Engineered fuel feed stock

Abstract

Disclosed are novel engineered fuel feed stocks, feed stocks produced by the described processes, and methods of making the fuel feed stocks. Components derived from processed MSW waste streams can be used to make such feed stocks which are substantially free of glass, metals, grit and noncombustibles. These feed stocks are useful for a variety of purposes including as gasification and combustion fuels.

1 . An engineered fuel feed stock, comprising at least one component derived from a processed MSW waste stream, the feed stock comprising
 a carbon content of between about 30% and about 80%;   a hydrogen content of between about 3% and about 10%,   a sulfur content of less than 2%;   an ash content of less than about 10%; and   wherein the feed stock contains substantially no glass, metals, grit, and noncombustibles.   
     
     
         2 . The feed stock of  claim 1 , further comprising a moisture content of less than about 30%. 
     
     
         3 . The feed stock of  claim 2 , wherein the moisture content is between about 5% and about 30%. 
     
     
         4 . The feed stock of  claim 3 , wherein the moisture content is between about 10% and 20%. 
     
     
         5 . The feed stock of  claim 1 , wherein the feed stock has a HHV of between about 3,000 BTU/lb and about 15,000 BTU/lb. 
     
     
         6 . The feed stock of  claim 1 , wherein the feed stock has a volatile matter content of about 40% to about 80%. 
     
     
         7 . The feed stock of  claim 1 , wherein the feed stock has a carbon content of between about 40% and about 50%. 
     
     
         8 . The feed stock of  claim 1 , wherein the feed stock has a carbon content of between about 60% and about 70%. 
     
     
         9 . The feed stock of  claim 1 , wherein the feed stock has a carbon content of about 75%. 
     
     
         10 . The feed stock of  claim 1 , wherein the feed stock has a hydrogen content of between about 6% and about 7%. 
     
     
         11 . The feed stock of  claim 1 , wherein the feed stock has a moisture content of about 15%. 
     
     
         12 . The feed stock of  claim 1 , wherein the feed stock has an ash content of less than about 5%. 
     
     
         13 . The feed stock of  claim 1 , wherein the feed stock has a HHV of between about 7,000 BTU/lb and about 11,000 BTU/lb. 
     
     
         14 . The feed stock of  claim 1 , wherein the engineered fuel feed stock has a ratio of H/C from about 0.09 to about 0.14. 
     
     
         15 . The feed stock of  claim 1 , wherein the engineered fuel feed stock has a ratio of O/C from about 0.3 to about 0.6. 
     
     
         16 . An engineered fuel feed stock, comprising at least one component derived from a processed MSW waste stream, the feed stock comprising
 a carbon content of between about 40% and about 50%;   a hydrogen content of between about 5% and about 6%,   a sulfur content of less than about 0.5%;   an ash content of less than about 10%; and   wherein the feed stock contains substantially no glass, metals, grit, and noncombustibles.   
     
     
         17 . The feed stock of  claim 16 , further comprising a moisture content of less than about 30%. 
     
     
         18 . The feed stock of  claim 17 , wherein the moisture content is between about 5% and about 30%. 
     
     
         19 . The feed stock of  claim 18 , wherein the moisture content is between about 10% and 20%. 
     
     
         20 . The feed stock of  claim 16  wherein the feed stock has a HHV of between about 5,000 BTU/lb and about 10,000 BTU/lb. 
     
     
         21 . The feed stock of  claim 16 , wherein the feed stock has a volatile matter content of about 40% to about 80%. 
     
     
         22 . The feed stock of  claim 16 , wherein the feed stock has an ash content of less than about 5%. 
     
     
         23 . The feed stock of  claim 16 , wherein the feed stock has a HHV of between about 7,000 BTU/lb and about 9,500 BTU/lb. 
     
     
         24 . The feed stock of  claim 16  wherein the engineered fuel feed stock has a ratio of H/C from about 0.11 to about 0.15. 
     
     
         25 . The feed stock of  claim 16  wherein the engineered fuel feed stock has a O/C ratio from about 0.6 to about 0.9. 
     
     
         26 . An engineered fuel feed stock, comprising at least one component derived from a processed MSW waste stream, the feed stock comprising
 a carbon content of between about 70% and about 80%;   a hydrogen content of between about 5% and about 7%,   a sulfur content of less than about 2%;   an ash content of less than about 7%; and   wherein the feed stock contains substantially no glass, metals, grit, and noncombustibles.   
     
     
         27 . The feed stock of  claim 26  further comprising a moisture content of less than about 30%. 
     
     
         28 . The feed stock of  claim 27 , wherein the moisture content is between about 5% and about 30%. 
     
     
         29 . The feed stock of  claim 28 , wherein the moisture content is between about 10% and 20%. 
     
     
         30 . The feed stock of  claim 26 , wherein the feed stock has a HHV of between about 13,000 BTU/lb and about 15,000 BTU/lb. 
     
     
         31 . The feed stock of  claim 26 , wherein the feed stock has a volatile matter content of about 60% to about 70%. 
     
     
         32 . The feed stock of  claim 26 , wherein the feed stock has an ash content of less than about 5%. 
     
     
         33 . The feed stock of  claim 26 , wherein the engineered fuel feed stock has a ratio of H/C from about 0.05 to about 0.1. 
     
     
         34 . The feed stock of  claim 26 , wherein the engineered fuel feed stock has a ratio of O/C from about 0.01 to about 0.05. 
     
     
         35 . An engineered fuel feed stock, comprising at least one component derived from a processed MSW waste stream, the feed stock comprising
 a carbon content of between about 60% and about 70%;   a hydrogen content of between about 6% and about 9%,   a sulfur content of less than about 0.2%;   an ash content of less than about 10%; and   wherein the feed stock contains substantially no glass, metals, grit, and noncombustibles.   
     
     
         36 . The feed stock of  claim 35 , further comprising a moisture content of less than about 30%. 
     
     
         37 . The feed stock of  claim 36 , wherein the moisture content is between about 5% and about 30%. 
     
     
         38 . The feed stock of  claim 37 , wherein the moisture content is between about 10% and 20%. 
     
     
         39 . The feed stock of  claim 35 , wherein the feed stock has a HHV of between about 11,000 BTU/lb and about 15,000 BTU/lb. 
     
     
         40 . The feed stock of  claim 35 , wherein the feed stock has a volatile matter content of about 80% to about 95%. 
     
     
         41 . The feed stock of  claim 35 , wherein the feed stock has an ash content of less than about 7%. 
     
     
         42 . The feed stock of  claim 35 , wherein the feed stock has a HHV of between about 7,000 BTU/lb and about 9,500 BTU/lb. 
     
     
         43 . The feed stock of  claim 35 , wherein the engineered fuel feed stock has a ratio of H/C from about 0.11 to about 0.15. 
     
     
         44 . The feed stock of  claim 35 , wherein the engineered fuel feed stock has a ratio of O/C from about 0.15 to about 0.3. 
     
     
         45 . The feed stock of  claim 1 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas comprising
 H 2  in an amount from about 6 vol. % to about 30 vol. %;   CO in an amount from about 14 vol. % to about 30 vol. %,   CH 4  in an amount from about 0.3 vol. % to about 6.5 vol. %,   CO 2  in an amount from about 6 vol. % to about 13% vol. %; and   N 2  in an amount from about 44 vol. % to about 68 vol. %.   
     
     
         46 . The feed stock of  claim 1 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio from about 0.3 to about 2.0. 
     
     
         47 . The feed stock of  claim 1 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio from about 0.5 to about 1.5. 
     
     
         48 . The feed stock of  claim 1 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio from about 0.8 to about 1.2. 
     
     
         49 . The feed stock of  claim 1 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio of about 1.0. 
     
     
         50 . The feed stock of  claim 1 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio of about 1.5. 
     
     
         51 . The feed stock of  claim 1 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas having an H 2 /CO ratio of about 2.0 
     
     
         52 . The feed stock of  claim 16 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas comprising
 H 2  in an amount of about 15 vol. % to about 20 vol. %;   N 2  in an amount of about 42 vol. % to about 48 vol. %;   CO in an amount of about 20 vol. % to about 30 vol. %;   CH 4  in an amount of about 0.5 vol. % to about 3 vol. %;   CO 2  in an amount of about 5 vol % to about 8 vol. %; and   an HHV of about 140 BTU/scf to about 180 BTU/scf.   
     
     
         53 . The feed stock of  claim 26 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas comprising
 H 2  in an amount of about 25 vol. % to about 30 vol. %;   N 2  in an amount of about 42 vol. % to about 48 vol. %;   CO in an amount of about 12 vol. % to about 17 vol. %;   CH 4  in an amount of about 2 vol. % to about 5 vol. %;   CO 2  in an amount of about 5 vol. % to about 10 vol. %; and   an HHV of about 160 BTU/scf to about 200 BTU/scf.   
     
     
         54 . The feed stock of  claim 35 , wherein the engineered fuel feed stock upon gasification at 850° C. and an ER of 0.34 produces synthesis gas comprising
 H 2  in an amount of about 16 vol. % to about 24 vol. %;   N 2  in an amount of about 42 vol. % to about 48 vol. %;   CO in an amount of about 15 vol % to about 20 vol. %;   CH 4  in an amount of about 4 vol. % to about 6 vol. %;   CO 2  in an amount of about 5 vol. % to about 10 vol. %; and   an HHV of about 180 BTU/scf to about 220 BTU/scf.   
     
     
         55 . The feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less GHG emissions as compared the known level of GHG emissions of biomasses when combusted. 
     
     
         56 . The feed stock of  claim 1 , wherein the biomass is selected from the group consisting of wood and switch grass. 
     
     
         57 . The feed stock of  claim 1 , wherein the engineered fuel feed stock is in a loose, non-densified form. 
     
     
         58 . The feed stock of  claim 1 , wherein the engineered fuel feed stock is in a densified form. 
     
     
         59 . The feed stock of  claim 1 , wherein the densified form is a cube. 
     
     
         60 . The feed stock of  claim 1 , wherein the densified form is a pellet. 
     
     
         61 . The feed stock of  claim 1 , wherein the engineered fuel feed stock further comprises at least one fuel component that enhances the gasification of the fuel feed stock. 
     
     
         62 . The feed stock of  claim 61 , wherein the enhancement is a reduction in the amount of sulfur emissions produced. 
     
     
         63 . The feed stock of  claim 61 , wherein the enhancement is the reduction of chlorine emissions produced. 
     
     
         64 . The feed stock of  claim 61 , wherein the enhancement is the reduction of heavy metal emissions produced. 
     
     
         65 . The feed stock of  claim 1 , wherein the engineered fuel feed stock is rendered inert. 
     
     
         66 . The feed stock of  claim 65 , wherein the engineered fuel feed stock further comprises at least one additive that renders the feed stock inert. 
     
     
         67 . The feed stock of  claim 66 , wherein the at least one additive that renders the feed stock inert is calcium hydroxide. 
     
     
         68 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has a diameter of between about 0.25 inches to about 1.5 inches. 
     
     
         69 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has a length of between about 0.5 inches to about 6 inches. 
     
     
         70 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has a surface to volume ratio of between about 20:1 to about 3:1. 
     
     
         71 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has a bulk density of about 10 lb/ft 3  to about 75 lb/ft 3 . 
     
     
         72 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has a porosity of between about 0.2 and about 0.6. 
     
     
         73 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has an aspect ratio of between about 1 to about 10. 
     
     
         74 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has a thermal conductivity of between about 0.023 BTU/(ft·hr·° F.) and about 0.578 BTU/(ft·hr·° F.). 
     
     
         75 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has a specific heat capacity of between about 4.78×10 −5  BTU/(lb·° F.) to 4.78×10 −4  BTU/(lb·° F.). 
     
     
         76 . The feed stock of  claim 1 , wherein the densified form of the engineered fuel feed stock has a thermal diffusivity of between about 1.08×10 −5  ft 2 /s to 2.16×10 −5  ft 2 /s.