Method for producing agglomerates from a biomass stream

Abstract

The present invention relates to a method for producing agglomerates from a feedstock comprising at least one biomass stream, the method comprising the steps of: combining the feedstock with one or more binding reagents; and introducing the feedstock into an agglomeration apparatus in the presence of a polymerisation activator to produce the agglomerates.

Claims

1. A method for producing agglomerates from a feedstock comprising at least one biomass stream, the method comprising the steps of: combining the feedstock with one or more binding reagents, wherein the one or more binding reagents comprise a monomer compound; and introducing the feedstock into an agglomeration apparatus in the presence of a polymerisation activator to produce the agglomerates, wherein the polymerisation activator is a substance which initiates the polymerisation or cross-linking of the one or more binding reagents.

2. A method according to claim 1, wherein the step of combining the feedstock with the one or more binding reagents occurs prior to the step of introducing the feedstock into the agglomeration apparatus to produce the agglomerates, such that the method comprises the steps of: combining the feedstock with the one or more binding reagents to produce an agglomeration mixture; then introducing the agglomeration mixture into the agglomeration apparatus in the presence of the polymerisation activator to produce the agglomerates.

3. A method according to claim 1, wherein the polymerisation activator is contacted with the feedstock and the one or more binding reagents prior to the step of introducing the feedstock into the agglomeration apparatus to produce the agglomerates.

4. A method according to claim 1, wherein the polymerisation activator is contacted with the feedstock and the one or more binding reagents simultaneous to, or after the feedstock is introduced into the agglomeration apparatus.

5. A method according to claim 2, wherein one or more further biomass streams and/or binding reagents are combined with the agglomeration mixture prior to the step of: introducing the agglomeration mixture into the agglomeration apparatus in the presence of the polymerisation activator to produce the agglomerates.

6. A method according to claim 1, wherein the one or more binding reagents is a styrene monomer compound or a silicon monomer compound.

7. A method according to claim 1, wherein the one or more binding reagents further comprises a surfactant.

8. A method according to claim 1, wherein the polymerisation activator is a monomer cross-linking compound.

9. A method according to claim 1, wherein the agglomerates undergo further treatment to harden or seal the outer layer of the agglomerates.

10. A method according to claim 9, wherein the further treatment comprises the application of a surface modifier to the surface of the agglomerates.

11. A method according to claim 1, wherein the method further comprises the contact of one or more binding reagents with an initiator reagent.

12. A method according to claim 1, wherein the method further comprises the step of: pre-treatment of the feedstock.

13. A method according to claim 12, wherein the step of pre-treatment of the feedstock occurs prior to the step of combining the feedstock with one or more binding reagents.

14. A method according to claim 12, wherein the step of pre-treatment of the feedstock comprises one of more of screening, shredding, grinding or size reduction of the feedstock.

15. A method according to claim 12, wherein the feedstock has a water content range of 5% to 80% moisture following the pre-treatment step.

16. A method according to claim 12, wherein the feedstock has a carbon content range of 15% to 98% following properties following the pre-treatment step.

17. A method according to claim 1, wherein the method comprises the step of: curing the agglomerates.

18. A method according to claim 17, wherein the step of curing the agglomerates further comprises the step of: polishing the agglomerates for a polishing period.

19. A method according to claim 17, wherein the step of curing the agglomerates comprises the step of: coating the agglomerates with a desiccation material.

20. A method according to claim 1, wherein the agglomerates are pellets or granules.

21. A method according to claim 1, wherein the agglomerates are suitable for use as combustible fuel source.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features of the present invention are more fully described in the following description of two non-limiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

(2) FIG. 1 is a flowsheet for the preparation of a combustible fuel source in accordance with one embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

(3) Throughout this specification, unless the context requires otherwise, the word “comprise” or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

(4) In FIG. 1, there is shown a method 10 for producing agglomerates 14 which are suitable for use as a biofuel in accordance with a first embodiment of the present invention. The method 10 allows for the production of the agglomerates 14 utilising one of more organic waste feedstocks 16. The organic waste feedstock 16 undergoes a pre-treatment step 18. The pre-treatment step 18 prepares the organic feedstock for the further processing and may contain one or more of the following pre-treatment steps; screening, shredding, grinding and dewatering to produce a treated organic feedstock 20. The required pre-treatment steps depends on the physical properties of the organic feedstock 16 and one or more of the aforementioned pre-treatment steps may not be required.

(5) The treated organic feedstock 20 is fed into a mixing step 22 where it is mixed with one or more binding reagents 24 to produce an agglomeration mixture 26. If required, additional water 28 may be added to the agglomeration mixture 26. The agglomeration mixture 26 is fed into a first agglomeration step 30 in the presence of a polymerisation activator 31 to produce agglomerates 32. The agglomerates 32 are then passed to a second agglomeration step 34 where a surface modifier 36 is sprayed on the agglomerates 32 to produce a secondary agglomerate 38. The secondary agglomerate 38 undergoes a screening step 40 to ensure correct physical specifications. Unsatisfactory agglomerates 41 are returned to the mixing step 32 for further processing. Satisfactory agglomerates are then passed to a green product curing step 42, followed by a final product curing step 44 to produce cured agglomerates 14.

Example 1

(6) Agglomerates suitable for use as a fuel source were prepared using Cellulosic Lignin waste sourced from Cresentino Cellulosic Ethanol plant, Italy as an organic feedstock.

(7) The binder reagent used was a styrene acrylic emulsion.

(8) The polymerisation activator was diethylene glycol in the presence of an ammonium persulphate initiator reagent.

(9) TABLE-US-00001 Dry Wet Calculated Calculated Material Weight g Weight g Water (g) Solids % Lignin sludge 3,308 9,450 Total dry feed 3,308 Reagent liquid used 50 Binder reagent used dry 12.40 Binder water Water trim added 0 Total weights 3,320 9,500 6,180 34.95 Results Weight g Green pellets produced 9,466 Drum losses 34 Pellets size range 15-25 mm Desiccating Conditions Tray stored open top - still air No fan ventilation No air conditioning Ambient Conditions during desiccation - Max/Min Max Temp Min Temp Time (° C.) (° C.) Humidity - reported Day 28 27 70% to 78% Night 18 17 63% to 65% Moisture Total Water % of Solids Day Weight Loss (g/d) Loss (g) wet % 0 9,466 0 1 8,901 565 565 5.97 37.30 2 8,350 551 1,116 11.79 39.76 3 7,780 570 1,686 17.81 42.67 4 7,292 488 2,174 22.97 45.53 5 6,825 467 2,641 27.90 48.64 6 6,382 443 3,084 45.19 52.02 7 5,970 412 3,496 54.78 55.61 8 5,540 430 3,926 65.76 59.93 9 5,204 336 4,262 76.93 63.80 10 4,892 312 4,574 87.89 67.86 11 4,679 213 4,787 97.85 70.95 12 4,439 240 5,027 107.44 74.79 13 4,287 152 5,179 116.67 77.44 14 4,182 105 5,284 123.26 79.39 15 4,112 70 5,354 128.02 80.74 16 4,050 62 5,416 131.71 81.97 17 3,990 60 5,476 135.21 83.21 18 3,945 45 5,521 138.37 84.15 19 3,920 25 5,546 140.58 84.69 20 3,892 28 5,574 142.19 85.30 21 3,878 14 5,588 143.58 85.61 22 3,865 13 5,601 144.43 85.90 45 3,835 30 5,631 145.69 86.57 60 3,815 20 5,651 147.35 87.02 Final weight 3,815 Final Moisture content 13.0%

Example 2

(10) Agglomerates suitable for use as a fuel source were prepared using Cellulosic Lignin waste sourced from a Korean R&D laboratory in Seoul, Korea as an organic feedstock.

(11) The binder reagent used was a styrene acrylic emulsion.

(12) The polymerisation activator was diethylene glycol in the presence of an ammonium persulphate initiator reagent.

(13) TABLE-US-00002 Dry Wet Calculated Calculated Data for Run #3 Weight g Weight g Water (g) Solids % Lignin sludge 2,470 6,500 Total dry feed 2,470 Reagent liquid used 37 Binder reagent used dry 9.26 Binder water Water trim added 0 Total weights 2,479 6,537 4,058 37.93 Results Weight g Green pellets produced 6,505 Drum losses 32 Pellets size range 10-15 mm Desiccating Conditions Tray stored open top - still air No fan ventilation No air conditioning Ambient Conditions during desiccation - Max/Min Time Max Temp (° C.) Min Temp (° C.) Humidity - reported Day 34 31 70% to 78% Night 23 20 63% to 65% Moisture Total Water % of Solids Day Weight Loss (g/d) Loss (g) wet % 0 6,505 0 1 6,102 403 403 6.20 40.63 2 5,744 358 761 11.70 43.16 3 5,370 374 1,135 17.45 46.17 4 5,010 360 1,495 22.98 49.49 5 4,701 309 1,804 27.73 52.74 6 4,380 321 2,125 45.20 56.60 7 4,090 290 2,415 55.14 60.62 8 3,790 300 2,715 66.38 65.42 9 3,501 289 3,004 79.26 70.82 10 3,335 166 3,170 90.55 74.34 11 3,180 155 3,325 99.70 77.96 12 3,060 120 3,445 108.33 81.02 13 2,983 77 3,522 115.10 83.11 14 2,942 41 3,563 119.44 84.27 15 2,907 35 3,598 122.30 85.29 16 2,890 17 3,615 124.36 85.79 17 2,880 10 3,625 125.43 86.09 18 2,872 8 3,633 126.15 86.33 19 2,868 4 3,637 126.64 86.45 20 2,865 3 3,640 126.92 86.54 21 2,863 2 3,642 127.12 86.60 22 2,862 1 3,643 127.24 86.63 45 2,840 22 3,665 128.06 87.30 60 2,829 11 3,676 129.44 87.64 Final weight 2,829 Final Moisture content 12.4%

Example 3

(14) Agglomerates suitable for use as a fuel source were prepared using chicken litter sourced from the University of Queensland and the University of Southern Queensland as an organic feedstock.

(15) The binder reagent used was a methoxysilane solution.

(16) The polymerisation activator was diethylene glycol in the presence of an ammonium persulphate initiator reagent.

(17) TABLE-US-00003 Dry Wet Calculated Calculated Data for Run #3 Weight g Weight g Water (g) Solids % Chicken Litter 3,825 8,500 Total dry feed 3,825 Reagent liquid used 46 Binder reagent used dry 11.48 Binder water Water trim added 0 Total weights 3,836 8,546 4,709 44.89 Results Weight g Green pellets produced 8,522 Drum losses 24 Pellets size range 10-15 mm Desiccating Conditions Tray stored open top - still air No fan ventilation No air conditioning Ambient Conditions during desiccation - Max/Min Max Temp Min Temp Time (° C.) (° C.) Humidity - reported Day 24 20 65% to 72% Night 15 12 52% to 56% Moisture Total Water % of Solids Day Weight Loss (g/d) Loss (g) wet % 0 8,522 0 1 8,006 516 516 6.05 47.92 2 7,560 446 962 11.29 50.75 3 7,159 401 1,363 15.99 53.59 4 6,780 379 1,742 20.44 56.59 5 6,420 360 2,102 24.67 59.76 6 6,156 264 2,366 36.85 62.32 7 5,903 253 2,619 42.54 64.99 8 5,680 223 2,842 48.15 67.54 9 5,494 186 3,028 53.31 69.83 10 5,350 144 3,172 57.74 71.71 11 5,215 135 3,307 61.81 73.57 12 5,090 125 3,432 65.81 75.37 13 4,980 110 3,542 69.59 77.04 14 4,884 96 3,638 73.05 78.55 15 4,799 85 3,723 76.23 79.94 16 4,715 84 3,807 79.33 81.37 17 4,645 70 3,877 82.23 82.59 18 4,590 55 3,932 84.65 83.58 19 4,551 39 3,971 86.51 84.30 20 4,532 19 3,990 87.67 84.65 21 4,524 8 3,998 88.22 84.80 22 4,520 4 4,002 88.46 84.88 45 4,480 40 4,042 89.42 85.64 60 4,460 20 4,062 90.67 86.02 Final weight 4,460 Final Moisture content 14.0%

Example 4

(18) Agglomerates suitable for use as a fuel source were prepared using chicken litter sourced from Lombardia, Italy as an organic feedstock.

(19) The binder reagent used was a methoxysilane solution.

(20) The polymerisation activator was diethylene glycol in the presence of an ammonium persulphate initiator reagent.

(21) TABLE-US-00004 Dry Wet Calculated Calculated Data for Run #3 Weight g Weight g Water (g) Solids % Chicken Litter 3,255 7,750 Total dry feed 3,255 Reagent liquid used 39 Binder reagent used dry 9.77 Binder water Water trim added 0 Total weights 3,265 7,789 4,524 41.91 Results Weight g Green pellets produced 7,762 Drum losses 27 Pellets size range 8-12 mm Desiccating Conditions Tray stored open top - still air No fan ventilation No air conditioning Ambient Conditions during desiccation - Max/Min Max Temp Min Temp Time (° C.) (° C.) Humidity - reported Day 24 20 70% to 78% Night 15 12 63% to 65% Moisture Total Water % of Day Weight Loss (g/d) Loss (g) wet Solids % 0 7,762 0 1 7,121 641 641 8.26 45.85 2 6,622 499 1,140 14.69 49.30 3 6,285 337 1,477 19.03 51.95 4 5,859 426 1,903 24.52 55.72 5 5,460 399 2,302 29.66 59.79 6 5,070 390 2,692 49.30 64.39 7 4,790 280 2,972 58.62 68.16 8 4,568 222 3,194 66.68 71.47 9 4,380 188 3,382 74.04 74.54 10 4,240 140 3,522 80.41 77.00 11 4,121 119 3,641 85.87 79.22 12 4,020 101 3,742 90.80 81.21 13 3,933 87 3,829 95.25 83.01 14 3,866 67 3,896 99.06 84.45 15 3,827 39 3,935 101.78 85.31 16 3,799 28 3,963 103.55 85.94 17 3,779 20 3,983 104.84 86.39 18 3,761 18 4,001 105.87 86.81 19 3,755 6 4,007 106.54 86.94 20 3,750 5 4,012 106.84 87.06 21 3,748 2 4,014 107.04 87.11 22 3,747 1 4,015 107.12 87.13 45 3,712 35 4,050 108.09 87.95 60 3,690 22 4,072 109.70 88.48 Final weight 3,690 Final Moisture content 11.5%

Example 5

(22) Agglomerates suitable for use as a fuel source were prepared using fine cut pine sawdust sourced from Montenegro as an organic feedstock.

(23) The binder reagent used was a methoxysilane solution.

(24) The polymerisation activator was silyl acetate in the presence of ammonium persulphate solution initiator reagent.

(25) TABLE-US-00005 Dry Wet Calculated Calculated Data for Run #3 Weight g Weight g Water (g) Solids % Sawdust 3,850 7,000 Total dry feed 3,850 Reagent liquid used 77 Binder reagent used dry 19.25 Binder water Water trim added 120 Total weights 3,869 7,197 3,328 53.76 Results Weight g Green pellets produced 7,178 Drum losses 19 Pellets size range 15-25 mm Desiccating Conditions Tray stored open top - still air No fan ventilation No air conditioning Ambient Conditions during desiccation - Max/Min Max Temp Min Temp Time (° C.) (° C.) Humidity - reported Day 18 17 50% to 55% Night 8 7 45% to 48% Moisture Total Water % of Solids Day Weight Loss (g/d) Loss (g) wet % 0 7,178 0 1 6,745 433 433 6.03 57.36 2 6,335 410 843 11.74 61.08 3 5,965 370 1,213 16.90 64.87 4 5,682 283 1,496 20.84 68.10 5 5,460 222 1,718 23.93 70.87 6 5,277 183 1,901 34.82 73.32 7 5,104 173 2,074 39.30 75.81 8 4,946 158 2,232 43.73 78.23 9 4,798 148 2,380 48.12 80.64 10 4,695 103 2,483 51.75 82.41 11 4,615 80 2,563 54.59 83.84 12 4,544 71 2,634 57.07 85.15 13 4,482 62 2,696 59.33 86.33 14 4,429 53 2,749 61.33 87.36 15 4,382 47 2,796 63.13 88.30 16 4,342 40 2,836 64.72 89.11 17 4,317 25 2,861 65.89 89.63 18 4,296 21 2,882 66.76 90.07 19 4,284 12 2,894 67.36 90.32 20 4,275 9 2,903 67.76 90.51 21 4,267 8 2,911 68.09 90.68 22 4,260 7 2,918 68.39 90.83 45 4,225 35 2,953 69.32 91.58 60 4,201 24 2,977 70.46 92.10 Final weight 4,201 Final Moisture content 7.9%

Example 6

(26) Agglomerates suitable for use as a fuel source were prepared using fine cut pine sawdust sourced from Scotland as an organic feedstock.

(27) The binder reagent used was a methoxysilane solution.

(28) The polymerisation activator was silyl acetate in the presence of ammonium persulphate solution initiator reagent.

(29) TABLE-US-00006 Dry Wet Calculated Calculated Data for Run #3 Weight g Weight g Water (g) Solids % Sawdust 3,510 6,750 Total dry feed 3,510 Reagent liquid used 70 Binder reagent used dry 17.55 Binder water Water trim added 105 Total weights 3,528 6,925 3,398 50.94 Results Weight g Green pellets produced 6,902 Drum losses 23 Pellets size range 15-20 mm Desiccating Conditions Tray stored open top - still air No fan ventilation No air conditioning Ambient Conditions during desiccation - Max/Min Max Temp Min Temp Time (° C.) (° C.) Humidity - reported Day 22 20 65% to 72% Night 12 10 48% to 55% Moisture Total Water % of Solids Day Weight Loss (g/d) Loss (g) wet % 0 6,902 0 1 6,440 462 462 6.69 54.78 2 6,010 430 892 12.92 58.69 3 5,620 390 1,282 18.57 62.77 4 5,355 265 1,547 22.41 65.87 5 5,096 259 1,806 26.17 69.22 6 4,880 216 2,022 39.68 72.29 7 4,667 213 2,235 45.80 75.58 8 4,471 196 2,431 52.09 78.90 9 4,297 174 2,605 58.26 82.09 10 4,173 124 2,729 63.51 84.53 11 4,099 74 2,803 67.17 86.06 12 4,033 66 2,869 69.99 87.47 13 3,982 51 2,920 72.40 88.59 14 3,940 42 2,962 74.38 89.53 15 3,897 43 3,005 76.27 90.52 16 3,862 35 3,040 78.01 91.34 17 3,841 21 3,061 79.26 91.84 18 3,826 15 3,076 80.08 92.20 19 3,817 9 3,085 80.63 92.42 20 3,811 6 3,091 80.98 92.56 21 3,806 5 3,096 81.24 92.68 22 3,804 2 3,098 81.40 92.73 45 3,789 15 3,113 81.83 93.10 60 3,780 9 3,122 82.40 93.32 Final weight 3,780 Final Moisture content 6.7%

Example 7

(30) Agglomerates suitable for use as a fuel source were prepared using a mixture of sewage digestate sourced from the University of Queensland and bagasse compost sourced in Queensland as an organic feedstock. The mixture of the organic feedstock was 50:50 by dry weight.

(31) The binder reagent used was a styrene acrylic emulsion.

(32) The polymerisation activator was diethylene glycol in the presence of an ammonium persulphate initiator reagent.

(33) TABLE-US-00007 Dry Wet Calculated Calculated Data for Run #3 Weight g Weight g Water (g) Solids % Sludge & Biomass 2,384 7,450 Total dry feed 2,384 Reagent liquid used 48 Binder reagent used dry 11.92 Binder water Water trim added 0 Total weights 2,396 7,498 5,102 31.96 Results Weight g Green pellets produced 7,441 Drum losses 57 Pellets size range 10-15 mm Desiccating Conditions Tray stored open top - still air No fan ventilation No air conditioning Ambient Conditions during desiccation - Max/Min Max Temp Min Temp Time (° C.) (° C.) Humidity - reported Day 32 29 70% to 65% Night 21 20 66% to 65% Moisture Total Water % of Solids Day Weight Loss (g/d) Loss (g) wet % 0 7,441 0 1 6,919 522 522 7.02 34.63 2 6,429 490 1,012 13.60 37.27 3 5,955 474 1,486 19.97 40.23 4 5,505 450 1,936 26.02 43.52 5 5,093 412 2,348 31.55 47.04 6 4,705 388 2,736 53.72 50.92 7 4,353 352 3,088 65.63 55.04 8 4,040 313 3,401 78.13 59.30 9 3,747 293 3,694 91.44 63.94 10 3,481 266 3,960 105.68 68.83 11 3,286 195 4,155 119.36 72.91 12 3,196 90 4,245 129.18 74.97 13 3,125 71 4,316 135.04 76.67 14 3,059 66 4,382 140.22 78.32 15 3,011 48 4,430 144.82 79.57 16 2,978 33 4,463 148.22 80.45 17 2,951 27 4,490 150.77 81.19 18 2,936 15 4,505 152.66 81.60 19 2,926 10 4,515 153.78 81.88 20 2,918 8 4,523 154.58 82.11 21 2,912 6 4,529 155.21 82.28 22 2,908 4 4,533 155.67 82.39 45 2,843 65 4,598 158.12 84.27 60 2,818 25 4,623 162.61 85.02 Final weight 2,818 Final Moisture content 15.0%

Example 8

(34) Agglomerates suitable for use as a fuel source were prepared using a mixture of sewage digestate and fine cut pine sawdust each sourced from Lombardia, Italy as an organic feedstock. The mixture of the organic feedstock was 50:50 by dry weight.

(35) The binder reagent used was a methoxysilane solution.

(36) The polymerisation activator was silyl acetate in the presence of ammonium persulphate solution initiator reagent.

(37) TABLE-US-00008 Dry Wet Calculated Calculated Data for Run #3 Weight g Weight g Water (g) Solids % Sludge & Sawdust 2,830 7,860 Total dry feed 2,830 Reagent liquid used 57 Binder reagent used dry 14.15 Binder water Water trim added 0 Total weights 2,844 7,917 5,073 35.92 Results Weight g Green pellets produced 7,895 Drum losses 22 Pellets size range 10-20 mm Desiccating Conditions Tray stored open top - still air No fan ventilation No air conditioning Ambient Conditions during desiccation - Max/Min Max Temp Min Temp Time (° C.) (° C.) Humidity - reported Day 23 21 55% to 62% Night 11 12 45% to 53% Moisture Total Water % of Solids Day Weight Loss (g/d) Loss (g) wet % 0 7,895 0 1 7,351 544 544 6.89 38.69 2 6,850 501 1,045 13.24 41.51 3 6,365 485 1,530 19.38 44.68 4 5,903 462 1,992 25.23 48.17 5 5,470 433 2,425 30.72 51.99 6 5,079 391 2,816 51.48 55.99 7 4,731 348 3,164 62.30 60.11 8 4,426 305 3,469 73.32 64.25 9 4,145 281 3,750 84.73 68.61 10 3,872 273 4,023 97.06 73.44 11 3,623 249 4,272 110.33 78.49 12 3,477 146 4,418 121.94 81.79 13 3,389 88 4,506 129.59 83.91 14 3,322 67 4,573 134.94 85.60 15 3,267 55 4,628 139.31 87.04 16 3,224 43 4,671 142.98 88.21 17 3,193 31 4,702 145.84 89.06 18 3,171 22 4,724 147.95 89.68 19 3,162 9 4,733 149.26 89.94 20 3,156 6 4,739 149.87 90.11 21 3,152 4 4,743 150.29 90.22 22 3,150 2 4,745 150.54 90.28 45 3,135 15 4,760 151.11 90.71 60 3,130 5 4,765 151.99 90.85 Final weight 3,130 Final Moisture content 9.1%