A process and system for producing an engineered fuel product that meets customer specifications for composition and combustion characteristics is provided. The engineered fuel product is preferably a high-BTU, alternative fuel that burns cleaner than coal or petroleum coke (petcoke) and has significantly reduced NOx, SO.sub.2 and GHG emissions.

A method for producing briquettes made of a waste material includes provisioning of at least one metal and at least one organic material. The waste material is mechanically prepared in a single or multiple stages and at least one first fraction of the waste material is separated. A briquette mixture containing the at least one first fraction is produced, wherein the at least one first fraction has a calorific value of 0 MJ/kg to 30 MJ/kg. A calorific value of the briquette mixture is adjusted by varying at least the first fraction. The briquette mixture is introduced into a briquetting device and pressed into briquettes. Briquettes with a calorific value of 5 MJ/kg to 30 MJ/kg and with a maximum copper content of 0.1 wt % to 20 wt % are produced.

This alternative fuel is a reclaimed waste product which has a solid, particulate consistency at ambient temperature. The fuel comprises a composite of petroleum pitch and a powder coating. The powder coating penetrates into the surface of the pitch. The powder coating is recycled ash, pulverized coal, or pulverized petroleum coke.

A process for producing biocoke is provided, comprising: providing a heated biogas stream comprising carbon-containing vapors; providing a kinetic interface media, in solid form; introducing the kinetic interface media and the heated biogas stream to a kinetic interface reactor, operated to convert at least some of the carbon-containing vapors to biocoke; removing the solid biocoke-containing kinetic interface media from the kinetic interface reactor; and recovering the solid biocoke-containing kinetic interface media. Other variations provide a process for producing biocoke, comprising: providing a bioliquid stream comprising carbon-containing liquids; providing a kinetic interface media, in solid form; introducing the kinetic interface media and the bioliquid stream to a kinetic interface reactor, operated to convert at least some of the carbon-containing liquids to biocoke; removing the solid biocoke-containing kinetic interface media from the kinetic interface reactor; and recovering the solid biocoke-containing kinetic interface media. Many embodiments are described.

A power source that provides at least one of thermal and electrical power and method of use thereof such as direct electricity or thermal to electricity is provided that powers a power system comprising (i) at least one reaction cell comprising a fuel having atomic hydrogen, nascent H.sub.2O; and a material to cause the fuel to be highly conductive, (iii) at least one set of electrodes that confine the fuel and an electrical power source that provides a short burst of low-voltage, high-current electrical energy to initiate a reaction and an energy gain, (iv) a product recovery systems such as a condensor, (v) a reloading system, (vi) at least one of hydration, thermal, chemical, and electrochemical systems to regenerate the fuel from the reaction products, (vii) a heat sink that accepts the heat from the power-producing reactions, (viii) a power conversion system.

A power source that provides at least one of thermal and electrical power and method of use thereof such as direct electricity or thermal to electricity is provided that powers a power system comprising (i) at least one reaction cell comprising a fuel having atomic hydrogen, nascent H.sub.2O; and a material to cause the fuel to be highly conductive, (iii) at least one set of electrodes that confine the fuel and an electrical power source that provides a short burst of low-voltage, high-current electrical energy to initiate a reaction and an energy gain, (iv) a product recovery systems such as a condensor, (v) a reloading system, (vi) at least one of hydration, thermal, chemical, and electrochemical systems to regenerate the fuel from the reaction products, (vii) a heat sink that accepts the heat from the power-producing reactions, (viii) a power conversion system.

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.

Char fuels are described that result from a simple and efficient carbonization of cellulosic and/or lignin-containing materials, and can be provided as pellets, briquettes, or powders. Such char fuels show very low water absorption.

The invention relates to a method for producing pellets which are capable of providing free flowing powder suitable for firing an industrial furnace from municipal and/or other waste, the process comprising the following steps: (i) providing waste material comprising one or more thermoplastic material(s) of more than 40%, based on the total dry weight of the waste and one or more cellulosic material(s) of more than 30%, based on the total dry weight of the waste, wherein the waste has a particle size distribution with more than 80% larger than 5 mm, more than 95% smaller than 60 mm, (ii) subjecting the waste material through a pelletiser with holes between 4-16 mm and a length ratio of more than 2, and subjecting the pellets through a second pelletiser with holes between 4 and 10 mm, and a length ratio of more than 2 to provide pellets with a diameter between 4 and 10 mm, and a length of between 3 and 50 mm. The invention also relates to pellets obtained and having advantageous properties.

A composite ash produced by thermally processing paper and/or carpet exothermic processing waste, the composite ash being an inorganic mineral product or oxidized material of common crystalline and amorphous non-crystalline composition comprising metakaolin and at least one of a group consisting of mineral oxide and mineral carbonate, the composite ash being reactive with a pH greater than about 7.0.