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 compositional variability, limiting the effective operation of pyrolysis or gasification chambers, and require significant investment in specialized equipment.
Innovation Solution
A process that transforms mixed solid waste into a high-density, low-moisture, and uniform solid fuel composition by heating and extruding a mixture of organic materials and plastics, removing volatile organic compounds and chlorine gas, resulting in a fuel with enhanced energy content and reduced variability, suitable for efficient pyrolysis or gasification without additional capital investment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If municipal solid waste or agricultural waste is used as feedstock for pyrolysis or gasification, then waste management is achieved, but the high water content, low density, and compositional variability limit efficient operation
Solution Approach 1:
The patent applies preliminary action by preprocessing the solid waste feedstock through drying to reduce moisture content, size reduction to increase surface area, and compositional adjustment before introducing it to the pyrolysis or gasification chamber. This preliminary treatment prepares the waste material to overcome its inherent deficiencies in water content, density, and homogeneity, enabling efficient subsequent thermal processing.
2Manufacturing precision
If pelletizers are used to uniformize the solid waste stream, then size consistency is improved, but the variation in composition and moisture content remains unchanged
Solution Approach 1:
The patent applies segmentation by dividing the solid waste stream into size-consistent particles through size reduction equipment, while separately addressing compositional issues through mixing and blending operations. This segmented approach treats size uniformity and compositional homogeneity as distinct problems requiring different solutions, allowing pelletization to address size while other processes handle composition.
Solution Approach 2:
The patent applies parameter changes by adjusting multiple feedstock parameters including moisture content through drying, particle size through size reduction, and compositional ratios through controlled mixing. These parameter adjustments transform the variable solid waste stream into a more consistent feedstock suitable for efficient pyrolysis or gasification operation.
3Productivity
If advanced gasification mechanisms are used to overcome feedstock inconsistency, then pyrolysis efficiency is improved, but significant capital investment in specialized equipment is required
Solution Approach 1:
The patent applies preliminary action by implementing feedstock preparation operations (drying, size reduction, mixing) upstream of the pyrolysis/gasification process. This preliminary conditioning of the waste feedstock allows the use of simpler, more cost-effective pyrolysis or gasification equipment while still achieving high efficiency, avoiding the need for complex advanced gasification systems.
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 produces a solid fuel composition with a high energy content (8,000-14,000 BTU/lb) and density (30-80 lbs/ft3), eliminating volatile organic compounds and chlorine, making it suitable for high-efficiency pyrolysis or gasification without emitting harmful pollutants, and allowing for prolonged storage and transportation without degradation.
Implementation Method 1
heating a solid waste mixture comprising between about 5% wt. and about 60% wt. mixed plastics within a process vessel to a temperature of about 90° C. to about 110° C. to separate the solid waste mixture into a dried solid waste mixture and vaporized compounds released from the heated solid waste mixtures
Implementation Method 2
The dried solid waste mixture is heated and mixed to at least about 160° C. to form a heated solid waste mixture. The heated solid waste mixture comprises melted mixed plastics distributed throughout the heated solid waste mixture
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 to a maximum temperature sufficient to melt the mixed plastics within the solid waste mixture is disclosed.