Biological Coal Slurry Processing for Fuel and Fertilizer Production

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Solution Overview

Problem

There is a growing need for efficient systems and methods to convert hydrocarbon-containing substances into sustainable fuels, gases, and fertilizers, while addressing environmental concerns and waste management issues.

Innovation Solution

The method involves creating a predigested coal slurry by mixing coal fines, water, urea, a culture of Bacillus Firmus bacteria, and a dispersant agent, which is then heated in a vacuum digester to produce naphtha vapors. These vapors are condensed and stored, and the process further converts combustion gases into fertilizer through a series of scrubber tanks and chemical tote bins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydrocarbon-containing substances are converted into sustainable fuels and chemicals, then energy security and environmental sustainability are improved, but the complexity of the processing system increases

Engineering Contradiction:

Improveenergy securityVSAvoidprocessing system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The processing system is divided into multiple functional units: a pre-digestion tank for initial breakdown, a vacuum digester for hydrocarbon extraction, condensation equipment for vapor separation, and scrubber tanks for gas purification. Each unit performs a specific function, making the overall complex process manageable and modular.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pre-digestion tank performs preliminary breakdown of hydrocarbon-containing substances before they enter the vacuum digester. This preliminary action reduces the complexity of the main processing by preparing the material in advance, making the subsequent extraction and processing steps more efficient.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If waste hydrocarbon substances are processed into valuable products, then waste management is improved, but the production of toxic by-products may increase

Engineering Contradiction:

Improvewaste conversion efficiencyVSAvoidtoxic by-products

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The system converts harmful waste hydrocarbon substances into valuable products including sustainable fuels, chemicals, and fertilizer. The vacuum distillation process separates useful hydrocarbons from waste materials, transforming what would be harmful waste into beneficial energy sources and chemicals.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

Scrubber tanks act as intermediaries between the vacuum digester and the final product output. These scrubber tanks purify the combustion gases by removing toxic by-products through absorption and chemical reactions, allowing the system to produce valuable products while minimizing harmful emissions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If combustion gases are processed through scrubbing, then environmental impact is reduced, but the time required for processing increases

Engineering Contradiction:

Improveenvironmental impactVSAvoidprocessing time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The scrubber tanks operate continuously to purify combustion gases as they are produced. The system maintains continuous flow through the scrubbing process, allowing environmental purification to occur simultaneously with the main processing operations rather than as a separate time-consuming step.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The scrubbing process utilizes changes in physical and chemical parameters including temperature, pressure, and chemical composition to efficiently remove toxic by-products. By optimizing these parameters, the system achieves effective purification without excessive processing time.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method effectively transforms waste into valuable hydrocarbon fuels and fertilizer, while purifying combustion gases and reducing environmental impact, thus addressing the challenges of energy scarcity and waste management.

Implementation Method 1

a culture of Bacillus Firmus bacteria

Methodology Applied

Scientific EffectBiological decomposition: Decomposition (biological)

Implementation Method 2

heating the predigested coal slurry via the first burner lance, producing combustion gases and first naphtha vapors

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

condensing and storing the first naphtha vapors

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 4

a series of scrubber tanks and chemical tote bins

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS20250188359A1Methods for biological processing of hydrocarbon-containing substances and system for ealization thereof

Publication Date: 2025.06.12 ANRITSU CORP

AI summary

The present disclosure is related to systems and methods for the biological processing of hydrocarbon-containing substances. The systems and methods can relate to pre-digestion of hydrocarbon-containing substances and further processing of the same to produce hydrocarbon fuels, fertilizer, and/or other products.