Engineered fuel feed stock useful for displacement of coal in coal firing plants

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 co-firing with coal and as substitutes for coal.

1 . An engineered fuel feed stock, comprising at least one component derived from a processed MSW waste stream, the engineered fuel feed stock comprising
 a carbon content of between about 30 wt. % and about 40 wt. %;   a hydrogen content of between about 3 wt. % and about 10 wt. %;   wherein the engineered fuel feed stock contains substantially no glass, metals, grit, and noncombustible waste.   
     
     
         2 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has a moisture content of less than about 30 wt. %. 
     
     
         3 . The engineered fuel feed stock of  claim 2 , wherein the moisture content is between about 10 wt. % and about 30 wt. %. 
     
     
         4 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has a HHV of between about 5.000 BTU/lb and about 15,000 BTU/lb. 
     
     
         5 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has a volatile matter content of between about 40 wt. % and about 80 wt. %. 
     
     
         6 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has a sulfur content of less than about 2 wt. %. 
     
     
         7 . The engineered fuel feed stock of  claim 1 , wherein the processed MSW waste stream contains bioderadable and non-bioderadable waste. 
     
     
         8 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has a chlorine content of less than about 1 wt. %. 
     
     
         9 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has a hydrogen content of between about 6% and about 9%. 
     
     
         10 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has an ash content of less than about 15 wt. %. 
     
     
         11 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has a HHV of between about 10,000 BTU/lb and about 14,000 BTU/lb. 
     
     
         12 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has an H/C ratio of between about 0.075 (w/w) and about 0.20 (w/w). 
     
     
         13 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock has a ratio of O/C of between about 0.01 and about 1.0. 
     
     
         14 . The engineered fuel 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 of between about 25 vol. %, to about 30 vol. %; 
 N 2  in an amount of between about 42 vol. % to about 48 vol. %; 
 CO in an amount of between about 12 vol. % to about 17 vol. %; 
 CH 4  in an amount of between about 2 vol. % to about 5 vol. %; 
 CO 2  in an amount of between about 5 vol. % to about 10 vol. %; and 
 an HHV of between about 160 BTU/scf to about 200 BTU/scf. 
 
     
     
         15 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less emissions as compared to a known level of emissions of coal when combusted. 
     
     
         16 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less sulfur emission as compared to a known level of sulfur emissions of coal when combusted. 
     
     
         17 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less chlorine emission as compared a known level of chlorine emissions of coal when combusted. 
     
     
         18 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less heavy metal emissions as compared a known level of heavy metal emissions of coal when combusted. 
     
     
         19 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less emission of particulate matters as compared to a known level of particulate matters emitted by coal combustion. 
     
     
         20 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less emission of NOx, as compared to a known level of NOx emitted by coal combustion. 
     
     
         21 .- 45 . (canceled) 
     
     
         46 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less emission of CO, as compared to a known level of CO emitted by coal combustion. 
     
     
         47 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less emission of CO 2 , as compared to a known level of CO 2  emitted by coal combustion. 
     
     
         48 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less emission of volatile organic compounds (VOCs), as compared to a known level of VOCs emitted by coal combustion. 
     
     
         49 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less emission of halogen gases as compared to a known level of halogen gases emitted by coal combustion. 
     
     
         50 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock when combusted produces less GHG emissions as compared to a known level of GHG emitted by coal when combusted. 
     
     
         51 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock is in a loose, non-densified form. 
     
     
         52 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock is in a densified form. 
     
     
         53 . The engineered fuel feed stock of  claim 52 , wherein the densified form is a cube. 
     
     
         54 . The engineered fuel feed stock of  claim 52 , wherein the densified form is a pellet. 
     
     
         55 . The engineered fuel feed stock of  claim 52 , wherein the densified form of the engineered fuel feed stock has a diameter of between about 0.25 inches to about 1.5 inches. 
     
     
         56 . The engineered fuel feed stock of  claim 52 , wherein the densified form of the engineered fuel feed stock has a length of between about 0.5 inches to about 6 inches. 
     
     
         57 . The engineered fuel feed stock of  claim 52 , 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. 
     
     
         58 . The engineered fuel feed stock of  claim 52 , wherein the densified form of the engineered fuel feed stock has a bulk density of between about 10 lb/ft 3  to about 75 lb/ft 3 . 
     
     
         59 . The engineered fuel feed stock of  claim 52 , wherein the densified form of the engineered fuel feed stock has a porosity of between about 0.2 and about 0.6. 
     
     
         60 . The engineered fuel feed stock of  claim 52 , wherein the densified form of the engineered fuel feed stock has an aspect ratio of between about 1 to about 10. 
     
     
         61 . The engineered fuel feed stock of  claim 52 , 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.). 
     
     
         62 . The engineered fuel feed stock of  claim 52 , 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.). 
     
     
         63 . The engineered fuel feed stock of  claim 52 , wherein the densified form of the engineered fuel feed stock has a thermal diffusivity of between about 1.08×10 −5  ft2/s to 2.16×10 −5  ft 2 /s. 
     
     
         64 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock further comprises at least one component that provides an enhancement to gasification or combustion of the engineered fuel feed stock. 
     
     
         65 . The engineered fuel feed stock of  claim 64 , wherein the enhancement is a reduction in an amount of sulfur emissions produced. 
     
     
         66 . The engineered fuel feed stock of  claim 64 , wherein the enhancement is a reduction of chlorine emissions produced. 
     
     
         67 . The engineered fuel feed stock of  claim 1 , wherein the enhancement is a reduction of heavy metal emissions produced. 
     
     
         68 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock is rendered inert. 
     
     
         69 . The engineered fuel feed stock of  claim 1 , wherein the engineered fuel feed stock further comprises at least one additive. 
     
     
         70 . The engineered fuel feed stock of  claim 69 , wherein the at least one additive is calcium hydroxide.