# US 8,784,514 B1 · Carpet fuel processing boiler > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,784,514 B1 - Document ID: US8784514B1 - Status: Granted - Kind: B1 - Application number: 13/298,197 - Filed: 2011-11-16 - Granted: 2014-07-22 - Earliest claimed: 2010-11-17 - Assignees: Columbia Insurance Company - Applicants: Reese Edward Graves, Jr.; John Daniel Hall; Garrett Townsend Hicks, Jr.; Gregory Glenn Wimpy - Inventors: Reese Edward Graves, Jr.; John Daniel Hall; Garrett Townsend Hicks, Jr.; Gregory Glenn Wimpy - Web page: https://patentgrep.com/patent/US8784514B1 ## CPC - F23G 5/033: comminuting or crushing - C10L 5/48: on industrial residues and waste materials {(C10L5/403, C10L5/406 take precedence)} - C10L 2290/02: Combustion or pyrolysis - C10L 2290/08: Drying or removing water - C10L 2290/28: Cutting, disintegrating, shredding or grinding - C10L 2290/54: Specific separation steps for separating fractions, components or impurities during preparation or upgrading of a fuel - Y02E 20/12: Heat utilisation in combustion or incineration of waste - F23G: CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION - C10L: FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract The present invention relates generally to the production of energy and the reclaimation of carpet waste material. More particularly, the invention relates to a method and system for storing and using post industrial and post consumer carpet as fuel in an energy generation process and for producing at least one recyclable carpet waste material. ## Claims ### Claim 1 A method for energy production, comprising: providing a carpet waste composition, the carpet waste composition comprising an inorganic filler component and a first organic component; mechanically treating the carpet waste composition such that at least a portion of the first organic component of the carpet waste composition is separated from the carpet waste composition; producing a first combustible stream comprising the at least a portion of the first organic component of the carpet waste composition; from the carpet waste composition, producing a first waste stream comprising a reclaimed inorganic filler composition that is substantially free of the organic component of the carpet waste composition; delivering the first waste stream to a first waste storage unit; selectively delivering the first combustible stream to a boiler; and directly combusting the first combustible stream within the boiler. ### Claim 2 (depends on 1) The method of claim 1, further comprising the steps of: generating ash and at least one useable energy product upon directly-combusting the first combustible stream within the boiler, thereby producing a second waste stream comprising the ash; and delivering the second waste stream to a second waste storage unit. ### Claim 3 (depends on 1) The method of claim 1, wherein the carpet waste composition comprises a post consumer carpet. ### Claim 4 (depends on 1) The method of claim 1, wherein the carpet waste composition comprises a post industrial carpet. ### Claim 5 (depends on 1) The method of claim 1, wherein the inorganic filler component of the carpet waste composition comprises carpet fines. ### Claim 6 (depends on 1) The method of claim 1, wherein the inorganic filler component of the carpet waste composition comprises calcium carbonate. ### Claim 7 (depends on 1) The method of claim 1, wherein the organic component of the carpet waste composition comprises carpet fibers. ### Claim 8 (depends on 2) The method of claim 2, wherein the at least one useable energy product comprises steam. ### Claim 9 (depends on 2) The method of claim 2, wherein the at least one useable energy product comprises electricity. ### Claim 10 (depends on 2) The method of claim 2, wherein the first waste stream is distinct and isolated from the second waste stream. ### Claim 11 (depends on 1) The method of claim 1, wherein the carpet waste composition is provided in the form of bales. ### Claim 12 (depends on 1) The method of claim 1, wherein the first combustible stream has a BTU/weight content ranging from about 8,000 BTU/lb to about 12,000 BTU/lb. ### Claim 13 (depends on 12) The method of claim 12, wherein the carpet waste composition has an overall BTU/weight content, and wherein the BTU/weight content of the first combustible stream is greater than the overall BTU/weight content of the carpet waste composition. ### Claim 14 (depends on 1) The method of claim 1, wherein the first combustible stream has a BTU/weight content of at least 10,400 BTU/lb. ### Claim 15 (depends on 2) The method of claim 2, further comprising adding a second organic component to the first combustible stream before delivery of the first combustible stream to the boiler. ### Claim 16 (depends on 15) The method of claim 15, wherein the first and second organic components each have a BTU/weight content, and wherein the second organic component has a higher BTU/weight content than the first organic component. ### Claim 17 (depends on 2) The method of claim 2, further comprising conditioning the second waste stream through maceration and dewatering. ### Claim 18 (depends on 1) The method of claim 1, wherein the step of mechanically treating the carpet waste composition comprises shredding the carpet waste composition into reduced portions. ### Claim 19 (depends on 18) The method of claim 18, wherein the step of mechanically treating the carpet waste composition further comprises vibrating the shredded carpet waste composition such that at least a portion of any post-consumer dirt within the carpet waste composition is separated from the remainder of the carpet waste composition and directed to the first waste stream. ### Claim 20 (depends on 1) The method of claim 1, wherein at least a portion of the first waste stream comprises recyclable material. ### Claim 21 (depends on 1) The method of claim 1, wherein the first waste stream comprises recyclable material. ### Claim 22 (depends on 1) The method of claim 1, wherein the step of selectively delivering the first combustible stream to the boiler comprises selectively delivering the first combustible stream to a grate section of the boiler, the grate section having a plurality of stepped grates that are configured to burn the first combustible stream, wherein at least every other grate of the plurality of stepped grates is configured to articulate in a reciprocating motion to affect the sequential downward tumbling of the first combustible stream as it is burned and consumed. ### Claim 23 A method for energy production, comprising: providing a carpet waste composition, the carpet waste composition comprising an inorganic filler component and a first organic component; mechanically treating the carpet waste composition such that at least a portion of the first organic component of the carpet waste composition is separated from the carpet waste composition; producing a first combustible stream comprising the at least a portion of the first organic component of the carpet waste composition; from the carpet waste composition, producing a first waste stream comprising a reclaimed inorganic filler composition that is substantially free of the organic component of the carpet waste composition; delivering the first waste stream to a first waste storage unit, wherein at least a portion of the first waste stream comprises recyclable material; selectively delivering the first combustible stream to a boiler; and directly combusting the first combustible stream within the boiler. ### Claim 24 A method for energy production, comprising: providing a carpet waste composition, the carpet waste composition comprising an inorganic filler component and a first organic component; mechanically treating the carpet waste composition such that at least a portion of the first organic component of the carpet waste composition is separated from the carpet waste composition; producing a first combustible stream comprising the at least a portion of the first organic component of the carpet waste composition; from the carpet waste composition, producing a first waste stream comprising a reclaimed inorganic filler composition that is substantially free of the organic component of the carpet waste composition; delivering the first waste stream to a first waste storage unit, wherein at least a portion of the first waste stream comprises recyclable material; selectively delivering the first combustible stream to a boiler; and directly combusting the first combustible stream within the boiler, wherein the step of selectively delivering the first combustible stream to the boiler comprises selectively delivering the first combustible stream to a grate section of the boiler, the grate section having a plurality of stepped grates that are configured to burn the first combustible stream, wherein at least every other grate of the plurality of stepped grates is configured to articulate in a reciprocating motion to affect the sequential downward tumbling of the first combustible stream as it is burned and consumed. ### Claim 25 (depends on 23) The method of claim 23, wherein the first combustible stream has a BTU/weight content ranging from about 8,000 BTU/lb to about 12,000 BTU/lb, and wherein the carpet waste composition has an overall BTU/weight content, and wherein the BTU/weight content of the first combustible stream is greater than the overall BTU/weight content of the carpet waste composition. ### Claim 26 (depends on 1) The method of claim 1, further comprising the steps of: generating ash and at least one useable energy product upon directly-combusting the first combustible stream within the boiler, thereby producing a second waste stream comprising the ash; and delivering the second waste stream to a second waste storage unit. ### Claim 27 (depends on 26) The method of claim 26, further comprising conditioning the second waste stream through maceration and dewatering. ### Claim 28 (depends on 23) The method of claim 23, wherein the step of selectively delivering the first combustible stream to the boiler comprises selectively delivering the first combustible stream to a grate section of the boiler, the grate section having a plurality of stepped grates that are configured to burn the first combustible stream, wherein at least every other grate of the plurality of stepped grates is configured to articulate in a reciprocating motion to affect the sequential downward tumbling of the first combustible stream as it is burned and consumed. ### Claim 29 (depends on 23) The method of claim 23, wherein the step of mechanically treating the carpet waste composition comprises shredding the carpet waste composition into reduced portions. ### Claim 30 (depends on 29) The method of claim 29, wherein the step of mechanically treating the carpet waste composition further comprises vibrating the shredded carpet waste composition such that at least a portion of any post-consumer dirt within the carpet waste composition is separated from the remainder of the carpet waste composition and directed to the first waste stream. ### Claim 31 (depends on 24) The method of claim 24, wherein all of the first waste stream comprises recyclable material.