AU2024227585A1 - Reactor and fuel source - Google Patents

Abstract

The invention relates to a method for generating biomass material, the method including the steps of preparing raw biomass material having a moisture content of between 10 and 14%; drying the raw biomass material with a heat source between 100 and 130 0C; and compressing the raw biomass material with a compression device to produce biomass material. QQ' 1/10 2 4 E~~ BIOCOAL RRCCESSSEPI MA ~STEP 2 RLEIS STEP GO L O ING PROCESS F I STEP N-CRUSHINC/S REENING LiSTEP 7 - RIOOETTING 10 L F FUEL SOURCE 121 r7 0 16/ 18 26 ~ 30 24M 22 - _____________________T 20 -T - - - - - - - - - - - - - Figure 1

Description

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REACTORANDFUELSOURCE FIELD OF APPLICATION OF THE INVENTION

The present invention relates to the field of energy generation and biomass

processing. More specifically, it pertains to a system and method for enhancing the

efficiency of reactors and bioreactors used in the production of energy and the

conversion of biomass into energy.

BACKGROUND TO THE INVENTION

Reactor technology has a rich history, primarily associated with nuclear reactors. The

development of nuclear reactors began in the early 20th century, with significant

advancements made during the Manhattan Project in the 1940s. The first sustained

nuclear chain reaction occurred in December 1942 under the leadership of Enrico

Fermi in Chicago, marking a pivotal milestone in reactor development.

Over the years, nuclear reactors have been used for various purposes, including

research, power generation, and propulsion for naval vessels. Different reactor

designs have been developed, such as pressurized water reactors (PWRs), boiling

water reactors (BWRs), and advanced reactor concepts like molten salt reactors

(MSRs) and small modular reactors (SMRs).

Bioreactors have evolved from the broader field of chemical and biochemical reactors.

The development of bioreactors gained momentum with the advent of biotechnology

I1 and the increasing demand for bioprocessing applications. The first generation of bioreactors emerged in the mid-20th century, primarily focused on the growth of microorganisms for producing antibiotics and other biochemicals.

As biotechnology advanced, bioreactors became essential tools for various

applications, such as fermentation processes, enzyme production, wastewater

treatment, and biofuel production. Bioreactor designs have diversified, including

stirred-tank bioreactors, airlift bioreactors, membrane bioreactors, and more recently,

microfluidic and disposable bioreactors.

Advancements in bioreactor technologies led to the development of biogas upgrading

techniques. Upgrading processes, such as pressure swing adsorption (PSA) and

membrane separation, were introduced to remove impurities from biogas, such as

carbon dioxide and hydrogen sulfide, resulting in higher-purity methane. This

upgraded biomethane could be injected into natural gas pipelines or used as a vehicle

fuel. The emergence of microbial fuel cells (MFCs) introduced a new approach to

bioreactor-based energy generation. MFCs employ electroactive microorganisms that

generate electricity through the oxidation of organic compounds. This technology

opened avenues for energy production from various organic sources, including

wastewater, food waste, and agricultural byproducts.

The utilization of microalgae in bioreactors gained attention as a promising pathway

for energy generation. Algal bioreactors capture solar energy and utilize

photosynthesis to convert carbon dioxide into biomass and biofuels, such as biodiesel

and bioethanol. Advances in cultivation techniques, including photobioreactors and raceway ponds, improved algal biomass productivity and biofuel yields. Recent advancements in synthetic biology and metabolic engineering have enabled the development of genetically modified organisms with enhanced capabilities for energy generation. Bioreactors equipped with engineered microbes can efficiently convert biomass into desired energy products, such as bioethanol, biobutanol, and biohydrogen.

A further process is pyrolysis, which is a thermal decomposition process that

transforms organic materials into valuable products in the absence of oxygen. It

involves heating the material, such as biomass or plastic, to high temperatures

(typically between 300°C to 800°C) in a controlled environment. During pyrolysis, the

material breaks down into three main products: gas, liquid, and solid char. The gas

can be used as a fuel or chemical feedstock, while the liquid (bio-oil or pyrolysis oil)

has applications in biofuels and chemicals. The solid char can be used as a soil

conditioner or activated carbon. Pyrolysis is an environmentally friendly method that

helps reduce waste and offers a sustainable approach to energy and chemical

production

However, the disadvantages of these processes typically include their requirement for

specific nutrients and feedstock, low product yield and efficiency, and significant

energy and fuel required to initiate the operation of the bioreactor.

Given the above, it is clear that there exists a present need for a bioreactor and

biomass for operating same that is capable of generating sufficient energy, while

requiring a low threshold to power the reactor. In addition, a bioreactor that is capable

Q2 of being self-sustaining or self-fuelled would alleviate the disadvantages described above.

OBJECT OF THE INVENTION

It is accordingly an object of the present invention to provide a reactor and fuel source

that seeks to, at least partially, overcome or lessen the above disadvantages and/or

will be a useful alternative to existing reactors that use conventional fossil fuels.

SUMMARY OF THE INVENTION

According to a first aspect thereof, there is provided a method for generating biomass

material, the method including the steps of:

- Preparing raw biomass material having a moisture content of between 10 and

14%;

- Drying the raw biomass material with a heat source at a temperature of between

100 and 130 °C; and

- Compressing the raw biomass material with a compression device to produce

biomass material.

The raw biomass material may be high calorie biomass selected from a group

consisting of animal manure, animal excrement, pig manure, horse manure, bagasse,

sugar cane, plant husks, Oilseeds, Nuts, Fats and Oils, Animal Fats, Animal Feed,

A

Wood Biomass, Algae, Organic Waste, Peat, Seaweeds, and a combination thereof.

The heat source may be a dry steam.

The heat source may be excess heat generated from a chemical process.

The chemical process may be a carbonizing process. The carbonize process may be

capable of carbonise up to 10 tons at a time

The heat source may be generated by one or more electrical devices.

The biomass material may be one or more pellets.

The biomass material may be in powder form.

The pellets may be 5mm to 25 mm in diameter and 5mm to 50mm in length.

The compression device may be a flat die ring pelletizer.

The compression device may be a hydraulic disk ram or a mechanical disk ram.

The method may include an additional step of sterilizing the biomass material.

According to a second aspect thereof, there is provided a process of producing

synthetic gas from biomass material, the process including the steps of:

F,

- Feeding between 50 and 70 kilograms of biomass material into a reactor;

- Between 3 and 1000 kilograms of biomass material is placed in a burning

chamber locatable in the reactor;

- Igniting the biomass material in the burning chamber to obtain an elevated

temperature of between 340 and 360 °C to release volatile matter and gasses;

- Combustion of the volatile matter and gasses in the burning chamber to

increase the temperature in the burning chamber to between 840 and 860 °C;

- Cooling the burning chamber to [TEMP 50 - 701 C to transform the biomass

material to a coal-like material;

- Crushing the coal-like material to units that are smaller than 6mm in size;

- Mixing the crushed coal-like material with a binding agent to form one or more

briquettes that are between 15 - 30mm in width and 25-50mm in length; and

- Curing the briquettes.

The burning chamber may be a burning tube.

The volatile matters may be between 3% and 30%

The gasses may be selected from the group consisting of carbon dioxide, carbon

monoxide, nitrous oxide, methane, hydrogen sulphide, and a combination thereof.

According to a third aspect thereof, there is provided a process of producing synthetic

gas from biomass material, the process including the steps of:

- providing biomass material having a moisture content between 6 - 15%;

- displacing the biomass material using displacement means from a collection

region to a process region;

- storing the biomass material in a storage region available in the process

region;

- moving the biomass material from the storage region to a pelletizing plant for

pelletizing the biomass material;

- providing the pelletizing plant with magnet means for removing ferrous

material from the biomass material and a conditioner for homogenizing the

biomass material;

- moving the homogenized biomass material from the conditioner to a

screening device for removing material sized 10mm by 10mm;

- using a heat source of between 100 to 1300C to heat the homogenized

biomass material;

- compressing the homogenized biomass material in the pelletizing plant into

8mm x 30mm pellets;

- using sorting means to remove homogenized biomass material measuring

3mm by 3mm;

- cooling the homogenized biomass material until the moisture measures at a

level below 5%;

- carbonizing of the homogenized biomass material by heating the homogenized

biomass material to a value between 200 and 300 degrees Celsius to form a

carbonized pellet;

- heating of the carbonized pellets in a pyrolysis region of the pelletizing plant by

heating the carbonized pellets in plurality of heating zones having temperatures

between 350 and 800 degrees Celsius;

- cooling of the carbonized pellets in a cooling region of the pelletizing plant to a

temperature of between 30 - 50 degrees Celsius;

- crushing the carbonized pellets with crushing means to carbon ore having a

size of 3mm in length and 3mm in width;

- weighing the carbon ore with weighing means to a predetermined weight;

- mixing of the carbon ore with a binding agent with mixing means;

- compression of the carbon ore mixed with the binding agent in a compression

device to form briquettes; and

- curing of the briquettes

The predetermined weight may be 1000 kg.

The binding agent may be a wet binding agent or a dry binding agent.

According to a fourth aspect thereof, there is provided an apparatus for producing

synthetic gas from biomass material, the reactor including:

- 1) Pellet burning tube,

o Receives the pellets to start the heating process of the Biomass Reactor.

o Receives the gasses released from the gas collection tube

- 2) Biomass Reactor tube o Contains the Biomass pellets and creates a oxygen deprived environment.

o Contains the Pellet burning tube as well as the Gas collection tube

- 3) Gas Collection tube

o Situated inside the Biomass reactor tube and collects all the gasses and

volatiles

o Directs the gasses and volatiles to the burn tube

- 4) Flue Pipe

o The flue pipe exhaust all the burned gasses from the pellet burning tube.

The above and other characteristics, features and advantages of the present invention

will become apparent from the following detailed description, taken in conjunction with

the accompanying drawing which illustrate, by way of example, the principles of the

invention. This description is given for the sake of example only, without limiting the

scope of the invention. The reference figures quoted below refer to the attached

drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below with reference to the

accompanying figures, wherein:

Figure 1 is a schematic illustration of the biocoal process;

Figure 2 is a front perspective view of the reactor;

Figure 3 is a second front and/or back perspective view; of the reactor;

a

Figure 4 is a front view of the reactor;

Figure 5 is a side view of the reactor;

Figure 6 is a further side view of the reactor;

Figure 7 is a top view of the reactor;

Figure 8 is a diagram of the reactor;

Figure 9 is a sample analysis result sheet dated January 2023; and

Figure 10 is a sample analysis result sheet dated February 2023.

The presently disclosed subject matter will now be described more fully hereinafter

with reference to the accompanying Example, in which representative embodiments

are shown. The presently disclosed subject matter can, however, be embodied in

different forms and should not be construed as limited to the embodiments set forth

herein. Rather, these embodiments are provided so that this disclosure will be

thorough and complete, and will fully convey the scope of the embodiments to those

skilled in the art.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

A non-limiting example of a preferred embodiment of the invention is described in more

detail below, with reference to Figures 1 to 10.

With reference to Figure 1, there is provided the 7 steps of the process 2. Biomass 4

is used in step 1 in a drum dryer 6. In step 2, pelletizer 8 is used with an augur 10 to

transport the pellets to a roller crusher 12 in steps 3 and 4. A second augur 14 is used

in step 5. A second roll crusher 16 and a screen 18 are used in step 6. In step 7, there

I ( is provided a weigh bin 20, mixer 22, hydraulic power pack 24, force feeder 26, briquette machine 28, and a second hydraulic power pack 30.

With reference to Figures 2 to 7, there is provided a reactor including a Support frame,

Pellet Burning Tube, Biomass Reactor tube, Gas collection tube, and Flue Pipe.

With reference to Figure 8, there is provided a diagram of the reactor illustrating the

heating zone, carbonization zone, cooling zone, retractable platform, water inlet, water

outlet, gas outlet and gas inlet.

With reference to Figures 9 and 10, there is provided sample analysis results of the

biomass material.

Example 1:

The steps are discussed in more detail below.

Step 1 - Drying:

The raw biomass material is collected and dried to a moisture content of 12%. The

excess heat from the process is used to dry the biomass.

Step 2 - Pelletizing:

The biomass material is heated to 110°C using dry steam. The biomass material is

then pelletized using a flat die ring pelletizer. The pellets produced measure 8mm in

diameter and 30mm in length. The process sterilizes the pellets from any pathogens.

Step 3 - Carbonization:

Approximately 60 kg of the pelletized biomass material is fed into a reactor, whereafter

the reactor is sealed to contain heat therein.

Step 4 - Carbonization:

Approximately 4 kg pelletized biomass material is placed inside a burn tube located

inside of the reactor to be used as a fuel source. The pelletized biomass material is

then ignited. The burn tube runs through the length of the reactor and heats it to 3500C.

During this initial startup phase, volatile matters are gasses are released, collected

inside the reactor, and then transferred to the burn tube where it is combusted and

burned. This results in the reactor reaching a temperature of 8500C.

Step 5 - Cooling Process:

The reactor is allowed to cool down to an approximate temperature of 50 to 70 degrees

Celsius, whereafter the pelletized biomass material has been transformed to biomass

material coal (having coal-like properties).

The following steps are optional.

Optional step 6 - Crushing / Screening:

The biomass material coal is then crushed and screened to have a size of

approximately 3mm in diameter and 3mm in length.

Optional step 7 - Briquetting:

The crushed and screened biomass material coal is then mixed with a binding agent

and agglomerated into briquettes that measure 20mm in diameter and 25 mm in

length. The briquettes are then allowed to cure to form briquette having increased

stability and durability. The curing process involves a first step of placing the briquettes

in one or more windrows measuring approximately 5m at the base and approximately

3 in height and approximately 30m in length. The briquettes are then allowed to cure

naturally through use of wind to speed up the process if necessary.

Example 2:

Step 1: Raw Material

Raw material collection

Broiler chickens are reared in broiler production houses, the typical dimensions of a

broiler production house are approximately 16.5m by 132m. The total cycle from chick

to cleaning out broiler production house is 6 weeks. Bedding, which consists of

IQ2 sawdust, wood shavings, sunflower husk or peanut husks are spread onto the floor of the broiler house is approximately 20mm to 30mm thick. The bedding can be a combination of the above material or could consist of only one material.

The broiler houses are kept at a constant temperature of approximately 25 - 30°C,

which keeps the broiler litter dry. When the broilers are market ready, the broilers are

removed from the broiler house. Contractors come and clean the broiler house within

approximately 48 hours. The raw material is then between 80mm and 100mm thick

which equates to approximately 170 - 200 m 3 of raw material per broiler house.

The average size broiler producer has a total of 10 broiler production houses in

production at any given stage. The total broiler chicken litter per cycle would be

between approximately 1700m 3 to 2000m 3 .

The total volume of raw material to be moved within approximately 2 Days (48 Hours).

An important consideration would be to sanitize the truck and trailer.

Raw Material Transport

The raw material moisture content is between approximately 6 - 12% and is

considered dry and dust is formed when handling the material. The raw material is

loaded onto trailer via front end loaders, TLB's, bobcats or conveyor belts by a

contractor who is appointed to clean out the broiler production houses.

The broiler production houses need to be cleaned out within approximately 2 days

which equates to approximately 2000m3 in approximately 48 hours. It is suggested

1A that the raw material is loaded onto walking floor type trailers with tarpaulins to cover the material when transported. The loaded raw material is transported from the broiler production house to the process plant.

A first important consideration would be a requirement for a special permit required to

transport raw material. A second important consideration would be the classification

of broiler litter in terms of legislation. A third consideration would be control of dust

during handling and transport. A fourth and fifth consideration would be pathogens

and pesticides in litter. A sixth consideration would be rain during the cleaning of the

houses/loading/transport can wet the raw material.

Raw Material offloading and storage

The raw material enters the process plant via truck and trailer. The truck is weighed

on the weighbridge and a weigh-in slip is produced. The process plant is capable of

have its own weighbridge. The weighed truck is diverted to the raw material off-loading

bay.

The trailer off loads the raw material into the designated raw material storage bunkers.

Once the truck is offloaded, the truck and trailer passes over the weighbridge and is

weighed empty. A weigh slip is produced, and the data is entered into the system for

record keeping.

The raw material storage bunker should be under roof and should be in an enclosed

building with sufficient ventilation. The raw material should be kept dry. Wet raw

material will attract vectors like flies and rodents and will start the composting process.

The raw material storage bunkers should be designed to accommodate a full load from

a broiler production operation clean out of approximately 2000m3

. Two important considerations are waste management license requirement and zoning

of the property.

Raw material loading into pelletizinq plant

The raw material is loaded with a front-end loader and/or a telehandler and moved to

the intake hopper/ even feeder of the pelletizing plant. The intake hopper/ Even feeder

should be designed to hold min of approximately 4 hours of raw material.

From the intake hopper / even feeder the raw material is moved via a conveyor fitted

with a belt magnet to a conditioner. The belt magnet removes any ferrous material

from the raw material.

The conditioner is a cylindrical body with a rotating shaft to homogenize the feed

material for the pellet mill. It breaks up all the lumps from the raw material.

The homogenized raw material is moved from the conditioner via a conveyor to a

rotating screen. The rotating screen removes all oversize material of approximately

10mm and bigger.

Step 2: Pelletizing

Raw material heating

The homogenized screened raw material is moved from the rotating screen to a pre

heater where dry steam is introduced to heat the raw material to a temp of between

approximately 100 to 130 degrees Celsius. The preheater to uniformly spread the heat

through the raw material and move the material into the pelletizer. The preheater

should be designed to switch the heat source from steam to warm air produced from

the carbonizing process. The steam to be used during the startup phase of the

process.

Pelletizing raw material

The heated raw material enters the flat die ring pelletizer, and the raw material is

compressed into approximately 8mm x 30mm long green pellets. The green pellet

exits flat die ring pelletizer at a temperature of between approximately 80 - 120

degrees Celsius. The raw material bulk density entering the flat die ring pelletizer

measures at approximately 320kg/m 3 . The green pellet bulk density measures at

approximately 780kg/M3 with a specific gravity of 1300kg/m 3 .

Important considerations are the gases and odours released during the pelletizing

process and the pathogen count from the raw material to green pellet.

Screening and cooling of green pellets

The green pellets are moved from the flat die rig pelletizer with a bucket conveyor unto

a vibrating screen removing all the approximately 3mm fines. The approximately 3mm

fines are recirculated back into preheater with a bucket conveyor.

The screened green pellet is moved from the vibrating screen to a cooling unit to

remove excess heat and moisture from the green pellet. The green pellet to be cooled

to ambient temperature with a moisture content of less than approximately 5%.

Storage of green pellets

The cooled down green pellet is moved from the cooling unit with a bucket elevator to

the green pellet storage silos. The storage silos to be fitted with air filter units.

Important considerations are the dust formed inside silo due to handling and whether

the green pellet absorbs moisture and decomposes. From the Silo it will be discharged

into a bulk tanker or moved to a bagging plant where it may be bagged into 1ton to

50kg bags.

Step 3: Carbonizing

Loading green pellet

The green pellets are moved from the storage silo with a rotary valve unto a belt

conveyor. The belt conveyor moves the green pellets to a torrefaction unit.

Pre Heating green pellets (Torrefaction Unit)

1Q

The torrefaction unit slowly heats the green pellets to a temperature of between

approximately 200 to 300 degrees Celsius to form a stable mildly carbonized pellet.

The torrefaction unit releases all the moisture from the green pellet as well as some of

the volatile matter. The loss of moisture and volatile matter (+/- 20%) stabilizes the

green pellet to not break up in the carbonizing process.

Important considerations to be considered are air emissions from the torrefaction

process to be measured, startup heat source to be either LPG and/or Heavy Fuel oil,

steam / Vapor released from green pellet, and whether once the complete process is

running the excess heat from the Carbonizing process should be used.

Loading torrefied pellets

The torrefied pellets are moved from the torrefaction unit with an enclosed bucket

elevator to the top of the reactor. The bucket elevator loads the torrefied pellets into

an airtight hopper with rotary valve. The torrefied pellets are moved into the reactor

with the rotary valve / air lock. Important considerations are whether the bucket

elevator and hopper to be designed to operate in an oxygen deprived environment

and whether air from Carbonizing unit to keep temp high inside the bucket elevator.

Carbonizing torrefied pellets in reactor

The reactor is designed in which pyrolysis can proceed in an autogenous mode (heat

for the process is supplied by the decomposition of the product).

in

The torrefied pellets enter the reactor at the top via the rotary valve. The rotary valve

ensures no air enters the reactor. The torrefied pellet progress downwards through the

reactor. As the torrefied pellets progress down the reactor the temperature increases

until it reaches the reaction zone. Once the torrefied pellets have passed the reaction

zone it moves to the cooling zone and then the discharge zone.

The reactor is fuelled by raw pellets to start the process and heats the reactor to

approximately 350 degrees Celsius via a burn tube located in the centre of the reactor.

The pyroligneous gases produced inside the reactor is conveyed back to the burn tube

and combusted. The combusted pyroligneous gases allows the reactor to operate at

temp between approximately 600 - 800 degrees Celsius.

Important considerations are air emissions measurements of the burned pyroligneous

gases from the burn tube and air emissions measurements from the burning of the

green pellets during the startup phase.

Cooling of carbon pellets

The coal pellets pass through the cooling zone and is cooled to between approximately

30 - 50 degrees Celsius. The cooling zone comprises a cooling water inlet for

supplying cooling water to a cooling water heat exchanger, and a cooling water outlet.

The flow of cooling water through the cooling water heat exchanger reduces the

temperature of the material as it passes through the cooling zone.

The cooling zone further comprises a retractable platform. When the retractable

platform is in its retracted state, material is able to pass through the cooling zone and

into the discharge port. When the retractable platform is in its extended state, material

in the cooling zone is unable to pass into the discharge port.

The discharge port comprises a water and gas cooling system for cooling the

carbonized organic material prior to discharge. The water-cooling system comprises

cooling water inlets for supplying cooling water to cooling water heat exchangers, and

cooling water outlets. The gas cooling system comprises a cooling gas inlet and a

cooling gas outlet. The cooling gas, introduced through the cooling gas inlet, rises

through the carbonized organic material in the discharge port and is extracted through

the cooling gas outlet. The cooling gas extracts thermal energy from the carbonized

organic material through direct contact heat exchange and becomes heated cooling

gas.

The following steps are optional.

Optional step 4: Milling of carbon pellets

Loading of carbon pellets

The coal pellets are moved from the cooling zone with an enclosed belt conveyor to

the mill feed hopper. The hopper design has an approximately 1hr capacity. An

important consideration is the dust from handling of the coal.

Milling of carbon pellets to the approximately 3mm carbon ore

The hopper discharges the coal pellets into the crushing area of the roller mill. The

roller mill comprises of two counter rotating wheels set at 3mm apart to crush the coals

pellets to a size of approximately 3mm. An important consideration is the dust from

handling of the coal.

Optional step 5: Briquetting

Loading and weighing of approximately 3mm carbon ore

The milled approximately 3mm carbon ore is moved from the roller mill with an

enclosed conveyor to the briquette plant feed hopper. The feed hopper to have a

capacity of approximately 4hr. The feed hopper is fitted with a belt conveyor to extract

the milled approximately 3mm carbon ore into a weigh bin. The weigh bin is fitted with

loadcells and is controlled via a PLC. Once the desired weight is reached in the weigh

bin the belt conveyor of the feed hopper is stopped.

Once the correct weight is achieved in the weigh bin, a belt conveyor empties the

weigh bin and moves the weighed approximately 3mm carbon ore (ex 1000kg) to the

mixer. The important considerations are the dust from handling of the coal and the

dust from the extraction on all transfer points.

Loading and weighing of binder

01)

Both dry and wet binders are utilized. The dry binder is delivered to the site in bulk

bags. The wet binder is delivered to the site in flow bins. Dry binder is loaded into a

debagger weighing approximately 1 ton with a Forklift or Telehandler. The debagger

moves the binder into a binder dosing system with a screw feeder. The binder dosing

system comprises of a load hopper, loadcells and an unloading screw. The load

hopper has a capacity of approximately 4hr. The binder system is PLC controlled. The

binder system doses the desired amount of binder into the mixer.

Wet binder is pumped from the flow bin via a pump through a flow meter to determine

the correct amount of wet binder required. The wet binder is pumped into the mixer

and controlled by the PLC. The important considerations are the dust from handling of

the coal, the dust from the extraction on all transfer points, and spillages of wet binder.

Mixing the approximately 3mm carbon with binder

The binder and the approximately 3mm carbon ore are mixed inside a high intensity

mixer. The high intensity mixer uses a high-speed spindle and a mixing star to mix the

material. Once the desired mixed is achieved the mixer is emptied by a hydraulic

operated gate. The mixed material is released from the mixer. Important

considerations are the dust from the transfer point into the mixer, and the dust from

the opening of the mixer gate.

Briquetting -the approximately 3mm carbon / binder into briquette

The mixed approximately 3mm carbon is moved from the mixer with a conveyor belt

and fed into a load hopper. The load hopper is fitted with a feed screw which feeds the

approximately 3mm carbon at a constant rate into the force feeder.

The force feeder moves the approximately 3mm carbon into the compression chamber

of the briquette machine. The approximately 3mm carbon is then compressed into

briquettes by the two counter rotating wheels of the briquette machine.

Screening of green Bio-Coal briquette

The briquettes are released from the bottom of the 2 counter rotating wheels and

moves unto a vibrating screen. The briquettes are vibrated on the screen to remove

any of the approximately 3mm carbon generated during the briquetting process. The

excess finer material is recalculated back to a holding bin which is then fed back into

the force feeder.

Stockpiling and Curing of Bio-Coal briquette

The screened Bio-Coal briquettes are moved from the vibrating screen with a conveyor

to the stockpile area for natural curing. The stockpile conveyor moves on a rail system.

The stockpile conveyor stacking head can be lowered and raised to minimize the fall

distance of the briquette.

Important considerations are the fines generated due to incorrect transfer points, fines

collection and recycling back into plant, stockpile area to have a bunker wall, and

stockpiles are to be under roof.

Final Screening and loading of Bio-Coal briquettes

Once the briquettes have naturally cured in the stock pile. The cured Bio-Coal

briquettes is loaded with a front-end loader into a hopper weighing approximately 40

ton. The load hopper is fitted with loadcells. The hopper is emptied with a belt conveyor

and moves the Bio-Coal briquettes to a vibrating screen. The Bio-Coal briquettes is

screed to remove any fine material from the curing process.

The screen Bio-Coal briquettes is moved from the vibrating screen with a belt

conveyor. The belt conveyor moves the bio-coal briquettes into the side tipper truck at

approximately 34 tons per truck. The side tipper truck enters the process plant and

weighs in on the weighbridge. Once the truck is loaded with bio-coal briquettes, the

trucks again pass over the weighbridge to confirm the weight of bio-coal briquettes

loaded. The Bio-Coal is then delivered to the client / buyer.

Important considerations are the fines generated due to screening process, screen

fines collection and recycling back into plant, and loading of the trucks to be under

roof.

Claims (28)

1. A method for generating biomass material, the method including the steps of:

- Preparing raw biomass material having a moisture content of between 10 and

14%;

- Drying the raw biomass material with a heat source between 100 and 130 °C;

and

- Compressing the raw biomass material with a compression device to produce

biomass material.

2. The method according to claim 1, wherein the raw biomass material is a high

calorie biomass selected from a group consisting of animal manure, animal

excrement, pig manure, horse manure, sugar cane, plant husks, Oilseeds, Nuts,

Fats and Oils, Animal Fats, Animal Feed, Wood Biomass, Algae, Organic Waste,

Peat, Seaweeds, or combinations thereof.

3. The method according to claim 1, wherein the raw biomass material is a

4. The method according to claim 1, wherein the heat source is a dry steam.

5. The method according to claim 1, wherein the heat source is excess heat

generated from a chemical process.

6. The method according to claim 1, wherein the chemical process is a carbonizing

process

7. The method according to claim 1, wherein the heat source is generated by one

or more electrical devices.

8. The method according to claim 1, wherein the biomass material comprises one

or more pellets.

9. The method according to claim 8, wherein the pellets is between 5mm and 25

mm in diameter and between 5mm and 50mm in length.

10. The method according to claim 1, wherein the biomass material is in powder

form.

11. The method according to claim 1, wherein the compression device is a flat die

ring pelletizer.

12. The method according to claim 1, wherein the compression device is a hydraulic

disk ram or a mechanical disk ram.

13. The method according to claim 1 comprising a further step of sterilizing the

biomass material.

14. A process of producing synthetic gas from biomass material, the process

including the steps of:

- Optionally feeding between 50 and 10 000 kilograms of biomass material into

a reactor;

- Optionally placing between 3 and 1000 kilograms of biomass material is placed

in a burning chamber locatable in the reactor;

- Igniting the biomass material in the burning chamber to obtain an elevated

temperature of between 340 and 360 °C to release volatile matter and gasses;

- Combustion of the volatile matter and gasses in the burning chamber to

increase the temperature in the burning chamber to between 840 and 860 °C;

- Cooling the burning chamber to a temperature between 50 and 70 °C to

transform the biomass material to a coal-like material;

- Crushing the coal-like material to units that are smaller than 6mm in size;

- Mixing the crushed coal-like material with a binding agent to form one or more

briquettes that are between 15 - 30mm in width and 25 - 50mm in length; and

- Curing the briquettes.

15. The process according to claim 14 wherein the burning chamber is a burning

tube.

16. The process according to claim 14 wherein volatile matters is between 3% and

30%.

17. The process according to claim 14 wherein the gasses is selected from the group

consisting of carbon dioxide, carbon monoxide, nitrous oxide, methane,

hydrogen sulphide, or combinations thereof.

18. A process of producing synthetic gas from biomass material, the process

including the steps of:

- providing biomass material having a moisture content between 6 - 15%;

- displacing the biomass material using displacement means from a collection

region to a process region;

- storing the biomass material in a storage region available in the process

region;

- moving the biomass material from the storage region to a pelletizing plant for

pelletizing the biomass material;

- providing the pelletizing plant with magnet means for removing ferrous

material from the biomass material and a conditioner for homogenizing the

biomass material;

- moving the homogenized biomass material from the conditioner to a

screening device for removing material sized 10mm by 10mm;

- using a heat source of between 100 to 1300C to heat the homogenized

biomass material;

- compressing the homogenized biomass material in the pelletizing plant into

8mm x 30mm pellets;

- using sorting means to remove homogenized biomass material measuring

3mm by 3mm;

- cooling the homogenized biomass material until the moisture measures at a

level below 5%;

- carbonizing of the homogenized biomass material by heating the homogenized

biomass material to a value between 200 and 300 degrees Celsius to form a

carbonized pellet;

- heating of the carbonized pellets in a pyrolysis region of the pelletizing plant by

heating the carbonized pellets in plurality of heating zones having temperatures

between 350 and 800 degrees Celsius;

- cooling of the carbonized pellets in a cooling region of the pelletizing plant to a

temperature of between 30 - 50 degrees Celsius;

- crushing the carbonized pellets with crushing means to carbon ore having a

size of 3mm in length and 3mm in width;

- weighing the carbon ore with weighing means to a predetermined weight;

- mixing of the carbon ore with a binding agent with mixing means;

- compression of the carbon ore mixed with the binding agent in a compression

device to form briquettes; and

- curing of the briquettes

19. The process according to claim 18, wherein the predetermined weight is between

900 kg and 1100 kg.

20. The process according to claim 19, wherein the binding agent is a wet binding

agent or a dry binding agent, or a wet binding agent and a dry binding agent in

combination.

21. An apparatus for producing synthetic gas from biomass material, the reactor

including:

- A pellet burning tube;

- A biomass reactor tube;

- A gas collection tube; and

- A flue pipe.

22. The apparatus according to claim 21, wherein the pellet burning tube is capable

of receiving pellets to start the heating process of the biomass reactor.

23. The apparatus according to claim 21, wherein the pellet burning tube is capable

of receiving the gasses released from the gas collection tube.

24. The apparatus according to claim 21, wherein biomass reactor tube is capable

of containing biomass pellets and creating an oxygen deprived environment.

25. The apparatus according to claim 21, wherein the biomass reactor tube is

capable of containing the biomass pellets or the gas collection tube.

26. The apparatus according to claim 21, wherein the gas collection tube is situated

inside the biomass reactor tube and collects all gasses and volatiles.

27. The apparatus according to claim 21, wherein the gas collection tube directs the

gasses and volatiles to a burn tube.

Q21

28. The apparatus according to claim 21, wherein the flue pipe discharges burned

gasses from the pellet burning tube.

Q0'