Process for producing solid biomass fuel
OwnerHong Mei Baiinventor
Life of this patent
Estimating the term…
Abstract
The present invention relates to a process for producing a solid biomass fuel, as well as a solid biomass fuel produced by said process. Additionally, the present invention relates to a combustion process comprising combusting said solid biomass fuel so as to produce energy.
Claims57
A process for producing a solid biomass fuel, wherein the process comprises the following sequential steps:
- (i) providing one or more sources of biomass;
- (ii) pulverising the one or more sources of biomass to provide a pulverised biomass powder with an average particle diameter (D50) of from 1000 μm to 20,000 μm;
- optionally, (iii) compressing the pulverised biomass powder to provide a compressed biomass powder;
- (iv) washing the compressed biomass powder or the pulverised biomass powder with an aqueous wash liquid to provide a washed biomass powder;
- (v) mechanically dewatering the washed biomass powder to provide a dewatered biomass powder and an aqueous effluent;
- (vi) drying the dewatered biomass powder to provide a dried biomass powder;
- (vii) molding the dried biomass powder so as to provide a molded biomass product;
- (viii) heating the molded biomass product to a temperature of from 160° C. to 420° C. for a time period of from 0.25 to 5 hours so as to provide a solid biomass fuel;
- and
- (ix) washing the solid biomass fuel with an aqueous wash liquid.
A process according to any preceding claim, wherein the one or more sources of biomass comprise, consist essentially of, or consist of agricultural waste such as corn straw, sesame straw, straw, banana tree, peanut straw, palm empty fruit bunches (EFB), palm fiber, palm shell, bamboo, palm tree trunk, or any combination thereof.
A process according to any preceding claim, wherein the one or more sources of biomass comprise, consist essentially of, or consist of straw, corn straw, or a combination thereof.
A process according to any preceding claim, wherein step (i) of providing one or more sources of biomass comprises (a) compressing the one or more sources of biomass so as to have a moisture content of less than 50% by weight;
- and/or (b) chopping the one or more sources of biomass so as to have an average particle diameter (D50) of from 30,000 μm to 60,000 μm;
- preferably wherein the process comprises both steps (a) and (b) and more preferably wherein the process comprises step (a) of compressing the one or more sources of biomass prior to step (b) of chopping the one or more sources of biomass.
A process according to any preceding claim, wherein step (ii) of pulverising the one or more sources of biomass to provide a pulverised biomass powder with an average particle diameter (D50) of from 1000 μm to 20,000 μm comprises crushing the one or more sources of biomass in a process involving the use of a negative pressure pneumatic conveyancing apparatus where the moisture content of the one or more sources of biomass is 20% by weight or less.
A process according to any preceding claim, wherein step (iii) of compressing the pulverised biomass powder to provide a compressed biomass powder comprises squeezing the pulverised biomass powder to provide a compressed biomass powder and an aqueous effluent, optionally wherein the pulverised biomass powder is squeezed to provide a compressed biomass powder with a moisture content of less than 30% by weight, preferably less than 25% by weight, and more preferably less than 20% by weight.
A process according to any preceding claim, wherein step (iv) of washing the compressed biomass powder or pulverised biomass powder with an aqueous wash liquid to provide a washed biomass powder comprises washing the compressed biomass powder or pulverised biomass powder more than once, preferably, wherein the compressed biomass powder or pulverised biomass powder is washed in from two to ten successive washing stages, more preferably, wherein the compressed biomass powder or pulverised biomass powder is washed in from two to five successive wash stages.
A process according to any preceding claim, wherein the aqueous wash liquid is at a temperature of from 5° C. to 160° C. during step (iv) of washing the compressed biomass powder or pulverised biomass powder with an aqueous wash liquid to provide a washed biomass powder, preferably, wherein the aqueous wash liquid is at a temperature of from 5° C. to 160° C. during each successive wash stage of step (iv).
A process according to any preceding claim, wherein the aqueous wash liquid is at a temperature of from 5° C. to 35° C. during step (iv) of washing the compressed biomass powder or pulverised biomass powder with an aqueous wash liquid to provide a washed biomass powder, preferably, wherein the aqueous wash liquid is at a temperature of from 5° C. to 35° C. during each successive wash stage of step (iv).
A process according to any preceding claim, wherein step (iv) of washing the compressed biomass powder or pulverised biomass powder with an aqueous wash liquid to provide a washed biomass powder is carried out at a pressure of from 1.1 bar to 15 bar, preferably, wherein step (iv) is carried out at atmospheric pressure, more preferably, wherein step (iv) is carried out at atmospheric pressure and a temperature of from 5° C. to 35° C.
A process according to any preceding claim, wherein the process comprises step (iii) of compressing the pulverised biomass powder to provide a compressed biomass powder.
A process according to any preceding claim, wherein step (v) of mechanically dewatering the washed biomass powder to provide a dewatered biomass powder and an aqueous effluent comprises compressing the washed biomass powder.
A process according to any preceding claim, wherein step (vi) of drying the dewatered biomass powder to provide a dried biomass powder comprises drying the dewatered biomass to provide a dried biomass powder with a moisture content of less than 15% by weight, and preferably from 10% to 15% by weight.
A process according to any preceding claim, wherein step (vi) of drying the dewatered biomass powder to provide a dried biomass powder further comprises mixing the pulverised biomass powder particles whilst drying.
A process according to any preceding claim, wherein step (vi) of drying the dewatered biomass powder to provide a dried biomass powder comprises drying the pulverised biomass powder in a drying cylinder.
A process according to any preceding claim, wherein (a) the moisture content of the dewatered biomass powder is 20% by weight or less, and wherein the process comprises drying the dewatered biomass powder in a single drying cylinder, or, (b) the moisture content of the dewatered biomass powder is 20% by weight or more, and wherein the process comprises drying the dewatered biomass powder in multiple drying cylinders.
A process according to any preceding claim, wherein step (vii) of molding the dried biomass powder so as to provide a molded biomass product comprises adapting the molding step such that the density of the molded biomass product is controlled, optionally wherein adapting the molding step such that the density of the molded biomass product is controlled comprises controlling the compression ratio of a mold used in said molding step.
A process according to any preceding claim, wherein an additive is added to the dried biomass powder prior to step (vii) of molding the dried biomass powder, optionally wherein the additive increases the yield of the molded biomass product.
A process according to any preceding claim, wherein step (viii) of heating the molded biomass product is carried out for a time period of from 0.4 to 2.5 hours, and/or wherein the step of heating the molded biomass product comprises heating the molded biomass product to a temperature of from 180° C. to 350° C., optionally from 210° C. to 280° C.
A process according to any preceding claim, wherein step (viii) of heating the molded biomass product comprises heating the molded biomass product under conditions so as to induce torrefaction of the molded biomass product.
A process according to any preceding claim, wherein step (viii) of heating the molded biomass product is adapted so as to control the uniformity of the solid biomass fuel, optionally wherein adapting step (viii) so as to control the uniformity of the solid biomass fuel comprises conducting step (viii) in an apparatus in which the molded biomass product is rotated whilst being heated, optionally, wherein adapting step (viii) so as to control the uniformity of the solid biomass fuel comprises controlling the speed or direction of rotation of the molded biomass product, optionally wherein the molded biomass product is rotated in the apparatus in both an anticlockwise and clockwise direction.
A process according to any preceding claim, wherein the process further comprises a step of cooling the solid biomass fuel after heating step (viii) and prior to (ix) of washing the solid biomass fuel with an aqueous wash liquid.
A process according to any preceding claim, wherein step (ix) of washing the solid biomass fuel with an aqueous wash liquid comprises spraying the solid biomass fuel with the aqueous wash liquid.
A process according to any preceding claim, wherein the process further comprises a step of removing dust particles from the solid biomass fuel, preferably wherein the step of removing dust particles from the solid biomass fuel is carried out concurrently to step (ix) of washing the solid biomass fuel with an aqueous wash liquid.
A process according to any preceding claim, wherein the step of removing dust particles from the solid biomass fuel comprises subjecting the solid biomass fuel to vibration, rotation, rolling, or any combination thereof.
A process according to any preceding claim, wherein the one or more sources of biomass consist essentially of, or consist of corn straw, sesame straw, straw, banana tree, peanut straw, palm empty fruit bunches (EFB), palm fiber, oil palm tree such as oil palm tree trunk, palm shell, bamboo, or any combination thereof, and wherein:
- (i) the solid biomass fuel has a potassium content of less than 10% by weight of the potassium content of the one or more sources of biomass, per unit weight;
- (ii) the washed biomass powder a potassium content of less than 10% by weight of the potassium content of the one or more sources of biomass, per unit weight;
- (iii) the washed biomass powder a nitrogen content of less than 90% by weight of the nitrogen content of the one or more sources of biomass, per unit weight;
- (iv) the washed biomass powder has a chlorine content of less than 90% by weight of the chlorine content of the one or more sources of biomass, per unit weight;
- (v) the washed biomass powder has a sulphur content of 60% or less of the sulphur content of the one or more sources of biomass, per unit weight;
- and/or
- (vi) the solid biomass fuel has a sulphur content of 50% or less of the sulphur content of the one or more sources of biomass, per unit weight.
A process according to any preceding claim, wherein the one or more sources of biomass consist essentially of, or consist of corn straw, sesame straw, straw, banana tree, peanut straw, palm empty fruit bunches (EFB), palm fiber, palm shell, oil palm tree such as oil palm tree trunk, bamboo, or any combination thereof, and wherein:
- (i) the ash content of the washed biomass powder is 75% or less by weight of the ash content of the one or more sources of biomass, per unit weight;
- (ii) calorific value of the washed biomass powder is 2% or more than the calorific value of the one or more sources of biomass, per unit weight;
- (iii) the fixed carbon content of the solid biomass fuel is 40% or more by weight than the fixed carbon content of the one or more sources of biomass, per unit weight;
- (iv) the volatile matter content of the solid biomass fuel is 94% or less of the volatile matter content of the one or more sources of biomass, per unit weight;
- and/or
- (v) the calorific value of the solid biomass fuel is 16% or more higher than the calorific value of the one or more sources of biomass, per unit weight.
A process according to any preceding claim, wherein the solid biomass fuel has one or more of the following properties:
- an ash content of the solid biomass fuel is 15% by weight or less, preferably 12% by weight or less;
- the potassium content of the solid biomass fuel is 0.2% by weight or less, preferably 0.1% by weight or less;
- the nitrogen content of the solid biomass fuel is 2% by weight or less, preferably 1% by weight or less;
- the chlorine content of the solid biomass fuel is 0.05% by weight or less, preferably 0.02% by weight or less;
- the sulphur content of the slid biomass fuel is 0.2% by weight or less, preferably 0.1% by weight or less;
- the fixed carbon content of the solid biomass fuel is 40% by weight or less, preferably 30% by weight or less;
- the volatile matter content of the solid biomass fuel is 15% by weight or less, preferably 12% by weight or less;
- the internal moisture content of the solid biomass fuel is 1% by weight or less, preferably 0.5% by weight or less;
- the received base moisture content of the solid biomass fuel is 6% by weight or less, preferably 4% by weight or less;
- or the calorific value of the solid biomass fuel is 4500 MJ/Kg or more, preferably 4750 MJ/Kg or more;
- preferably, wherein the solid biomass fuel has all of said properties.
A process according to any preceding claim, wherein the bulk density of the solid biomass fuel as determined according to DIN EN 15103 is from 1.0 to 1.4 g/cm3, preferably from 1.1 to 1.3 g/cm3, and more preferably from 1.2 to 1.3 g/cm3.
A process according to any preceding claim, wherein the solid biomass fuel is waterproof for up to 20 days, preferably up to 30 days, and more preferably up to 40 days.
A process according to any preceding claim, wherein the PM1.0 emissions of the solid biomass fuel upon combustion is less than 175 mg/kg, preferably less than 150 mg/kg.
A process according to any preceding claim, wherein the bulk density of the molded biomass product is A, and the bulk density of the biomass solid fuel is B, and wherein B/A is 0.55 to 1, wherein the bulk density is determined in accordance with DIN EN 15103.
A process according to any preceding claim, wherein material derived from biomass is present in the solid biomass fuel in an amount of at least 95% by weight of the total fuel content of the solid biomass fuel.
A process for producing a solid biomass fuel, wherein the process comprises the following sequential steps:
- (i) providing one or more sources of biomass;
- (ii) pulverising the one or more sources of biomass to provide a pulverised biomass powder with an average particle diameter (D50) of from 1000 μm to 20,000 μm;
- optionally, (iii) compressing the pulverised biomass powder to provide a compressed biomass powder;
- (iv) washing the compressed biomass powder or pulverised biomass powder with an aqueous wash liquid to provide a washed biomass powder;
- (v) mechanically dewatering the washed biomass powder to provide a dewatered biomass powder and an aqueous effluent;
- (vi) drying the dewatered biomass powder to provide a dried biomass powder;
- (vii) molding the dried biomass powder so as to provide a molded biomass product;
- and
- (viii) heating the molded biomass product to a temperature of from 160° C. to 420° C. for a time period of from 0.25 to 5 hours so as to provide a solid biomass fuel;
- wherein the one or more sources of biomass comprise, consist essentially of, or consist of sesame straw, palm empty fruit bunches (EFB), palm fiber, oil palm tree such as oil palm tree trunk, banana tree, Calliandra calothyrsus, Acacia mangium, Albizia chinensis, Hevea brasiliensis, rice husk, yam, corn cob, wood such as mixed wood, Pennisetum sinese Roxb, or any combination thereof.
A solid biomass fuel obtainable or obtained by a process according to any preceding claim.
A solid biomass fuel derived from one or more sources of biomass, wherein the one or more sources of biomass:
- (i) consist of, or consist essentially of sesame straw;
- (ii) consist of, or consist essentially of palm empty fruit bunches;
- (iii) consist of, or consist essentially of palm fiber;
- (iv) consist of, or consist essentially of banana tree;
- (v) consist of, or consist essentially of oil palm tree trunk;
- or
- (vi) comprise, consist of, or consist essentially of agricultural waste, Calliandra calothyrsus, Acacia mangium, Albizia chinensis, Hevea brasiliensis, rice husk, straw, yam, corn cob, wood such as mixed wood, grass such as Pennisetum sinese Roxb, bagasse, sunflower stalks, wheat stalks, corn stalks, sorghum stalks, soybean stalk, peanut stalks, cotton stalks, rape stalks, coconut husks, palm kernel shell (PKS), oil palm tree such as oil palm tree trunk, seaweed, peanut hulls, or any combination thereof, wherein the solid biomass fuel has one or more of the following properties:
- an ash content of the solid biomass fuel is 15% by weight or less, preferably 12% by weight or less;
- the potassium content of the solid biomass fuel is 0.2% by weight or less, preferably 0.1% by weight or less;
- the nitrogen content of the solid biomass fuel is 2% by weight or less, preferably 1% by weight or less;
- the chlorine content of the solid biomass fuel is 0.05% by weight or less, preferably 0.02% by weight or less;
- the sulphur content of the slid biomass fuel is 0.2% by weight or less, preferably 0.1% by weight or less;
- the fixed carbon content of the solid biomass fuel is 40% by weight or less, preferably 30% by weight or less;
- the volatile matter content of the solid biomass fuel is 15% by weight or less, preferably 12% by weight or less;
- the internal moisture content of the solid biomass fuel is 1% by weight or less, preferably 0.5% by weight or less;
- the received base moisture content of the solid biomass fuel is 6% by weight or less, preferably 4% by weight or less;
- or the calorific value of the solid biomass fuel is 4500 MJ/Kg or more, preferably 4750 MJ/Kg or more;
- preferably, wherein the solid biomass fuel has all of said properties.
Use of one or more sources of biomass to produce a solid biomass fuel, wherein (i) the one or more sources of biomass:
- comprise, consist of, or consist essentially of agricultural waste, Calliandra calothyrsus, Acacia mangium, Albizia chinensis, Hevea brasiliensis, rice husk, straw, yam, corn cob, wood such as mixed wood, grass such as Pennisetum sinese Roxb, bagasse, sunflower stalks, wheat stalks, corn stalks, sorghum stalks, soybean stalk, peanut stalks, cotton stalks, rape stalks, coconut husks, oil palm tree such as oil palm tree trunk, palm kernel shell (PKS), seaweed, peanut hulls, or any combination thereof, wherein the solid biomass fuel has one or more of the following properties:
- an ash content of the solid biomass fuel is 15% by weight or less, preferably 12% by weight or less;
- the potassium content of the solid biomass fuel is 0.2% by weight or less, preferably 0.1% by weight or less;
- the nitrogen content of the solid biomass fuel is 2% by weight or less, preferably 1% by weight or less;
- the chlorine content of the solid biomass fuel is 0.05% by weight or less, preferably 0.02% by weight or less;
- the sulphur content of the slid biomass fuel is 0.2% by weight or less, preferably 0.1% by weight or less;
- the fixed carbon content of the solid biomass fuel is 40% by weight or less, preferably 30% by weight or less;
- the volatile matter content of the solid biomass fuel is 15% by weight or less, preferably 12% by weight or less;
- the internal moisture content of the solid biomass fuel is 1% by weight or less, preferably 0.5% by weight or less;
- the received base moisture content of the solid biomass fuel is 6% by weight or less, preferably 4% by weight or less;
- or the calorific value of the solid biomass fuel is 4500 MJ/Kg or more, preferably 4750 MJ/Kg or more;
- preferably, wherein the solid biomass fuel has all of said properties;
- or (ii) wherein the one or more sources of biomass consist of, or consist essentially of sesame straw, banana tree, palm empty fruit bunches (EFB), palm fiber, oil palm tree trunk or a combination thereof.
Dependencies are inferred from the claim text.