (such as sludge or biomass blending) in the solid waste, and the combustion process still produces carbon dioxide. Other studies focus on aluminothermic reactions, but these usually require the addition of elemental substances such as metallic aluminum as high-energy fuels, resulting in high costs and violent, difficult-to-control reactions.

[0004] Therefore, developing a new type of fuel that fully utilizes inorganic solid waste, does not rely on hydrocarbon elements, and can spontaneously undergo exothermic reactions at high temperatures to release a large amount of calorific value is of great significance for realizing the high-value utilization and energy utilization of industrial solid waste and for deep emission reduction. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a high-energy fuel that is entirely derived from inorganic solid waste, requires no external hydrocarbon fuel, and releases heat through multi-level solid-phase chemical reactions under high temperature, thereby achieving "waste treatment and turning waste into treasure" and clean energy supply.

[0006] To achieve the above objectives, the technical solution of this invention is as follows: Firstly, embodiments of this invention provide a non-hydrogen fuel that continuously releases energy through an inorganic solid waste coupled with a high-temperature triggered chain polymerization reaction. The fuel is entirely composed of inorganic industrial solid waste, without any added hydrocarbon components. By dry weight percentage, the raw material components and proportions are: 20%-50% calcium-based solid waste, 30%-60% aluminum-silicon-based solid waste, 5%-20% iron-based solid waste, and 5%-15% magnesium-based solid waste. Each component synergistically constructs a chain polymerization energy release system. Under high-temperature excitation above 700℃, a multi-level, chain-like, and cross-linked solid-phase chemical reaction is triggered. Heat is continuously released through the chemical reactions between inorganic components. The reaction process produces no carbon dioxide and emits no toxic or harmful gases, achieving zero-carbon stable energy release.

[0007] The non-hydrogen fuel proposed in this invention has a clear and controllable chain polymerization energy release logic: high temperature first activates CaO in calcareous solid waste, which undergoes a primary solid-phase combination reaction with Al2O3 and SiO2 in aluminosilicate solid waste and Fe2O3 in ferrous solid waste to generate calcium aluminate, calcium silicate, and calcium ferrite. The heat released by the primary reaction further triggers secondary reactions. In the secondary reaction, calcium aluminate reacts with calcium sulfate in calcareous solid waste to generate calcium sulfoaluminate, while MgO in magnesium solid waste reacts with the above primary products and raw material components to form composite minerals such as calcium aluminoferrite, magnesium silicate calcium stone, and magnesium aluminum spinel. Each level of reaction is triggered step by step and cross-linked to form a stable chain polymerization reaction system that can ensure continuous heat output without the need for continuous external energy supply.

[0008] Optionally, the calcium-based solid waste is selected from one or more of calcium carbide sludge, desulfurized gypsum, alkali tailings salt sludge, and steel slag. Its function is to provide CaO as the core triggering component for solid-phase chemical reactions, ensuring the initiation and advancement of chain reactions. The aluminosilicate solid waste is selected from one or more of aluminum tailings red mud, aluminum ash slag, fly ash, coal gangue, and metal tailings. It is used to provide Al2O3 and SiO2 as key raw materials for the formation of aluminates and silicates, supporting the primary reactions. The iron-based solid waste is selected from one or more of red mud, steel slag, and pyrite slag. It provides Fe2O3, participates in the formation of calcium ferrite and calcium aluminoferrite, and enhances the sustainability and energy release intensity of chain reactions. The magnesium-based solid waste is selected from one or more of magnesium tailings slag, olivine tailings, and dolomite tailings. It provides MgO, promotes the formation of composite minerals, and optimizes the energy release stability and calorific value range.

[0009] Optionally, the exothermic calorific value of the fuel is in the range of 5000-15000 kcal / kg.

[0010] By adjusting the proportions of each solid waste component, the calorific value range can be flexibly controlled to meet the needs of different industrial heating scenarios. It can satisfy the heat demand of high-temperature kilns as well as adapt to medium and low-temperature heating scenarios.

[0011] Secondly, embodiments of the present invention provide a method for preparing the above-mentioned non-hydrocarbon fuel, comprising the following steps: S1. The raw materials of calcium solid waste, aluminum-silica solid waste, iron solid waste and magnesium solid waste are dried, crushed and ground respectively.

[0012] The drying process is used to remove free moisture from the raw materials to avoid problems such as agglomeration and abnormal porosity during subsequent mixing and reaction, and to ensure the uniformity of the materials. After crushing, the materials are processed by grinding equipment to make the particle size ≤0.2mm, ensuring that the particles of each component are in full contact, which provides a guarantee for the smooth triggering and step-by-step advancement of the chain polymerization reaction. At the same time, it removes large impurities mixed in the raw materials to avoid affecting the stability of the reaction.

[0013] S2. According to the above dry basis mass percentage ratio, accurately weigh each raw material component after grinding, and put them into the mixing equipment for thorough mixing and homogenization.

[0014] The mixing process must ensure that all components are evenly distributed to avoid the interruption of the chain reaction caused by excessively high or low concentrations of local components. The mixing and homogenization time should be adjusted according to the type of equipment, with the standard being that the material has no obvious stratification and uniform color, ensuring that the material in each particle size range contains complete reaction components.

[0015] S3. Depending on the actual application scenario requirements, the mixed and homogenized material can be granulated to obtain spherical, columnar or other predetermined shaped molded bodies.

[0016] The molding process can improve the bulk density and mechanical strength of the fuel, making it easier to store, transport, and distribute evenly in the reaction device. The molding pressure and moisture content are adjusted according to the characteristics of the raw materials to ensure that the molded body is not prone to pulverization or cracking, thus ensuring the stability of subsequent use.

[0017] S4. Perform low-temperature drying treatment on the homogenized mixture or the molded body obtained in step S3. The drying temperature is controlled at 150-300℃, and the moisture content of the material after drying is ≤5%.

[0018] Low-temperature drying can remove residual moisture from materials, avoid heat loss and temperature fluctuations in the reaction system caused by moisture evaporation during the high-temperature activation stage, and prevent cracking of the molded body, ultimately resulting in a stable finished non-hydrocarbon fuel.

[0019] Thirdly, the embodiments of the present invention provide the application of the above-mentioned non-carbon-hydrogen fuel, which is mainly used for industrial heating. The specific application method is as follows: the non-carbon-hydrogen fuel is placed in a suitable reaction device, and the fuel temperature is excited to above 700°C by an external heat source (such as gas ignition, electric heating, industrial waste heat, etc.) to trigger a chain polymerization solid-phase chemical reaction; after the reaction starts, the supply of external heat source can be stopped or reduced, and industrial heating is achieved by utilizing the heat energy continuously released by the fuel itself, forming a green heating mode of "external triggering-autonomous energy release", which greatly reduces the dependence on traditional heat sources.

[0020] Optionally, the application scenarios include serving as auxiliary or alternative fuel for industrial kilns (such as cement kilns, ceramic kilns, and metallurgical kilns) to reduce the use of traditional hydrocarbon fuels and reduce carbon emissions; serving as a supplementary combustion energy source for solid waste incineration to improve incineration efficiency, reduce combustion energy consumption, and achieve synergy between solid waste disposal and energy recovery; or being used in combination with other low-calorific-value fuels to compensate for the insufficient energy release of low-calorific-value fuels, improve heating stability and continuity, and adapt to diverse industrial heating needs.

[0021] Optionally, the reaction device is a rotary kiln, a vertical reactor, or a high-temperature boiler. The device must have high-temperature resistance characteristics to adapt to reaction temperatures above 700°C. It is also equipped with a heat recovery module to maximize the recovery of heat energy released from fuel and improve energy utilization efficiency. The inner wall of the device must be treated with high-temperature protection to prevent it from being corroded by high temperatures during the reaction process and to extend the service life of the equipment.

[0022] Fourthly, embodiments of the present invention provide an industrial heating system, comprising a fuel supply device, a combustion reaction device, and a heat recovery device, all working in concert to achieve zero-carbon continuous heating. The fuel supply device stores and transports the aforementioned non-hydrocarbon fuels, enabling continuous or intermittent fuel supply according to heating demand. It is equipped with a metering module to precisely control the feed rate and ensure stable reaction. The combustion reaction device, such as a rotary kiln, vertical reactor, or high-temperature boiler, provides a site for the fuel chain polymerization reaction. It is equipped with an external trigger heat source, a temperature monitoring module, and sealing components to ensure stable start-up and continuous operation of the reaction without heat leakage. The heat recovery device recovers the heat energy released by the combustion reaction device and transports it to industrial heating terminals through heat exchange and circulation. It also has insulation functions to reduce heat loss and improve heating efficiency.

[0023] The beneficial effects of this invention are: Truly zero carbon emissions: The non-hydrogen fuel described in this invention uses only inorganic industrial solid waste as raw material, containing no hydrocarbon components. The reaction process releases heat based on a multi-level chain polymerization solid-phase chemical reaction between inorganic components, without involving the combustion of hydrocarbons throughout the entire process. This completely eliminates the generation of carbon dioxide at the source, thus completely avoiding carbon emission issues. Simultaneously, oxygen may be released during some solid-phase chemical reactions, further optimizing emission characteristics. After the reaction, there are no toxic or harmful gases, dust, or other pollutants emitted, resulting in clean and environmentally friendly emissions that align with global dual-carbon strategies and environmental protection requirements.

[0024] High-value utilization of solid waste: This invention achieves large-scale disposal of various inorganic solid wastes that are difficult to dispose of and have low added value through precise component synergistic formulation. These solid wastes originally relied on landfill and stockpiling for disposal, which easily caused environmental pollution. However, this invention uses them as raw materials to prepare high-value non-hydrocarbon fuels, which not only solves the environmental problem of solid waste accumulation, but also gives solid waste energy value, achieving a dual improvement in environmental and economic benefits, and promoting the transformation of solid waste resource utilization towards high-value utilization.

[0025] Energy originates from chemical bond recombination: This invention breaks through the inherent logic of traditional fuels relying on hydrocarbon combustion for energy release. The calorific value of the fuel comes from the phase change and chemical bond recombination process of inorganic solid waste components triggered by high temperature. Through solid-phase chemical reaction between inorganic components, the original chemical bonds are broken and new chemical bonds with lower energy are formed, releasing stable chemical energy. This breaks away from the dependence on carbon-based energy and opens up a new fuel path based on chemical bond recombination and energy release using inorganic non-carbon-based materials as carriers, filling the gap in existing technology.

[0026] Controllable Reaction: This invention allows for the targeted design of core reaction parameters by adjusting the proportions of key elements such as calcium, silicon, aluminum, iron, sulfur, and magnesium in the raw materials. Specifically, the calcium component directly affects the initiation temperature of the chain reaction, while the aluminum, silicon, and iron components regulate the intensity and duration of exothermic reactions. The magnesium component optimizes the mineral phase structure of the products, thereby achieving precise design of the reaction initiation temperature, exothermic intensity, energy release cycle, and the final product mineral phase. This controllability allows for flexible matching of heating needs in different scenarios such as industrial kilns, high-temperature boilers, and solid waste incineration, improving fuel adaptability and practicality.

[0027] The products are stable and harmless: After the fuel undergoes a chain-polymerization solid-phase chemical reaction, the final products are stable silicate, aluminate, and composite mineral phases, with no toxic or harmful residues and stable physicochemical properties. These products can be directly reused as building material raw materials, for example, as conditioning components in cement clinker to optimize clinker performance, or as raw materials for microcrystalline glass to prepare high-value-added building materials, forming a closed-loop resource utilization process encompassing inorganic solid waste, non-hydrocarbon fuels, and building material raw materials, with no secondary waste generated, achieving resource utilization throughout the entire life cycle. Detailed Implementation

[0028] The present invention will be further described below with reference to the embodiments. Example

[0029] This embodiment selects inorganic industrial solid wastes such as calcareous solid waste, aluminosilicate solid waste, and magnesium solid waste to prepare non-hydrogen fuels that release energy continuously through a high-temperature-triggered chain polymerization reaction coupled with inorganic solid wastes, as detailed below: Raw material ratio (by dry weight percentage): 35% calcium carbide sludge (main component CaO) is selected for calcareous solid waste, 45% red mud (main components Al2O3, Fe2O3, SiO2) is selected for aluminous-silica and ferrous composite solid waste, 10% desulfurized gypsum is selected for calcareous solid waste supplementation, and 10% magnesium slag is selected for magnesium solid waste. Each component covers the core types of calcium, aluminous-silica, ferrous and magnesium, meeting the component requirements of the chain polymerization reaction.

[0030] Preparation method: First, the four inorganic solid waste raw materials mentioned above are dried and crushed to remove free moisture and large impurities. Then, they are further ground to a particle size of 0.08 mm to ensure that the particles of each component are in full contact to ensure smooth triggering of the chain reaction. The ground raw materials are accurately weighed according to the above proportions and put into a mixing device for thorough mixing and homogenization to ensure that the components are evenly distributed without stratification. Then, the mixture is pressed into spherical molded bodies with a diameter of 20 mm to improve the mechanical strength and bulk density of the fuel. Finally, the pellets are placed in a low-temperature drying device and dried at 250°C to remove residual moisture, thus obtaining the finished non-hydrocarbon fuel.

[0031] Application testing employed a high-temperature tubular furnace as the reaction device to simulate the high-temperature triggering and energy release process in an industrial heating scenario: The prepared pellets were placed inside the furnace, and a programmed heating rate of 10℃ / min was set. When the furnace temperature reached 750℃ (above 700℃), the temperature inside the furnace began to deviate from the preset programmed heating curve, exhibiting a significant self-heating phenomenon. This indicated that the high temperature had successfully triggered the chain polymerization solid-state chemical reaction, and the fuel entered the self-release stage. In the 800-1100℃ temperature range, the reaction entered a violent energy release stage, exhibiting a strong exothermic peak, corresponding to multi-level, cross-functional solid-state chemical reactions between components (e.g., CaO reacts with Al2O3 and Fe2O3 to form calcium aluminate and calcium ferrite, subsequently triggering secondary reactions). Calculations showed that the total exothermic value of this fuel formulation throughout the entire reaction range was approximately 8500 kcal / kg, suitable for medium- and high-temperature industrial heating needs. Example

[0032] This embodiment uses different types of inorganic solid waste to prepare non-hydrocarbon fuel in powder form and verifies its application effect in a rotary kiln scenario, as detailed below: Raw material ratio (by dry weight percentage): 25% salt mud (main components are Ca(OH)2 and NaCl) for calcareous solid waste, 40% aluminum ash slag (main components are AlN and Al2O3) for aluminous and silicate solid waste, 20% steel slag (main components are Fe2O3, CaO and SiO2) for ferrous and composite solid waste, and 15% fly ash (main components are SiO2 and Al2O3) to supplement aluminum siliceous solid waste. The components work together to construct a chain-like polymerization and energy release system.

[0033] The preparation process simplifies the granulation steps and is suitable for powder fuel application scenarios: The above four inorganic solid waste raw materials are dried, crushed and ground for pretreatment to remove moisture and impurities. After all the raw materials are ground to 0.08mm, they are fully mixed and homogenized and then used directly as powder fuel without additional granulation and forming, which meets the requirements of jet feeding.

[0034] Application testing employed a small rotary kiln simulator as the reaction device to simulate the actual application scenario of an industrial kiln. The simulator was preheated to 800℃ to reach the chain reaction trigger temperature before powdered fuel was injected into the kiln. Upon entering the high-temperature environment, the fuel was rapidly activated, triggering a vigorous chain polymerization solid-phase chemical reaction that released a large amount of heat energy. This caused the kiln temperature to rise autonomously from 800℃ to over 1150℃ within 10 minutes, and this high-temperature state was maintained stably for more than 30 minutes, demonstrating continuous energy release characteristics. After the reaction, the product was a stable mineral phase, mainly consisting of silicate and aluminate composite minerals such as 2CaO・SiO2 and 4CaO・Al2O3・Fe2O3. This dense structure allows for direct use as a building material raw material for secondary resource recovery. Example

[0035] This embodiment optimizes the raw material ratio by increasing the calcium sulfate content, specifically promoting the formation reaction of calcium sulfoaluminate and enhancing the sustainability of the chain energy release, as detailed below: Raw material ratio (by dry weight percentage): 40% desulfurized gypsum for calcareous solid waste, 30% fly ash for aluminosilicate solid waste, 15% red mud for aluminosilicate and ferrous composite solid waste, 10% magnesium slag for magnesia solid waste, and 5% pyrite slag for ferrous solid waste. The purpose of this ratio is to increase the calcium sulfate content, promote the secondary chain reaction of calcium sulfate and calcium aluminate to form calcium sulfoaluminate, and optimize the duration of exothermic reaction.

[0036] The preparation process adopts conventional granulation technology: the above five inorganic solid waste raw materials are dried, crushed, and ground for pretreatment, then mixed according to the ratio and ground and homogenized. Subsequently, they are granulated and shaped, and then subjected to low-temperature drying to remove residual moisture, so as to obtain finished fuel, ensuring uniform distribution and stable reaction of fuel in the reaction device.

[0037] The testing process focused on monitoring the exothermic characteristics: the fuel exhibited two distinct exothermic plateaus in the 900-1250℃ temperature range, corresponding to a series of secondary chain reactions involving calcium sulfate. First, calcium sulfate reacts with the primary reaction product calcium aluminate to form calcium sulfoaluminate, which then further triggers cross-reactions between calcium sulfoaluminate and other components. The sequential exothermic release of heat through these two plateaus makes the energy release process more sustained and gradual. Calculations show that the fuel has a total calorific value of approximately 12,000 kcal / kg, making it suitable for industrial scenarios with high continuous heating demands.

[0038] The above embodiments demonstrate that by adjusting the coupling ratio of different types of inorganic solid waste, the exothermic characteristics of the non-hydrocarbon fuel of the present invention can be controlled, including the chain reaction initiation temperature, exothermic peak temperature, total calorific value and reaction duration, thereby flexibly matching the differentiated heating needs of different industrial scenarios such as industrial kilns and high-temperature boilers, verifying the feasibility and adaptability of the technical solution of the present invention.

[0039] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A non-hydrogen fuel that continuously releases energy through an inorganic solid waste coupled with a high-temperature triggered chain polymerization reaction, characterized in that, The fuel is composed of inorganic industrial solid waste. By dry basis mass percentage, the raw material components include: 20%-50% calcium solid waste, 30%-60% aluminum-silicon solid waste, 5%-20% iron solid waste, and 5%-15% magnesium solid waste. Under high temperature activation above 700℃, the fuel continuously releases heat through multi-level, chain-like, and cross-linked solid-phase chemical reactions between the raw material components. No carbon dioxide is generated during the reaction process. The solid-phase chemical reactions constitute a high-temperature triggered chain polymerization energy release reaction system.

2. The non-hydrocarbon fuel according to claim 1, characterized in that, The calcareous solid waste is selected from one or more of calcium carbide sludge, desulfurized gypsum, alkali tailings salt sludge, and steel slag; the aluminosilicate solid waste is selected from one or more of aluminum tailings red mud, aluminum ash slag, fly ash, coal gangue, and metal tailings; the ferrous solid waste is selected from one or more of red mud, steel slag, and pyrite slag; and the magnesian solid waste is selected from one or more of magnesium tailings magnesium slag, olivine tailings, and dolomite tailings.

3. The non-hydrocarbon fuel according to claim 1 or 2, characterized in that, The multi-level, chain-like, and cross-linked solid-phase chemical reactions include one or more combinations of the following reactions occurring in different temperature ranges: the reaction of CaO and Al2O3 to form calcium aluminate, the reaction of CaO and Fe2O3 to form calcium ferrite, the reaction of CaO and SiO2 to form calcium silicate, the reaction of calcium aluminate and calcium sulfate to form calcium sulfoaluminate, and the reaction to form calcium aluminoferrite, calcium magnesium silicate, and calcium magnesium aluminum spinel. Each reaction is triggered step by step to form a chain-like energy release effect.

4. The non-hydrocarbon fuel according to claim 1, characterized in that, The exothermic calorific value of the fuel ranges from 5000 to 15000 kcal / kg.

5. A method for preparing a non-hydrocarbon fuel that continuously releases energy through an inorganic solid waste coupled with a high-temperature triggered chain polymerization reaction, based on the non-hydrocarbon fuel according to any one of claims 1 to 4, characterized in that, Includes the following steps: a. The raw materials of calcium solid waste, aluminum-silica solid waste, iron solid waste and magnesium solid waste are dried, crushed and ground respectively to remove moisture and impurities from the raw materials and refine the particle size of the materials; b. Weigh each raw material component after grinding according to the predetermined ratio, put them into the mixing equipment and mix them thoroughly to ensure that each component is evenly distributed to ensure the smooth triggering of the chain polymerization reaction; c. Depending on the application requirements, the homogenized mixture can be granulated to obtain a molded body of a predetermined shape; d. The mixed and homogenized material or the molded body obtained in step c is subjected to low-temperature drying treatment to remove residual moisture and obtain the finished non-hydrocarbon fuel.

6. The method according to claim 5, characterized in that, In step a, the particle size of the material after grinding is ≤0.2mm; in step d, the temperature of low-temperature drying is 150-300℃, and the moisture content of the material after drying is ≤5%.

7. The application of non-hydrocarbon fuels as described in any one of claims 1-4 in industrial heating, characterized in that, The non-hydrocarbon fuel is placed in a reaction device, and its temperature is excited to above 700°C by an external heat source, triggering a chain polymerization solid-phase chemical reaction, and industrial heating is achieved by utilizing the heat energy continuously released by the fuel itself.

8. The application of non-hydrocarbon fuels in industrial heating according to claim 7, characterized in that, The application scenarios include using it as auxiliary or alternative fuel for industrial kilns, as a supplementary combustion energy source for solid waste incineration, or in combination with other low-calorific-value fuels to improve heating stability.

9. The application of non-hydrocarbon fuels in industrial heating according to claim 7, characterized in that, The reaction device is a rotary kiln, a vertical reactor, or a high-temperature boiler, and the device has the functions of high temperature resistance and heat recovery.

10. An industrial heating system, characterized in that, The device includes a supply device and a combustion reaction device for using non-carbon high-energy fuel as the main or auxiliary fuel as described in any one of claims 1-4.