Process and System for Drying and Heat Treating Materials

Abstract

This invention discloses systems and methods for conversion of high moisture waste materials to dry or low moisture products for recycle or reuse. The equipment systems comprise a gas turbine generator unit (preferred heat source), a dryer vessel and a processing unit, wherein the connection between the gas turbine and the dryer vessel directs substantially all the gas turbine exhaust into the dryer vessel and substantially precludes the introduction of air into the dryer vessel and wherein the processing unit forms the dried material from the dryer vessel into granules, pellets or other desired form for the final product. Optionally, the systems and methods further provide for processing ventilation air from manufacturing facilities to reduce emissions therefrom.

1 . A method of treating paper manufacturing waste materials having a moisture content of at least about 30% by weight, the method comprising:
 operating a gas turbine to produce exhaust gases;   contacting the exhaust gases of the gas turbine with the paper manufacturing waste materials for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials.   
   
   
       2 . A method according to  claim 1 , wherein the paper manufacturing waste materials are in the form of a pulp. 
   
   
       3 . A method according to  claim 1 , wherein the gas turbine includes a gas turbine generator for producing electricity. 
   
   
       4 . A method according to  claim 1 , further comprising providing a dryer vessel for holding the paper manufacturing waste materials during treatment of the paper manufacturing waste materials, wherein outside air is substantially precluded from entering the dryer vessel. 
   
   
       5 . A method according to  claim 4 , wherein the dryer vessel is connected to the gas turbine so as to substantially preclude the introduction of outside air into the dryer vessel. 
   
   
       6 . A method according to  claim 4 , further comprising directing essentially 100% of the gas turbine exhaust gases into the dryer vessel. 
   
   
       7 . A method according to  claim 1 , further comprising contacting the exhaust gases of the gas turbine with the paper manufacturing waste materials to reduce the moisture content of the paper manufacturing wastes without significant oxidation of the paper manufacturing waste materials. 
   
   
       8 . A method according to  claim 1 , further comprising contacting the exhaust gases of the gas turbine with the paper manufacturing waste materials to reduce the moisture content of the paper manufacturing wastes without significant pyrolysis of the paper manufacturing waste materials. 
   
   
       9 . A method according to  claim 1 , wherein the gas turbine is operated to produce exhaust gases having a temperature of at least 700° F. 
   
   
       10 . A method according to  claim 1 , further comprising processing the paper manufacturing waste materials to form a compacted product after the moisture content of the paper manufacturing wastes has been reduced. 
   
   
       11 . A method according to  claim 10 , wherein the paper manufacturing waste materials are compacted through a granulating process. 
   
   
       12 . A method according to  claim 10 , wherein the paper manufacturing waste materials are compacted through a pelletizing process. 
   
   
       13 . A method according to  claim 1 , further comprising producing a fuel product from the paper manufacturing waste materials. 
   
   
       14 . A method according to  claim 1 , wherein the exhaust gases of the gas turbine are contacted with the paper manufacturing waste materials for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials to less than about 20% by weight. 
   
   
       15 . A method according to  claim 1 , further comprising blending the paper manufacturing waste materials with other materials including carbon after the moisture content of the paper manufacturing waste materials has been reduced. 
   
   
       16 . A method of making a fuel product from paper manufacturing waste materials, the method comprising:
 operating a gas turbine to produce exhaust gases;   contacting the exhaust gases with paper manufacturing waste materials having a moisture content of at least about 30% by weight, in a dryer vessel for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials initially entering the dryer vessel, without significant oxidation of the paper manufacturing waste materials;   after the paper manufacturing waste materials have been contacted by the exhaust gases, compacting the paper manufacturing waste materials to form a compacted fuel product.   
   
   
       17 . A method according to  claim 16 , wherein the paper manufacturing waste materials are compacted through a granulating process. 
   
   
       18 . A method according to  claim 16 , wherein the paper manufacturing waste materials are compacted through a pelletizing process. 
   
   
       19 . A method according to  claim 16 , wherein the paper manufacturing waste materials initially entering the dryer vessel are in the form of a pulp. 
   
   
       20 . A method according to  claim 16 , wherein the gas turbine includes a gas turbine generator for producing electricity. 
   
   
       21 . A method according to  claim 16 , wherein outside air substantially precluded from entering the dryer vessel. 
   
   
       22 . A method according to  claim 21 , wherein the dryer vessel is connected to the gas turbine so as to substantially preclude the introduction of outside air into the dryer vessel. 
   
   
       23 . A method according to  claim 16 , further comprising directing essentially 100% of the gas turbine exhaust gases into the dryer vessel. 
   
   
       24 . A method according to  claim 16 , further comprising contacting the exhaust gases of the gas turbine with the paper manufacturing waste materials to reduce the moisture content of the paper manufacturing wastes without significant pyrolysis of the paper manufacturing waste materials. 
   
   
       25 . A method according to  claim 16 , wherein the gas turbine is operated to produce exhaust gases having a temperature of at least 700° F. 
   
   
       26 . A method according to  claim 16 , further comprising contacting the exhaust gases with paper manufacturing waste materials for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials to less than about 20% by weight. 
   
   
       27 . A method according to  claim 16 , further comprising blending the paper manufacturing waste materials with other materials including carbon after the moisture content of the paper manufacturing waste materials has been reduced. 
   
   
       28 . A fuel product comprising:
 a compacted fuel product having a moisture content of less than about 20% by weight made from paper manufacturing waste materials initially in the form of a pulp having a moisture content of at least about 30% by weight that are contacted directly with exhaust gases having a temperature of at least 700° F., without significant oxidation and significant pyrolysis of the paper manufacturing waste materials.   
   
   
       29 . A fuel product according to  claim 28 , wherein the compacted fuel product is produced through a granulating process. 
   
   
       30 . A fuel product according to  claim 28 , wherein the compacted fuel product is produced through a pelletizing process. 
   
   
       31 . A fuel product according to  claim 28 , wherein the compacted fuel product includes materials including carbon blended into the paper manufacturing waste materials after the paper manufacturing waste materials have been contacted directly with the exhaust gases. 
   
   
       32 . A method of making a fuel product from paper manufacturing waste materials, the method comprising:
 operating a gas turbine generator to produce electricity and to produce exhaust gases having a temperature of at least 700° F.;   providing a dryer vessel for holding the paper manufacturing waste materials, wherein outside air substantially precluded from entering the dryer vessel;   directly contacting essentially 100% of the exhaust gases produced from the gas turbine generator with paper manufacturing waste materials having a moisture content of at least about 30% by weight, in the dryer vessel for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials initially entering the dryer vessel, without significant oxidation and significant pyrolysis of the paper manufacturing waste materials;   after the paper manufacturing waste materials have been contacted by the exhaust gases, compacting the paper manufacturing waste materials to form a compacted fuel product.   
   
   
       33 . A method according to  claim 32 , wherein the paper manufacturing waste materials are compacted through a granulating process. 
   
   
       34 . A method according to  claim 32 , wherein the paper manufacturing waste materials are compacted through a pelletizing process. 
   
   
       35 . A method according to  claim 32 , further comprising blending the paper manufacturing waste materials with other materials including carbon after the moisture content of the paper manufacturing waste materials has been reduced. 
   
   
       36 . A method according to  claim 32 , further comprising contacting the exhaust gases with paper manufacturing waste materials for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials to less than about 20% by weight. 
   
   
       37 . A system for processing paper manufacturing waste materials comprising
 a gas turbine;   a dryer vessel configured to receive essentially 100% of the exhaust gases from the gas turbine though a connection, wherein the connection between the gas turbine and the dryer vessel substantially precludes the introduction of outside air into the dryer vessel, the dryer vessel configured to receive and dry the paper manufacturing waste materials by direct contact of the exhaust gases with the paper manufacturing waste materials to produce a converted material;   a blending unit for blending other materials including carbon into the converted material to produce a blended material; and   a processing unit configured to receive the blended material and form the blended material into a compacted form.   
   
   
       38 . A system according to  claim 37 , wherein the gas turbine includes a gas turbine generator for producing electricity. 
   
   
       39 . A system according to  claim 37 , wherein the processing unit is configured to form the blended material into a compacted form through a granulating process. 
   
   
       40 . A system according to  claim 37 , wherein the processing unit is configured to form the blended material into a compacted form through a pelletizing process. 
   
   
       41 . A method of making a fuel product from paper manufacturing waste materials, the method comprising:
 operating a gas turbine to produce exhaust gases;   contacting the exhaust gases with paper manufacturing waste materials having a moisture content of at least about 30% by weight for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials.   
   
   
       42 . A method of making a fuel product from paper manufacturing waste materials, the method comprising:
 operating a gas turbine to produce exhaust gases;   
     contacting the exhaust gases with paper manufacturing waste materials having a moisture content of at least about 30% by weight, in a dryer vessel for a contact time sufficient to reduce the moisture content of the paper manufacturing waste materials initially entering the dryer vessel, without significant oxidation of the paper manufacturing waste materials.