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 - 45 . (canceled) 
     
     
         46 . 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 50 wt. % and about 70 wt. %;   a hydrogen content of between about 3 wt. % and about 10 wt. %;   a moisture content of less than 10% (w/w);   wherein the MSW contains biodegradable and non-biodegradable materials; and   wherein the feed stock contains substantially no glass, metals, grit, and noncombustible waste.   
     
     
         47 . The engineered fuel feed stock of  claim 46 , wherein the engineered fuel feed stock has a HHV of between about 5,000 BTU/lb and about 15,000 BTU/lb (dry basis). 
     
     
         48 . The feed stock of  claim 47 , wherein the feed stock has a HHV of between about 9,000 to 15,000 Btu/lb (dry basis). 
     
     
         49 . The engineered fuel feed stock of  claim 46 , wherein the engineered fuel feed stock has a volatile matter content of between about 40 wt. % and about 80 wt. %. 
     
     
         50 . The feed stock of  claim 46 , wherein the feed stock has a volatile matter content of about 40% (w/w) to about 80% (w/w). 
     
     
         51 . The feed stock of  claim 46 , wherein the feed stock has a chlorine content of less than about 1% (w/w). 
     
     
         52 . The feed stock of  claim 46 , wherein the engineered fuel feed stock when combusted produces less harmful emissions as compared to the known level of harmful emissions of coal when combusted. 
     
     
         53 . The feed stock of  claim 46 , wherein the engineered fuel feed stock when combusted produces less sulfur emission as compared to the known level of sulfur emissions of coal when combusted. 
     
     
         54 . The engineered fuel feed stock of  claim 46 , wherein the engineered fuel feed stock when combusted produces less chlorine emission as compared a known level of chlorine emissions of coal when combusted. 
     
     
         55 . The engineered fuel feed stock of  claim 46 , 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. 
     
     
         56 . The engineered fuel feed stock of  claim 46 , 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. 
     
     
         57 . The engineered fuel feed stock of  claim 46 , wherein the engineered fuel feed stock when combusted produces less emission of NO x , as compared to a known level of NO emitted by coal combustion. 
     
     
         58 . The engineered fuel feed stock of  claim 46 , wherein the engineered fuel feed stock has a hydrogen content of between about 6% and about 9%. 
     
     
         59 . The engineered fuel feed stock of  claim 46  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. 
 
     
     
         60 . The engineered fuel feed stock of  claim 46 , wherein the engineered fuel feed stock is in a loose, non-densified form. 
     
     
         61 . The engineered fuel feed stock of  claim 46 , wherein the engineered fuel feed stock is in a densified form. 
     
     
         62 . The engineered fuel feed stock of  claim 61 , 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.). 
     
     
         63 . The engineered fuel feed stock of  claim 61 , 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.). 
     
     
         64 . The engineered fuel feed stock of  claim 61 , 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. 
     
     
         65 . The engineered fuel feed stock of  claim 61 , wherein the densified form of the engineered fuel feed stock has a diameter of between about 0.25 inches to about 1.5 inches. 
     
     
         66 . The engineered fuel feed stock of  claim 61 , wherein the densified form of the engineered fuel feed stock has a length of between about 0.5 inches to about 6 inches. 
     
     
         67 . The engineered fuel feed stock of  claim 61 , 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. 
     
     
         68 . The engineered fuel feed stock of  claim 61 , 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 . 
     
     
         69 . The engineered fuel feed stock of  claim 61 , wherein the densified form of the engineered fuel feed stock has a porosity of between about 0.2 and about 0.6. 
     
     
         70 . The engineered fuel feed stock of  claim 61 , wherein the densified form of the engineered fuel feed stock has an aspect ratio of between about 1 to about 10.