Pyrolysis Fuel Char Particle Size Reduction
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Solution Overview
Problem
Rapid pyrolysis of biomass produces char particles larger than 5 microns, which cannot be separated by cyclones, leading to reduced heating value and oil loss when removed for diesel engine combustion, as current methods fail to effectively process pyrolysis fuels to prevent engine damage and retain char's high heating value.
Innovation Solution
Resizing char particles to a maximum dimension of less than 5 microns using a ball mill grinder or similar processing units, allowing their safe combustion in diesel engines without oil loss, by separating and processing pyrolysis fuels to include resized char particles blended with pyrolysis oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If char particles are removed from pyrolysis fuel before combustion, then engine damage is prevented, but heating value is reduced and oil is lost
Solution Approach 1:
The patent changes the size parameter of char particles from large (>5 microns) to fine (≤5 microns) through mechanical grinding. This parameter change allows the particles to meet engine requirements without removal, preserving their heating value while preventing engine damage. The fine particles can pass through engine filters and burn completely without causing wear.
Solution Approach 2:
The patent extracts only the harmful size characteristic of char particles through selective grinding, separating the harmful property (large size) from the useful property (heating value). By reducing particle size while retaining the char in the fuel, the solution removes only the detrimental aspect while preserving the beneficial energy content.
2Quantity of substance
If char particles are removed by filtration or centrifugation, then solids are separated, but pyrolysis oil is lost in the process
Solution Approach 1:
The patent performs preliminary size reduction of char particles before combustion. By grinding the particles to fine sizes in advance, the harmful large particles are eliminated beforehand, eliminating the need for subsequent filtration or centrifugation steps that would cause oil loss. The fine particles remain suspended in the oil and can be combusted directly.
3Quantity of substance
If cyclone separation is used to remove char, then some solids are separated, but particle size distribution prevents complete separation
Solution Approach 1:
The patent replaces the cyclone separation mechanical system with a mechanical grinding system. Instead of relying on density-based separation that cannot achieve complete removal, the solution uses mechanical energy to directly reduce particle size to the required specification, achieving precise control over the final particle size distribution.
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
Increases the heating value of pyrolysis fuel, reduces oil loss during processing, and ensures safe combustion in diesel engines by maintaining a low solids content, enhancing the yield of electricity from biomass energy by 5% or more compared to current methods.
Implementation Method 1
resizing a portion of the char particles from the pyrolysis fuel... resizing char particles from the pyrolysis fuel... using a ball mill grinder or similar processing units
Implementation Method 2
Rapid pyrolysis of biomass is a thermal treatment process in the absence of air, which produces char, liquid, and gaseous products. During rapid pyrolysis, the pyrolysis temperatures range from 450° C. to 600° C.
Implementation Method 3
In a typical reactor for rapid pyrolysis, a cyclone is used at the termination of the riser reactor to separate sand and char from other pyrolysis products
Implementation Method 4
combusting the pyrolysis fuel, including the pyrolysis oil and resized char particles
Data Source
AI summary
Pyrolysis fuels and methods for processing pyrolysis fuel are provided. In one embodiment, a method of processing pyrolysis fuel converts biomass to pyrolysis fuel including pyrolysis oil and char particles. Also, the method includes resizing a portion of the char particles so that substantially all resized char particles have a largest dimension no greater than about 5 microns.