Mobile solid fuel production system

Abstract

A fuel production system includes a first modular unit and a second modular unit. The first modular unit includes a first housing, a process vessel, an agitator rotor assembly, a first drivetrain, an extrusion screw, a second drivetrain, a first separation vessel, and a product shaping system. The second modular unit includes a second housing, a thermal fluid heater system, a condenser, a second separation vessel, and a vacuum pump. The second modular unit is configured to be coupled to the first modular unit. At least a portion of each of the process vessel, the agitator rotor assembly, the first drivetrain, the extrusion screw, the second drivetrain, the first separation vessel, and the product shaping system are contained in the first housing. At least a portion of each of the thermal fluid heater system, the condenser, the second separation vessel, and the vacuum pump are contained in the second housing.

What is claimed is: 
     
         1 . A method comprising:
 coupling a first modular unit to a second modular unit, wherein:
 the first modular unit comprises:
 a process vessel; 
 an agitator rotor assembly passing through the process vessel;
 a first drivetrain coupled to the agitator rotor assembly; 
 an extrusion screw passing through the process vessel; 
 a second drivetrain coupled to the extrusion screw; 
 a first separation vessel in fluid communication with the process vessel; and 
 a product shaping system; 
 the second modular unit comprises: 
 a thermal fluid heater system; 
 a condenser; 
 a second separation vessel in fluid communication with the condenser; and 
 a vacuum pump in fluid communication with the second separation vessel; 
 
 
   wherein coupling the first modular unit to the second modular unit comprises:
 fluidly coupling the thermal fluid heater system of the second modular unit to one or both of the process vessel and the agitator rotor assembly of the first modular unit; and 
 fluidly coupling the first separation vessel of the first modular unit to the condenser of the second modular unit. 
   
     
     
         2 . The method of  claim 1 , further comprising:
 providing a solid waste mixture to the process vessel;   producing a solid fuel composition from the solid waste mixture, wherein producing the solid fuel composition comprises:
 rotating the agitator rotor assembly using the first drivetrain, thereby agitating the solid waste mixture within the process vessel; and 
 providing heat to the solid waste mixture within the process vessel; and 
   extruding the solid fuel composition from the process vessel, wherein extruding the solid fuel composition comprises:
 rotating the extrusion screw using the second drivetrain; and 
 shaping the solid fuel composition using the product shaping system. 
   
     
     
         3 . The method of  claim 2 , wherein providing heat to the solid waste mixture comprises flowing a thermal fluid from the thermal fluid heater system to one or both of the process vessel and the agitator rotor assembly. 
     
     
         4 . The method of  claim 3 , further comprising flowing the thermal fluid from one or both of the process vessel and the agitator rotor assembly to the thermal fluid heater system. 
     
     
         5 . The method of  claim 3 , further comprising:
 flowing a fluid stream from the process vessel to the first separation vessel;   separating phases of matter of the fluid stream using the first separation vessel;   flowing the fluid stream from the first separation vessel to the condenser;   cooling the fluid stream using the condenser;   flowing the fluid stream from the condenser to the second separation vessel; and   separating phases of matter of the fluid stream using the second separation vessel, wherein the vacuum pump facilitates each of:
 flowing the fluid stream from the process vessel to the first separation vessel, 
 flowing the fluid stream from the first separation vessel to the condenser, and 
 flowing the fluid stream from the condenser to the second separation vessel. 
   
     
     
         6 . The method of  claim 3 , wherein:
 the product shaping system comprises:
 an extrusion barrel coupled to the process vessel, the extrusion barrel defining a plurality of annular spaces configured to allow the solid fuel composition to pass through the extrusion barrel; 
 a reducer coupled to the extrusion barrel; and 
 a die coupled to the reducer, the die defining a plurality of openings; and 
   shaping the solid fuel composition comprises passing the solid fuel composition through the plurality of annular spaces of the extrusion barrel, the reducer, and the die, thereby shaping the solid fuel composition by the plurality of openings defined by the die.   
     
     
         7 . The method of  claim 6 , wherein the reducer comprises a thermal fluid piping, and shaping the solid fuel composition comprises flowing the thermal fluid through the thermal fluid piping, thereby heating the solid fuel composition as the solid fuel composition passes through the reducer.