Abstract:
A method of drying a moisture-containing or water-laden biomass material is provided that includes the steps of sending the biomass material into an apparatus having a feeding device, a rotary biomass dryer, a reflux condenser, an aftercooler, and an exit mechanism. The biomass material may be pretreated, and then heated in order to separate the moisture-containing or water laden biomass material into steam and dry biomass material. The steam is removed as the steam and the dry biomass material passes through the reflux condenser, the dry biomass is cooled in the aftercooler stage, and the dry biomass material is collected after exiting the apparatus through the exit mechanism.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of provisional application Ser. No. 62/130,820, filed on Mar. 10, 2015, the entire contents of which are incorporated herein by reference in their entirety. 
     
    
     FIELD 
       [0002]    The present disclosure relates generally to an apparatus and method used to process biomass materials. More specifically, this disclosure relates to equipment and methods that improve properties or performance of biomass materials and the development of additional energy bi-products from the processing thereof. 
       BACKGROUND 
       [0003]    The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
         [0004]    A rotary biomass dryer provides a low cost alternative to conventional biomass drying which requires significant energy inputs. The rotary biomass dryer requires no external energy, only a motor to rotate the compression auger effectively heating the biomass by compression and friction to generate in-situ steam. Additionally, none of the conventional drying methods can increase the BTU content of biomass material. 
         [0005]    Biomass materials, either woody or non-woody, lack the energy density of coal. Therefore, methods have been developed over the years to increase the energy density including Hydrothermal Carbonization (HTC), Ammonia Fiber Explosion (AFEX), torrefaction, and steam explosion. Each of these methods requires significant external energy input to cause an increase in energy density. 
       SUMMARY 
       [0006]    The present disclosure generally provides an apparatus and a method for drying a moisture-containing or water-laden biomass material. The apparatus comprises a feeding device, a rotary biomass dryer, a reflux condenser, an aftercooler stage, and an exit mechanism. In one form of the present disclosure, the biomass material is subjected to a pretreatment involving in-situ acid or basic treatment and optionally, inorganic sequestering. 
         [0007]    In one form, the present disclosure provides a method of drying a moisture-containing biomass material using the apparatus as described herein, including feeding moisture-containing biomass material into the feeding device, pretreating the biomass material, heating the moisture-containing biomass material in the rotary biomass dryer to separate the moisture-containing biomass material into steam and dry biomass material, removing the steam from the apparatus as the steam and the dry biomass material passes through the reflux condenser, cooling the dry biomass material in the aftercooler, and collecting the dry biomass material after exiting the apparatus through the exit mechanism. 
         [0008]    According to additional forms of the present disclosure, the apparatus may comprise a crammer feeder, and in one form a funnel feeder, an in-feed mixer, a preheater, or a dual-belt feeder. The dual belt feeder generally comprises a top belt that levels the inflow of moisture-containing or water-laden biomass material by raking or leveling and a lower belt that provides metered feed provisions to the rotary biomass dryer. The apparatus may also comprise a mixer located prior to the feeding device in order to mix together more than one moisture-containing or water-laden biomass material. 
         [0009]    According to another aspect of the present disclosure, the rotary biomass dryer comprises a multiple screw design capable of co-rotating or counter rotation. Alternatively, the rotary biomass dryer comprises a fixed screw design with a rotating barrel. The rotary biomass dryer may also include a screw with a compression zone having a blind aperture extending from a drive end, optionally, near the compression zone end of the screw, with appropriate provisions for receiving a liquid filter, such as by way of example a “banjo” style rotary liquid filter. A hollow device may be used to deliver cooling fluid to the opposite end of the blind aperture. 
         [0010]    According another aspect of the present disclosure, pretreatment of biomass materials involves in-situ acid or basic treatment. Alternatively, the in-situ acid treatment utilizes acetic acid, citric acid, or the like. Optionally, the pretreatment may further comprise inorganic sequestering through the use of one or more sequestering agents, for example, kaolin. The pretreatment may be injected into the barrel of the rotary biomass dryer immediately after the feeding device. 
         [0011]    In the method and apparatus of the present disclosure, the rotary biomass dryer subjects the moisture-containing biomass material to hydrolysis and steam explosion. The reflux condenser subjects the dry biomass material to recapture carbonization and removes steam from the apparatus. The aftercooler stage subjects the dried biomass material to cooling condensation. The reflux condenser may also be used in other biomass processing equipment systems that utilize other biomass processing components, including without limitation extruders, pelletizers, and briquetters. 
         [0012]    A rate at which the moisture-containing material is provided to the feeding device may be uniform in one variation of the present disclosure. When desired, more than one type of moisture-containing biomass material may be mixed together at the time of, or prior to, entering the apparatus through the feeding device. 
         [0013]    According to another aspect of the present disclosure, a conventional screw press, also known as a dewatering press, may be used to denature or remove excess water by hydraulically or mechanically expelling the moisture-containing biomass material through a tapered screw/screen filter arrangement that diverts excess water prior to the moisture-containing biomass material being fed into the rotary biomass dryer. 
         [0014]    According to yet another aspect of the present disclosure a biomass material is dried according to the method and/or using the apparatus described above and further disclosed herein. When the biomass material is dried using the apparatus of the present disclosure, the apparatus may subject the biomass material to an auto acid hydrolysis zone, a hydrolysis zone, a steam explosion zone, a recapture carbonization zone, and/or a cooling condensation zone, either individually or in any combination. 
         [0015]    Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0016]    In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings in which: 
           [0017]      FIG. 1  is a schematic representation of a rotary biomass dryer apparatus adapted according to the teachings of the present disclosure; 
           [0018]      FIG. 2A  is a perspective view of a dual-belt feeder that may be utilized in the apparatus according to the teachings of the present disclosure; 
           [0019]      FIG. 2B  is a perspective side view of the dual-belt feeder of  FIG. 2A ; 
           [0020]      FIG. 3A  is a schematic representation of a reflux condenser that may be combined with the apparatus of the present disclosure; 
           [0021]      FIG. 3B  is a side view of the reflux condenser of  FIG. 3A  shown in context with the biomass dryer according to the teachings of the present disclosure; 
           [0022]      FIG. 4  is a perspective view of one form of a crammer feeder having a funnel configuration constructed in accordance with the teachings of the present disclosure; and 
           [0023]      FIG. 5  is a side cross-sectional view of the crammer feeder of  FIG. 4 . 
           [0024]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
         [0026]    The present disclosure addresses the drying of moisture-containing or water laden biomass materials by providing an apparatus and method that adapts a rotary biomass dryer to incorporate or adopt one or more pretreatment methods and/or a reflux condenser. Pretreatment provides a means to remediate undesirable chlorides and salts present in especially some non-woody biomass materials followed by drying in a rotary biomass dryer with acid injection to facilitate the breakdown of certain cellulose. Biomass materials are generally a mixture of three basic cellulosic materials, namely, cellulose, hemicellulose and lignin. According to one aspect of the present disclosure, the pretreatment is performed after commutation by immersing the biomass materials in water followed by mechanical dewatering to solubilize salts and nutrients, comprising ions of chlorine (Cl), nitrogen (N), potassium (K), and/or phosphorus (P). 
         [0027]    A rotary biomass dryer can function as a hydrolysis processor or steam dryer as it uses the heat of compression in the Second Law of Thermodynamics to produce steam thereby effectively drying with interstitial bound and unbound or added water. The drying of biomass materials falls into two broad categories or ranges, namely, non-destructive drying and destructive drying. The rotary biomass dryer typically functions in the non-destructive range, up to a temperature of about 350° F. Within this temperature range, both unbound waters and bound waters are released from the biomass materials. Drying above about 350° F. is considered destructive drying because it creates biochar. 
         [0028]    Referring to  FIG. 1 , an apparatus  10  of the present disclosure generally comprises a feeding device  12 , a feed throat  14 , a rotary biomass dryer  16 , a reflux condenser  18 , an aftercooler  20 , and an exit mechanism  25 . Along the length of the apparatus  10 , various portions may also be described to comprise various zones, namely, an auto acid hydrolysis zone  30 , a hydrolysis zone  35 , a steam explosion zone  40 , a recapture carbonization zone  45 , and a cooling condensation zone  50 . Some of these zones may overlap with one another as shown with respect to the hydrolysis zone  35  and the steam explosion zone  40 . Biomass material may be introduced to any of these zones either individually or in any combination. Further details associated with the rotary mass dryer are described in U.S. Pat. No. 8,667,706, which is commonly assigned with the present application, and the entire contents of which are hereby incorporated by reference in their entirety. 
         [0029]    In another form of the present disclosure, pretreatment of biomass materials includes without limitation in-situ acid or basic treatment, e.g., auto acid hydrolysis. The in-situ acid treatment of the biomass materials within the non-destructive temperature range using predetermined acid compositions that include without limitation, acetic acid, citric acid, or the like, provides a means to improve the production of fixed carbon while enhancing moisture content. The in-situ hydroxide treatment using predetermined basic compositions that include, by way of example, any hydroxide such as sodium or calcium hydroxide, or any ammonia. An acid/water mixture, or a hydroxide/water mixture, may be injected into a barrel of the rotary biomass dryer  16  immediately after the feeding device  12  in order to increase exposure time. Acid injection catalyzes the hydrolysis in conjunction with elemental iron and/or the acids serve to dehydrate and solubilize halogen elements (e.g., chlorine) and alkali metals (e.g., sodium, potassium, etc.), as well as flash-off the corresponding salts (e.g., KCl) and/or NaCl) along with the steam. This acid treatment also increases the amount of fixed carbon present in the biomass materials, which may be desirable for some applications. 
         [0030]    Additionally, in another form acidic and basic materials, such as any hydroxide such as sodium or calcium hydroxide or any ammonia, are introduced to the biomass materials while being processed through the rotary biomass dryer  16 . Acidic and basic chemicals act to catalyze the breakdown of lignin, hemicellulose and cellulose of lignocellulosic biomass. This breakdown of the lignin, hemicellulose and cellulose results in the carbonization of biomass. When using organic acids such as acetic, formic, citric and the like in the rotary biomass dryer  16  to process to treat corn stover, BTU content was increased from 7,650 BTU/lb in raw stover to 8,395 BTU/lb in a partially carbonized sample of corn stover. In processing runs without the use of acids, the heat capacity of the partially carbonized corn stover was only 8,060 BTU/lb. The use of organic acids in the rotary biomass dryer  16  with corn stover also resulted in a moisture content decrease and a fixed carbon increase compared to stover that was not treated with acid in tandem to the rotary biomass dryer  16 . Samples of raw corn stover were analyzed at 10% moisture content and 20.2% fixed carbon. The use of organic acids increased the fixed carbon composition of the corn stover to 29% and decreased the moisture content to 2.5%, while the fixed carbon composition of the stover without acid treatment did not increase and the moisture content only decreased to 6.8%. When using basic chemicals in tandem with the rotary biomass dryer  16  and oak sawdust, similar increases in heat capacity are seen as well as a noticeably faster darkening of the color of the material as it was being processed compared to processing without the addition of chemical, indicating a faster carbonization rate. 
         [0031]    According to another aspect of the present disclosure, the biomass materials may contain inorganic materials derived from silicic acid, in the form of silica, plant nutrients, and chlorides. Under certain conditions, these inorganic materials may result in a film or glazing being formed on the boiler walls. In the present disclosure, inorganic sequestering may be utilized as an additional pretreatment to effectively tie up the silica and chloride in the resulting ash that is formed. Such inorganic sequestering may be accomplished by the addition of sequestering agents to the biomass materials in the process of the present disclosure. 
         [0032]    The rotary biomass dryer  16  in one form employs a uniform feed rate in order to improve efficiency, or to achieve a more uniform flow rate. According to additional aspects of the present disclosure, which are described in greater detail below, one or more feed improvements such as variations of the feeding device  12  as a funnel feeder or crammer feeder, an in-feed mixer, a preheater, and a dual-belt feeder may be utilized to enhance the uniformity of the flow rate. The funnel feeder and crammer feeder forms provide a feeding device that increases the bulk density of the biomass materials as they enter a screw of the rotary biomass dryer  16 . An in-feed mixer may also be employed, which is a combination or use of two or more feed units in combination with a mixer to mix different biomass materials together. A variety of biomass materials are available and mixing of some of these biomass materials together may be advantageous due to seasonal supply for improvement of certain properties such as BTU content or the like. A preheater may also be utilized to deploy waste heat generated by the process back to the feeding device  12  in order to temper the incoming biomass materials entering the feed throat  14 . 
         [0033]    Referring now to  FIGS. 2A and 2B , a dual-belt feeder  100  may be utilized that levels the inflow of biomass material by raking/leveling with a top belt  105  while the lower belt  110  provides metered feed provisions to the feed throat  14  of the rotary biomass dryer  16 . The dual-belt feeder  100  provides for both improved metering and feeding functions. 
         [0034]    The rotary biomass dryer  16  defines a compression screw (see U.S. Pat. No. 8,667,706), however, this configuration is output limited by a root diameter of a feed section. A multiple screw design with co-rotating or counter-rotating screws may be employed according to the teachings of the present disclosure in order to to provide increased throughput. Alternatively, a fixed screw design with a rotating barrel may be used to improve efficiency. 
         [0035]    Since the rotary biomass dryer  16  is a steam dryer, generating steam by flashing off both bound and unbound water, excessive heat build-up may control issues with the screw due to steam forming too early in the process. According to another aspect of the present disclosure, this issue can be addressed by incorporating a blind aperture from a drive end (the front/loading end), such as, but not limited to near a compression zone of the screw, with appropriate provisions for receiving a liquid filter. Further, in another form, a hollow rod/device may be used to deliver cooling fluid to an opposite end of the blind aperture. 
         [0036]    According to yet another aspect of the present disclosure, tandem dewatering methods may be utilized. These methods include using a conventional dewatering and screw press to denature or remove excess water by hydraulically or mechanically expelling the water laden material through a tapered screw/screen filter arrangement. After the water is diverted, the expressed material may be fed directly into the rotary biomass dryer  16 . 
         [0037]    Referring now to  FIG. 3A  a reflux condenser  18  is shown that comprises a column-like device device, such as but not limited to an auger  60 , to move the biomass material. The auger  60  includes a member, such as a plate or a blade  62 , over which some of the evaporated materials provide a gas blanket and flow back through the rotary biomass dryer  16  in order to inhibit the contents of the apparatus  10  from combusting and to provide material for recapture carbonization wherein the volatiles released during steam explosion are condensed into the solid material  45  (see  FIG. 1 ). The reflux condenser  18  also comprises a port  64  through which the evaporated excess water is removed, forced, or pulled from the apparatus prior to the biomass material losing an excessive amount of heat. 
         [0038]    Referring now to  FIGS. 1 and 3B , the reflux condenser  18  is located in the apparatus  10  between the rotary biomass dryer  16  and the aftercooler stage  20 . It should be understood, however, that the reflux condenser  18  is not limited to use in tandem with a rotary biomass dryer  16  and instead may be employed with any biomass processing component, such as by way of example, extruders, pelletizers, or briquetters, to form a biomass processing equipment system, while remaining within the scope of the present disclosure. 
         [0039]    The aftercooler stage  20  is utilized to lower the temperature of the dried biomass materials prior to the dry materials exiting the apparatus  10  through the exit mechanism  25  or port. Any gases, and in some forms any uncondensable gases, including but not limited to CO, CO 2 , H 2  may be processed in a subsequent thermal oxidizer. 
         [0040]    In another method of the present disclosure, the dried biomass materials exiting the apparatus  10  may be further compacted into a dense and ready-to-transport shapeform. 
         [0041]    Referring now to  FIGS. 4 and 5 , one form of the feeding device  12  as a crammer feeder with a funnel configuration is illustrated and generally indicated by reference numeral  70 . As shown, the funnel feeder  70  includes a tapered proximal portion  72  and a cylindrical distal end portion  74 . A shaft  76  extends through the funnel feeder  70  and is driven by a motor (not shown). The shaft  76  further comprises an auger  78  in order to feed the biomass materials into the rotary biomass dryer  16 . Optionally, a bracket  80  is used to mount the funnel feeder  70  to an adjacent component of the apparatus  10 , such as by way of example, the motor. It should be understood that this crammer feeder device in the form of a funnel feeder is merely exemplary and should not be construed as limiting the scope of the present disclosure. Other types of feeders as set forth herein, in addition to vibratory feeders and gravity feeders may also be employed while remaining within the scope of the present disclosure. 
         [0042]    Testing 
         [0043]    Two different moisture-containing biomass materials were tested using the apparatus and methods according to the present disclosure, namely, corn stover and oak sawdust. As shown in Table 1 below, the corn stover and oak sawdust processed through the apparatus of the present disclosure demonstrated higher BTU/lb while reducing overall volatile matter: 
         [0000]    
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                   
                   
                 Corn Stover - 
                   
                 Oak Sawdust - 
               
               
                 Output Characteristic 
                 Analytical 
                 Corn Stover - 
                 After RCU/RC 
                 Oak Sawdust - 
                 After RCU/RC 
               
               
                 Proximate/Elemental 
                 Method 
                 Unprocessed 
                 Processing 
                 Unprocessed 
                 Processing 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Ash (wt. %) 
                 ASTM D1102 
                 10.79 
                 16.97 
                 1.50 
                 13.67 
               
               
                 Volatile Matter (wt. %) 
                 ASTM D3175 
                 69.00 
                 55.44 
                 80.59 
                 50.91 
               
               
                 Fixed Carbon (wt. %) 
                 ASTM D3172 
                 20.21 
                 27.59 
                 17.92 
                 35.43 
               
               
                 Sulfur (wt. %) 
                 ASTM D4239 
                 0.13 
                 0.10 
                 0.01 
                 0.10 
               
               
                 ross Calorific Value (BTU/lb) 
                 ASTM E711 
                 7650 
                 8831 
                 8381 
                 9254 
               
               
                 Carbon (wt. %) 
                 ASTM D5373 
                 43.93 
                 51.50 
                 49.60 
                 54.39 
               
               
                 Hydrogen (wt. %) 
                 ASTM D5373 
                 5.32 
                 4.46 
                 5.85 
                 4.27 
               
               
                 Nitrogen (wt. %) 
                 ASTM D5373 
                 1.18 
                 1.40 
                 &lt;0.20 
                 1.12 
               
               
                 Oxygen (wt. %) 
                 ASTM D5373 
                 38.65 
                 25.57 
                 &gt;42.83 
                 26.45 
               
               
                   
               
             
          
         
       
     
         [0044]    The foregoing description of various forms of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Numerous modifications or variations are possible in light of the above teachings. The forms discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various forms and with various modifications as are suited to the particular use contemplated.