Super compaction of biomass and other carbon-containing materials to high energy content fuels

A method of creating a brick suitable as fuel for power generation from biomass, the method comprising:

• (a) positioning the biomass;
• (b) pre-processing the biomass to a suitable size and water content;
• (c) delivering the biomass to a compaction chamber of a super compactor;
• (d) actuating the super compactor to exert a predetermined amount of pressure of between 10,000 psi and 200,000 psi on the biomass, thereby squeezing water out of and collapsing voids in the biomass, the super compactor having a moveable slide gate that is configured to switch between a closed configuration, a slotted configuration, and an open configuration, such that when the moveable slide gate is in the slotted configuration, at least a portion of the water passes through at least a pair of recesses extending at least partially through a thickness of a movable slide gate;
• (e) collecting the water squeezed out of the biomass;
• (f) positioning the movable slide gate in the open configuration;
• (g)moving the biomass from the compaction chamber to a heated extrusion chamber, the heated extrusion chamber being separated from the compaction chamber by the movable slide gate;
• and
• (h) heating the biomass to form the brick.

A super compactor configured to receive biomass and deliver a brick suitable as fuel for power generation, the super compactor comprising:

• an inlet adapted to receive the biomass from an external source;
• a compaction chamber configured to receive the biomass from the inlet and having:
• (a) at least one ram configured to reciprocate along a travel path and exert a predetermined amount of pressure on the biomass,
• (b) a movable slide gate compressible against the biomass, the slide gate being configured to switch between a closed configuration, a slotted configuration, and an open configuration, the gate defining a center and an outer perimeter, wherein, when the moveable slide gate is in the slotted configuration, the movable slide gate defines at least one recess that extends between the center and the outer perimeter, the at least one recess extending at least partially through a thickness of the gate so as to promote the removal of moisture from the biomass, and
• (c) one or more dewatering apertures configured to permit moisture to pass through a moisture collector configured to capture moisture that passes through the dewatering apertures;
• a power unit configured to provide power to the at least one ram;
• and
• a heated extrusion chamber configured to receive the biomass from the compaction chamber, the heated extrusion chamber being separated from the compaction chamber by the movable slide gate, wherein the heated extrusion chamber is configured to receive the biomass from the compaction chamber when the movable slide gate is in the open configuration, the heated extrusion chamber being further configured to heat and compact the biomass to bind the biomass and form the brick.