A device for producing electric current from vibrations

Abstract

Embodiments of the present invention provide a device for torrefaction of a raw material, such as a biomass. The device includes a rotating cylinder with a number of baffles and stiffener to rotate and stir the raw material, performing torrefaction in partially oxidative atmosphere. The torrefaction process takes part inside the long multiple reactors of a rotary drum, that the timing of the material to be fed is not particularly dependent on the timing or instances of outputting of torrefied material, because some of the reactors maytorrefy the material (e.g., 6 out of 8), while some of the last reactors may cool down the torrefied material (e.g., 2 out of 8), ensuring continuous process.

Description

Agent ’s File Reference No. CIP -074681 -24A DEVICE FOR PRODUCING ELECTRIC CURRENT FROM VIBRATIONSFIELD OF INVENTION

[0001] The present invention is generally related to thermochemical processes. More particularly, the present invention relates to designs and methods for torrefaction processes.BACKGROUND OF INVENTION

[0002] Torrefaction is a thermo-chemical treatment process of biomass, which may typically be executed at 200-350 °C, in the absence of oxygen or with a very low level of oxygen, at atmospheric pressure with low particle heating rates. The torrefaction process causes a biomass to partly decompose, creating torrefied biomass or char, also referred to as 'bio-coal'.

[0003] Torrefied biomass is the most elegant solution to convert raw biomass into a coallike material. The process may involve the heating of biomass with limited oxygen to a temperature of typically 200 to 300°C. Torrefaction generally enhances the fuel properties. The resultant product has better fuel characteristics than the original biomass.

[0004] Considerable research has been done on torrefaction of biomass to make it more energy dense, to reduce moisture thereby enhance hydrophobicity, improve flow, transportability and storage. The raw biomass has the above concerns, plus, high oxygen content, rigidity, mechanical strength issue, poor flow and fluidization properties, feeding difficulties, hydrophilic tendencies, soot formation, deterioration, lower energy yield and severe handling, transport costs and storage issues which are adequately addressed through torrefaction.

[0005] In the Indian context, commercially established and proven cost-effective technology has been till now not achieved. Internationally, a handful of companies have developed torrefaction technologies on pilot scale and select few on commercial scale projects using multiple design technologies with mixed results. One aspect which is common is the high and at times prohibitive cost of adopting the same especially in the Indian context.

[0006] To put the ramifications of what has been developed under the Make in India prerogative is a decentralized modular rotary torrefaction system with proven results at a fraction of the cost of such systems worldwide.Agent ’s File Reference No. CIP -074681 -24

[0007] The global scenario is that biomass is the fourth largest available fuel resource and accounts for 18% of the greenhouse emissions due to burning of bio mass in raw state.

[0008] Indian scenario is perfectly amenable to biomass renewable energy availability of 600 million tons annually coupled with other forest and industrial waste convertible as per my patented technologies of about 400 million tons.

[0009] Crop burning especially rice straw is the biggest challenge with 140 million tons of straw being generated annually. The 10% co-firing of torrefied rice straw can convert the entire thermal plants to this renewable energy source and bring down coal consumption accordingly. The other crop residues if added to this chain a significant portion of coal can be converted into co-fired torrefied biomass. Use of torrefied biomass in co-firing in higher proportions than 10% is easily possible and without changes to the existing coal handling systems. 20% mix already achieved by the Indian Government Organization “NTPC”.

[0010] As per the revised policy of Ministry of Power on biomass utilization for power generation through co- firing in coal based in thermal power plants, it is mandatory for them to mix torrefied biomass in the percentage of 5, 7 and 10 in the first, second and third year respectively which translates to approximately, 35, 50 and 70 million tonnes of torrefied biomass being used. Thus, the torrefaction technology serves as an immensely useful tool and no parallel economic solution compensates for the same.

[0011] Multiple objectives of money to the farmer, the environment protection and having economic high energy fuel at low cost to replace fossil fuels.

[0012] Some very complex torrefaction technologies have been tried all over the world. For the long-term sustainability, there are established criteria, majority of which need to be satisfactorily addressed for technical, operational and economic feasibility.

[0013] Non-torrefied material suffers from inherent limitations; hence co-firing torrefied biomass is predominantly preferred.

[0014] Below listed problems have been major issue in torrefaction of the biomass:1. Grind ability is a major issue, as HGI is well before desired level. It is usually 20- 30.2. Intent to pass through 3 mm mesh, the entire material becomes a challenge as well, especially as pellet size mentioned is up to 25mm. Unless finely ground in the first place this is a near impossibility.Agent ’s File Reference No. CIP -074681 -243. General perception is that only 5 percent is being added but overall tonnage is so high that this 5 percent becomes a major figure.4. The ash limitation has been prescribed earlier at 20 percent primarily to accommodate rice straw and now this is done away with. A very difficult operational situation is thus precipitated. Clinker formation can be severe. This problem is further accentuated by allowing using of many other additional materials to the extent of 25 percent including press mud, etc.5. This combined with no ash limitation, the usability of the product becomes counterproductive. The oxygen as well as heat intake becomes imperfect, accentuating the grind ability uniformly as well as complete combustion, particle size reduction and so on.6. The temperature profile for ignition is further compromised and lowered and the required temperature profile with co-firing of coal is affected to the detriment of the entire heat balance. Becomes a severe bane to be able to use biomass thus made.7. Co-firing particle size post the grinding along with coal just is not possible and the cost of grinding is high and unproductive as well.8. The pressure required for co-firing is also mitigated and velocity of the joint material, there is a mismatch between biomass thus made and used and coal.9. The moisture of the biomass has to be low for several reasons of heat balance, grind ability, more uniform particle size with significant degree of brittleness. With the moisture levels allowed at times 14-15 percent, this does not allow effective use and makes the use of pellets a fate accompli with failure written on it.10. World over torrefaction or roasting of the biomass is the norm. Google direct and first interpretation of torrefaction as we type it out is “bio-coal”. But we are not making bio-coal, as the inherent properties thus achieved are nowhere translated in the specifications which have been developed and enumerated. This massive anomaly and contradiction of the basic tenets of what is torrefied material and its advantages gets negated ab initio.

[0015] Now comes the pelleting Vs biomass conversion and direct use in non -pelletizedAgent ’s File Reference No. CIP -074681 -24 form. For thermal applications, 700 million of coal being used. Just 5 percent of that is 35 million tons of biomass use going over 50 million tons is 2 years.

[0016] Typically, 1 ton of pellets consumes about 100 Kw of energy in making and then we are against pulverizing the same before use. So, in effect a huge quantum of power being used to produce power in a cleaner manner. This is being defeated at the outset itself.

[0017] It is pertinent to note that densification has its advantages but in thermal plants the densified material is again pulverized before use.

[0018] To torrefy 1 ton of biomass, the equivalent energy consumed is about 5 Kw or l / 20th of pelleting.

[0028] Thus, serious thought and impetus needs to be given to enabling use of torrefied biomass for direct firing at a point amenable for effective use.

[0019] The selection of agro-residues also is a key factor for maximizing the yield post torrefaction. The composition of the biomass becomes a crucial element as torrefaction essentially is reducing the moisture and removing the low volatiles. Unlike coal which has a linear mass to weight profile biomass is totally different with the elements comprising the biomass having different mass to energy capability. That is why for what is lost in terms of weight much more is gained in terms of energy density.OBJECTIVE OF THE INVENTION

[0020] It is an objective of the present invention to design a torrefaction device that generates low cost of conversion, thereby providing an efficient and cost-effective device.

[0021] It is an objective of the present invention to design a torrefaction device that is not only environmentally friendly but cost effective as well.

[0022] It is an objective of the present invention to design a torrefaction device that avoids use of fossil fuels to produce heat for the thermal process in the torrefaction ensuring oxidative torrefaction.

[0023] It is an objective of the present invention to design a torrefaction device that is simple and convenient for further ensuring ease of flow of material.

[0024] It is further an objective of the present invention to design a torrefaction device that allows for maximum feed at any given time and thus allows for maximum output, hence increasing the operational efficiency of the device.

[0025] Further, it is also an objective of the present invention to design a torrefaction deviceAgent ’s File Reference No. CIP -074681 -24 that reduces moisture content in the fuel production, and aims to reduce the moisture to between 2% or 3% and impactfully decompose the low energy hemi-cellulose without disturbing significantly the composition of the cellulose and high energy dense lignin.

[0026] Furthermore, it is also an objective of the present invention to design a torref action device that reuses its by-products (e.g., gases, other fluids used in the device) for reducing waste products and increasing efficiency. For example, the design of the torrefaction aims to re-use the heat used to heat the biomass, water used to cool the end product, flue gases (excessive moisture or evaporated steam), etc. back into the device.

[0027] It is also an objective of the present invention to produce torrefied biomass that has sufficiently high heating value, higher yield, low residence time, low moisture content, high moisture resistance as well as a high transport and energy density in order to be a suitable clean coal substitute.

[0028] It is an objective of the present invention for being capable of running continuously on 24h / 7d basis without releasing volatile organic compound (VOC) as emissions.

[0029] It is also an objective of the present invention to design an easy-to-operate process controls that requires only a small crew of operators and minimum maintenance.

[0030] It is also an objective of the present invention to produce torrefied biomass, using pyrolysis residence times that are short enough to ensure adequate throughput and high yield.

[0031] An objective of the present invention is to be able to accept feedstock that is of standard industry sizes that do not need special pre-treatment such as pulverization or excess drying.

[0032] Another objective of the present invention is to employ automated process controls in order to maintain temperatures within ranges that will foster complete mild pyrolysis of the woody biomass.

[0033] Yet another objective of the present invention is to employ process controls that can adjust easily to various mixtures of woody biomass feeds without adversely impacting production efficiency or quality of the torrefied biomass produced.

[0034] It is an objective of the present invention to produce torrefied biomass that is uniform and that can also be pelletized or reformed into briquettes.

[0035] It is an objective of the present invention to facilitate a scale-up to higher capacity levels at a later date. In other words, the cost of a torrefaction plants with the capacity ofAgent ’s File Reference No. CIP -074681 -24 producing 10,000 metric tons per year of torrefied biomass should not double if a later scale- up to 20,000 metric tons per year is undertaken.

[0036] It is an objective of the present invention to be versatile to convert raw biomass into torrefied biomass and alternatively convert biomass pellets into torrefied pellets.

[0037] It is another objective of the invention to pre-cool the material which is torrefied within the reactor prior to exit. Additional cooling is subsequent to exit in-line.

[0038] It is another objective of the present invention to urgently cool the outputted torrefied material for safety from embers igniting themselves as well as prevent or at least restrict further torrefaction once the torrefied material is outside the reactor (yet slowly decomposing and destroying yield). For urgently cooling, one way can include an output water jacketed conveyer which transports the torrefied material into a ribbon mixer / blender wherein the material is churned clockwise & anti-clockwise. During this phase, water is sprinkled inside. The churned material then goes to a belt conveyer having a canopy and again sprinkling water / air for cooling and transporting material to finished goods silo.

[0039] It is another objective of the invention to provide versatility of use as well as multiple products manufacture with same device but different separating parameters.

[0040] It is another objective of the invention to clean the flue gases prior to recycling in the furnaces etc. A wet scrubber system is in place to capture the particulates and then recycle the gases to aid torrefaction at no cost.

[0041] It is another objective of the present invention to remove the infirmities of the raw biomass and enable the Effective Oxidative Torrefaction, which is a combination of at least the following variables:1. Particle size2. Input moisture3. Composition of the biomass especially the hemi-cellulose4. At what point to stop and not overdo torrefaction?5. The temperature profile of the biomass6. The residence time versus the temperature profile.7. The yield curve based on what biomass given the choice to prefer for optimization.8. The understanding of pelleting and its implications for effective torrefaction.9. Selection of inputs which have inherently higher levels of energy release.Agent ’s File Reference No. CIP -074681 -2410. Mass to energy curves of the components of the biomass to maximize the advantage.11. To channelize the flue gases to achieve maximum waste heat utilization at multiple points and reduce the already reduced cost of torrefaction.

[0042] Key elements or overriding advantages of torrefaction stand at the outset itself defeated as the norms not defined of moisture below 5 percent, grid ability with less than 1 / 8 of the power for raw biomass, ability to co- fire higher percentages, particle size reduction with the enabled torrefied material of well over HGI index of 50, the H / C and O / C ratios conducive for combustion with higher carbon and lesser oxygen, the higher ignition temperature possible with torrefied material due to these more apt ratios all get defeated.

[0043] Torrefied biomass allows for use significantly more effectively as:- HGI above 50- Grind-ability at about 15 percent or normal power

[0052] - O / C ratio more suitable as oxygen significantly reduced- ignition temperature gets elevated from 180-degree C to between 220-280- degree C depending on the material-moisture well below 5 percent allowing better heat efficacy and pneumatic movement of material as with pulverized coal and ability to achieve near desired pressure levels more suitably.In short becoming more coal like.

[0044] Further, as mentioned above, to torrefy 1 ton of biomass, the equivalent energy consumed is about 5 Kw or l / 20th of pelleting. In firing the torrefyer, again predominantly biomass is used. Thus, under a closed loop arrangement, as adapted by the present invention, the flue gases are recycled and essentially fire the torrefyer heat requirement.

[0045] The present invention enables the use of torrefied biomass for direct firing at a point amenable for effective use. Where pelleting has to be done, the model has to pelletize and then torrefy for maximum results and even torrefaction.

[0046] To further clarify advantages and features of the present invention, a more elaborate description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope.Agent ’s File Reference No. CIP -074681 -24SUMMARY OF THE INVENTION

[0047] Accordingly, the present invention provides for a torrefaction device for torrefying a biomass fuel, comprising: at least one oxidative indirect-fired twin drum torrefy er reactor 100 including: at least one inner rotary drum 102 which rotates and receives preheated raw material for being torrefied; and at least one outer stationary drum 104 surrounding the inner rotary drum 102 and maintaining an annular space between the at least one inner rotary drum 102 and the at least one outer stationary drum 104, and configured in that the at least one inner rotary drum 102 having a length within the range of 18 meters - 36 meters, and is divided into multiple sections; configured in that the inner diameter of the at least one inner rotary drum 102 is within the range of 1 meter - 1.8 meter; wherein, for torrefying the raw material, the at least one inner rotary drum 102 receives the pre-heated raw material, rotates and breaks the raw material down as it passes through the at least one inner rotary drum 102, and the raw material is indirectly heated, under partial oxidative torrefaction, from the heat produced from hot fluids or flue gases, travelling into the annular space; and wherein torrefying the raw material is executed in at least some of the first sections from among the multiple sections of the at least one inner rotary drum 102, while simultaneously, cooling down the hot torrefied material is executed in at least rest of the sections from among the multiple sections of the at least one inner rotary drum 102, ensuring a continuous torrefaction process inside the at least one oxidative indirect-fired twin drum torrefy er reactor 100, and wherein, owing to the length and diameter of the at least one inner rotary drum 102 and that at least some of the sections perform torrefaction while rest of the sections, simultaneously, perform cooling of the torrefied material, feeding time for the raw material into the at least one inner rotary drum 102 is independent of outputting time of the torrefied material from the at least one inner rotary drum 102.Agent ’s File Reference No. CIP -074681 -24

[0048] In another embodiment of the invention, the torrefaction device for torrefying a biomass fuel, comprising: at least one oxidative indirect-fired twin drum torrefyer reactor 100 including: at least one inner rotary drum 102 which rotates and receives preheated raw material for being torrefied; and at least one outer stationary drum 104 surrounding the inner rotary drum 102 and maintaining an annular space between the at least one inner rotary drum 102 and the at least one outer stationary drum 104, configured in that the at least one inner rotary drum 102 having a length within the range of 18 meters - 36 meters, and is divided into multiple sections; and configured in that the inner diameter of the at least one inner rotary drum 102 is within the range of 1 meter - 1.8 meter; a two-stage fluidized bed furnaces 118 running on biomass for effectively providing heat over a length of the at least one inner rotary drum 102; and a multifaceted cooling system to cool down the hot torrefied material using cooling fluid and / or water individually or in combination, the multifaceted cooling system includes at least a cooling system of sprinklers installed inside the at least one inner rotary drum 102 or the at least one outer stationary drum 104, individually or in combination, towards end of the torrefaction device for cooling the hot torrefied material before exiting the torrefaction device; and wherein, for torrefying the raw material, the at least one inner rotary drum 102 receives the pre-heated raw material, rotates and breaks the raw material down as it passes through the at least one inner rotary drum 102, and the raw material is indirectly heated, under partial oxidative torrefaction, from the heat produced from hot fluids or flue gases travelling into the annular space; and wherein torrefying the raw material is executed in at least some of the first sections from among the multiple sections of the at least one inner rotary drum 102, using the two-stage fluidized bed furnaces 118, while simultaneously, cooling down the hot torrefied material is executed in at least rest of the sections from among the multiple sections, using the multifaceted cooling system,Agent ’s File Reference No. CIP -074681 -24 ensuring a continuous torrefaction process inside the at least one oxidative indirect-fired twin drum torrefy er reactor 100, and wherein, owing to the length and diameter of the at least one inner rotary drum 102 and that at least some of the sections perform torrefaction while rest of the sections, simultaneously, perform cooling of the torrefied material, feeding time for the raw material into the at least one inner rotary drum 102 is independent of outputting time of the torrefied material from the at least one inner rotary drum 102.BRIEF DESCRIPTION OF DRAWINGS

[0049] 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:FIG. 1 and 5 illustrate an exemplary diagram of a perspective view showing a torrefaction device, where the FIG. 1 shows a single torrefaction device 100, while FIG. 5 shows a double torrefaction device 500 working on the same principles and same constructions, difference only being in the length of the devices and the number of reactors / chambers, according to an embodiment of the present invention;FIG. 2 illustrates an exemplary diagram of a side view showing a torrefaction device, according to an embodiment of the present invention;FIG. 3A and 3B illustrate an exemplary diagram of an internal of the torrefaction device, showing baffles and stiffeners of a rotary drum, according to an embodiment of the present invention; andFIG. 4 illustrates an exemplary diagram showing multiple sections or shells of the torrefaction device, according to an embodiment of the present invention.FIG.6 illustrates an exemplary diagram showing a bottom cover of an outer shell with a cut at the bottom for bed furnace installation, according to an embodiment of the present invention; FIG.7 illustrates an exemplary diagram showing a partial component that works both as top component and bottom component of the outer shell other than bed furnace area, according to an embodiment of the present invention;Agent ’s File Reference No. CIP -074681 -24FIG.8 illustrates an exemplary diagram showing an exit end outlet cover for discharge of the terrified material to an attached output conveyer, according to an embodiment of the present invention;FIG.9 illustrates an exemplary diagram showing a gear design on which the rotary drum / reactor will rotate, according to an embodiment of the present invention. In the twin chamber reactor the single gear will rotate the chamber shells in sync.FIG.10 illustrates an exemplary diagram showing an entry point front reactor cover to enable closing of the entry point where feed is through a screw conveyer, according to an embodiment of the present invention;

[0069] FIGs. 11-13 illustrate an exemplary diagram showing a base frame of the torrefaction device with an area column & a base column design respectively for support to the torrefaction device and ease of installation with screw and anchor bolting, according to an embodiment of the present invention;FIG.14 illustrates an exemplary process layout showing the complete process layout of the torrefying system, according to an embodiment of the present invention;FIG.15 illustrates an exemplary diagram showing the installation drawing of the torrefying system, according to an embodiment of the present invention.The furnaces are strategically placed below the first reactor and as well in the second reactor. The fuel is biomass fed with an automatic screw feeder with independent electronic panel for auto on / off of the feed as per temperature required.DETAILED DESCRIPTION OF INVENTION

[0050] This patent describes the subject matter for patenting with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. The principles described herein may be embodied in many different forms.

[0051] Illustrative embodiments of the invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0052] The present invention provides a torrefaction device for torrefying a biomass fuel.Agent ’s File Reference No. CIP -074681 -24The torrefaction device is an oxidative indirect-fired rotary torrefyer, that is designed to produce torrefied fuel from locally available waste raw material such as Agri residues (Groundnut, rice husk, peanut, cotton stalk etc.), industrial waste such as Dolochar, and even forest residues and invasive species such as Juliflora, Lantana etc.

[0053] The current torrefaction device performs torrefaction in partially oxidative atmosphere, which is a non- traditional approach to the thermal pre-treatment of biomass. The partially oxidative or oxygen-lean conditions enable energy and cost saving compared to inert operating process. The benefits arising from this compared to traditional torrefaction undertaken under costly inert atmospheres show that solid biofuel torrefied under partially oxidative atmospheres has superior chemical functionality (e.g., less oxygenates and higher thermal stability), but comparable physical properties to inert atmospheres. In addition, improved thermodynamic features and lower combustion activation energy for partially oxidative torrefied biomass was also observed. Overall, the results suggest that the use of partially oxidative atmospheres for torrefaction not only produce a high-quality solid biofuel but can also improve process efficiency by using waste heat and flue gases from other combustion processes to thermally pre-treat biomass.

[0054] The current torrefaction device performs a continuous operation, where material feed is not particularly dependent on timing or instances of outputting of torrefied material, owing to the length and diameter of the torrefaction device. The torrefaction device can be as long as 12 meters in length, and as long as 24 meters in length too. The torrefaction process takes part inside the long multiple section reactors of a rotary drum, that the timing of the material to be fed is not particularly dependent on the timing or instances of outputting of torrefied material, because some of the reactors may torrefy the material (e.g., 6 out of 8), while some of the last reactors may cool down the torrefied material (e.g., 2 out of 8), ensuring continuous process. The continuous operation of the torrefaction device is also explained in details below.

[0055] In the 24 meter device there are eight sections of 3 meters each. The first six sections there is heat and flue gas recycling while the last 2 sections totalling 6 meters are for cooling the material prior to exit. Thus, 6+2 chamber design is considered most apt and effective for quantity output and yield.

[0056] In addition to the above-mentioned variables and features of an effective partiallyAgent ’s File Reference No. CIP -074681 -24 oxidative torrefaction in paragraph 47, following may also be the process features:1- During torrefaction, there are distinct stages through which a raw material goes through, for example, de-hydrogenation, de -polymerization, de-volatilization which reflect on the oxidative reactions.2- During torrefaction in the current torrefaction device, the intent remains to enable endothermic reactions to absorb heat and minimize exothermic release of heat to maximize yield and minimize char forming reactions. This further enables positive heat absorptions and carrier gas formations of the recycled combustion flue gases.3- The reaction rates are faster in oxidative torrefaction, enabling reactor residence time and faster rate of decomposition with higher concentration of CO release at lower temperature.4- There are primary and secondary torrefaction reactions, where by whereby the primary reactions take care of the free volatiles and almost complete dehydrogenation of the raw material. The secondary reactions build up through the reaction of Co2 and the water vapour with the solid residue, as the temperature increases, as the Co2 / CO ratio decreases with increased residence time. Combining with the hydrogen, it aids the overall torrefaction process.

[0057] The torrefaction device may be fed with an appropriate raw material, for example, the raw material may include and is not limited to a biomass or biomass pellets or agricultural waste or forest waste, such as like poplar, eucalyptus, saw dust, grass, hay, sugarcane trash leaves and tops, paddy straw, Dried cashew nut shells, Groundnut shells, Maize stalk and cobs, Wheat straw, Rice straw, Soya stalk and husk, Cotton stalk, Jute sticks, Mustard stalk, Almond shell, Wood shavings, Wood chips and the like, including even Municipal Solid Waste

[0058] (MSW). Based on different geographical locations, the locally available agro-residue may be readily converted into torrefied biomass / torrefied pellets in the present torrefaction device. It may be appreciated by the person ordinarily skilled in the art that the torrefaction device may torrefy any type of biomass, or biological waste for producing a torrefied fuel, without departing from the meaning and scope of the present invention.

[0059] Depending on the design of the torrefaction device, the conveying of the raw material to the torrefaction device can be via a belt or a screw conveyor or a bucket elevator controlledAgent ’s File Reference No. CIP -074681 -24 through a variable frequency device. {VFD}

[0060] In an embodiment, the torrefaction device may be installed with wheels or may be attached to an automobile for providing mobility to the torrefaction device for on field torrefaction or mounted on a trailer.

[0085] Referring to FIGs. 1-4, a torrefaction device 100 is a machine where raw material is subjected to partially oxidative environment, in which the raw material conduction heated to remove moisture and some of the low volatiles. According to an embodiment, of the present invention, the torrefaction device 100 may include at least one twin drum torrefyer reactor that has at least one inner rotary drum and an outer stationary drum surrounding the inner rotary drum. Referring to FIG. 5, which illustrates another embodiment of the present invention, shows a double torrefaction device that has at least two twin drum torrefyer reactors which may be interconnected with flanges to double the length of the torrefaction device. The double torrefaction device includes two inner interconnected rotary drums, running in sync with each other, where each of which is surrounded by an outer stationary drum. Both the single and double torrefaction devices (100 and 500) work on the same principles and same constructions, difference only being in the length of the devices and the number of reactors / chambers. Fig. 14 shows the process layout, while Fig. 15 shows an exemplary layout of installing the devices 100 / 500 at a site, both figures corresponding to Figs. 1 and 5 and include at least some or all of the description of Figs. 1-13, as described below.

[0061] The torrefaction device 100 also includes at least one or more of the following components:1. Furnace2. Raw Material3. Feeding Conveyor4. Inlet5. Feeding Cover6. Roller Ring7. Carrier Roller8. Drum9. Transmission10. Gear RingAgent ’s File Reference No. CIP -074681 -2413. Discharge Cover14. Dust Collector with wet scrubber system & recycling of gases15. Chimney16. Induced Draft Fan17. Motor18. Outlet19. Discharging Conveyor20. Past production conveying & further cooling & mixer to control inadvertent ignition.20. Feed belt with 3 HP motor to convey the raw material to Torrefyer at desired speed based on the VFD controls in a control panel. In case the rotation of an inner drum stops, the feeding will automatically stop for safety.21. Output jacketed water-cooled conveyor for transporting and simultaneously cooling the torrefied biomass into the storage silo / receptacle with 3hp motor.23. Electrical panel24. Mini cooling tank cum tower with water pump with 2 HP motor.25. Suction blower for cleaning of the torrefyer at regular intervals.26. Laser guns for periodically checking the temperature inside a chamber.27. Chimney- for natural draught, the chimney of appropriate height (e.g., 30m) is included in the system.

[0062] A raw material in appropriate amount is fed to the torref action device 100, where the raw material is heated using conduction heating to remove moisture and some of the low volatiles. The torrefaction device 100 may have twin drums or cylinders: one rotating drum or cylinder 102 and a stationary drum or cylinder 104 surrounding the rotary drum 102. The rotary drum 102 is fed with the raw material that needs to be torrefied.

[0063] In an embodiment, the rotary drum 102, which is made of 6mm-thick SS plate, has a diameter of 1.2 m and a length of 12 meters long or about 40 feet, rotating at a variable speed. Under a twin reactor model the total length is about 80 feet of the twin system. A driving motor assembly including a driving motor rotates the rotary drum 102 and, in an embodiment, the drive with 10- HP gear motor (1 : 14) is used to rotate the rotary drum 102.

[0064] In an embodiment, the rotary drum 102 is inclined at an angle of inclination to allow slow movement of the raw material from an inlet to an outlet end of the rotary drumAgent ’s File Reference No. CIP -074681 -24102. The angle of inclination is 2 degrees, according to an embodiment. Also, the rotary drum 102 may also have roller tracks on its outer surface that helps in rotation of the rotary drum 102.

[0065] The feeding system of the torrefaction devices plays an important role in the current invention. The feeding system may incorporate a multiple point feeding pre- torrefaction. According to an embodiment, as shown in FIG. 1, the feeding system may include at least one pre -bin hopper 106 where the material to be fed in the inner rotary drum 102 is stored. This may be a jacketed pre -bin hopper 106 which circulates heat to preheat the stored raw material. Furthermore, this heat may also be transferred to a jacketing chamber of the torrefaction device (which is explained below), which can also recycle the waste flue gases as well, if required.

[0066] The torrefaction process to be uniform requires a regulated continuous feed, once the operating temperature of the inner chamber of the rotary drum 102 is reached. From the pre-heated pre -bin hopper 106, the preheated raw material is connected to a conveyer 108, with feed control and having intermediate hopper 110, prior to a main screw connected to the input point of the inner chamber of the rotary drum 102. This is to ensure and enable the torrefy er device 100 to run and have requisite feed as necessary.

[0067] In an embodiment, the conveyer 108 is screw feeder conveyer.

[0068] In an embodiment, the conveyer 108 may also be jacketed and in the outer jacket of the conveyer 108, a low temperature heat is circulating (again waste heat recycled). In effect by the time the material goes into the inner chamber of the rotary drum 102, it is pre-heated, thereby enhancing the overall efficiency of the device 100.

[0069] The screw outlet has been so elongated that the material enters the reactor at certain point beyond the edge of the inlet point and at an angle subservient to proper drop and circulation inside.

[0070] The present invention implements a three-stage channelizing of heat that integrates the process and minimizes the stack release of the gases. The uniqueness of the device 100 enables the torrefaction to take place with frugal energy in terms of electricity as also the fuel for firing the device 100 to generate the required temperature.

[0071] For implementing the three-stage channelizing of heat, the design of the device 100 incorporates the pre -bin hopper 106 wherein the waste heat is sent into a mixer-blender andAgent ’s File Reference No. CIP -074681 -24 while the blending of the raw material is taking place with the waste heat, the raw material is being semi-dried. The next stage is the transfer of the raw material into the torrefyer device 100 which is again via the jacketed feeding conveyer 108. The feeding conveyer 108 feeds the raw material into the torrefaction device 100. In an embodiment, the feeding conveyer 108 can be a jacketed screw conveyor, a belt, or a bucket elevator, individually or in combination.

[0072] After getting semi-dried in the first stage in the mixer blender, the waste heat is fed into the outer or jacketed chamber of the feeding conveyer 108 to further reduce the moisture profile prior to feeding into the torrefaction device 100. The third stage of pre-heating takes place wherein the balance waste heat that is remaining after first and second stages is fed into the biomass furnace which is firing the heat into a reactor outer chamber of the torrefaction device 100. Thus, with this three -pronged or three-stage moisture reduction prior to firing into the torrefaction device 100 using the waste heat, the biomass consumption into the furnace, post the initial firing and reaching the temperature profile, becomes the fraction of the initial feed into the furnace. This highly efficient three-stage moisture reduction is the essence of frugal energy use in the invention.

[0073] Heat is then transferred to the raw material by conduction heating in the rotating cylinder 302 where moisture and some volatile matters are removed.

[0074] In an embodiment, the heat source may include and is not limited to gas, diesel, coal, Wood, etc. In an embodiment, the present invention may use wood along with the process waste heat for environmental and lower cost consideration, and further to ensure closed operation of the furnaces.

[0075] Inside the rotary drum 102, there are number of straight baffles 112, with a stiffener 114 (also 116) for each baffle 112, which lifts and stirs the raw material while passing from one end to the other end of the rotary drum 102. The baffles 112 are so positioned at different levels and tapered over the length of the rotary drum 102 to enable the free circulation of the raw material and movement from one end to the other. In an embodiment, the rotary drum 102 has around 260 pcs of 10 cm wide baffles 112, with 1-cm stiffener 114. In an embodiment, the stiffener 114 is positioned between the baffles 112 in a first section or shell (e.g., 402 in FIG. 4) of the rotary drum 102, whereas the stiffener 116 is positioned between the baffles 112 in the next second section or shell (e.g., 404 in FIG. 4) ofAgent ’s File Reference No. CIP -074681 -24 the rotary drum 102, being rotated at 45 degrees.

[0076] Different levels and sizes and tapering of the baffles 112 and stiffener 114 (also 116), based on positioning, to allow material to smoothly drop, are possible. One single inner rotary drum 102 is 12 meters long or about 40 feet, preferably. With the double torrefaction device 500, this length gets doubled. In an embodiment, the inner diameter of the inner rotary drum 102 is 1.2 meter, thereby maintaining a diameter to length ratio of 1 : 10 per rotary drum 102. With this design, the torrefaction process can be controlled effectively by varying the torrefaction temperature, rotational velocity, length and angle of the rotary drum 102. The rotary drum 102 rotation causes particles in its bed / cavity to mix properly and exchange heat, however the friction on its wall also increases the fine fraction.

[0077] The rotary drum 102 is heated by a hot flue gas from a biomass furnace (explained later). Flue gas enters and travels through an annular space between the rotary drum 102 and the stationary cylinder 104 and exits through a chimney 124 located at the end section of the rotary drum 102. As the flue gases are at a usable temperature, the heat is recycled at multiple points, as a part of this technology used in the present invention, for efficient use of the waste heat. Flue gases travelling through the annular space between the rotary drum 102 and the stationary cylinder 104 indirectly heats the raw material conveyed inside the rotary drum 102 under oxidative torrefaction.

[0078] The inner or the rotary drum 102 has been made of stainless steel for improved transfer of heat from the stationary cylinder 104 body to the rotary drum’s 102 outer surface. The ability to withstand higher temperature is also elevated with this along with durability and life of the torrefaction device 100 and restricting thermal expansion.

[0079] Referring to FIG. 4-5, each torrefaction device with one rotary drum 102 has at least four chambers or four shells (402-408). This means the double torrefaction device 500 will have at least eight chambers. Preferably, in the single torrefaction device 100, each chamber (402-408) is 3 meters long, making the entire device 12 meters long. In an embodiment, the torrefying area in the single torrefaction device 100 is around 6 meters that extends from the first chamber 402 till the second chamber 404. With each chamber as 3 meters long, the double torrefaction device 500 becomes 24 meters long, which has the capacity of 3 times the single torrefaction device 100. Instead of one reactor with 4 sections two for torrefaction heat and two for cooling, the twin system has 8 sections with 6Agent ’s File Reference No. CIP -074681 -24 continuous heat sections and last 2 sections for cooling

[0080] In both the single and double torrefaction devices (100 and 500), as the moisture has already been negated in the first torrefaction reaction, virtually pure flue gas stream devoid of moisture takes place to remove the volatiles without charring or excessive loss of yield or increase in temperature profile, energy, ash enhancement which is witnessed and prevalent in carbonization. In the second torrefaction reaction, the reactions become significantly agnostic to yield depletion. With the double torrefaction device 500, there is an option of doubling the capacity of the torrefaction system, resulting in economies of scale and higher quantitative and quantitatively output. In the double torrefaction device 500, two reactors including the rotary drum 102 and the outer drum 104 are interconnected with flanges to another reactor, including another rotary drum and the outer drum, to double the length of the torrefaction device. This double torrefaction device 500, thus, includes the two inner and outer drums joined. In a rotary system, the contact of the material in the inner drum 102 is with its body. The diameter of the inner drum 102 plays a key role in torrefaction qualitative control. The diameter is thus kept such as to near optimize its operating parameters and not too excessive. The length, however, can be prolonged over a longer stretch to maximize the output and consequent effective yield while allowing versatility in different products manufacture and with diverse applications.

[0081] Now for providing heat to the rotary drum reactor 102, it is fired with biomass-based bed furnace 118 with additional option of pellet burner, if required. In case flue gases are available at the existing facility, 150-170 degree Celsius could be channelized for saving on the biomass operations. Further, the flue gases from the torrefaction device 100 can also be redirected into the torrefaction device 100 depending on their moisture level.

[0082] The heating of the rotary drum reactor 102 and other parts of the torrefaction device 100 is preferably with biomass, as an intent to have renewable energy fueling this system. To effectively provide heat over the length of the rotary drum reactor 102, a two- stage fluidized bed furnace 118 running on biomass is considered. Further, at least inside the second chamber of the device 100 (e.g., 404, 504), a wall is designed, below the furnace gate of the second hot air chamber, to block the ash and let it drop in the second chamber below for easy removal. This constitutes as the ash collection system. This prevents the fly ash so generated from blowing out of the exhaust system. Since the torrefaction device 100 or 500Agent ’s File Reference No. CIP -074681 -24 already use dry torrefied fuel, this ash collection system may doubly ensure that emissions, if any, are minimized.

[0083] The positioning of the bed furnacel l8 is most important as it should not be at the start of the inlet so as to dissipate the effect where torrefaction has to take place over the length nor too much after the material is once adequately torrefied, so as to affect the need for cooling of the material after being torrefied. The two-stage bed furnace 118 allows for more efficient heating in which a first / primary furnace runs on fuel while the secondary furnace more so on the process flue gases recycled into the secondary furnace.The two-stage bed furnaces 118 are connected at an attachment 120, whereby a spreading device with a blower is attached on top of the furnace 118 gate to dissipate the heat for feeding the biomass. Additionally, the automated temperature controlled independent screw feeder to the bed furnace 118 of the rotary drum 102 also dissipates the heat into the inside of the chambers of the rotary drum 102, with the blower situated at the point of entry into the bed furnace 118. The spreading device with the blower is also strategically positioned at the top of the bed furnace 118, so as not to disturb the furnace or heat produced Auto on / off system in placed to maintain temperature while optimizing and economizing on the use of fuel.

[0084] With the material being used as fuel being the smaller waste of the material being torrefied, it enables faster heat level achievement, lower emissions escaping due to the moisture being virtually absent in the fuel that is fed to the torrefaction device 100 / 500. Additionally, fly ash, which is already low due to input fuel characteristics, is also captured in the second chamber 404 / 504 of the torrefaction device. A blower is additionally used to allow the heat from the first chamber 402 / 502 to transfer more effectively the same to the second chamber 404 / 504 of the torrefaction device. Since the feeding of fuel is temperature linked with auto cut-off, the efficiency in fuel usage is achieved. Also, since the flue gases are being recycled back into the chambers of torrefaction device 100 / 500, the usage of fresh fuel post the initial feed (to reach desired temperature profile for flue gas generation) is optimized as well.

[0085] Referring to single torrefaction device 100 that torrefies material in 4 sections / chambers (402- 408) of 3 meters each, the fluidized furnace 118 is placed in the second chamber 404 and flowing into the third chamber 406 with an inner blower connecting the bed furnaces 118 in the second / third chamber 404 / 406. Accordingly, in the doubleAgent ’s File Reference No. CIP -074681 -24 torrefaction device 500 with eight chambers (502-516), first six chambers are torrefying while the last 2 chambers are gradually cooling the torrefied material. This allows for higher capacity utilization and continuous operation.

[0086] FIGs. 6-13 show different components or parts of the torrefaction devices 100 / 500. For example, fig. 6 shows a bottom cover 600 of the outer stationary drum 104, with a cut 502 at the bottom for the bed furnace 118 installation. Fig. 7 shows a partial component 700 that works both as the top partial component and the bottom partial component of the outer stationary drum 104 other than the furnace 118 area, in an embodiment. Such top and bottom partial components 700 are joined to form the outer stationary drum 104 and with such multiple partial components the inner rotary drum 102 gets encased in this outer stationary drum 104.

[0087] Fig. 8 shows the exit end outlet cover 800 that covers the outlets of the torrefaction device 100 for discharge of the terrified material to a further attached output conveyer. The exit end outlet cover 800 prevents immediate contact of the volatile torrefied material with outside air.

[0088] Fig. 9 shows the gear design 900 on which the rotary drum / reactor 102 rotates. Further, fig. 10 shows the entry point front reactor (e.g., 402) cover 1000 to enable closing of the entry point where feed is fed through the feeding screw conveyer 108. Other components of the device 100 / 500 are shown in figs. 11-13 showing a base frame 1100 of the torrefaction device 100 / 500 with an area column 1200 & a base column 1300 design respectively for support to the torrefaction device 100 / 500 and ease of installation with screw and anchor bolting.

[0089] For ease of operation, optimizing efficiency of fuel, a fluidized system which can also use the torrefied material for firing can be utilized, in an embodiment.

[0090] In an embodiment, the moisture of input should be below 12% with maximum of 20%. In case higher input moisture is there then pre-drying is necessary.

[0091] Depending upon the raw material to be torrefied, the temperature ranges between 220- 270 degree Celsius, according to an embodiment. This is the most critical aspect of torrefaction which is complemented by the ability to control the residence time and the rotational velocity.

[0092] The flue gases generated in the entire process of torrefaction is successfullyAgent ’s File Reference No. CIP -074681 -24 recirculated as the process design is a closed loop. As the flue gases are at a usable temperature, the heat is recycled at multiple points as a part of this invention for efficient use of the waste heat. Once scrubbed and recycled the waste heat in next stage after use is let off into the stack as exhaust. The three-stage channelizing of heat integrates the process and minimizes the stack release of the gases. The uniqueness of the device 100 enables the torrefaction to take place with frugal energy in terms of electricity as also the fuel for firing the system to generate the required temperature.

[0093] Recycling of flue gases at multiple points after wet scrubbing and before moving to the stack, back into the furnace 118 directly, where already combustible temperature profile is in operation, and as the waste heat is fed in a closed loop back and it will immediately combust. It may be noted that as cleaner and cooled gases are being recycled, the volume of gas available for recycling will nearly double, thereby minimizing the surplus gases going to stack. At one point, the recycled exhaust gases will move directly to stack and the furnace 118 runs almost completely on fresh flue gases going directly inside. This continuous feed, post the initial firing of the furnace 118 and achieving the temperature profile, will virtually negate the need to add fresh fuel, thus becomes a frugal means of operating the torrefaction system.

[0094] Additionally, because the scrubbed gases are being recycled at multiple points, there would be little chance of tar or soot being formed. Also, as the particulate matter is being wet scrubbed and collected, the stack output will be virtually free of such matter. In entirety, this integrated set of features are key elements of the unique process control invention.

[0095] The flue gases are passed through a wet scrubbing twin chamber with cyclones system, whereby the small quantum of particulates get settled in the scrubber tray and clean filtered gas is resent to the pre-bin hopper 106, until to the screw inlet feeder of the rotary drum 102 and to the furnace 118. The particles so collected are the lighter material which can again be fed into the reactor / rotary drum 102 and wastage of output avoided. There is a system to control with valves, etc. the flow and if any surplus clean gas is let off through a 30 meters chimney above. This efficient use of waste heat is unparalleled.

[0096] In an embodiment, the torrefaction device 100 employs a parallel flow, which means the wettest raw material comes in contact with the hottest gas as they enter the torrefaction device 100. This results in a rapid evaporation and rapid cooling of the hot process gas. ThisAgent ’s File Reference No. CIP -074681 -24 typically allows the torrefyer shells / chambers (e.g., the shells 402, 404, 406, 408 in FIG. 4) to operate slightly cooler than the counter-flow configuration, which extends the life cycle and decreases maintenance of the torrefaction device 100.

[0097] At the input area, the hot surface is much higher than the raw material which leads a rapid heat exchange between the hot surface and the raw material, moisture becomes easy to evaporate. As explained above, the moisture reduction through the unique three-stage process of using waste heat enhances the ability to do this moisture reduction faster and most efficiently. This heat way is suitable for high moisture materials.

[0098] For the viscous materials, when it feeds into a torrefyer dryer, as the rapid water evaporates, the moisture goes down and helps to reduce the bonding rate, the easier-move material increases the torrefying efficiency.

[0099] The low negative pressure in the feeding place leads to low air leakage from the input, thus keeps the hot air in the torrefaction device 100 steadier with the temperature and the velocity.

[0100] In another embodiment, the torrefaction device 100 employs a counter flow, which means the wet material is introduced into the rotary drum 102 on the opposite end of which the hot gas enters the torrefaction device 100 and torrefy ed material discharges on the opposite end of the torrefaction device 100 as the exhausting vapors.

[0101] The counter flow is suitable for raw material with low moisture and low heat sensitive. The drying rate is evenly distributed. So counter flow is more suitable for the raw material which is strict with the final moisture. As the heating air move from the dry end to the wet end, as the function of the wet air, there will be less dust in the exhaust.

[0102] The torrefaction device 100 employs the parallel or the counter flow of heating depending on the requirement of the final product.

[0103] During torrefying the material inside the chambers of the rotary drum 102, the torrefaction is taking place at very high temperatures, for example, “between” 200 degrees C to 350 degrees C, depending on the input, its particle size, surface area, initial moisture, composition especially in terms of hemicellulose to be de-volatized and so on. As the torrefied material inside the torrefaction device 100 nears the last two chambers / sections, it is hot and can combust instantaneously on exit or coming in contact with oxygen. Thus, it is highly required that the product needs to be cooled considerably, which is done by keepingAgent ’s File Reference No. CIP -074681 -24 the torrefied material inside in the last section / chamber till it gradually cools and can exit generally.

[0104] The torref action device 100 implements a unique multifaceted cooling system (including a cooling system 126) to efficiently and economically perform this critical function, without compromising on the machine output, or holding the material for too long, thus enabling continuous operation and preventing / restricting the torrefaction reactions to happen which continued post initial torrefaction, while cooling. This adversely affects the yield which deteriorates, if it cools inside only, as during this phase torrefaction reaction persists.

[0105] To prevent all of this, the last chambers (e.g., last two chambers) of the torrefaction device 100 / 500 may install a cooling system of sprinkling water at designated intervals inside them, for example, inside the outer most section of the outer drum 104 inside it, in the last chamber / section before exit. The sprinkling cooling system immediately has a massive effect of partially cooling the output which has not yet exited. Additionally, the torrefaction device 100 / 500 may also include a sealed water jacketed screw conveyer 126, through which the torrefied output exits after the last chambers of the torrefaction device 100 / 500, on a continuous basis, so it does not come immediately in contact with the air. Thus, a combination of water sprinklers inside the chambers and sealed water jacketed screw conveyer outside provides an effective cooling method for the torrefied material. The water jacketed screw conveyer not only conveys the material to point of further storage but also the water circulating in an outer chamber of the water jacketed screw conveyer cools it. Thus, the deterioration in the continuing pyrolysis is avoided and yield loss minimized. The output torrefied and cooled material, one can then even touch by hand momentarily.

[0106] In an embodiment, a similar water jacketed conveyer system is also available at the point of entry of the material into the rotary drum 102, as an additional feature, for safety.

[0107] After being cooled and outputted, the torrefaction process includes a third stage of conveying and transporting the torrefied material for further cooling on the ground floor which may have an automated sprinkler system. This ensures that the torrefied material embers still inside do not self-ignite. This further improves the yield.

[0108] The water used for cooling is also recycled. The water exiting the output water jacketed screw conveyer and / or the floor automated sprinkler system is sent back in a waterAgent ’s File Reference No. CIP -074681 -24 tank wherein a pipe inside at top of the tank has sprinkler system and the release through multiple sprinkler holes allows for cooling the material. Mixing with the water in the tank for refeeding into the output conveyer at least cost.

[0109] Pressurized water pipes with nozzles may be used to give required water for circulation.

[0160] Because the material having been torrefied has become hydrophobic and it repels the moisture or water which may be used on the torrefied material instantaneously, for example during cooling, so, there is no re-ingress of moisture to the material. This enables highest continuous operation with abundant safety and minimal cost.

[0110] In another embodiment, the torref action device 100 may also include a touch screen PLC placed panel with interlocking of the feeding conveyer 108 and output conveyor that brings out the torrefied raw material from the device 100. The panel is equipped with variable frequency drive (VFD) for feed control. The panel also connects to the multiple thermocouples installed in the outer chamber to monitor the temperature at at least 8 points in the reactor 102.

[0111] The driving motor that is used to rotate the rotary drum 102 has a gear system with twin rollers driven by lOHp motor is installed, according to an embodiment. The rotational velocity based on the gear ratio and the VFD control can be minimized at 0.5 rotations per minute to 20 revolutions per minute of the inner rotary chamber which allows for flexibility in residence time. The torrefaction device 100 is placed at a certain angle to aid the flow of material and elevated at the starting point with a tapered decline over the length of the torrefaction device 100, as mentioned above.

[0112] There are thermocouple sensors at, may be, three points and rotation sensors at, may be, two points inside the reactor / chambers of the rotary drum 102, where heat is being infused to control the temperature and have digital reading on the panel. Auto cut-off for temperature control is inbuilt.

[0113] For example, a laser beam is fitted inside the reactor / chambers of the rotary drum 102 at least at two points which can provide real - time temperature readings on the PLC panel. This one-of-a-kind innovation is for process temperature control which is the key element in the operation of the torrefyer. In an embodiment, a thermocouple sensor at the exit point of the torrefy er device 100 / 500 may be installed to assess the temperature of the flue gases being released again for temperature management and safety.Agent ’s File Reference No. CIP -074681 -24

[0114] In another embodiment, to have real-time documented data of the emissions from the chimney stack, a flue gas analyzer may be installed at the exit point of the chimney to assess the Oxygen Sox and NOx emission. A printout as and when required would be available as a record.

[0115] These additional safeguards and process control devices enable proper temperature and gases management throughout the torrefaction system. These are also important safety features integrated into the system. The efficacy of operations greatly enhances and improves the product being torrefied, qualitatively. More precise temperature management improves further the yield for higher output.

[0116] Additionally, other conveying systems for feed and output are also automated. The interlocking or integration of these sections is to ensure auto cut off, etc., if particular section stops and the rest or any of the equipment sections need to also stop or start and so on. The programming of the operating parameters for different raw materials and varying products are thus realistically possible.

[0117] To be able to effectively drive the torrefaction device 100 / 500, a gear system with four sets of cast iron rollers mounted on a heavy metal frame. Mostly cast iron is used to do this and avoid any slippages, heat expansion, of the furnace lining etc. The gear system is so positioned as to be protected from the heat in order that the motor is not heated up. The positioning of the same is on the side of the torrefyer for easy checking and maintenance.

[0118] The rotary drum 102 of the torrefaction device 100 has higher capacity, continuous production; simple structure, easy on operating; low failure rate; low cost of maintenance. The rotary drum 102 can be used to dry variety of the raw material even with high adhesion. The rotary drum 102 has flexible operation, the quality of final product won’t be much changed when the capacity changes. Also, the rotary drum 102 is easy to clean.

[0119] In an embodiment, the torrefaction device 100 for oxidative torrefaction has twin drums of boiler grade steel. Outer drum or cylinder 104 is for indirect heating. Internal drum 102 rotates while the heat is passed into the outer drum cavity. The torrefaction device 100 is skid mounted for easy installation on a firm platform with anchor bolting.

[0120] The capacity of the torrefaction device 100 depends on the multiple factors such as input moisture, particle size, bulk density of the input material, desired output moisture level, surface area of the material, temperature profile, residence time, rotational velocity and so on.Agent ’s File Reference No. CIP -074681 -24The capacity for lighter material like groundnut shells, the estimated capacity would be 2TPH. Per reactor of 12 mts. Twin provide 4-5 TPH capacity on heavier inputs such as juli flora waste, the capacity would be higher. Again, it is important to note that multiple variables determine the final capacity.

[0121] In an embodiment, the rotary drum 102 has a diameter of 1.2 meters and length of 12 meters, and outer drum 104 is insulated with aluminum cladding on top. Similarly for twin reactors.

[0122] Further, as heat plays the sole important role in torrefaction process, the outer drum 104 needs to be insulated effectively to enable retention of heat inside the outer drum 104. A Linear Resin Bond (LRB) or similar insulation is generally used. The outer drum 104 can be covered with a ceramic wool blanket of double the normal thickness. This is protected and kept in a place over a cylindrical body with wire mesh netting. To further protect the insulation, the entire body of the torrefaction device is then cladded with aluminum sheet of up to 3mm to protect and not allow heat to penetrate in the external environment. This is a safety feature as well.

[0123] Advantageously, torrefaction device 100 fits all the mandatory criteria of producing torrefied biomass, according to the government, with sufficiently high heating value, low moisture content and high moisture resistance as well as a high transport and energy density. The torrefaction equipment is capable of running continuously on 24h / 7d basis without releasing volatile organic compound (VOC) as emissions. It has easy-to-operate process controls that requires only a small crew of operators and minimum maintenance. It further employs automated process controls in order to maintain temperatures within ranges fostering complete mild pyrolysis of the woody biomass. It is designed to facilitate a scale-up to higher capacity levels at a later date. In other words, the technology successfully caters to the need for the development of torrefied biofuels which is the need of the hour and has been considered as an important countermeasure to abate anthropogenic CO2 emissions, suppress deteriorated atmospheric greenhouse effect, and mitigate global warming at a cost and attendant efficiency which is unparalleled.

[0124] The torrefaction system and device explained herein above can process, with the same system, multiple products having most diverse application over a host of applications as illustrated here under:Agent ’s File Reference No. CIP -074681 -24-Torrefyer modern upgraded applications for value addition-Pre-treatment for energy use-Bio-Char-Soil remediation-Bio- Coke-Ideal substitute for pet coke (mostly banned in India by the Supreme Court)-Hybrid biomass cum industrial waste applications-LAM substitute-Soil amendment-Filtration Media-Filler or adsorbed in composites-Carbon black substitute-Precursor for activated carbon-Source for carbon sequestration-Ethanol pre-processing of residue for higher yield-DI-Methyl Ether (Bio based) - bio LPG-Bio- methanol-LCM (Lost Circulation Material)-Green Hydrogen

[0125] Other advantages may include: higher output; efficiency; ease of operation; fuel saving by re-circulating flue gases; versatility of use as well as durability and capacity; hydrophobicity; 24x7 continuous operation; feedstock versatility; ability to accept stock of standard industrial sizes without pretreatment; fully automated and integrated process control; lower residence times with high yield; uniformity of output; modular scalability; and Unmatched product range, possible for a host of applications spanning not only renewable energy use as fuel but for metallurgical industry to enhance steel output, as a making cellulose fiber pellets for improve highway project life, for plugging ruptures for foil drilling, carbon hydrogen specialized futuristic fuels, carbon capturing and sequestration and so on.

[0126] Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. Benefits, other advantages, and solutions to problems have been described above with regard to specificAgent ’s File Reference No. CIP -074681 -24 embodiments. However, the benefits, advantages, solutions to problems, and any component(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or component of any or all the claims.

[0127] It is intended that the disclosure and examples be considered as exemplary only. Though the present disclosure includes examples from torrefaction devices and methods, the system and method disclosed herein may be employed for various applications as would be appreciated by one skilled in the art. The references to measuring devices and machines used here are intended to be applied or extended to the larger scope and should not be construed as restricting the scope and practice of present invention.

Claims

Agent ’s File Reference No. CIP -074681 -24Claims1- A torrefaction device for torrefying a biomass fuel, comprising: at least one oxidative indirect-fired twin drum torrefy er reactor 100 including: at least one inner rotary drum 102 which rotates and receives preheated raw material for being torrefied; and at least one outer stationary drum 104 surrounding the inner rotary drum 102 and maintaining an annular space between the at least one inner rotary drum 102 and the at least one outer stationary drum 104, and configured in that the at least one inner rotary drum 102 having a length within the range of 18 meters - 36 meters, and is divided into multiple sections; configured in that the inner diameter of the at least one inner rotary drum 102 is within the range of 1 meter - 1.8 meter; wherein, for torrefying the raw material, the at least one inner rotary drum 102 receives the pre-heated raw material, rotates and breaks the raw material down as it passes through the at least one inner rotary drum 102, and the raw material is indirectly heated, under partial oxidative torrefaction, from the heat produced from hot fluids or flue gases, travelling into the annular space; and wherein torrefying the raw material is executed in at least some of the first sections from among the multiple sections of the at least one inner rotary drum 102, while simultaneously, cooling down the hot torrefied material is executed in at least rest of the sections from among the multiple sections of the at least one inner rotary drum 102, ensuring a continuous torrefaction process inside the at least one oxidative indirect-fired twin drum torrefy er reactor 100, and wherein, owing to the length and diameter of the at least one inner rotary drum 102 and that at least some of the sections perform torrefaction while rest of the sections, simultaneously, perform cooling of the torrefied material, feeding time for the raw material into the at least one inner rotary drum 102 is independent of outputting time of the torrefied material from the at least one inner rotary drum 102.Agent ’s File Reference No. CIP -074681 -242- The torrefaction device of claim 1 , further comprises another oxidative indirect-fired twin drum torrefyer reactor same as descried in claim 1 connected to the at least one oxidative indirect-fired twin drum torrefyer reactor 100 to form a double torrefaction device, wherein the two twin drum torrefyer reactors are interconnected with flanges to double the length of the torrefaction device, and wherein the double torrefaction device includes two interconnected inner rotary drums, running in sync with each other, and at least one outer stationary drum surrounding each of the inner rotary drums.3- The torrefaction device of claim 1, wherein the length of the at least one inner rotary drum 102 is 24 meters comprising at least 8 sections of at least 3meters length each, and the inner diameter of the at least one inner rotary drum 102 is 1.2 meter, and wherein at least first six sections torrefy the raw material using heat from hot fluids or glue gases, while at least the last two sections, simultaneously, cool the hot torrefied material prior to its exit.4- The torrefaction device of claim 1 , wherein the length of the at least one inner rotary drum 102 is 36 meters, and the inner diameter of the at least one inner rotary drum 102 is 1.2 meter, and wherein some of the at least first sections torrefy the raw material using heat from hot fluids or glue gases, while the rest sections, simultaneously, cool the hot torrefied material prior to its exit.5- The torrefaction device of claim 1 further comprises: a jacketed pre-bin hopper 106 for receiving the raw material and blending the raw material in a mixer-blender, for semi-drying the raw material using the heat that is circulating in the jacket of the pre -bin hopper 106; a feeding conveyor 108 with an outer jacketed chamber for receiving the semi-dried raw material from the mixer-blender and for receiving the heat, from the mixer-blender, into the outer jacketed chamber, to further reduce a moisture profile of the semi-dried rawAgent ’s File Reference No. CIP -074681 -24 material prior to feeding into the torref action device; a biomass furnace for receiving balance heat from the mixerblender and the feeding conveyor 108 along with the further dried raw material to further reduce the moisture profile of the raw material prior to feeding into the torrefaction device, wherein the mixer-blender, the feeding conveyor 108 and the biomass furnace pre-heats the raw material prior to feeding into the torrefaction device, and wherein the heat from the biomass furnace travels into an outer chamber and / or the annular space of the torrefaction device.6- The torrefaction device of claim 5, wherein the feeding conveyer 108 is a jacketed conveyer, and wherein the feeding conveyer 108 is at least one of a screw conveyor, a belt, or a bucket elevator, individually or in combination.7- The torrefaction device of claim 5 further comprises a multifaceted cooling system to cool down the hot torrefied material using cooling fluid and / or water individually or in combination, the multifaceted cooling system includes at least one or more of the following: a. a cooling system of sprinkling water at designated intervals installed inside the rest of the sections, of the at least one inner rotary drum 102, which cool down the hot torrefied material and / or installed inside the at least one outer stationary drum 104 towards end of the torrefaction device for cooling the hot torrefied material before exiting the torrefaction device; b. a sealed water jacketed screw conveyer 126, installed after the cooling system of sprinkling water and outside the last section from among the multiple sections, for further cooling the torrefied material, on a continuous basis, and to avoid any immediate contact of the hot torrefied material with the air; or c. an automated sprinkler system, installed outside the torrefaction device, for further cooling off the torrefied material to ensure that embers of the torrefied material still inside do not self-ignite.Agent ’s File Reference No. CIP -074681 -248- The torrefaction device of claim 7, wherein hot fluids or flue gases used for torrefying the raw material and the cooling fluid and / or water used in the multifaceted cooling system, both are recycled and reintroduced in the torrefaction device for using again, thereby maintaining a closed loop and continuous feed for both of the torrefaction and cooling processes, post the initial firing of the hot fluids or flue gases and achieving the required temperature profile for torrefaction.9- The torrefaction device of claim 1, wherein the at least one inner rotary drum 102 includes: multiple baffles 112 positioned along the inner periphery and along the length of the at least one inner rotary drum 102 to enable free circulation of the raw material and movement from one end to the other; at least two first stiffeners 114 diagonally positioned in between the multiple baffles 112 and at a first section of the at least one inner rotary drum 102; and at least two second stiffeners 116 diagonally positioned in between the multiple baffles 112, wherein the multiple baffles 112, the at least two first stiffeners 114 and the at least two second stiffeners 116 break down the raw material while it passes from one end to another end of the at least one inner rotary drum 102; and wherein the at least one inner rotary drum 102 has roller tracks on its outer surface that helps in its rotation; and wherein the at least one inner rotary drum 102 is inclined at an angle of inclination to allow slow movement of the raw material from one end to an another.10- The torrefaction device of claim 1 further comprises at least one or more thermocouple sensors and at least one or more rotation sensors installed at the at least one inner rotary drum 102 for providing real - time temperature readings and rotational speed of the at least one inner rotary drum 102, respectively; andAgent ’s File Reference No. CIP -074681 -24 wherein, at least one thermocouple sensor is installed at an exit point of the torrefaction device to assess the temperature of exiting hot fluids and flue gases for temperature management and safety.11- The torrefaction device of claim 10 further comprises a PLC panel for monitoring and controlling processes of the torrefaction device, wherein the PLC panel monitors and controls at least one or more of the following processes: a. controlling feed into and out of the torrefaction device using a variable frequency drive (VFD), based on output from the at least one or more rotation sensors; b. monitoring and controlling inside temperature of the at least one inner rotary drum 102 based on output from the at least one or more thermocouple sensors; c. auto cut-off for temperature control; d. monitoring temperature of exiting hot fluids and flue gases; e. monitoring real-time documented data of emissions out from a chimney installed at the torrefaction device, by communicating with a flue gas analyzer installed at an exit point of the chimney; or f. monitoring and controlling rotational movement of all the sections of the at least one inner rotary drum 102.12- The torrefaction device of claim 1, wherein the at least one outer stationary drum 104 is insulated with a Linear Resin Bond (LRB) or similar insulation layer to effectively retain heat inside the at least one outer stationary drum 104; and wherein, to further retain the heat inside, the entire body of the torrefaction device is cladded with aluminum sheet of up to at least 3mm to protect and not allow heat to penetrate in the external environment.13- The torrefaction device of claim 1, wherein the at least one inner rotary drum 102 is driven by using a driving motor with a gear system with twin rollers, and wherein the rotational velocity of the at least one inner rotary drum 102 is able to be minimized atAgent ’s File Reference No. CIP -074681 -240.3 rotations per minute to 20 revolutions per minute which allows for flexibility in residence time of the raw material inside the at least one inner rotary drum 102.14- A torrefaction device for torrefying a biomass fuel, comprising: at least one oxidative indirect-fired twin drum torrefyer reactor 100 including: at least one inner rotary drum 102 which rotates and receives preheated raw material for being torrefied; and at least one outer stationary drum 104 surrounding the inner rotary drum 102 and maintaining an annular space between the at least one inner rotary drum 102 and the at least one outer stationary drum 104, configured in that the at least one inner rotary drum 102 having a length within the range of 18 meters - 36 meters, and is divided into multiple sections; and configured in that the inner diameter of the at least one inner rotary drum 102 is within the range of 1 meter - 1.8 meter; a two-stage fluidized bed furnaces 118 running on biomass for effectively providing heat over a length of the at least one inner rotary drum 102; and a multifaceted cooling system to cool down the hot torrefied material using cooling fluid and / or water individually or in combination, the multifaceted cooling system includes at least a cooling system of sprinklers installed inside the at least one inner rotary drum 102 or the at least one outer stationary drum 104, individually or in combination, towards end of the torrefaction device for cooling the hot torrefied material before exiting the torrefaction device; and wherein, for torrefying the raw material, the at least one inner rotary drum 102 receives the pre-heated raw material, rotates and breaks the raw material down as it passes through the at least one inner rotary drum 102, and the raw material is indirectly heated, under partial oxidative torrefaction, from the heat produced from hot fluids or flue gases travelling into the annular space; and wherein torrefying the raw material is executed in at least some of the first sections from among the multiple sections of the at least one inner rotary drumAgent ’s File Reference No. CIP -074681 -24102, using the two-stage fluidized bed furnaces 118, while simultaneously, cooling down the hot torrefied material is executed in at least rest of the sections from among the multiple sections, using the multifaceted cooling system, ensuring a continuous torrefaction process inside the at least one oxidative indirect-fired twin drum torrefy er reactor 100, and wherein, owing to the length and diameter of the at least one inner rotary drum 102 and that at least some of the sections perform torrefaction while rest of the sections, simultaneously, perform cooling of the torrefied material, feeding time for the raw material into the at least one inner rotary drum 102 is independent of outputting time of the torrefied material from the at least one inner rotary drum 102.15- The torrefaction device of claim 14 further comprises an ash collection system including a blocking wall for blocking ash from inside of the multiple sections of the at least one inner rotary drum 102, and letting ash drop inside for easy removal.16- The torrefaction device of claim 15, wherein the two-stage fluidized bed furnaces 118 are connected via an attachment 120; and a spreading device with a blower is attached on top of the two-stage fluidized bed furnaces 118 to evenly dissipate the heat from the two-stage fluidized bed furnaces 118 into at least those sections of the at least one inner rotary drum 102 that torrefies the raw material, and wherein the torrefaction device further comprises an inner blower additionally installed above the two-stage fluidized bed furnaces 118 and inside the section of the at least one inner rotary drum 102 below which the two-stage fluidized bed furnaces 118 is installed, to allow the heat from that section to transfer effectively into the next section.17- The torrefaction device of claim 14, further comprises another oxidative indirect-fired twin drum torrefy er reactor same as descried in claim 14 connected to the at least one oxidative indirect-fired twin drum torrefy er reactor 100 to form a double torrefaction device, wherein the two twin drum torrefyer reactors are interconnected with flanges to double the length of the torrefaction device, and wherein the double torrefaction device includes two interconnected inner rotary drums, running in sync with eachAgent ’s File Reference No. CIP -074681 -24 other, and at least one outer stationary drum surrounding each of the inner rotary drums, and wherein the length of the at least one inner rotary drum 102 in the double torref action device is 24 meters, and the inner diameter of the at least one inner rotary drum 102 is 1.2 meter.18- The torrefaction device of claim 14, wherein the length of the at least one inner rotary drum 102 is 36 meters, and the inner diameter of the at least one inner rotary drum 102 is 1.2 meter, and wherein some of the at least first sections torrefy the raw material using heat from hot fluids or glue gases and the two-stage fluidized bed furnaces 118, while the rest sections, simultaneously, cool the hot torrefied material, using the multifaceted cooling system, prior to its exit.19- The torrefaction device of claim 14, wherein the multifaceted cooling system includes at least one or more of the following: a. a sealed water jacketed screw conveyer 126, installed after the cooling system of sprinkling water and outside the last section from among the at least four sections, for further cooling the torrefied material, on a continuous basis, and to avoid any immediate contact of the torrefied material with the air; or b. an automated sprinkler system, installed outside the torrefaction device, for further cooling off the torrefied material to ensure that embers of the torrefied material still inside do not self-ignite.20- The torrefaction device of claim 19, wherein hot fluids or flue gases used for torrefying the raw material and the cooling fluid and / or water used in the multifaceted cooling system, both are recycled and reintroduced in the torrefaction device for using again, thereby maintaining a closed loop and continuous feed for both of the torrefaction and cooling processes, post the initial firing of the hot fluids or flue gases and achieving the required temperature profile for torrefaction.21- The torrefaction device of claim 14 further comprises at least one or more thermocouple sensors and at least one or more rotation sensors installed at the at leastAgent ’s File Reference No. CIP -074681 -24 one inner rotary drum 102 for providing real - time temperature readings and rotational speed of the at least one inner rotary drum 102, respectively; and wherein, at least one thermocouple sensor is installed at an exit point of the torrefaction device to assess the temperature of exiting hot fluids and flue gases for temperature management and safety.22- The torrefaction device of claim 21 further comprises a PLC panel for monitoring and controlling processes of the torrefaction device, wherein the PLC panel monitors and controls at least one or more of the following processes: a. controlling feed into and out of the torrefaction device using variable frequency drive (VFD) using output from the at least one or more rotation sensors; b. monitoring and controlling inside temperature of the at least one inner rotary drum 102 using output from the at least one or more thermocouple sensors; c. auto cut-off for temperature control; d. monitoring temperature of exiting hot fluids and flue gases; e. monitoring real-time documented data of the emissions out from chimney installed at the torrefaction device, by communicating with a flue gas analyzer installed at an exit point of the chimney; or f. monitoring and controlling rotational movement of all the sections of the at least one inner rotary drum 102.23- The torrefaction device of claim 22, wherein the at least one inner rotary drum 102 is driven by using a driving motor with a gear system with twin rollers, and wherein the rotational velocity of the at least one inner rotary drum 102 is able to be minimized at 0.3 rotations per minute to 20 revolutions per minute which allows for flexibility in residence time of the raw material inside the at least one inner rotary drum 102.

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