Polyurethane Fuel Pellets with Controlled Chlorine and Density
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Solution Overview
Problem
The challenge lies in effectively utilizing polyurethane foam from discarded electrical appliances as fuel due to high residual chlorine concentrations, low bulk specific gravity leading to high transportation costs, and difficulties in handling and dust prevention during compression molding.
Innovation Solution
The development of a fuel pellet with a bulk specific gravity of 0.45 to 0.55 and residual chlorine concentration of 0.3 wt. percent or less, formed by compression molding powdered polyurethane, using a cylindrical shape with a specific length-to-diameter ratio, and processed under negative pressure conditions to enhance degassing efficiency without forced heating or dechlorination agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chlorofluorocarbon-expanded urethane foam is crushed into powdered state, then it can be processed as fuel, but the residual chlorine concentration remains high (1.0 wt. percent or more) making it unsuitable for ordinary fuel use
Solution Approach 1:
The patent changes the physical parameters of the polyurethane foam by controlling particle size distribution (mixing fine particles of 0.1-1mm with coarse particles of 1-10mm) and bulk density (0.45-0.55 g/cm³) to enable direct combustion without chemical dechlorination, thus reducing residual chlorine to acceptable levels while maintaining fuel usability
Solution Approach 2:
The patent creates a composite fuel structure by mixing polyurethane foam particles of different sizes and densities, forming a heterogeneous material that optimizes both combustion characteristics and chlorine release behavior, enabling effective fuel utilization
2Ease of operation
If urethane foam is light weight with small bulk specific gravity, then it is easy to handle, but it becomes difficult to transport due to high transportation costs
Solution Approach 1:
The patent optimizes the bulk specific gravity parameter to 0.45-0.55 g/cm³ by controlling particle size distribution and packing density, achieving a balance between handling ease and transportation efficiency, reducing transportation costs while maintaining operational convenience
3Loss of energy
If polyurethane foam is compressed into pellets, then transportation efficiency improves, but dust generation and handling difficulties increase
Solution Approach 1:
The patent applies different particle size qualities to different functional requirements: fine particles (0.1-1mm) fill gaps to reduce dust, while coarse particles (1-10mm) maintain structural integrity during handling, creating a locally optimized mixed-grain fuel pellet
Solution Approach 2:
The patent creates a composite particle structure combining different size classes of polyurethane foam particles, forming a multi-scale material that reduces dust generation through interlocking fine particles while maintaining bulk handling efficiency
4Device complexity
If ordinary compression molding is used on polyurethane foam, then the process is simple, but the residual chlorine concentration remains high and fuel standards are not met
Solution Approach 1:
The patent changes the compression parameters (pressure, temperature, duration) and particle configuration (size distribution, bulk density) to optimize chlorine release during compression, achieving fuel compliance through physical parameter optimization rather than complex chemical treatment processes
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 solution allows the polyurethane fuel pellets to be used in ordinary incinerators and boilers, reducing transportation costs, preventing dust generation, and improving handling while maintaining safety and efficiency in the manufacturing process.
Implementation Method 1
formed by compression molding powdered polyurethane that is obtained by crushing urethane foam, with the bulk specific gravity set to 0.45 to 0.55
Implementation Method 2
processed under negative pressure conditions to enhance degassing efficiency
Data Source
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AI summary
The fuel pellet of the present invention is formed by compression molding, powdered polyurethane that is obtained by crushing urethane foam, with the bulk specific gravity being 0.45 to 0.55, and the residual chlorine concentration being 0.3 wt. percent or less.