CA2550497A1 - Methods for binding particulate solids - Google Patents
Methods for binding particulate solids Download PDFInfo
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- CA2550497A1 CA2550497A1 CA002550497A CA2550497A CA2550497A1 CA 2550497 A1 CA2550497 A1 CA 2550497A1 CA 002550497 A CA002550497 A CA 002550497A CA 2550497 A CA2550497 A CA 2550497A CA 2550497 A1 CA2550497 A1 CA 2550497A1
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- Prior art keywords
- solid
- product
- particulate
- temperature
- particulate solids
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/40—Solid fuels essentially based on materials of non-mineral origin
- C10L5/48—Solid fuels essentially based on materials of non-mineral origin on industrial residues and waste materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
- B09B3/20—Agglomeration, binding or encapsulation of solid waste
- B09B3/21—Agglomeration, binding or encapsulation of solid waste using organic binders or matrix
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/34—Other details of the shaped fuels, e.g. briquettes
- C10L5/36—Shape
- C10L5/363—Pellets or granulates
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel
Abstract
Provided are methods for binding particulate solids in a polymer fiber matrix utilizing composite waste products. A mixture of composite waste products and particulate solids is formed into solid products to create degradation resistant solid units which capture the particulate solids.
Description
METHODS FOR BINDYNG PARTICULATE SOLIDS
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to co-pending U.S. provisional application entitled, " METHOD FOR BIIVDING PARTICLJLATE SOLII)S," having serial no. 60/530,728, filed December 17, 2003, which is entirely incorporated herein by reference.
'1'ECIiNICAL MLD
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to co-pending U.S. provisional application entitled, " METHOD FOR BIIVDING PARTICLJLATE SOLII)S," having serial no. 60/530,728, filed December 17, 2003, which is entirely incorporated herein by reference.
'1'ECIiNICAL MLD
[0002] The present disclosure is generally related to solid form production and, more particularly, is related to methods for binding particulate solids.
BACKGROUND
BACKGROUND
[0003] In the past, particulate materials, such as coal fiues, coke breeze, saw dust, and other biomass wastes, have presented storage, handling, and processiW
challenges.
Additionally, metal oxides fi.vm blast fiunaees, basic oxygen furnaces and eleetric arc furnaces have routinely been discarded, in large quantities,- creating a source of pollution and presenting an environmental bazard, which continaes for decades. Further, composite waste products, including post-consumer and post-industrial carpet waste, are routinely discarded into waste storage facilities, such as landfills. In addition to presenting challenges related to handling the composite waste products, the slow rate of decomposition results in an unfavorable environmental impact that continues for decades.
I
challenges.
Additionally, metal oxides fi.vm blast fiunaees, basic oxygen furnaces and eleetric arc furnaces have routinely been discarded, in large quantities,- creating a source of pollution and presenting an environmental bazard, which continaes for decades. Further, composite waste products, including post-consumer and post-industrial carpet waste, are routinely discarded into waste storage facilities, such as landfills. In addition to presenting challenges related to handling the composite waste products, the slow rate of decomposition results in an unfavorable environmental impact that continues for decades.
I
(0004) Prior attempts at disposing of coke breeze, coal fines, and other particulate solids by producing solid forms, such as briquettes or pellets, have beem largely unsuccessful because the particulate solids do not adequately bind and the resulting product can be mechanically unstable, disintegrating or degrading back into small, fine particles during storage and handling. Other attempts at producing solid forms from the particulate solids may use costly binder materials, such as petroleum pitcli or water-based latexes, and may use costly and complex processing techniques. Water-based materials will reduce the heating value of fuel based solids and produce a formed material which is unstable during outside storage and transport and may disintegrate causing fugitive dust emissions or ground water contamination. Further, previous attempts have utilized binders, including petroleum-based rnaterials, which become tacky and difficult to transport at ambient and elevated temperatures, and may cause contannination and run-offproblems when stored outside.
(0005) Thus, a heretofore-unaddressed need exists in the industry to address the aforementioned deficimcies and inadequacies.
SUMMARX
SUMMARX
(0006] Briefly described, an embodiment of the present disclosure caA be viewed as a method for binding partictilate solids, eomprising: reducing a composite waste product;
adding particulate solids to the composite waste product; blending the pariiculats solids with the composite waste product, wherein the particullite solids and the composite waste product constitute a consistent mixture; adding energy to the mixture to increase a process z temperature, such that a conciponent o#'the consposite waste product changes from a solid state to a fluid state; and forming the mixture into solid formed products.
adding particulate solids to the composite waste product; blending the pariiculats solids with the composite waste product, wherein the particullite solids and the composite waste product constitute a consistent mixture; adding energy to the mixture to increase a process z temperature, such that a conciponent o#'the consposite waste product changes from a solid state to a fluid state; and forming the mixture into solid formed products.
[0007] Another embodiment of the present disclosure can also be viewed as a method for eapturing particulate solids in a degradation resistant form, comprising: a reducing means for shredding or pelletizing carpet; a supplying means for adding particulate solids to the earpet; a mixing means for blending the carpet and the particulate solids into a mixture; a heating means for elevating the temperature of the mixture such that a binder element of the carpet achieves a liquid state and a fiber element of the carpet retains a solid state; and a forming means for converting the mixture into a formed solid, wherein the formed solid comprises a polymer fiber rnatrix which eapt.ures the particulate solids.
[o0oe] Another embodiment of the present disclosure can be viewed as a degradation resistant fiber matrix solid product comprising: a composite waste product including a binder element and a fiber element, whereftt the binder element fluidizes at a first temperature, wherein the fiber element fluidizes at a second temperature, and wherein the first temperature is lower than the second teraperature; and a particulate solid product, wherein the binder captures the particulate solid product when blended at.a teznperature in the range between the first temperature and the second temperature.
[00041 Other methods, objects, and features of the present disclosure will be orbecome apparent to one with skill in the art upon examination of the following drawings and detailed descriptiost, It is intended that all such additional systems, methods, features, and advantages be included within t}ais description, be within the scope of the present disclosure, and be protected by the accompanying clauns.
BTtIEF DESCRIPTION OF T$E DRAWINGS
[00101 Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly ilhustrating the principles of the present disclosure. Moreover, in the drawings, Iike reference num.erals designate corresponding parts throughout the several views, (00111 FIG. I is a block diagram ilIustrating an embodiment of the methods disclosed herein.
(0012] FIG. 2 is a block diagrarn illustrating an exemplary process under the methods disclosed herein.
{00133 FIG. 3 is a block diagram illustrating an exemplary process under the methods disclosed herein.
(0014] FIG. 4 is a block d.iagram iIlustrating a non-limiting example of elements in a composite waste product.
[0015] FIG. 5 is a block diagram illustrating an exemplary process under the methods disclosed herein.
[0016] FIG. 6 is a block diagram illustrating an exemplary process under the methods disclosed herein.
[0017] k'IG. 7 is a block diagram illustrating components of an exemplary production plant for practicing the methods disclosed herein.
DETAII.ED DESCRIPTION
[00181 Reference is now made in detail to the description of the embodimeuts as illustrated in the drawings. While several embodiments are described in connection with these drawings, there is no intent to limit the disclosure to an embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all altematives, modi.fications, and equivalents.
[0019] Reference is made to FIG. 1, which is a block diagram illustrating an embodiment of the methods disclosed herein. The method 100 includes reducing a composite waste product 110 through, for example, a shredding or pelletizin.g process. An exemplary composite waste product in an embodiment herein includes waste carpet. Waste carpet can be, for example, consumer recycled carpet or industrial waste carpet. One of ordina .ry skiTl in the art knows or will luiow that the reducing function can be performed as a separate step prior to the other steps of the method desaribed herein or, altematively, as an integrated step.
[0020] After the composite waste product is reduced, particulate solids are added to the composite waste product 120. The particulate solids maybe fuel solids including, but not limited to, coke breeze, coke 5nes, coal fines and wood wastes. Alternatively, the partieulate solids ihay be non-fuel particulate waste including, but not limited to, particulate radiation contaminates, metal wastes, toxic waste particulates and metal oxides. The adding step 120 maybe performed in a batch operation, where all of the particulate solids for a process batch are added at one time. Alternatively, the adding step 120 may be performed in a coutinuous process where the particulate solids are added in a continuous stream.
[0021j The particulate solids are blended with the composite waste product to create a mixture of the composite waste product and the particulate solids 130. In the case of recycled carpet, the composite waste product generally includes, for exaruple, a polypropylene binder element and a nylon fiber element. The temperature of the nwcture is increased to fluidize the binder element 140 through, for example, a combination of heat generated by the rnixing process and heat provided to the process by external devices 140. The fluid polypropylene binder element captures the fine patticulate solids.
Further, the nylon carpet fibers become tacky at the temperature at which the binder fluidizes, which causes the nylon carpet fiber to sinter to both the partioulate solids and the fluid binde=r. In an embodiment, the process temperatures for fluidizing the =
polypropylene binder without fluidizing the nylon fibers are in the exemplary range between 275 degrees F and 450 degrees F. The combination of the fluid polypropylene binder and the nylon fiber results in a mechanical capture of the particulate material in a combined polypropylene and nylon fiber polymer matrlx.
(0022] The mixture is then formed into solid formed products, such as, for example, briquettes or pellets, using heat and/or pressure 150. After the forming process, the resulting solid formed product is structurally stable and does not retrogress into fine particles during storage and handling. When particulate solids are fuel based, the solid formed product is bound reliably together and constitutes a high BTU fuel for industrial, utility, and residential use which does not materially pollute the air to a degree diffetent from conventional fuels. In the case of non-fllel particulate solids, such as industrial waste, the solid formed product is bound reliably togetber and constitutes a durable means of either recycling in a subsequent industrial process or long term stable storage which does not materially pollute the air, soil, or ground water.
[0023] Reference is now made to FIG. 2, which illustrates a block diagram of an exemplary process under the methods disclosed herein. The process 200 comibines recycled carpet 210 and particulate solids 220 into a mixture by heating and blendiug or mixing as indicated in block 230. Additionally, other polymers 250 may be optionally added to achieve specific characteristics relating to mechanical properties, cheuucal composition, or a combination thereaf. After the heating and blending or rnixing is completed, solid formed products are formed in block 240 using, for example, conventional briquette or pellet forming technology. Additionally, one of ordinary skill in the art knows or will know that the mixture may be formed into solid products including extrusions, sheets or other homogeneous or non-homogeueous shapes, as needed.
[0024) Reference is now made to FIG. 3, which illustrates a block diagrazn of an exemplary process under the methods disclosed herein. The process 300 utilizes recycled carpet 310, which is reduced in step 31 S. The reducing fimotion includes, but is not Iinlited to, shredding, grinding, pelletizing, and other teclmiques known by one of ordinary sldll in the art. Additionally, as indicated in block 325, particulate solids 320 are processed to achieve a maximum particle size by grinding or crushing. A
mixture of the reduced recycled carpet and the ground particulate solids is produced by heating and blending or mixing, as indicated in block 330. Additionally and optionally, reeycled plastics may be added to mixture for supplemental fuel content and/or environmentally benefici$1 disposal. After the heating and blending or mixing is completed, solid products are fonned, as indicated in block 340, using conventional forming technology including, but not limited to, the methods and forms discussed above.
[0025) Reference is briefly made to FIG. 4, which is a block diagram illustrating a non-limiting example of elements in a composite waste product. An embodiment of the composite waste product 400 includes, but is not limited to, a polypropylene backing material 410, nylon carpet fibers 420 and calcium carbonate 430. The polypmpylene backing materia1410 becomes fluid at a processing temperature allowing it to capture the particulate solids. The nylon carpet fibers 420 become tacky, but not fluid at the processing temperature and, in the process of blending, serve to form a fiber m.atrix in the mixture. The calcium carbonate element, when used in a sulfur containing fuel application and under present combustion methods may result in a reduction of sulftu dioxide emissions. This reduction dirninishes or eliminates the utility of powdered limestone injection associated with conventional sulfur dioxide emission reduction methods. Additionally, remaining binding ingredierns include other polymers (not shown) as normal components of carpet backing material.
(00261 Reference is now made to FIG. 5, which is a block diagram illustrabing an exemplary process under the methods disclosed herein. An embodiment of the process 500 applies recyclcd baled carpet $10 to a bale breaker 512 for subsequent processing by a shredder/grind:er 514. The shredderlgt'inder 514 is one of a number of reducing techniques known by one of ordinary sltYll in the art. The reduced carpet is then received by an accumulator 550. An accumuaator 550 receives raw or intennediately processed materials from multiple sources. For example, in this case, the accumulator 550 receives reduced carpet and other niaterials, as discussed below, for subsequent processing.
[00271 As discussed above, recycled plastic 530 is optionally ineluded in the mixture to facilitate improved fuel content, mechanical properties, or a combination thereof, and to facilitate an environmentally beneficial method of disposal. To aid in processing, the recycled plastic 530 is processed through a sluedder/grinder 532 and transferred to a mixer W. In the case where specific chemical or mechanical properties are desirable, additiomal virgin polymers 536 may be optionally added. Since the virgin polymers 536 are typically purchased in a form ready for processing, such as pellets, the virgin polymers 536 are deposited directly into the maixer 540.
[0028] In addition to the recycled plastic 530 and the virgin polymen 536, cellulose material 534, including but not limited to wood wastes, may be optionally added to the mixture 540. The blending of cellulose material 534 provides a partial fuel content from a renewable resource thus extending the Iife of available fossil fuels, such as the coaa.l, PET coke, or coke fines, with a clean burning alternative synthetic tiiel. The synthetic solid fuels can be formed into vanous shapes and sizes for use in devices including, but not limited to, stoker boilers, pulverized utility boilers, circulating fluidized bed (CFB) boilets, pressurized fluidized bed combustion (PFBC) boilers, coal gasification (IGCC) units, and wood and coal burning farnaces.
[0029] Coal or coke fines 520 are processed through a crusher or ainder 522 to reduce the particulate solid fuels to a maximum particle size. The crushed coal or coke fines are then transferred to the mixer 540. The contents of the mixer 540 including the processed coal or coke fines 520, recycled plastic 530, cellulose 534 and virgin polymers 536 is mixed and ttansfetTed to the accumulator 550. The accumulator 550, which includes the combined contents of the mixer 540 and the recycled carpet from the shredder/
grinder 514, conveys its contents to a pellet mil1560 using a feeder 552.
[0030] The pellet mill 560 blends the combined contents and uses, for example, a combination of heat, pressure, and forming technology to form solid products, including but not limited to pellets, briquettes, extrusions or sheets, of the mixture, which are then transferred to a cooler 562. After cooling, the solid products are structurally stable and do not retrogress into fine particles during storage and h.an.dling. The solid products are then transferred to storage 564 where they remain intact because the solid particulate materials are encapsulated to prevent degradation, leaching or contamination into the environment.
The solid products also exhibit resistance to moisture because the moisture is driven out by the process heat and then sealed out by the erteapsulating function of the binder clement.
[0031) Reference is now madc to FIG. 6, which illustrates a block diagram of an exemplary process under the methods disclosed herein. The process 600 includes reducing wasto carpet 610 including, but not liimited to, shredding, grindin,g or pelletiziuig the waste carpet. Particulate solids, which may have a fuel content are added 620 and the particulate solids are mixed with the waste cacpet 630. x'he mixture is heated using, for example, a combination of heat generated by the process plus auy supplemental heat necessary to fluidize the binder element of the waste carpet 640. One of ordinary skill in the art knows or will know that supplemental heat may be provided by any number of methods including, but not limited to, electric resistive and inductive devices, combustion causing devices, electromagnetic wave devices, and recaptured heat from other processes.
After the mixing is completed, the mixture is formed inito solid products by pressure, heat or extrasion 650, for example.
10032i Reference is now made to FIG. 7, which is a block diagram illustrating components of an exemplary production plant.for practicing the methods disclosed herein. The plant 700 includes a composite waste reducer 710, which, for example, shreds, grinds, or pelleti2es waste earpet. A solid particulate delivery device 720 provides solid particulates to the reduced composite waste at, for example, a conibini,ug device 730. The combining device 730 combines the reduced composite waste product with particulate solids to create a mixture. Additionally and possibly in combination with the combining device 730, heat generation/regulation equipment 740 provides sufficient supplemental heat to the mixture to fluidize one element of the composite waste product.
The heated mfixturte is then provided to a solid product forming device 750, configured to produce solid formed products. The solid formed products include but are not limited to pelaets, briquettes, extrusions and sheets, among others. As discussed above, the solid formed products may be produced for subsequent consumption wberein the solid particulates have a useful fuel content or other desirable recycle value.
Alternatively, the solid fortned product may provide a safe and effective method of stori.ng and handling useful or potentially harmful solid particulate materials. The plant 700 also includes sufficient process control equipment 760 such that the production steps are inte8rated into a continuous process. In the alternative, the process contcol equipment 760 is configured, for exatnple, to perform production steps in independent stages.
(0033] The methods described herein do not requiro water, acids or any other chemical or elemental component from the particulate solids to form the bond. As a result, virtu.ally il any particulate or blended materials can be reliably pelletized using methods described herein. Although waste carpet is presented in an etnbodiment described herein, one of ordinary skill in the art knows, or will know that any composite waste product having binder arid fiber elements may be used. For example, polytner unpregnated cloth used in some industrial processes may also be a suitable composite waste product.
(0034] It should be emphasized that the above-described embodiments of the present disclosare, particularly, any il]ustrated embodiments, are merely possible examples of implementations, merely set foitlk for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosirre and the present disclosure and protected by the following claims.
[o0oe] Another embodiment of the present disclosure can be viewed as a degradation resistant fiber matrix solid product comprising: a composite waste product including a binder element and a fiber element, whereftt the binder element fluidizes at a first temperature, wherein the fiber element fluidizes at a second temperature, and wherein the first temperature is lower than the second teraperature; and a particulate solid product, wherein the binder captures the particulate solid product when blended at.a teznperature in the range between the first temperature and the second temperature.
[00041 Other methods, objects, and features of the present disclosure will be orbecome apparent to one with skill in the art upon examination of the following drawings and detailed descriptiost, It is intended that all such additional systems, methods, features, and advantages be included within t}ais description, be within the scope of the present disclosure, and be protected by the accompanying clauns.
BTtIEF DESCRIPTION OF T$E DRAWINGS
[00101 Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly ilhustrating the principles of the present disclosure. Moreover, in the drawings, Iike reference num.erals designate corresponding parts throughout the several views, (00111 FIG. I is a block diagram ilIustrating an embodiment of the methods disclosed herein.
(0012] FIG. 2 is a block diagrarn illustrating an exemplary process under the methods disclosed herein.
{00133 FIG. 3 is a block diagram illustrating an exemplary process under the methods disclosed herein.
(0014] FIG. 4 is a block d.iagram iIlustrating a non-limiting example of elements in a composite waste product.
[0015] FIG. 5 is a block diagram illustrating an exemplary process under the methods disclosed herein.
[0016] FIG. 6 is a block diagram illustrating an exemplary process under the methods disclosed herein.
[0017] k'IG. 7 is a block diagram illustrating components of an exemplary production plant for practicing the methods disclosed herein.
DETAII.ED DESCRIPTION
[00181 Reference is now made in detail to the description of the embodimeuts as illustrated in the drawings. While several embodiments are described in connection with these drawings, there is no intent to limit the disclosure to an embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all altematives, modi.fications, and equivalents.
[0019] Reference is made to FIG. 1, which is a block diagram illustrating an embodiment of the methods disclosed herein. The method 100 includes reducing a composite waste product 110 through, for example, a shredding or pelletizin.g process. An exemplary composite waste product in an embodiment herein includes waste carpet. Waste carpet can be, for example, consumer recycled carpet or industrial waste carpet. One of ordina .ry skiTl in the art knows or will luiow that the reducing function can be performed as a separate step prior to the other steps of the method desaribed herein or, altematively, as an integrated step.
[0020] After the composite waste product is reduced, particulate solids are added to the composite waste product 120. The particulate solids maybe fuel solids including, but not limited to, coke breeze, coke 5nes, coal fines and wood wastes. Alternatively, the partieulate solids ihay be non-fuel particulate waste including, but not limited to, particulate radiation contaminates, metal wastes, toxic waste particulates and metal oxides. The adding step 120 maybe performed in a batch operation, where all of the particulate solids for a process batch are added at one time. Alternatively, the adding step 120 may be performed in a coutinuous process where the particulate solids are added in a continuous stream.
[0021j The particulate solids are blended with the composite waste product to create a mixture of the composite waste product and the particulate solids 130. In the case of recycled carpet, the composite waste product generally includes, for exaruple, a polypropylene binder element and a nylon fiber element. The temperature of the nwcture is increased to fluidize the binder element 140 through, for example, a combination of heat generated by the rnixing process and heat provided to the process by external devices 140. The fluid polypropylene binder element captures the fine patticulate solids.
Further, the nylon carpet fibers become tacky at the temperature at which the binder fluidizes, which causes the nylon carpet fiber to sinter to both the partioulate solids and the fluid binde=r. In an embodiment, the process temperatures for fluidizing the =
polypropylene binder without fluidizing the nylon fibers are in the exemplary range between 275 degrees F and 450 degrees F. The combination of the fluid polypropylene binder and the nylon fiber results in a mechanical capture of the particulate material in a combined polypropylene and nylon fiber polymer matrlx.
(0022] The mixture is then formed into solid formed products, such as, for example, briquettes or pellets, using heat and/or pressure 150. After the forming process, the resulting solid formed product is structurally stable and does not retrogress into fine particles during storage and handling. When particulate solids are fuel based, the solid formed product is bound reliably together and constitutes a high BTU fuel for industrial, utility, and residential use which does not materially pollute the air to a degree diffetent from conventional fuels. In the case of non-fllel particulate solids, such as industrial waste, the solid formed product is bound reliably togetber and constitutes a durable means of either recycling in a subsequent industrial process or long term stable storage which does not materially pollute the air, soil, or ground water.
[0023] Reference is now made to FIG. 2, which illustrates a block diagram of an exemplary process under the methods disclosed herein. The process 200 comibines recycled carpet 210 and particulate solids 220 into a mixture by heating and blendiug or mixing as indicated in block 230. Additionally, other polymers 250 may be optionally added to achieve specific characteristics relating to mechanical properties, cheuucal composition, or a combination thereaf. After the heating and blending or rnixing is completed, solid formed products are formed in block 240 using, for example, conventional briquette or pellet forming technology. Additionally, one of ordinary skill in the art knows or will know that the mixture may be formed into solid products including extrusions, sheets or other homogeneous or non-homogeueous shapes, as needed.
[0024) Reference is now made to FIG. 3, which illustrates a block diagrazn of an exemplary process under the methods disclosed herein. The process 300 utilizes recycled carpet 310, which is reduced in step 31 S. The reducing fimotion includes, but is not Iinlited to, shredding, grinding, pelletizing, and other teclmiques known by one of ordinary sldll in the art. Additionally, as indicated in block 325, particulate solids 320 are processed to achieve a maximum particle size by grinding or crushing. A
mixture of the reduced recycled carpet and the ground particulate solids is produced by heating and blending or mixing, as indicated in block 330. Additionally and optionally, reeycled plastics may be added to mixture for supplemental fuel content and/or environmentally benefici$1 disposal. After the heating and blending or mixing is completed, solid products are fonned, as indicated in block 340, using conventional forming technology including, but not limited to, the methods and forms discussed above.
[0025) Reference is briefly made to FIG. 4, which is a block diagram illustrating a non-limiting example of elements in a composite waste product. An embodiment of the composite waste product 400 includes, but is not limited to, a polypropylene backing material 410, nylon carpet fibers 420 and calcium carbonate 430. The polypmpylene backing materia1410 becomes fluid at a processing temperature allowing it to capture the particulate solids. The nylon carpet fibers 420 become tacky, but not fluid at the processing temperature and, in the process of blending, serve to form a fiber m.atrix in the mixture. The calcium carbonate element, when used in a sulfur containing fuel application and under present combustion methods may result in a reduction of sulftu dioxide emissions. This reduction dirninishes or eliminates the utility of powdered limestone injection associated with conventional sulfur dioxide emission reduction methods. Additionally, remaining binding ingredierns include other polymers (not shown) as normal components of carpet backing material.
(00261 Reference is now made to FIG. 5, which is a block diagram illustrabing an exemplary process under the methods disclosed herein. An embodiment of the process 500 applies recyclcd baled carpet $10 to a bale breaker 512 for subsequent processing by a shredder/grind:er 514. The shredderlgt'inder 514 is one of a number of reducing techniques known by one of ordinary sltYll in the art. The reduced carpet is then received by an accumulator 550. An accumuaator 550 receives raw or intennediately processed materials from multiple sources. For example, in this case, the accumulator 550 receives reduced carpet and other niaterials, as discussed below, for subsequent processing.
[00271 As discussed above, recycled plastic 530 is optionally ineluded in the mixture to facilitate improved fuel content, mechanical properties, or a combination thereof, and to facilitate an environmentally beneficial method of disposal. To aid in processing, the recycled plastic 530 is processed through a sluedder/grinder 532 and transferred to a mixer W. In the case where specific chemical or mechanical properties are desirable, additiomal virgin polymers 536 may be optionally added. Since the virgin polymers 536 are typically purchased in a form ready for processing, such as pellets, the virgin polymers 536 are deposited directly into the maixer 540.
[0028] In addition to the recycled plastic 530 and the virgin polymen 536, cellulose material 534, including but not limited to wood wastes, may be optionally added to the mixture 540. The blending of cellulose material 534 provides a partial fuel content from a renewable resource thus extending the Iife of available fossil fuels, such as the coaa.l, PET coke, or coke fines, with a clean burning alternative synthetic tiiel. The synthetic solid fuels can be formed into vanous shapes and sizes for use in devices including, but not limited to, stoker boilers, pulverized utility boilers, circulating fluidized bed (CFB) boilets, pressurized fluidized bed combustion (PFBC) boilers, coal gasification (IGCC) units, and wood and coal burning farnaces.
[0029] Coal or coke fines 520 are processed through a crusher or ainder 522 to reduce the particulate solid fuels to a maximum particle size. The crushed coal or coke fines are then transferred to the mixer 540. The contents of the mixer 540 including the processed coal or coke fines 520, recycled plastic 530, cellulose 534 and virgin polymers 536 is mixed and ttansfetTed to the accumulator 550. The accumulator 550, which includes the combined contents of the mixer 540 and the recycled carpet from the shredder/
grinder 514, conveys its contents to a pellet mil1560 using a feeder 552.
[0030] The pellet mill 560 blends the combined contents and uses, for example, a combination of heat, pressure, and forming technology to form solid products, including but not limited to pellets, briquettes, extrusions or sheets, of the mixture, which are then transferred to a cooler 562. After cooling, the solid products are structurally stable and do not retrogress into fine particles during storage and h.an.dling. The solid products are then transferred to storage 564 where they remain intact because the solid particulate materials are encapsulated to prevent degradation, leaching or contamination into the environment.
The solid products also exhibit resistance to moisture because the moisture is driven out by the process heat and then sealed out by the erteapsulating function of the binder clement.
[0031) Reference is now madc to FIG. 6, which illustrates a block diagram of an exemplary process under the methods disclosed herein. The process 600 includes reducing wasto carpet 610 including, but not liimited to, shredding, grindin,g or pelletiziuig the waste carpet. Particulate solids, which may have a fuel content are added 620 and the particulate solids are mixed with the waste cacpet 630. x'he mixture is heated using, for example, a combination of heat generated by the process plus auy supplemental heat necessary to fluidize the binder element of the waste carpet 640. One of ordinary skill in the art knows or will know that supplemental heat may be provided by any number of methods including, but not limited to, electric resistive and inductive devices, combustion causing devices, electromagnetic wave devices, and recaptured heat from other processes.
After the mixing is completed, the mixture is formed inito solid products by pressure, heat or extrasion 650, for example.
10032i Reference is now made to FIG. 7, which is a block diagram illustrating components of an exemplary production plant.for practicing the methods disclosed herein. The plant 700 includes a composite waste reducer 710, which, for example, shreds, grinds, or pelleti2es waste earpet. A solid particulate delivery device 720 provides solid particulates to the reduced composite waste at, for example, a conibini,ug device 730. The combining device 730 combines the reduced composite waste product with particulate solids to create a mixture. Additionally and possibly in combination with the combining device 730, heat generation/regulation equipment 740 provides sufficient supplemental heat to the mixture to fluidize one element of the composite waste product.
The heated mfixturte is then provided to a solid product forming device 750, configured to produce solid formed products. The solid formed products include but are not limited to pelaets, briquettes, extrusions and sheets, among others. As discussed above, the solid formed products may be produced for subsequent consumption wberein the solid particulates have a useful fuel content or other desirable recycle value.
Alternatively, the solid fortned product may provide a safe and effective method of stori.ng and handling useful or potentially harmful solid particulate materials. The plant 700 also includes sufficient process control equipment 760 such that the production steps are inte8rated into a continuous process. In the alternative, the process contcol equipment 760 is configured, for exatnple, to perform production steps in independent stages.
(0033] The methods described herein do not requiro water, acids or any other chemical or elemental component from the particulate solids to form the bond. As a result, virtu.ally il any particulate or blended materials can be reliably pelletized using methods described herein. Although waste carpet is presented in an etnbodiment described herein, one of ordinary skill in the art knows, or will know that any composite waste product having binder arid fiber elements may be used. For example, polytner unpregnated cloth used in some industrial processes may also be a suitable composite waste product.
(0034] It should be emphasized that the above-described embodiments of the present disclosare, particularly, any il]ustrated embodiments, are merely possible examples of implementations, merely set foitlk for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosirre and the present disclosure and protected by the following claims.
Claims (21)
1. A method for binding particulate solids, comprising:
reducing a composite waste product;
adding particulate solids to the composite waste product;
combining the particulate solids with the composite waste product to create a consistent mixture;
adding energy to the mixture to increase a process temperature, such that a component of the composite waste product changes from a solid state to a fluid state; and forming the mixture into a solid formed product.
reducing a composite waste product;
adding particulate solids to the composite waste product;
combining the particulate solids with the composite waste product to create a consistent mixture;
adding energy to the mixture to increase a process temperature, such that a component of the composite waste product changes from a solid state to a fluid state; and forming the mixture into a solid formed product.
2. The method of claim 1, wherein the composite waste product comprises carpet.
3. The method of claim 1, wherein the composite waste product comprises:
a first element comprising a backing material, wherein the backing material exhibits a first fluidizing temperature; and a second element comprising a fiber material, wherein the fiber material exhibits a second fluidizing temperature, and wherein the first fluidizing temperature is lower than the second fluidizing temperature.
a first element comprising a backing material, wherein the backing material exhibits a first fluidizing temperature; and a second element comprising a fiber material, wherein the fiber material exhibits a second fluidizing temperature, and wherein the first fluidizing temperature is lower than the second fluidizing temperature.
4. The method of claim 1, wherein the particulate solids comprise materials with fuel content.
5. The method of claim 4, wherein the particulate solids are selected from the group comprising: coke breeze, coke fines, and coal fines.
6. The method of claim 4, further comprising adding a cellulose material, wherein the cellulose material comprises a renewable fuel resource for supplementing the fuel content of the particulate solids.
7. The method of claim 4, wherein the fuel content per solid formed product is standardized.
8. The method of claim 1, wherein the particulate solids comprise non-fuel waste materials.
9. The method of claim 1, wherein the composite waste product comprises a fibrous component, wherein the fibrous component exhibits increased adhesive properties at the process temperature.
10. The method of claim 1, wherein the solid formed product comprises a polymer fiber matrix, such that the particulate solids are reliably retained.
11. The method of claim 1, further comprising adding a supplemental polymer, such that the supplemental polymer results in different solid formed product properties.
12. A degradation resistant fiber matrix solid product comprising:
a composite waste product including a binder element and a fiber element, wherein the binder element fluidizes at a first temperature, wherein the fiber element fluidizes at a second temperature, and wherein the first temperature is lower than the second temperature; and a particulate solid, wherein the binder captures the particulate solid when blended at a temperature in the range between the first temperature and the second temperature.
a composite waste product including a binder element and a fiber element, wherein the binder element fluidizes at a first temperature, wherein the fiber element fluidizes at a second temperature, and wherein the first temperature is lower than the second temperature; and a particulate solid, wherein the binder captures the particulate solid when blended at a temperature in the range between the first temperature and the second temperature.
13. The solid product of claim 12, wherein the particulate solid comprises fuel particulates.
14. The solid product of claim 13, wherein the fuel particulates are selected from the group including: coke breeze, coke fines, and coal fines.
15. The solid product of claim 12, further comprising a cellulose particulate product, wherein the cellulose particulate product provides a renewable resource fuel content to the solid product.
16. The solid product of claim 12, wherein the particulate solid comprises non-fuel particulate material.
17. The solid product of claim 16, wherein the non-fuel particulate material is selected from the group including: particulate radiation contaminants, metal particulates, toxic waste particulates, and metal oxide particulates.
18. The solid product of claim 12, wherein the composite waste product is carpet.
19. The solid product of claim 12, wherein the solid product is formed using an extrusion process.
20. A method for capturing particulate solids in a degradation resistant form, comprising:
a reducing means for shredding or pelletizing carpet;
a supplying means for adding particulate solids to the carpet;
a mixing means for blending the carpet and the particulate solids into a mixture;
a heating means for elevating the temperature of the mixture such that a binder element of the carpet achieves a fluid state and a fiber element of the carpet retains a solid state; and a forming means converting the mixture into a solid, wherein the solid comprises a polymer fiber matrix which captures the particulate solids.
a reducing means for shredding or pelletizing carpet;
a supplying means for adding particulate solids to the carpet;
a mixing means for blending the carpet and the particulate solids into a mixture;
a heating means for elevating the temperature of the mixture such that a binder element of the carpet achieves a fluid state and a fiber element of the carpet retains a solid state; and a forming means converting the mixture into a solid, wherein the solid comprises a polymer fiber matrix which captures the particulate solids.
21. A plant for binding particulate solids, comprising:
a composite waste product reducer;
a delivery device for adding a solid particulate product to a reduced composite waste product;
a combining device configured to provide a mixture of the reduced composite waste product and the solid particulate product;
a heater for increasing the temperature of the mixture such that a first element of the mixture fluidizes; and a forming device such that a solid product is created from the mixture.
a composite waste product reducer;
a delivery device for adding a solid particulate product to a reduced composite waste product;
a combining device configured to provide a mixture of the reduced composite waste product and the solid particulate product;
a heater for increasing the temperature of the mixture such that a first element of the mixture fluidizes; and a forming device such that a solid product is created from the mixture.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002550497A CA2550497A1 (en) | 2006-06-20 | 2006-06-20 | Methods for binding particulate solids |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002550497A CA2550497A1 (en) | 2006-06-20 | 2006-06-20 | Methods for binding particulate solids |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2550497A1 true CA2550497A1 (en) | 2007-12-20 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002550497A Abandoned CA2550497A1 (en) | 2006-06-20 | 2006-06-20 | Methods for binding particulate solids |
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| Country | Link |
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| CA (1) | CA2550497A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2513100A (en) * | 2013-02-28 | 2014-10-22 | Econpro Ltd | A solid recovered fuel composition |
-
2006
- 2006-06-20 CA CA002550497A patent/CA2550497A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2513100A (en) * | 2013-02-28 | 2014-10-22 | Econpro Ltd | A solid recovered fuel composition |
| GB2513100B (en) * | 2013-02-28 | 2018-08-29 | Econpro Ltd | A solid recovered fuel composition |
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Discontinued |
Effective date: 20140929 |