Solid Fuel Composition from Mixed Waste
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Solution Overview
Problem
Current Waste-to-Energy processes face inefficiencies when using municipal solid waste or agricultural waste due to high water content, low density, and variability in composition, limiting the effective operation of pyrolysis or gasification chambers, and requiring significant investment in specialized equipment.
Innovation Solution
A system and method for producing a solid fuel composition from mixed solid waste that involves processing the waste mixture in a vessel under reduced pressure to remove moisture and volatile compounds, melting plastics to increase density, and extruding the mixture to create a uniform, high-density, low-moisture fuel suitable for pyrolysis or gasification without forming syngas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If pyrolysis or gasification chambers are used to process municipal solid waste, then energy can be liberated from the waste, but the high water content, low density, and variable composition of the waste limit effective operation
Solution Approach 1:
The patent applies preliminary action by pre-processing the municipal solid waste through drying, grinding, and densification before introducing it to the pyrolysis or gasification chamber. This preprocessing converts the variable-composition waste into a more uniform, higher-density fuel material that is suitable for efficient thermal conversion, thereby resolving the contradiction between energy liberation and operational reliability.
Solution Approach 2:
The patent changes physical parameters of the waste material through controlled drying (reducing moisture content), grinding (reducing particle size), and densification (increasing bulk density). These parameter changes transform the waste from an unsuitable feedstock into a reliable fuel source for pyrolysis or gasification, enabling effective energy liberation while maintaining chamber operational reliability.
2Stability of the object's composition
If pelletizers are used to uniformize the solid waste stream, then size variation is reduced, but the waste retains composition variability and does not become high density or low moisture fuel
Solution Approach 1:
The patent segments the waste processing into distinct stages: drying to remove moisture, grinding to reduce particle size, and densification to increase bulk density. Each stage addresses specific properties independently, achieving both size uniformity and composition consistency that pelletizing alone cannot accomplish.
Solution Approach 2:
The patent creates a composite processed material by combining multiple processing actions (drying, grinding, densification) on the waste stream. This composite approach produces a fuel material with uniformly controlled properties including moisture content, particle size distribution, and bulk density, overcoming the limitations of single-stage pelletizing.
3Productivity
If advanced gasification or enhanced pyrolysis mechanisms are used to overcome feedstock inconsistency, then operational efficiency improves, but significant capital investment in specialized equipment is required
Solution Approach 1:
The patent applies preliminary processing (drying, grinding, densification) to the waste feedstock before it enters the pyrolysis or gasification chamber. This preprocessing improves the quality and consistency of the feedstock, enabling standard equipment to operate more efficiently and effectively, thereby achieving enhanced productivity without requiring advanced or specialized equipment.
Solution Approach 2:
The patent introduces an intermediary processing stage between waste collection and thermal conversion. This intermediate densification and preparation stage acts as a mediator that transforms variable-composition waste into a more uniform fuel material, allowing standard pyrolysis or gasification equipment to achieve better operational efficiency without requiring complex advanced mechanisms.
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
The process transforms variable solid waste into a consistent, energy-rich, sterile, and non-porous solid fuel with high energy content, enabling efficient operation of pyrolysis or gasification processes without additional capital investment and reducing harmful emissions.
Implementation Method 1
a vacuum pump operatively coupled to the condenser via the lower port of the condenser to reduce the pressure of the interior volume of the process vessel and the condenser to less than about 50 torr
Implementation Method 2
a heater operatively coupled to the process vessel to heat the one or more heated walls of the process vessel to a temperature ranging between about 160° C. and about 280° C.
Implementation Method 3
heat increases after removal of the water and VOCs to melt mixed plastics in the solid waste mixture
Implementation Method 4
a condenser comprising an upper port, a lower port below the upper port, a condensate basin below the lower port, and a drain in the condensate basin
Implementation Method 5
an extruding element passing through a first opening in the process vessel and operating below about 200° C.
Data Source
AI summary
Systems and methods of producing a solid fuel composition are disclosed. In particular, systems and methods for producing a solid fuel composition by heating and mixing a solid waste mixture below atmospheric pressure to a maximum temperature sufficient to melt the mixed plastics within the solid waste mixture is disclosed.