Coated particulate and shaped fuels and methods for making and using same

Abstract

Methods and system are disclosed for making coated burnable fuels from source materials and to the coated burnable fuels derived therefrom.

1 . A method for making a burnable fuel comprising:
 providing a first input material;   sizing the first input material to form a particulate material, and   coating the particulate burnable fuel during and/or after sizing with a particulate coating material to form a coated particulate burnable fuel, and   where the fuel is suitable for use in cement plants, power plants, municipal incinerators for steam generations, or any other facility that burns fuels and converts heat derived from the burning of the fuel into a usable form of energy or for use of the heat and/or ash to make an end product.   
     
     
         2 . The method of  claim 1 , wherein the first input material comprises one source material or a plurality of source material, where each source material comprises virgin, unused, experimental, used or waste industrial materials, virgin, unused, experimental, used or waste municipal materials, used or waste healthcare materials, used or waste medical materials, used or waste agricultural materials, virgin, unused, experimental, used or waste biomass materials, virgin, unused, experimental, used or waste electronic materials, virgin, unused, experimental, used or waste metal material, virgin, unused experimental, used or waste pharmaceutical materials, nutraceutical materials, other virgin, unused, experimental, used or waste materials produced by the pharmaceutical or nutraceutical industries, other virgin, unused, experimental, used or waste materials, virgin, unused, experimental, used or waste oils (synthetic or natural), USDA AIPHIS waste or mixtures or combinations thereof. 
     
     
         3 . The method of  claim 1 , further comprising:
 combusting a particulate burnable fuel including a coated particulate burnable fuel or a mixture of an uncoated particulate burnable fuel and a coated particulate burnable fuel in a combustion unit, where a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         4 . The method of  claim 1 , further comprising:
 packaging a particulate burnable fuel including a coated particulate burnable fuel or a mixture of an uncoated particulate burnable fuel and a coated particulate burnable fuel to form a containerized particulate burnable fuel, and   combusting the containerized particulate burnable fuel in a combustion unit, where a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         5 . The method of  claim 1 , further comprising:
 prior to the sizing, coating the first input material with an input coating material.   
     
     
         6 . The method of  claim 1 , further comprising:
 prior to the sizing, pre-treating the first input material.   
     
     
         7 . The method of  claim 1 , further comprising:
 providing a second input material,   pre-treating the second input material to form a pre-treated material, and   combining the pre-treated material with the first input material,   where the first input material is the same or different from the second input material.   
     
     
         8 . The method of  claim 1 , further comprising:
 shaping a particulate burnable fuel including a coated particulate burnable fuel or a mixture of an uncoated particulate burnable fuel and a coated particulate burnable fuel to form a shaped burnable fuel, and   combusting the shaped burnable fuel in a combustion unit, where a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         9 . The method of  claim 1 , further comprising:
 shaping a particulate burnable fuel including a coated particulate burnable fuel or a mixture of an uncoated particulate burnable fuel and a coated particulate burnable fuel to form a shaped burnable fuel,   packaging the shaped burnable fuel to form a containerized shaped burnable fuel, and   combusting the containerized shaped burnable fuel in a combustion unit, where a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         10 . The method of  claim 1 , further comprising:
 shaping a particulate burnable fuel including a coated particulate burnable fuel or a mixture of an uncoated particulate burnable fuel and a coated particulate burnable fuel to form a shaped burnable fuel,   coating the shaped burnable fuel with a shape coating material to form a coated shaped burnable fuel, and   combusting a shaped burnable fuel including a coated shaped burnable fuel or a mixture of an uncoated shaped burnable fuel and a coated shaped burnable fuel in a combustion unit, where a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         11 . The method of  claim 1 , further comprising:
 shaping a particulate burnable fuel including a coated particulate burnable fuel or a mixture of an uncoated particulate burnable fuel and a coated particulate burnable fuel to form a shaped burnable fuel,   coating the shaped burnable fuel with a shape coating material to form a coated shaped burnable fuel,   packaging a shaped burnable fuel including a coated shaped burnable fuels or a mixture of and uncoated shaped burnable fuel and a coated shaped burnable fuel to form a containerized shaped burnable fuel, and   combusting the containerized coated shaped burnable fuel in a combustion unit, where a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         12 . A method for making a burnable fuel comprising:
 providing a first input material;   sizing the first input material to form a particulate material, and   shaping a particulate burnable fuel including an uncoated particulate burnable fuel, a coated particulate burnable fuel or a mixture of an uncoated particulate burnable fuel and a coated particulate burnable fuel to form a shaped burnable fuel,   coating the shaped burnable fuel with a shape coating material to form a coated shaped burnable fuel, and   where the fuel is suitable for use in cement plants, power plants, municipal incinerators for steam generations, or any other facility that burns fuels and converts heat derived from the burning of the fuel into a usable form of energy or for use of the heat and/or ash to make an end product.   
     
     
         13 . The method of  claim 12 , wherein the first input material comprises one source material or a plurality of source material, where each source material comprises virgin, unused, experimental, used or waste industrial materials, virgin, unused, experimental, used or waste municipal materials, used or waste healthcare materials, used or waste medical materials, used or waste agricultural materials, virgin, unused, experimental, used or waste biomass materials, virgin, unused, experimental, used or waste electronic materials, virgin, unused, experimental, used or waste metal material, virgin, unused experimental, used or waste pharmaceutical materials, nutraceutical materials, other virgin, unused, experimental, used or waste materials produced by the pharmaceutical or nutraceutical industries, other virgin, unused, experimental, used or waste materials, virgin, unused, experimental, used or waste oils (synthetic or natural), USDA AIPHIS waste or mixtures or combinations thereof. 
     
     
         14 . The method of  claim 12 , further comprising:
 combusting a shaped burnable fuel including a coated shaped burnable fuel or a mixture of an uncoated shaped burnable fuel and a coated shaped burnable fuel in a combustion unit, where a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         15 . The method of  claim 12 , further comprising:
 packaging a shaped burnable fuel including a coated shaped burnable fuel or a mixture of an uncoated shaped burnable fuel and a coated shaped burnable fuel to form a containerized shaped burnable fuel, and   combusting the containerized shaped burnable fuel in a combustion unit, where a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         16 . The method of  claim 12 , further comprising:
 prior to the sizing, coating the first input material with an input coating material.   
     
     
         17 . The method of  claim 12 , further comprising:
 prior to the sizing, pre-treating the first input material.   
     
     
         18 . The method of  claim 12 , further comprising:
 providing a second input material,   pre-treating the second input material to form a pre-treated material, and   combining the pre-treated material with the first input material,   where the first input material is the same or different from the second input material.   
     
     
         19 . A system for making a burnable fuel comprising:
 a supply subsystem, where a first input material is produced from one source material or a plurality of source materials,   a sizing subsystem, where the first input material is sized or sized and partially or completely homogenized to form a particulate material having a desired particle size distribution, and   a particulate coating subsystem, where the particulate material is coated by a particulate coating material to form a coated particulate burnable fuel having a desired surface covering and a desired coating thickness, where coated particulate burnable fuel is adapted for use as a fuel or fuel component in cement plants, power plants, municipal incinerators for steam generation, or any other facility that burns fuels and converts heat derived from the burning of the fuel into a usable form of energy or for use of the heat and/or ash to make an end product.   
     
     
         20 . The system of  claim 19 , wherein the first input material comprises one source material or a plurality of source material, where each source material comprises virgin, unused, experimental, used or waste industrial materials, virgin, unused, experimental, used or waste municipal materials, used or waste healthcare materials, used or waste medical materials, used or waste agricultural materials, virgin, unused, experimental, used or waste biomass materials, virgin, unused, experimental, used or waste electronic materials, virgin, unused, experimental, used or waste metal material, virgin, unused experimental, used or waste pharmaceutical materials, nutraceutical materials, other virgin, unused, experimental, used or waste materials produced by the pharmaceutical or nutraceutical industries, other virgin, unused, experimental, used or waste materials, virgin, unused, experimental, used or waste oils (synthetic or natural), USDA AIPHIS waste or mixtures or combinations thereof. 
     
     
         21 . The system of  claim 19 , further comprising:
 a combustion subsystem, where a particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated particulate burnable fuels is burned and a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         21 . The system of  claim 19 , further comprising:
 a packaging subsystem, where a particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated particulate burnable fuels to form a containerized coated particulate burnable fuel, and   a combustion subsystem, where the containerized coated particulate burnable fuel is burned and a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         22 . The system of  claim 19 , further comprising:
 input material coating subsystem, where the first input material is coated with an input coating material.   
     
     
         23 . The system of  claim 19 , further comprising:
 an input pre-treating subsystem, where the first input material is pre-treated.   
     
     
         24 . The system of  claim 19 , wherein the supply subsystem produces a second input material, and where the system further comprises
 a second input pre-treating, where the second input material is pre-treated to form a pre-treated material, where the pre-treated material is combined with the first input material before it is sized in the sizing subsystem.   
     
     
         26 . The system of  claim 19 , further comprising:
 a shaping subsystem, where a particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated particulate burnable fuels is shaped to form a shaped burnable fuel, and   a combustion subsystem, where the shaped burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated shaped burnable fuels is burned and a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         27 . The system of  claim 19 , further comprising:
 a shaping subsystem, where a particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated particulate burnable fuels is shaped to form a shaped burnable fuel,   a packaging subsystem, where a shaped burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated shaped burnable fuels is containerized to form a containerized shaped burnable fuel, and   a combustion subsystem, where the containerized shaped burnable fuel is burned and a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         28 . The system of  claim 19 , further comprising:
 a shaping subsystem, where a particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated particulate burnable fuels to form a shaped burnable fuel,   a shape coating subsystem, where the shaped burnable fuel is coated with a shape coating material to form a coated shaped burnable fuel, and   a combustion subsystem, where a shaped burnable fuel including coated shaped burnable fuels or a mixture of uncoated and coated shaped burnable fuels is burned and a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         29 . The system of  claim 19 , further comprising:
 a shaping subsystem, where a particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated particulate burnable fuels to form a shaped burnable fuel,   a shape coating subsystem, where the shaped burnable fuel is coated with a shape coating material to form a coated shaped burnable fuel,   a packaging subsystem, where a shaped burnable fuel including coated shaped burnable fuels or a mixture of uncoated and coated shaped burnable fuels is containerized to form a containerized shaped burnable fuel, and   a combustion subsystem, where the containerized coated shaped burnable fuel is burned and a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         30 . A system for making a burnable fuel comprising:
 a supply subsystem, where a first input material is produced from one source material or a plurality of source materials,   a sizing subsystem, where the first input material is sized or sized and partially or completely homogenized to form a particulate material having a desired particle size distribution, and   a shaping subsystem, where a particulate burnable fuel including an uncoated particulate burnable fuel, a coated particulate burnable fuel, or a mixture of an uncoated particulate burnable fuel and a coated particulate burnable fuel is shaped to form a shaped burnable fuel having a desired surface covering and a desired coating thickness, and   a shape coating subsystem, where the shaped burnable fuel is coated with a shape coating material to form a coated shaped burnable fuel,   where the coated shaped burnable fuel is adapted for use as a fuel or fuel component in cement plants, power plants, municipal incinerators for steam generation, or any other facility that burns fuels and converts heat derived from the burning of the fuel into a usable form of energy or for use of the heat and/or ash to make an end product.   
     
     
         31 . The system of  claim 19 , wherein the first input material comprises one source material or a plurality of source material, where each source material comprises virgin, unused, experimental, used or waste industrial materials, virgin, unused, experimental, used or waste municipal materials, used or waste healthcare materials, used or waste medical materials, used or waste agricultural materials, virgin, unused, experimental, used or waste biomass materials, virgin, unused, experimental, used or waste electronic materials, virgin, unused, experimental, used or waste metal material, virgin, unused experimental, used or waste pharmaceutical materials, nutraceutical materials, other virgin, unused, experimental, used or waste materials produced by the pharmaceutical or nutraceutical industries, other virgin, unused, experimental, used or waste materials, virgin, unused, experimental, used or waste oils (synthetic or natural), USDA AIPHIS waste or mixtures or combinations thereof. 
     
     
         32 . The system of  claim 19 , further comprising:
 a combustion subsystem, where a shaped burnable fuel including a coated shaped burnable fuel or a mixture of an uncoated shaped burnable fuel and a coated shaped burnable fuel is burned and a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         32 . The system of  claim 19 , further comprising:
 a packaging subsystem, where a shaped burnable fuel including a coated shaped burnable fuel or a mixture of an uncoated shaped burnable fuel and a coated shaped burnable fuel is containerized to form a containerized shaped burnable fuel, and   a combustion subsystem, where the containerized shaped burnable fuel is burned and a portion of the heat is converted into a useable form of energy, where a portion of the heat is used directly, or where a portion of the heat and/or the ash are used to form a product.   
     
     
         33 . The system of  claim 19 , further comprising:
 input material coating subsystem, where the first input material is coated with an input coating material.   
     
     
         34 . The system of  claim 19 , further comprising:
 an input pre-treating subsystem, where the first input material is pre-treated.   
     
     
         35 . The system of  claim 19 , wherein the supply subsystem produces a second input material, and where the system further comprises:
 a second input pre-treating, where the second input material is pre-treated to form a pre-treated material, where the pre-treated material is combined with the first input material before it is sized in the sizing subsystem,   where the first input material is the same or different from the second input material.   
     
     
         36 . A burnable fuel composition comprising:
 from 0% to 100% of a particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated burnable fuels,   from 0% to 100% of a shaped burnable fuel including coated shaped burnable fuels or a mixture of uncoated and coated shaped burnable fuels,   from 0% to 100% of a containerized particulate burnable fuel comprising a particulate burnable fuel including coated particulate burnable fuels or a mixture of uncoated and coated particulate burnable fuels, and   from 0% to 100% of containerized shaped burnable fuel comprising a shaped burnable fuel including coated shaped burnable fuels or a mixture of uncoated and coated shaped burnable fuels.   
     
     
         37 . The composition of  claim 36 , wherein the first input material comprises one source material or a plurality of source material, where each source material comprises virgin, unused, experimental, used or waste industrial materials, virgin, unused, experimental, used or waste municipal materials, used or waste healthcare materials, used or waste medical materials, used or waste agricultural materials, virgin, unused, experimental, used or waste biomass materials, virgin, unused, experimental, used or waste electronic materials, virgin, unused, experimental, used or waste metal material, virgin, unused experimental, used or waste pharmaceutical materials, nutraceutical materials, other virgin, unused, experimental, used or waste materials produced by the pharmaceutical or nutraceutical industries, other virgin, unused, experimental, used or waste materials, virgin, unused, experimental, used or waste oils (synthetic or natural), USDA AIPHIS waste or mixtures or combinations thereof.