WO2006003444A1 - Produit combustible et procede correspondant - Google Patents

Produit combustible et procede correspondant Download PDF

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Publication number
WO2006003444A1
WO2006003444A1 PCT/GB2005/002635 GB2005002635W WO2006003444A1 WO 2006003444 A1 WO2006003444 A1 WO 2006003444A1 GB 2005002635 W GB2005002635 W GB 2005002635W WO 2006003444 A1 WO2006003444 A1 WO 2006003444A1
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WO
WIPO (PCT)
Prior art keywords
pellets
binder
fuel
coal
particulate material
Prior art date
Application number
PCT/GB2005/002635
Other languages
English (en)
Inventor
John Kenneth Gilbert
John Samuel Webster
Original Assignee
Applied Silicate Technologies Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Applied Silicate Technologies Limited filed Critical Applied Silicate Technologies Limited
Priority to CNA2005800222218A priority Critical patent/CN1997726A/zh
Priority to AU2005258956A priority patent/AU2005258956B2/en
Priority to EP05761525A priority patent/EP1784479A1/fr
Priority to US11/631,443 priority patent/US20080022586A1/en
Priority to EA200602216A priority patent/EA010323B1/ru
Priority to CA002570522A priority patent/CA2570522A1/fr
Priority to JP2007519874A priority patent/JP2008506000A/ja
Publication of WO2006003444A1 publication Critical patent/WO2006003444A1/fr

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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
    • C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
    • C10L5/06—Methods of shaping, e.g. pelletizing or briquetting
    • C10L5/10—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders
    • C10L5/105—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders with a mixture of organic and inorganic binders
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10F—DRYING OR WORKING-UP OF PEAT
    • C10F7/00—Working-up peat
    • C10F7/04—Working-up peat by moulding
    • C10F7/06—Briquetting
    • 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
    • C10L5/06—Methods of shaping, e.g. pelletizing or briquetting
    • C10L5/10—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders
    • C10L5/12—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders with inorganic binders

Definitions

  • the present invention relates to a fuel product and a process for making same.
  • peat industry Another industry using the briquetting process is the peat industry.
  • the peat To form a suitably crushable material, the peat must be significantly dried, often two or three times, as well as shredded and crushed, adding to the overall cost of forming the briquettes.
  • a process for producing rigid fuel pellets from a particulate carbon-based material and a binder comprising of the following steps:
  • the process is carried out at ambient temperature.
  • silicate-based binder which includes one or more surfactants allows the process of the present invention to create rigid fuel pellets at ambient temperature. Forming rigid fuel pellets at ambient temperature has not been achievable by any prior art process.
  • the fuel pellets are 'rigid' in the sense that they are handleable, and are able to be stored, stacked, and/or transported immediately, without requiring any separate active curing step or steps. That is, the pellets cure without any assistance or further treatment, especially heat and/or pressure treatment.
  • the prior art processes required fuel pellets formed by tumbling of agglomeration to be actively cured with heat and/or (forced air) pressure before such fuel pellets were rigid and handleable. Thus, the fuel pellets of the present invention could be packaged and/or transported immediately after forming.
  • the tumbling action serves to agglomerate the particles and bind the mixture into the pellets, usually with a variable size distribution.
  • No mechanical compression force is required, (with its attendant low production rate and high cost) , and the process of the present invention can be carried out at ambient temperature.
  • no additional equipment is required for any active second stage treatment, or to provide an elevated temperature. This naturally eliminates the need for a power source, e.g. fuel to be burnt, to create the elevated temperature, which action is usually a significant economic requirement of an industrial process .
  • the binder of the present invention allows the fuel pellets of the present invention to be formed and to cure in a 'cold fusion' process. That is, the pellets can be formed and cure without the need for any external heat input.
  • the present invention is particularly advantageous by being able to be a 'single stage' process, avoiding the need for any pre-mixing or treatment of the constituents involved, and the requirement for any post-forming treatment.
  • a single stage process reduces the requirements needed to set up a plant adapted to provide the process of the present invention, and lowers the costs of operation by having a single stage process which is run at ambient temperature.
  • the present invention is also advantageous in using inorganic binders, as opposed to the generally organic materials used as binders in prior art processes.
  • the use of inorganic binders reduces the complexity of the process, and again reduces the need for any pre-treatment or mixing of binder materials .
  • the use of an inorganic silicate-based binder has two further advantages. Firstly, such binders do not impact on the burn quality of the carbonaceous material (as they do not burn) , in contrast with organic materials such as starches, (which do burn, and which therefore effect the burn quality and thus heat content value of the formed material) . Such binders are also clear of any environmental implications (as they do not burn) , again in contrast with organic binders .
  • the rigid fuel pellets Once the rigid fuel pellets are formed, they cure to provide the final form of the fuel pellets .
  • such curing can occur at ambient temperature, and can also occur without any active and/or separate curing step, especially a heat treatment step as used in the prior art.
  • the rigid fuel pellets will cure over time without any external influence. Thus, they could be allowed to stand, for example, for some time, such as 1-10 days, at a suitable position or location, whilst curing occurs after the tumbling. Like concrete, curing may continue for some time, for example over several days, but the invention provides rigid pellets with sufficient solidity after tumbling, that they are ready to be stored, stacked, transported etc as they cure.
  • the concept of curing as used herein includes any drying required of the formed pellets in addition to the chemical process occurring at at least the surface of the pellets as they are being formed, preferably to provide a hardened shell. As such, it is not intended that the present invention provides any separate drying step or action, ( being in relation to one or more liquid materials or substances, such as water, evaporating from the pellets as they are formed and cured) . Any such post pellet-forming drying action is regarded as secondary or minor compared to the act of forming and curing the pellets.
  • the process provides pellets having a hardened outer portion, skin, casing or shell. More preferably, the interior of the pellets is dry, and wholly or substantially has a small, preferably micro, aerated or porous form. That is, the action of the surfactant to draw the silicate binder to the surface of the pellets as they are being formed creates air pockets and bubbles in the interior, the benefit of which is discussed hereinafter.
  • water is part of the material and binder mixture, either by being part of the material, part of the binder, added separately, or a combination of any of these.
  • the amount of water needed or desired for the process of the present invention may depend upon the nature of the particulate material and the binder. For example, listed below are various types of mined coal, and their generally found moisture content (m/c) as the coal is mined, their heat content (h/c) and their carbon content.
  • the heat content of coal can be directly linked to the moisture content. Therefore, the heat content of high grade anthracite with a moisture content of 15% will have a heat content of 26-33mj/kg on a moist mineral-matter free basis . At the other end of the scale, lignite, the lowest rank of coal, will have a moisture content of up to 45%, with a heat content of only 10-20 mj/kg on a moist, mineral matter free basis.
  • coal In most power stations using coal, the coal is generally ground into a fine powder to be sprayed into the combustion furnaces.
  • the power for crushing coal having a moisture content of, for example, 25% is relatively high.
  • freshly mined bituminous coal can have a moisture content of up to 20%
  • lower ranking coal can have a moisture content of up to 30%, with lignite going up to 45%.
  • the present invention can use any type of 'wet' or 'dry' particulate carbon-based material, although any wet material preferably has a maximum water content of 10-15%.
  • a moisture level can be achieved by grinding, which has a drying effect, (although the power required therefor is a lot lower than the power required for grinding coal to a powderous form ready for immediate burning as described above) .
  • Such material is generally still regarded in the art as being 'wet', especially in relation to e.g. the briquetting process, which requires its material to be absolutely dry.
  • the material may be derived from a wet fuel source, such as peat and coal tailings dams, and any reduction in the amount of drying needed (compared with for example the briquetting process) reduces the overall energy input required to form the fuel product.
  • the process of the present invention is directly usable with moisture-rich coal fines and similar products, as any water content of the binder can be reduced in line with the level of moisture in the coal without affecting the process.
  • their hardened shell wholly or substantially stops or significantly reduces water ingress, especially if waterproofing additives are used.
  • the pellets Once fully cured, the pellets can have a moisture content of at least half that of the particulate starting material, and possibly less than 5%, and thus be sufficiently dry for immediate and easy grinding to form a suitable fuel product for a power station.
  • a reduction in moisture also provides a direct increase in the heat content value of the product which it is burned, hence increasing its efficiency and economic value.
  • This economic benefit extends to transportation of such a product, in comparison with cost of transporting 'wet' or moisture-rich material as described hereinabove.
  • the present invention provides a process whereby with consideration of the type and amount of binder(s) used, and the process parameters, a fuel material can be provided which has a desired or pre- determined burn value or the like, which, in particular, could suit the local economic conditions for the fuel source. Different locations and countries mine different types and grades of coal, and they therefore use such coals in different ways in order to try and maximise their economic value.
  • the present invention provides a particular advantageous process to benefit what is currently regarded as a waste material from current industrial processes.
  • the present invention also provides significant moisture reduction in a fuel product, converting an inefficient fuel product into an efficient fuel product.
  • the amount of water for the process is adjusted in the binder component prior to its admixing with the particulate material.
  • the calculation of this binder to water adjustment is dependent on the moisture content of the particulate material.
  • the particulate material is generally of a maximum size or grade of 3mm or lower. Coal 'dust' or 'fines' can often be of a sub-micron size.
  • Peat is a fuel material which is generally dried/shredded/dried/crushed prior to briquetting. Some shredding of the peat material may still be required to provide a particulate material suitable for the present invention, but to a much lesser extent than that required for briquetting. More preferably, the particulate material has a range of sizes or grades; preferably biased towards fine or finer particle sizes.
  • Carbon-based particulate material suitable for the present invention can be accepted wet or dry, and could be provided by any type of maceral fuel, including peat and lignite through to sub-bituminous coals, anthracite fines, petroleum coke fines and the like, as well as sewerage wastes, biomass, animal wastes and other hydrocarbon materials that could be considered a fuel source.
  • the particulate material may also be a combination of two or more starting materials or 'ingredients', not necessarily premixed, and such as those hereinbefore mentioned, so as to provide 'hybrid' fuel pellets.
  • Suitable materials also include low grade or processed fuels, as well as hitherto 'waste' products, whose clean combustion would help lower overall pollution levels.
  • the present invention is not affected by high ash content or sulphur content in the particulate material.
  • any suitable silicate-based binder can be used for the present invention, which binder may be a homogeneous or heterogeneous material, such as cements and raw silicates like calcium, sodium or potassium.
  • the process may include the addition of one or more further ingredients into the mix, either separately or integrally with the binder.
  • Such further ingredients include lime, inorganic binders, cements, and waterproofing additives.
  • a cementitious material can assist in the green-strength of the pellets, and possibly in forming the hardened outer surface or shell for the pellets as described hereinafter
  • Lime or cement helps to inhibit sulphur emission upon burning of the so-formed pellets. It is a particular advantage of the present invention that the use of lime or other types of calcium hydroxide (which are known to be sulphur-absorbing agents) are admixed with the particulate carbon-based material.
  • the increased mixing of such sulphur-absorbing agents with sulphur-containing carbon-based materials reduces the need for current sulphur- absorbing apparatus such as scrubbers and the like at the end of fuel-burning process .
  • the present invention can achieve a reduction of sulphur emission (usually in the form of sulphur dioxide) by 70-90%, or possibly more. Again, this is a significant reduction in current power station requirements, and therefore costs.
  • the coal In most coal-burning power stations, the coal is generally ground into a fine material and then injected into the fuel burner to provide the power.
  • a sulphur-absorbing agent into the pellet-forming process, along with grinding of the pellets for subsequent use in a fuel-burning plant, therefore provides two particular advantages .
  • the ability of the process of the present invention to provide wholly or substantially 'dry' pellets reduces the energy input required to effect the grinding of the pellets prior to their burning, as described above, and secondly, grinding of the pellets increases the mixing of the sulphur- absorbing agent (s) with the carbon-based material, thus increasing the efficiency of the sulphur- absorption, and so reducing the sulphur-emission.
  • the present invention helps achieve such reduction without requiring additional or other physical and/or chemical sulphur absorption apparatus or processes such as scrubbers and the like, (which also require regular regeneration to work effectively, which is another energy intense process) .
  • the process of the present invention can further include the step of grinding, crushing or otherwise particularising the pellets, preferably in a form ready to use in a fuel-burning power plant.
  • One or more other mineral additives such as zeolites or vermiculite could also be used as a further ingredient to help bind any metallic contaminants in the ash of the pellets, and so prevent any soluble metals being released from the ash.
  • the particulate material and binder, and any other separate reagents or ingredients to be added can be admixed using any known process or arrangement, including simple mixing. Because the next part of the process is a tumbling action, absolute homogenous mixing of the reagents or ingredients prior to the tumbling is not essential, as the tumbling action will generally further the mixing action if necessary or desired. In some circumstances, the admixing may at least partly occur during the tumbling action, such that the actions of the invention may not be wholly distinct.
  • the binder is coated on to the particulate material.
  • One method of coating is to spray the binder on to the material.
  • the particulate material is moving prior to and/or during mixing with the binder, and/or the material is in a dispersed arrangement.
  • a falling curtain of particulate material such as at conveyor transfers, inside pelletising drums or pans, and from stockpile load outs, etc.
  • the particulate material and binder are directly and/or immediately undergo tumbling after their contact with each other.
  • the tumbling action serves to agglomerate the particulate material and binder mixture to form particles of greater and greater size, generally having a spherical or ovoid shape.
  • the size of the so-formed pellets can be adjusted based on the process conditions for tumbling, such as rotation speed, moisture content, impact force and residence time.
  • the pellets could also be screened and/or recycled during or after pelletising to produce a desired, e.g. narrower, size distribution.
  • Rotary drums are well known in the art. Their output can be dependent upon the length, diameter, speed of rotation and angle of mounting of the drum, and the output can vary from single figure tonnes per hour, to hundreds of tonnes per hour per drum.
  • agglomerator drums such as pan, rotary and conical drums
  • process variations to provide variation in the products formed. See for example UK Patent No 787993.
  • Rotary drums have low capital and low operating costs, especially in comparison with briquetting plants . They can even be provided in mobile form, such that the process of the present invention can be provided where desired or necessary, e.g. moved and located to where a particulate material is currently stored or 'dumped', rather than requiring significant movement (and therefore cost) for transporting the material to a fixed processing site.
  • the agglomeration action may be carried out in one or more stages, which stages could be connected, such as the tumbling conditions changing in the same drum, or the material being fed directly into another agglomerator. Or, such actions could be separate.
  • the tumbling conditions are variable or varied for each stage. The conditions may be altered either in a continuous manner or action, or discretely.
  • one or more rotary drums may be used for the agglomeration, preferably in series.
  • the surfactant (s) serve to draw the silicate-based binder towards the surface of the forming pellets, such that as they are created and start to cure, the pellets will form and then continue to have a harder outer portion, skin, shell or surface, compared to their interior.
  • the pellets have a variable density towards the core; the density being greater at the surface.
  • the 'shell' layer or portion will generally have a high density in comparison with the lower density of the 'interior' .
  • the pellets have sufficient hardness once formed to allow handling, stacking and/or transportation without any significant breakage.
  • the curing of the pellets may start during or be part of the agglomeration action.
  • the method of the present invention may include one or more sizing steps. That is, to grade the size of the so-formed pellets to that desired or necessary. This could include extracting those pellets which are damaged or undersized, which pellet material could be recycled back into the process of the present invention.
  • sizing steps that is, to grade the size of the so-formed pellets to that desired or necessary. This could include extracting those pellets which are damaged or undersized, which pellet material could be recycled back into the process of the present invention.
  • the present invention can form this fine coal into approximately 50mm lumps with very low moisture, without any change to the chemical properties of the coal. The pellets can then be handled, transported and used as normal lump coal.
  • the formed pellets are rested for some time, possibly a number of days such as 3-7 days, to provide or allow for curing to finish. Like other curing products, the pellets continue to cure to gain strength over time, such as a further number of days or weeks .
  • the present invention provides a process for producing rigid fuel pellets at ambient temperature from a particulate carbon-based material and a silicate-based binder which includes one or more surfactants, the process comprising the steps of: admixing the material and binder, and agglomerating the so-formed mixture by tumbling to form the rigid fuel pellets .
  • a rigid fuel pellet product formable at ambient temperature by agglomeration of a particulate carbon-based material and a silicate-based binder including one or more surfactants .
  • a fuel pellet product whenever formed by a process as herein described.
  • the fuel pellet product of the present invention is a material which is easily storable. It is also easily transportable due to its variable diameter distribution. This enhances stacking concentration, which also reduces abrasion and consequential breakage of the pellets.
  • the product of the present invention is ready for use as a fuel in many situations, e.g. domestically such as in a home fire, industrially, such as in a power plant, etc.
  • the product is formed from currently 'waste' materials, thereby increasing the efficiency of current solid-fuel extraction and production.
  • the product preferably allows a very high percentage of combustion (possibly 100% combustion) , so as to leave little or no combustible fuel in the ash.
  • Figure 1 is a flow diagram of a process according to one embodiment of the present invention in the context of the material handling and production stages in an industrial plant;
  • Figure 2 is a front view of tumbling action of agglomerating pellets according to the present invention.
  • Figure 3 is a view of a number of pellets according to another embodiment of the present invention.
  • Fine coal recovery systems are now a common part of modern coal process operations, but there has been a requirement for a cost effective high tonnage solution for utilising the wet coal fines generated by the various beneficiation (benefaction) processes.
  • Briquetting is a process where some type of material is compressed under high pressure. Compression of the material causes the temperature to rise, which makes the raw material liberate various adhesives.
  • the current method of forming peat briquettes requires initial drying of the dug peat to about 55% moisture, shredding, further drying to a lower moisture content, followed by crushing, followed by high pressure briquetting. Each mechanical step requires significant energy input.
  • Other waste materials include petroleum coke, a by- product from cracking oil, which is sold off at a low cost.
  • the process of the present invention allows for use of all these materials in a cost-efficient process, to provide a beneficial fuel product.
  • Figure 1 shows a flow diagram for the process of the present invention in the context of an industrial plant.
  • the raw fuel feed is prepared for agglomeration. Depending on its raw state, it may - be beneficial to carry out some grinding, screening or drying. The finer the raw feed is, the more effective the process. Preferably, (but not limiting), the moisture content of the feed is 10-15% (by weight) at most.
  • the liquid feed is adjusted to suit. This will involve balancing the quantity of water relative to the binder and surfactants ' used.
  • the fuel feed is carried along and any dry reagents are added to the feed. It then falls from the end of a conveyor belt.
  • the liquid binder is sprayed onto the falling curtain of fines, which together fall into a rotating drum, generally l-5m (such as 3m) in diameter. As the mixture tumbles while being sprayed with the binder and water mixture, it forms small pellets which agglomerate and grow, forming rigid pellets of desired shape and size as shown in Figure 2.
  • the drum can be lined with loosely fitting heavy duty rubber sheet to avoid material sticking to the sides of the drum.
  • the drum is set at an incline (e.g. 1-3%) to aid progression of the pellets therealong, and to control the residence time in the drum.
  • the completed pellets exit at the opposite end of the drum onto another conveyor.
  • Pellets can be varied in size with only operational drum adjustments (speed of rotation, moisture content and longitudinal drum angle which directly affects residence time in the drum) . Expensive mould changes, such as in present briquetting operations, are not required to vary the product dimensions. Some forming and even some curing may take place in another rotating drum, similar to but having a larger diameter than the agglomerating drum. It may also be of greater diameter and longer than the agglomeration drum. Here the pellets progress slowly through the drum, allowing sufficient time for the pellets to initially cure or receive surface treatment, and thereby allow immediate handling and stacking. The residence time within this drum is dependent on the fuel characteristics, and its use can be determined in pre-production tests.
  • Selected surface treatment additives can be added at this stage to increase the surface area of the pellet skin, to prevent sticking, and/or to prevent leaking fluid into bags, etc.
  • pellets can be further graded to the desired cross section if necessary. Any damaged and undersized pellets can then be returned to the agglomerating drum for reprocessing.
  • the pellet sizing could even be designed to be made dependent upon proposed use.
  • the pellet size can be adjusted by means of changes to process conditions, equipment configuration, and even reagent dosage.
  • the pellets can then be stockpiled for curing. During this time, generally between 3-7 days for coal fine pellets, and depending on ambient temperature, the pellets reach such strength as to allow full handling. No heating or force draught drying is required.
  • An example of formed pellets is shown in Figure 3.
  • the spherical shape of the pellets will allow air to move freely through the stockpile to assist the curing process and prevent heat build up and the risk of spontaneous combustion.
  • the pellet surface is also tightly sealed, preventing air ingress into the pellets, and so also slowing the effect or chance of any spontaneous combustion. If spontaneous combustion is still a problem, preventative reagents can be added during agglomeration.
  • Transportation and Packing Tumble and growth agglomeration can result in a wide variation in the final pellet size - as in natural lump coal. This has the advantage of lowering the bulking factor of the pelletised product, resulting in lower transportation costs.
  • the formed product could then be bagged or stacked and allowed to continue to cure at ambient temperatures, curing time being dependent upon local humidity. Generally, the higher the moisture content of the feed, the longer the pellets will require to be cured at ambient temperatures and humidity.
  • Process rates can be selected, but production rates of between 10-100 tonnes per hour of coal material per drum would be a general rate.
  • the production rate can be scaled up using multiple process units, or scaled down with smaller equipment.
  • Production costs are dependent upon the production rate, particle size distribution of the feed, and characteristics of the particulate materials.
  • energy input per tonne of product has been measured at approximately 0.5 to 2kWh, at least a hundred times less than the energy input needed for briquetting.
  • the process of the present invention can be modified to treat very high ash and/or very high sulphur coals, as the pellets remain stable throughout the combustion process, allowing even for low rank coals to burn efficiently.
  • the present process is also suitable for fuel products that need to lower ash and sulphur to be sellable.
  • the present process allows fine grinding to release contaminants by gravity or flotation methods, generating a much higher quality fuel source.
  • the process also provides the manner of re- forming the fine pure concentrate into a usable stable and valuable product form.
  • Sulphur emissions even from very poor quality coal, can be wholly or substantially eliminated by simple adjustment of pelletising additives, significantly reducing or even possibly eliminating any sulphur dioxide pollution leading to acid rain.
  • the process of pelletising also simultaneously reduces ' fly ash by the inherent cementation, silicification and stabilisation of the residual ash instigated by the reagents used. Additionally, higher product combustion temperatures are easier to generate due to high gas transfer rates, not only between the pellets, but also between particles within the pellets, providing more rapid and/or more controllable combustion than normal fuels.
  • a further advantage of the present invention is the very complete combustion of the contained fuel in the pellets due to the high gas transfer rates and the maintenance of the integral structure of the pellets until combustion is complete.
  • the retaining hardened shell, skin, etc allows for significant heat increase or build-up inside the pellet, causing very high levels of combustion, resulting in the completion of any pre-designed chemical reactions in the interior content of the pellet.
  • the pellets maintain their form even at white heat, and show very stable combustion characteristics.
  • the process of the present invention can involve no forced drying of the pellets because the action of any surfactant(s) used is maximised in ambient temperatures.
  • the surfactant causes the binder-containing moisture to rapidly migrate to the surface of the pellet by capillary action, giving the 'egg shell' effect of a hardened surface and softer interior, due to the final heavy surface concentration of the binder. This results in a significantly enhanced skin strength, giving a very robust and low moisture content pellet (approximately 5%) , which also resists moisture absorption from the air.
  • One further application of the present process is lowering the feed moisture of pulverised coal fuels in power and heat stations, where the coal fines or coal tailings are pelletised and allowed to thoroughly cure and dry before being pulverised and burnt in the furnace.
  • the general moisture content found in current coal fines dumps is usually in the range 12-35%, making them very difficult to use or blend with other feeds.
  • the process of the present invention overcomes or solves a number of financial and operational problems .
  • the pellet will retain its strength even during white heat combustion. This allows high temperature reactions to take place inside the pellet resulting in much higher levels of combustion of the fuel, giving effective oxidation and sequestration of any contained sulphur, and negligible unburnt carbon levels in the residue ash.
  • the shell effect allows the pellet to retain its structure during combustion, resulting in less particulate emissions in the flue gas.
  • the egg shell pelletisation could also be used on sulphide concentrates and iron ores to allow the manufacture of pre-fluxed furnace feeds which can lead to 'sulphur emission free' smelter technology. This could be used in existing operations cost . effectively with high industrial tonnage output.
  • the present invention provides significant benefits compared with present technologies, including:
  • coal/lignite fines can be pelletised dry or direct from a filtration plant.
  • Tonnage throughput can be from 10 tones per hour (community size) up to 100 tonnes per hour per pelletising line.
  • High level of automation can be used during pelletising for accurate control and reagent usage.
  • Pellets just air dry while chemically 'curing' can be handled by bulk handling equipment when cured or alternatively bagged when 'green' .
  • Pellet size can be customised from 5mm to 150mm if required depending upon coal characteristics and process parameters.
  • Special heavy duty reagents can be added for high strength, for rapid cure, for high temperature strength, and for enhanced water resistance.
  • Residual ash can also be pelletised with similar binder reagents for concrete feedstock, aggregate blending and high porosity landfill.
  • Lignite and peat can be treated with identical technology or can be blended with other fuel sources to create hybrid pellet fuels with pre- designed characteristics such as smokeless burning.
  • the present invention is usable with all types of coal fines, which will have a varying amount of moisture and sulphur content.
  • pellets ranging from 5-50 mm diameter are formed, which sized pellets are easily handable, storable, transportable and then burnable, and, if required, in an optimal form and size for grinding prior to burning.
  • the present invention provides a simple but efficient process for using waste carbon-based materials, and forming a useable fuel product, which is easily transportable and efficiently combustible.
  • Rotating drum or pan agglomerators are relatively low cost to build, and are capable of very high tonnage throughputs.
  • Customised products can be produced and the present invention enhances the economics of ash and sulphur removal in coal upgrade plants . .

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
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  • Environmental & Geological Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Geology (AREA)
  • Solid Fuels And Fuel-Associated Substances (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

La présente invention porte sur un procédé de production de pastilles de combustible. Ces pastilles peuvent être obtenues à partir d'un matériau à base de carbone particulaire et d'un liant. Ce procédé comprend les étapes suivantes consistant: à mélanger le matériau et le liant puis à agglomérer le mélange ainsi formé par culbutage. L'étape de culbutage, mise en oeuvre par exemple dans un tambour rotatif, sert a agglomérer les particules et à lier le mélange en pastilles, d'ordinaire avec une répartition granulométrique variable. Ce procédé ne requiert aucune force de compression mécanique et, avec les liants utilisés, il peut être mis en oeuvre à température ambiante. Ce procédé constitue un procédé simple mais efficace d'utilisation de résidus à base de carbone et de formation d'un produit combustible utilisable, qui est facilement transportable et efficacement combustible. Le tambour rotatif ou des agglomérateurs à cuve sont relativement peu coûteux à fabriquer et sont capables de produire de très hauts rendements en tonnage. Des produits personnalisés peuvent être produits au moyen de ce procédé, lequel renforce la rentabilité des cendres et l'élimination du soufre dans les installations de valorisation du charbon.
PCT/GB2005/002635 2004-07-07 2005-07-06 Produit combustible et procede correspondant WO2006003444A1 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
CNA2005800222218A CN1997726A (zh) 2004-07-07 2005-07-06 燃料产品和方法
AU2005258956A AU2005258956B2 (en) 2004-07-07 2005-07-06 Fuel product and process
EP05761525A EP1784479A1 (fr) 2004-07-07 2005-07-06 Produit combustible et procede correspondant
US11/631,443 US20080022586A1 (en) 2004-07-07 2005-07-06 Fuel Product and Process
EA200602216A EA010323B1 (ru) 2004-07-07 2005-07-06 Топливный продукт и способ его изготовления
CA002570522A CA2570522A1 (fr) 2004-07-07 2005-07-06 Produit combustible et procede correspondant
JP2007519874A JP2008506000A (ja) 2004-07-07 2005-07-06 燃料製品及び燃料製品を製造する方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
PCT/GB2004/002936 WO2006003354A1 (fr) 2004-07-07 2004-07-07 Pastille de combustible et procede
GBPCT/GB2004/002936 2004-07-07

Publications (1)

Publication Number Publication Date
WO2006003444A1 true WO2006003444A1 (fr) 2006-01-12

Family

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Family Applications (2)

Application Number Title Priority Date Filing Date
PCT/GB2004/002936 WO2006003354A1 (fr) 2004-07-07 2004-07-07 Pastille de combustible et procede
PCT/GB2005/002635 WO2006003444A1 (fr) 2004-07-07 2005-07-06 Produit combustible et procede correspondant

Family Applications Before (1)

Application Number Title Priority Date Filing Date
PCT/GB2004/002936 WO2006003354A1 (fr) 2004-07-07 2004-07-07 Pastille de combustible et procede

Country Status (10)

Country Link
EP (1) EP1784479A1 (fr)
JP (1) JP2008506000A (fr)
CN (1) CN1997726A (fr)
AU (1) AU2005258956B2 (fr)
CA (1) CA2570522A1 (fr)
EA (1) EA010323B1 (fr)
GB (1) GB2416542B (fr)
UA (1) UA91981C2 (fr)
WO (2) WO2006003354A1 (fr)
ZA (1) ZA200610697B (fr)

Cited By (9)

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WO2009147361A1 (fr) * 2008-06-04 2009-12-10 Solsys Limited Pastille de combustible et procédé
WO2009147360A1 (fr) * 2008-06-04 2009-12-10 Solsys Limited Produit combustible et procédé
CN104704089A (zh) * 2012-10-01 2015-06-10 格雷特波因特能源公司 附聚的颗粒状低煤阶煤原料及其用途
US9102887B2 (en) 2010-02-01 2015-08-11 Silform Technologies Ltd. Pellets and processes therefor
CN106978228A (zh) * 2017-04-27 2017-07-25 神雾环保技术股份有限公司 制备混合球团的方法
WO2017134566A1 (fr) * 2016-02-05 2017-08-10 Coal Tech Llc Procédé d'agglomération d'une boue de charbon comprenant des ultrafines
WO2021094784A1 (fr) 2019-11-14 2021-05-20 Changeover Technologies Limited Formule et procédé pour produire des pastilles de combustible
WO2021094786A1 (fr) 2019-11-14 2021-05-20 Changeover Technologies Limited Procédé permettant de former des pastilles de combustible
WO2023227878A1 (fr) 2022-05-24 2023-11-30 Changeover Technologies Limited Appareil et procédé de densification

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GB0823261D0 (en) * 2008-12-20 2009-01-28 Solsys Ltd Fuel product and process
GB2483426A (en) * 2010-06-15 2012-03-14 Brian David Ferbrache Manufacturing pellets or bricks from damp digested waste material
CN104685039B (zh) * 2012-10-01 2016-09-07 格雷特波因特能源公司 附聚的颗粒状低煤阶煤原料及其用途
RU2652109C1 (ru) * 2016-12-20 2018-04-25 Общество с ограниченной ответственностью "Эксперт Энерго" Способ автоматизированного управления процессом прессования торфяного топлива
EP3601499B1 (fr) * 2017-03-28 2024-05-01 Pelleton Global Renewables Ltd. Procédé de production d'agglomérats à partir d'un flux de biomasse
RU2707297C2 (ru) * 2018-02-05 2019-11-26 Федеральное государственное казенное военное образовательное учреждение высшего образования "Военный учебно-научный центр Военно-воздушных сил "Военно-воздушная академия имени профессора Н.Е. Жуковского и Ю.А. Гагарина" (г. Воронеж) Министерства обороны Российской Федерации Топливный брикет и способ его получения
CN114538813A (zh) * 2020-11-24 2022-05-27 香港理工大学深圳研究院 一种基于圆盘制粒机的地聚合物人工骨料及其制备方法

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US4357145A (en) * 1981-03-27 1982-11-02 Dondelewski Michael A Carbonaceous pellets and method of making

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GB2103237B (en) * 1982-06-14 1985-01-03 Larry Deal Byrne A method for agglomerating powdered coal or carboniferous material by compaction
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DE3445503A1 (de) * 1984-12-13 1986-06-19 Woellner-Werke GmbH & Co, 6700 Ludwigshafen Verfahren zur herstellung von briketts

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US3377146A (en) * 1967-01-26 1968-04-09 Ireland James D Process for pelleting and extruding materials
US4025596A (en) * 1973-10-03 1977-05-24 The Dow Chemical Company Method for pelletizing finely divided solids
US4133718A (en) * 1976-05-17 1979-01-09 Dravo Corporation Method for agglomerating finely divided agglomerative materials in a rotary drum assembly
GB2037809A (en) * 1978-12-04 1980-07-16 American Minechem Corp Conversion of Carbonaceous Materials into Fluid Products
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Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009147361A1 (fr) * 2008-06-04 2009-12-10 Solsys Limited Pastille de combustible et procédé
WO2009147360A1 (fr) * 2008-06-04 2009-12-10 Solsys Limited Produit combustible et procédé
US9102887B2 (en) 2010-02-01 2015-08-11 Silform Technologies Ltd. Pellets and processes therefor
CN104704089A (zh) * 2012-10-01 2015-06-10 格雷特波因特能源公司 附聚的颗粒状低煤阶煤原料及其用途
CN104704089B (zh) * 2012-10-01 2017-08-15 格雷特波因特能源公司 附聚的颗粒状低煤阶煤原料及其用途
WO2017134566A1 (fr) * 2016-02-05 2017-08-10 Coal Tech Llc Procédé d'agglomération d'une boue de charbon comprenant des ultrafines
CN106978228A (zh) * 2017-04-27 2017-07-25 神雾环保技术股份有限公司 制备混合球团的方法
WO2021094784A1 (fr) 2019-11-14 2021-05-20 Changeover Technologies Limited Formule et procédé pour produire des pastilles de combustible
WO2021094786A1 (fr) 2019-11-14 2021-05-20 Changeover Technologies Limited Procédé permettant de former des pastilles de combustible
WO2023227878A1 (fr) 2022-05-24 2023-11-30 Changeover Technologies Limited Appareil et procédé de densification

Also Published As

Publication number Publication date
AU2005258956B2 (en) 2010-10-28
GB2416542B (en) 2006-06-28
GB0513780D0 (en) 2005-08-10
EP1784479A1 (fr) 2007-05-16
EA010323B1 (ru) 2008-08-29
CN1997726A (zh) 2007-07-11
EA200602216A1 (ru) 2007-08-31
JP2008506000A (ja) 2008-02-28
AU2005258956A1 (en) 2006-01-12
UA91981C2 (ru) 2010-09-27
GB2416542A (en) 2006-02-01
CA2570522A1 (fr) 2006-01-12
AU2005258956A2 (en) 2008-08-07
ZA200610697B (en) 2008-09-25
WO2006003354A1 (fr) 2006-01-12

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