MOBILE SOLID FUEL PRODUCTION SYSTEM

Abstract

A fuel production system includes a first modular unit and a second modular unit. The first modular unit includes a first housing, a process vessel, an agitator rotor assembly, a first drivetrain, an extrusion screw, a second drivetrain, a first separation vessel, and a product shaping system. The second modular unit includes a second housing, a thermal fluid heater system, a condenser, a second separation vessel, and a vacuum pump. The second modular unit is configured to be coupled to the first modular unit. At least a portion of each of the process vessel, the agitator rotor assembly, the first drivetrain, the extrusion screw, the second drivetrain, the first separation vessel, and the product shaping system are contained in the first housing. At least a portion of each of the thermal fluid heater system, the condenser, the second separation vessel, and the vacuum pump are contained in the second housing.

Claims

1. A method comprising: coupling a first modular unit to a second modular unit, wherein: the first modular unit comprises: a process vessel; an agitator rotor assembly passing through the process vessel; a first drivetrain coupled to the agitator rotor assembly; an extrusion screw passing through the process vessel; a second drivetrain coupled to the extrusion screw; a first separation vessel in fluid communication with the process vessel; and a product shaping system; the second modular unit comprises: a thermal fluid heater system; a condenser; a second separation vessel in fluid communication with the condenser; and a vacuum pump in fluid communication with the second separation vessel; wherein coupling the first modular unit to the second modular unit comprises: fluidly coupling the thermal fluid heater system of the second modular unit to one or both of the process vessel and the agitator rotor assembly of the first modular unit; and fluidly coupling the first separation vessel of the first modular unit to the condenser of the second modular unit.

2. The method of claim 1, further comprising: providing a solid waste mixture to the process vessel; producing a solid fuel composition from the solid waste mixture, wherein producing the solid fuel composition comprises: rotating the agitator rotor assembly using the first drivetrain, thereby agitating the solid waste mixture within the process vessel; and providing heat to the solid waste mixture within the process vessel; and extruding the solid fuel composition from the process vessel, wherein extruding the solid fuel composition comprises: rotating the extrusion screw using the second drivetrain; and shaping the solid fuel composition using the product shaping system.

3. The method of claim 2, wherein providing heat to the solid waste mixture comprises flowing a thermal fluid from the thermal fluid heater system to one or both of the process vessel and the agitator rotor assembly.

4. The method of claim 3, further comprising flowing the thermal fluid from one or both of the process vessel and the agitator rotor assembly to the thermal fluid heater system.

5. The method of claim 3, further comprising: flowing a fluid stream from the process vessel to the first separation vessel; separating phases of matter of the fluid stream using the first separation vessel; flowing the fluid stream from the first separation vessel to the condenser; cooling the fluid stream using the condenser; flowing the fluid stream from the condenser to the second separation vessel; and separating phases of matter of the fluid stream using the second separation vessel, wherein the vacuum pump facilitates each of: flowing the fluid stream from the process vessel to the first separation vessel, flowing the fluid stream from the first separation vessel to the condenser, and flowing the fluid stream from the condenser to the second separation vessel.

6. The method of claim 3, wherein: the product shaping system comprises: an extrusion barrel coupled to the process vessel, the extrusion barrel defining a plurality of annular spaces configured to allow the solid fuel composition to pass through the extrusion barrel; a reducer coupled to the extrusion barrel; and a die coupled to the reducer, the die defining a plurality of openings; and shaping the solid fuel composition comprises passing the solid fuel composition through the plurality of annular spaces of the extrusion barrel, the reducer, and the die, thereby shaping the solid fuel composition by the plurality of openings defined by the die.

7. The method of claim 6, wherein the reducer comprises a thermal fluid piping, and shaping the solid fuel composition comprises flowing the thermal fluid through the thermal fluid piping, thereby heating the solid fuel composition as the solid fuel composition passes through the reducer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0063] FIG. 1 is a first side cutaway view of an example of a mobile solid fuel production system.

[0064] FIG. 2 is a second side cutaway view of the mobile solid fuel production system of FIG. 1.

[0065] FIG. 3 is a top cutaway view of the mobile solid fuel production system of FIG. 1.

[0066] FIG. 4 is a first end cutaway view of a first skid of the mobile solid fuel production system of FIG. 1.

[0067] FIG. 5 is a second end cutaway view of the first skid of the mobile solid fuel production system of FIG. 1.

[0068] FIG. 6 is a top cutaway view of the first skid of the mobile solid fuel production system of FIG. 1.

[0069] FIGS. 7 and 8 are perspective views of portions of the first skid of the mobile solid fuel production system of FIG. 1.

[0070] FIGS. 9A and 9B are perspective views of the first end of the mobile solid fuel production system of FIG. 1.

[0071] FIG. 10A is a first side cutaway view of a second skid of the mobile solid fuel production system of FIG. 1.

[0072] FIG. 10B is a second side cutaway view of the second skid of the mobile solid fuel production system of FIG. 1.

[0073] FIG. 10C is a top cutaway view of the second skid of the mobile solid fuel production system of FIG. 1.

[0074] FIG. 10D is a first end cutaway view of the second skid of the mobile solid fuel production system of FIG. 1.

[0075] FIG. 10E is a second end cutaway view of the second skid of the mobile solid fuel production system of FIG. 1.

[0076] FIGS. 10F and 10G are perspective cutaway views of the second skid of the mobile solid fuel production system of FIG. 1.

[0077] FIG. 11 is a schematic flow diagram of the mobile solid fuel production system of FIG. 1.

[0078] FIG. 12 is a perspective view of a reducer of the mobile solid fuel production system of FIG. 1.

DETAILED DESCRIPTION

[0079] The mobile solid fuel production systems described in this specification have a size, shape, and weight suitable for fitting into and being shipped in a shipping container having outer dimensions of about 20 feet by about 8 feet by about 8 feet. In one example, a shipping container has outer dimensions of about 19.5 feet by about 8 feet by about 8 feet, and a standard weight limit of about 20,000 pounds. The size, shape, and weight facilitate shipping and avoid the need for escort vehicles, or special permits, and higher shipping costs.

[0080] The materials processing, materials-to-fuel, or waste-to-fuel processing systems described in this specification are “mobile systems.” Here, “mobile systems” generally refer to systems that can be moved from a first location to a second location, and run as a stand-alone system. For example, the mobile system provided herein can be moved from a first location to a second location and simply be provided utilities (such as power and cooling water) without requiring the additional installation of auxiliary equipment to produce a solid fuel composition from a solid waste mixture. In one example, a mobile solid fuel production system provides for fluid spill containment within the system. Mobile systems are configured to be placed and prepared into operational mode within 24 hours or 48 hours. Thus, a mobile solid fuel production system can be installed as a stand-alone unit at a disaster relief site, construction site, landfill/field site, or other site in the absence of a larger facility.

[0081] A mobile solid fuel production system, or any one or more of its components, provided herein can be powered by an electric, natural gas, kerosene, diesel, or oil power source. In some embodiments, a suitable source of electric power supplied to the system can include a generator.

[0082] A mobile solid fuel production system, or any one or more of its components, provided herein is configured for receiving a water from a water supply source. The system can have one or more connections and conduits for receiving water and/or removing water from the system. In some embodiments, the system does not require a constant water connection and supply. For example, in some embodiments, water can circulate through the system in a closed loop cycle with a heat exchanger within the system for a duration of time.

[0083] The mobile solid fuel production system is sized and shaped to have dimensions on the order of a shipping container (e.g., about 20′×8′×8′ or about 40′×8′×8′). The processing volume of the mobile solid fuel production system is maximized within the selected volume. The weight of the system (e.g., about 20,000 lbs or less for 20′×8′×8′) is advantageously compatible with standard shipping options. In some embodiments, the weight of the system can range from about 10,000 lbs to about 30,000 lbs, about 50,000 lbs to about 60,000 lbs, or about 30,000 lbs to about 40,000 lbs. In some embodiments, the weight of the system can be about 10,000 lbs or less, 20,000 lbs or less, about 30,000 lbs or less, about 40,000 lbs or less, about 50,000 or less, about 60,000 lbs or less, about 70,000 lbs or less, or about 80,000 lbs or less.

[0084] In some embodiments, the mobile solid fuel production system includes a module. In some embodiments, the mobile solid fuel production system includes multiple modules. Each module includes a housing. In some embodiments, each module is sized and shaped to fit within a shipping container. In such embodiments, each module is configured to operate once removed from the respective shipping container. In some embodiments, each module is sized and shaped to have dimensions on the order of a shipping container and can operate as a shipping container and therefore be transported from a first location to a second location without requiring the module to be placed within a shipping container. For example, the housing of the module can be a shipping container. In some embodiments, the housing includes removable panels. In some embodiments, each module is configured to be transported from the first location to the second location with the panels of the housing installed. In some embodiments, each module is configured to be transported from the first location to the second location with the panels of the housing removed.

[0085] The mobile solid fuel production system includes a thermal fluid heater system 150. The heater system 150 heats a thermal fluid, which circulates through a conduit system in the mobile solid fuel production system. A thermal fluid is a fluid that can be heated and flowed through the mobile solid fuel production system to provide heat to component(s) of the mobile solid fuel production system. In some embodiments, after the thermal fluid flows through component(s) of the mobile solid fuel production system, the thermal fluid is recirculated to the heater system 150, where the thermal fluid is re-heated so that it can be recycled and flow through the component(s) of the mobile solid fuel production system again. The thermal fluid can be, for example, a thermal oil. An expansion tank allows for the fluid to expand and contract as it heats and cools. Nitrogen gas is used in the conduit system to fill void space and allow the expansion tank to be placed within the heights of the conduit system, such that the expansion tank fits inside a “standard” or “high cube” shipping container. The expansion tank can contain the nitrogen gas and the thermal fluid. In some embodiments, the heater system 150 can be heated using an electric, natural gas, kerosene, diesel, or oil power source. In some embodiments, the heater system 150 includes a deaerator to remove vapor (such as nitrogen gas) from the thermal fluid. For example, vapor can be dissolved or entrained in the thermal fluid, and the deaerator can be used to remove such vapor from the thermal fluid.

[0086] During operation, heat is generated in the mobile solid fuel production system 100. The thermal fluid lines and the powertrains (gearboxes, motors, etc.) generate heat. For example, thermal fluid can provide heat, and the thermal fluid can flow through the mobile solid fuel production system 100. The mobile fuel production system includes an air handling system for processing or containing the heat. A duct or series of ducts draws the heat from each module and allows it to vent outside the system. For example, the system 100 includes multiple openings that allow for air circulation through the system.

[0087] FIGS. 1-3 views of an example of a mobile fuel production system 100 including modules 102, 102′. FIG. 1 shows a cutaway view of modules 102, 102′ from a first side. FIG. 2 shows a cutaway view of module 102 from a second side. FIG. 3 shows a cutaway view of modules 102, 102′ from the top.

[0088] Each module 102, 102′ includes a skid (floor) 104. In some embodiments, each skid 104 has a sloped bottom. The sloped bottom can direct spilled fluid to a low point of the skid 104 due to gravity. In some embodiments, each skid 104 includes a drain. The drain can collect spilled fluid on the skid 104. In some embodiments, the drain is included at the low point of the sloped bottom. To the left of the leftmost beam is shown the product shaping system 106. Conduit 110 is an exhaust valve for escaping steam. In some embodiments, each module 102, 102′ includes a first opening and a second opening, such that air can flow through the modules 102, 102′. For example, air can flow into the module 102 through the first opening and exit the module 102 through the second opening and vice versa. In some embodiments, the first opening is located near the bottom of the module (102 or 102′), and the second opening is located at a ceiling of the module (102 or 102′). Product shaping system 106 includes an extrusion barrel 106a that can be coupled to a reducer (shown in FIG. 12 and described in more detail later) and die 106b to form the product into the desired shape. At the end of the die 106b, a plate with one or more openings is configured to further shape the solid fuel product. The solid fuel product is cut by a guillotine-style cutter, powered by air or hydraulic.

[0089] Mobile fuel production system 100 includes hydraulic motor 112. Rotary joints and reinforcements 114 hold the ends of the rotors. The feedstock is processed in process vessel 116. Process vessel 116 is typically cylindrical. The mobile fuel production system 100 includes an agitator rotor assembly. In some embodiments, the agitator rotor assembly includes multiple agitator rotors. Drivetrain 118 include gearboxes 120. An additional gearbox is on the other side of the system (not shown). Each gearbox 120 is coupled to an agitator rotor and is coupled to a corresponding motor 122.

[0090] Large single motor 124 powers a conveyor screw within the vessel. Gearboxes are coupled to appropriate equipment within the system and to a conveyor screw inside process vessel 116. Mobile fuel production system 100 includes two separation vessels 128. Inlet thermal fluid line 130 and outlet thermal fluid line 132 couple modules 102, 102′. Thermal fluid can flow through the agitator rotors. The thermal fluid can provide heat within the process vessel 116 (and in turn, to the solid composition within the process vessel 116) as the thermal fluid flows through the agitator rotors. In some embodiments, thermal fluid flows from inlet thermal fluid line 130 into one of the agitator rotors and then from the other agitator rotor to the outlet thermal fluid line 132. Exhaust line 134 is configured to transfer steam/condensate from process vessel 116. As depicted in FIG. 3, exhaust line 134 splits to connect to the separation vessels 128. The separation vessels 128 facilitate condensation, separation of liquid from vapor, and/or coalescence of liquid droplets from the exhaust of the process vessel 116. In some embodiments, the separation vessels 128 are knock-out pots. In some embodiments, the separation vessels 128 include filters. The outlet streams from the separation vessels 128 can combine and flow from module 102 to module 102′.

[0091] Feedstock (e.g., solid municipal waste) is provided to process vessel 116. Processed feedstock (solid fuel) from process vessel 116 is provided to product shaping system 106. Product shaping system 106 shapes (e.g., cuts) the solid fuel to yield a shaped solid fuel product. In some embodiments, feedstock can be added manually. Non-limiting methods for manually adding feedstock include use of a hopper, a chute, a motorized feeding system (e.g., a rotary airlock valve).

[0092] FIGS. 4-9 depict additional details of mobile fuel production system 100. FIG. 4 shows a cutaway view of module 102 from a first end. FIG. 5 shows a cutaway view of module 102 from a second end. FIG. 6 shows a cutaway view of module 102 from the top. FIG. 7 shows a portion of module 102 that includes gearboxes 120 and extrusion gear 121. The gearboxes 120 rotate the agitator rotors to facilitate agitation of the solid composition being processed within the process vessel 116. The extrusion gear 121 is used to rotate the extrusion screw to extrude the solid fuel product out of the process vessel 116. As depicted in FIG. 7, the gearboxes 120 deviate from a vertical orientation. For example, the gearboxes 120 are angled toward each other and toward a centerline of module 102. In some embodiments, each gearboxes 120 deviates from the vertical by an angle in a range of from 1 degree)(°) to 30°. The angled orientations of the gearboxes 120 provide room for the extrusion gear 121 to be disposed between the gearboxes 120. In some cases, the orientation of the gearboxes 120 and extrusion gear 121 can protect them from heat exposure (for example, from the heated thermal fluid flowing through the system 100). FIG. 8 shows a portion of module 102 that includes an extrusion barrel 106a. As depicted in FIG. 8, the extrusion barrel 106a defines multiple annular spaces through which the solid fuel composition can be extruded from the process vessel 116. The configuration of the extrusion barrel 106a allows for the solid fuel composition to exit the process vessel 116 through the annular spaces while also structurally supporting component(s) of the product shaping system 106 (for example, the die 106b and/or the reducer 106c). FIGS. 9A and 9B show a perspective view of the first end of module 102 with a cover 108 in a closed position and an open position, respectively. As depicted in FIGS. 9A and 9B, the product shaping system 106 includes a hinge that allows the cover to be moved between open and closed positions.

[0093] The mobile fuel production system 100 can be made operational by installing a mechanism for introducing the feedstock. For example, in some embodiments, a hopper or chute or motorized feeding system may be added to the system. In some embodiments, no installations are needed to make the system operational because material can be manually loaded in.

[0094] The mobile fuel production system 100 can be made operational by connecting the system to a power source (e.g., an electrical source). A water inlet must be connected, which be a continuous source (such as a building's plumbing) or a closed loop. In various embodiments, a pipe (e.g., hose) is connected to the condensate/water recovery outlet.

[0095] FIGS. 10A-10G depict additional details of mobile fuel production system 100. FIG. 10A shows a cutaway view of module 102′ from a first side. FIG. 10B shows a cutaway view of module 102′ from a second side. FIG. 10C shows a cutaway view of module 102′ from the top. FIG. 10D shows a cutaway view of module 102′ from a first end. FIG. 10E shows a cutaway view of module 102′ from a second end. FIGS. 10F and 10G show cutaway perspective views of module 102′.

[0096] FIG. 11 is a schematic flow diagram of the mobile fuel production system 100. Thermal fluid (e.g., hot oil) is heated in heater system 150 positioned on module 102′. Heated thermal fluid flows from the heater system 150 to the agitator rotors on module 102 via inlet thermal line 130. Heated thermal fluid flows into at least one of the agitator rotors and provides heat within the process vessel 116 positioned on module 102. In some embodiments, heated thermal fluid flows through the agitator rotors in series (for example, through rotor 131a and then through 131b). In such embodiments, the heated thermal fluid enters rotor 131a, flows through rotor 131a, exits rotor 131a, enters rotor 131b, flows through rotor 131b, exits rotor 131b, and flows back to the heater system 150 on module 102′ via outlet thermal fluid line 132. In some embodiments, heated thermal fluid flows through the agitator rotors in parallel (for example, a first portion of the heated thermal fluid flows through rotor 131a while a second portion of the heated thermal fluid flows through rotor 131b). In such embodiments, the heated thermal fluid splits, enters both agitator rotors 131a, 131b, flows through agitator rotors 131a, 131b, exits agitator rotors 131a, 131b, recombines, and flows back to the heater system 150 on module 102′ via outlet thermal fluid line 132. The thermal fluid can flow through the agitator rotors 131a, 131b while the agitator rotors 131a, 131b are rotated by the respective gearboxes 120.

[0097] As the agitator rotors 131a, 131b rotate and provide heat within the process vessel 116, compounds can evaporate from the solid composition being agitated and heated within the process vessel 116. Vaporized compounds (e.g., steam/condensate) flow from the process vessel 116 through exhaust line 134 to separation vessels 128. As mentioned previously, the exhaust line 134 splits the exhaust flow between two separation vessels 128. Condensate can be knocked out from the exhaust line within the separation vessels 128. Because the separation vessels 128 can remove component(s) from the fluid stream flowing from the process vessel 116, the fluid stream entering each separation vessel 128 may have a different composition from the vapor stream exiting the respective separation vessel 128. In some embodiments, condensate outlets of the separation vessels 128 are combined and flowed to a condensate storage tank by a condensate pump 190 positioned on module 102′. In some embodiments, the condensate storage tank is positioned on module 102′.

[0098] The condenser 160 is supplied with a coolant (e.g., cooling water) to provide cooling to the vapor flowing from the separation vessels 128. As the vapor flows through the condenser 160, compounds may condense to form condensate. Vapor from the condenser 160 can flow through an additional separation vessel 129. The separation vessel 129 facilitates condensation, separation of liquid from vapor, and/or coalescence of liquid droplets from the stream exiting the condenser 160. In some embodiments, the separation vessel 129 is a knock-out pot or a cyclonic separator. In some embodiments, the separation vessel 129 includes a filter. In some embodiments, the vapor inlet to the separation vessel 129 is a tangential inlet, which can facilitate centrifugal separation of vapor and liquid within the separation vessel 129. Because the separation vessel 129 can remove component(s) from the fluid stream flowing from the condenser 160, the fluid stream entering the separation vessel 129 may have a different composition from the vapor stream exiting the separation vessel 129. Condensate knocked out within the separation vessel 129 can combine with condensate from the separation vessels 128 and the condensate from the condenser 160 and be pumped to the condensate storage tank by the condensate pump 190.

[0099] The vapor flow of the exhaust from the process vessel 116, through the separation vessels 128, condenser 190, and separation vessel 129 is facilitated by the vacuum pump VP-001. In some embodiments, vapor from the separation vessel 129 flows through vacuum pump VP-001 to an adsorption filter. In some embodiments, the adsorption filter is positioned on module 102′.

[0100] FIG. 12 is a perspective view of a reducer 106c that can be coupled to the extrusion barrel 106a of the product shaping system 106. In some embodiments, the reducer 106c has a first end shaped to couple to the extrusion barrel 106a. In some embodiments, the reducer 106c has a second end shaped to couple to the die 106b. In some embodiments, the product shaping system 106 includes thermal fluid piping 106d which can be used to flow thermal fluid and provide heat as the solid fuel moves through the product shaping system 106. For example, the thermal fluid piping 106d can branch from the inlet thermal fluid line 130 and branch into the outlet thermal fluid line 132.

[0101] As used in this disclosure, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed in this disclosure, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

[0102] As used in this disclosure, the term “about” or “approximately” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.

[0103] As used in this disclosure, the term “substantially” refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

[0104] Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “0.1% to about 5%” or “0.1% to 5%” should be interpreted to include about 0.1% to about 5%, as well as the individual values (for example, 1%, 2%, 3%, and 4%) and the sub-ranges (for example, 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “X, Y, or Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

[0105] The details of one or more embodiments of the subject matter of this disclosure are set forth in the accompanying drawings and the description. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.

[0106] Although this disclosure contains many specific embodiment details, these should not be construed as limitations on the scope of the subject matter or on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are described in this disclosure in the context of separate embodiments can also be implemented, in combination, in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments, separately, or in any suitable sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

[0107] Particular embodiments of the subject matter have been described. Other embodiments, alterations, and permutations of the described embodiments are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results.

[0108] Accordingly, the previously described example embodiments do not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.