Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION:
Methods for Utilizing Biomass fuel composition in a Biocoil Boiler
2. APPLICANT(S)
Name Nationality Address

Steamax Envirocare Private Limited Indian B-54, Upper Ground, New Krishna Park, Vikaspuri, New Delhi, 110018

PREAMBLE TO THE DESCRIPTION

PROVISIONAL
The following specification describes the invention.
COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.
4. DESCRIPTION (Description shall start from next page.)
5. CLAIMS (not applicable for provisional specification. Claims should start with the preamble— “I/ We claim” on separate page)
6. DATE AND SIGNATURE (to be given at the end of last page of specification)
7. ABSTRACT OF THE INVENTION (to be given along with complete specification on separate page)

FIELD OF THE INVENTION
The field of this invention generally relates to a biomass fuel system and more particularly to Non-Indian Boiler Regulations.

BACKGROUND OF THE INVENTION
Existing boiler designs often suffer from inefficiencies in heat transfer, resulting in high fuel consumption and increased environmental impact. These designs may also occupy significant space, making them less suitable for installations with limited area availability. Additionally, the recovery of waste heat from flue gases is often suboptimal, leading to further energy wastage. Therefore, there is a need for a novel boiler design that addresses these challenges by maximizing heat transfer efficiency, reducing fuel consumption, and optimizing energy recovery, all within a compact and integrated configuration.
Prior art suggest that the existing boiler designs suffer from inadequate heat transfer mechanisms, leading to suboptimal thermal efficiency and excessive fuel consumption. These inefficiencies contribute to a significant environmental impact in terms of greenhouse gas emissions and energy wastage.
Conventional boiler systems often present challenges in installations where space availability is limited. Their bulky and sprawling configurations make them less ideal for compact environments, impeding efficient utilization of available area. The recovery of waste heat from flue gases in traditional boilers is typically characterized by suboptimal extraction methods. As a result, valuable energy resources are lost and go untapped, exacerbating the overall energy inefficiency of the system.
To address these pressing concerns, there is a critical need for an innovative boiler design that incorporates advanced heat transfer technologies. This novel system would focus on maximizing thermal efficiency, minimizing fuel consumption, and optimizing energy recovery from waste heat sources.
The desired solution should embrace a compact and integrated configuration, leveraging cutting-edge engineering principles to effectively utilize limited space while achieving superior performance metrics.
In traditional boiler designs, the combustion process often leads to the formation of harmful pollutants, such as nitrogen oxides (NOx) and particulate matter (PM), contributing to air pollution and adverse health effects. Addressing these emissions challenges is crucial for promoting cleaner and more sustainable energy systems.

The complex and decentralized nature of existing boiler systems can pose challenges in terms of monitoring, control, and optimization. Implementing advanced digital technologies and intelligent control algorithms can enhance system performance and enable proactive maintenance, reducing downtime and enhancing operational efficiency.
Traditional boiler designs often lack flexibility in fuel options, limiting their ability to adapt to changing energy demands and environmental regulations. Developing multifuel-compatible systems that can efficiently utilize a wide range of renewable and alternative fuels is essential for achieving energy diversification and decarbonization goals
A significant portion of energy is lost through the exhaust flue gases in traditional boiler systems. Developing innovative heat recovery solutions that can capture and utilize this wasted energy presents an opportunity to further improve overall system efficiency and reduce environmental impact.
Non-IBR (Non-Indian Boiler Regulations) boilers are advanced, safe, environmental sustainable and efficient boiler systems that comply with international standards while excluding the requirements of the Indian Boiler Regulations. These boilers showcases significant advancements such as robust construction, multi-fuel compatibility, more fuel efficient, and enhanced control and safety features for secure operations. Robustness, durability and life span of these non-IBR boilers have been improved by using High-quality materials to ensure their resistance corrosion, thermal stress, and mechanical wear; and materials employed in their construction includes stainless steel, carbon steel, and alloy combinations. The overall energy efficiency of these boilers are enhanced by improvising the combustion systems, introducing heat recovery mechanisms, and providing proper insulation systems that results in efficient utilization of fuel and reduced operation cost. Compatibility of these boilers with multiple fuels like natural gas, diesel, biomass, offers freedom for the users to choose the most economical and sustainable fuel source of their choice; however, emphasizes for integration with renewable energy for sustainability. Besides, these boilers are also made more sustainable and environmental friendly by minimizing their environmental impacts, by integrating advanced emissions control systems like selective catalytic reduction (SCR), flue gas recirculation (FGR), and low-NOx burners, and ensure compliance with stringent emission regulations. Furthermore, integrating Automation and control systems like pressure relief valves and temperature sensors, with these boilers allows precise monitoring and control of parameters for optimal performance and safety. Overall, the current state of art for non-IBR boilers reflects a strong commitment to enhanced safety features, energy efficiency, digitalization, modular designs, and sustainability measures.

SUMMARY OF THE INVENTION
Bio coil boiler was to create a compact and integrated steam generation system with a capacity of less than 1 tonne per hour, designed to operate under non-IBR (Indian Boiler Regulations) terms and norms. This enables the user to install the boiler directly into their system without the need for any IBR certifications or approvals. Due to its compact and integrated design, the entire boiler system experiences minimal heat loss, which is efficiently converted into usable heat for steam generation. Any boiler exhibits enhanced performance upon supplying fuel with reduced particle size, assuming small particles gets combusted completely due to maximum surface area. The biofuel has been developed accordingly by reducing their particle size to ensure uninterrupted transportation inside boiler, completion of combustion and eliminate unburnt fuel. The biofuel have also been processed to eliminate any residual oil content and moisture content from it by suitable natural adsorption technique. As mentioned earlier, the physical characteristics of the developed biofuel, comprising a mix of 2-3 biomass mixed carefully according to the clients requirement, includes moisture content ranging between 5-8%, ash content between 1-3%, fixed carbon content between 17-20%, and volatile matter ranging between 70-75%, calorific value ranging between 4200-4500 kcal, and bulk density between 400-450 kg/m3. Consequently, this bio coil boiler can be considered a working example of an integrated, compact steam generation system, specifically designed to meet lower steam demands without the necessity for IBR clearances

BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1. Working model of Biocoil Boiler
Figure 2. Full view of Biocoil Boiler

DETAILED DESCRIPTION OF THE INVENTION
.
The novel bio-coil boiler has been designed and developed to address all these issues, by utilizing multiple components in an integrated manner to optimize heat transfer and energy recovery within the system. This bio-coil boiler comprises of an auto fuel feeding kit comprising of a hopper, screw press feeder, biomass furnace, helical water heating coil, shell and tube arrangement for preheating water, F.D.fan, and exhaust vent to chimney.
The boiler comprises of 5 sections and detailed explanations about their construction are as follows:

Section 1: This section comprises of a biomass fired furnace and is connected with the outlet of fuel feeding system. The furnace is provided with a perforated ash plate at its bottom and fitted to the ash box.
Section 2: This section comprises of a single cylinder shell with their outer walls insulated using refractories. The helical water heating coil is positioned inside the shell sitting exactly on top of the furnace, and receives direct heating from the furnace. The helical coil is provided with perforated spacers, which allows the flue gas to vent out through it and helps heating the other side of the coil.
Section 3: This section acts as an economiser and comprises of shell and tube arrangement meant for water preheating. The arrangement includes feed water passing inside the shell, with the tubing for flue gases placed perpendicular to each other. The outlet of the shell is connected to a water pump which in turn is connected to the inlet of the helical water heating coil. The entire setup is mounted on section 2. The outlet of the water tubing is connected to a water pump which in turn is connected to the inlet of the helical water heating coil. The outlet of tubes of the economiser is connected to the chimney to vent out the exhaust gas.
Section 4: This system comprises of a setup for air pumping and automatic fuel feeding system. Here, the auto fuel feeding kit comprises of a bunker hopper and screw type feeder. Here, the outlet of hopper is connected with mouth of the casing, which houses the feeder screw, whereas, the outlet of the feeder is connected with the opening found at other end of the furnace again as mentioned earlier. The feeder screw is driven by a variable speed motor. A Forced draught fan (F.D.Fan) is used for forcing air into the furnace, with its outlet connected along with the outlet of screw feeder casing.

The bio coil boiler is designed to accommodate any type of solid biomasses, accounting the present market scenario and availability. However, it is always recommended to use to small sized fuel for efficient combustion and maximised heat output. Hence, this boiler is designed to handle crushed biomass and briquettes, and pellets; yet, they can run efficiently on even uncrushed large biomass and briquettes.

In addition, a dedicated biomass fuel has been developed for making this boiler run for prolonged duration with or without needed for major maintenance, and run efficiently without causing any operational issues such as tube choking, pipe blocks or damage to boiler surfaces or refractories. This fuel has been proven to be very effective for running this boiler uninterrupted and also found to be compatible with other boilers. This developed fuel is a mixture of 2-3 crushed biomass, mixed in various proportions and contribute significantly to complete combustion, uninterrupted fuel supply and minimal ash handling.

Type of Material Biomass Mixing Range Practised Range
Base Material Deoiled cashew nut shell cake 75-85 % 75-85 %
Oil Absorbent 1. Saw Dust 5-10 % Upto 10 %
2. Spent Coffee Grounds dust 5-7 %
3. Crushed Ground nut shell dust Upto 10 %
Burn Stabiliser 1. Torrefied biomass
(i) Mustard Straw
(ii) Groundnut shell 10-15 % Upto 10 %
2. Wood Chips 10-15 %
3. Crushed Palm Kernel Shell Upto 15 %

Any boiler exhibits enhanced performance upon supplying fuel with reduced particle size, assuming small particles gets combusted completely due to maximum surface area. Keeping this as rule of thumb, the biofuel has been developed accordingly by reducing their particle size to ensure uninterrupted transportation inside boiler, completion of combustion and eliminate unburnt fuel. The biofuel have also been processed to eliminate any residual oil content and moisture content from it by suitable natural adsorption technique. As mentioned earlier, the physical characteristics of the developed biofuel, comprising a mix of 2-3 biomass mixed carefully according to the clients requirement, includes moisture content ranging between 5-8%, ash content between 1-3%, fixed carbon content between 17-20%, and volatile matter ranging between 70-75%, calorific value ranging between 4200-4500 kcal, and bulk density between 400-450 kg/m3. The recipe of this developed biofuel is as follows: base material, primarily the deoiled cakes of cashew nut shell comprising about 70-80%; oil absorbent, primarily a highly porous biomass with good oil absorbing property and calorific value equivalent to base material; and lastly, burn stabiliser, another biomass with good calorific value dedicated for providing stable flame, ensure complete combustion of particles, preventing fuel accumulation and bridging, uniform heat distribution and also moderating the flame temperature. Here, the composition of both oil absorbent and burn stabilizer can be up to 5-10% and 10-15%, respectively depending upon the function of boiler.

About the understanding the energy density of the biomass used for the bio-coil boilers, the loose biomass reports Lowest energy density due to high void space and low mass per volume, crushed biomass reports Slightly higher energy density due to reduced particle size, biomass briquettes reports Moderate to high energy density, while crushing them reduces their energy density slightly. Interestingly, biomass pellets, recommended for bio-coil boilers have highest energy density. Similarly, the developed biofuel also has very good energy density, post processing. The combination of base medium in crushed form, along with oil absorbent and burn stabiliser balances the energy density and also bulk density. However, the appropriate mix can be decided based on the boiler usage, local biomass availability and environmental norms. For instance, boiler with low steam demand can use less amount of base material and more amount of burn stabiliser; whereas, high steam demand conditions require large quantity of base material and oil absorbent medium than burn stabiliser.

The only fuel type encouraged for using in the bio coil burner are biomass type fuel, which are basically sulphur free. So biomass fuel of any type doesn’t account to SOx emissions, however, since they are solid in nature, they tend to contribute a portion of particulate matter. Eventually, complete combustion ensures minimal generation of these particulate matters, which are handled by the Air pollution control devices, and prevents their escape into the environment effectively. Likewise, solid biomass also generates a small amount of NOx emissions, which are accounted to their fuel bound nitrogen content, excess combustion temperature, air to fuel ratio maintained, and sometimes, furnace deign itself. These NOx can be either handled using suitable absorption filters and can be exhausted into environment, if found within the permissible range. The primarily targeted emissions from the bio coil boiler using solid biomass are the by-product of their combustion that includes carbon di oxide and water vapour, and a portion of NOx due to both fuel bound and air bound nitrogen. This trend is entirely applicable to the developed biofuel, irrespective of any biomass mixed with it. Unique characteristics of the developed biofuel includes very minimal ash content, zero sulphur emissions, NOx emissions under permissible range and particulate matter fairly sufficient to get removed using APC Devices itself.

Similarly, the bio coil boiler is also designed primarily to handle crushed biomass and briquettes, pellets, and most importantly, the developed biofuel. All the design corresponding to the fuel, such as fuel handling system, furnace grates, refractories and castables, furnace area and exhaust ducting have been developed with respect to these high energy density biomass fuels. In fact, the high calorific content and net high energy density of these fuels have enabled us to develop the fully functional, compact boiler under non IBR category which can meet the dynamic demand of steam load at industrial scale.

The working principle can be described as follows:
The biomass is feed into the bunker hopper either manually or mechanically, and enters into the feeder system. The feeder screw rotating at its axis drives the biomass falling into it through gravity, towards the furnace and feeds it into it. The combustion of biomass is initiated manually by means of manual firing. Meanwhile, the FD fan pumping the air is turned on for supplying the air into the combustion chamber of the furnace. The air enters into the FD fan and forces it out towards the furnace. Here, the amount of air supplied into the chamber is decided based on the quantity of the biomass used for a unit time. Post initiation of proper combustion, the water pump is tuned on, and suctions the water into the shell of the economiser. Here, the hot flue gas from combustion chamber heats the water inside the coil, and converts into steam as per required quality. Simultaneously, the unused flue gas exits through the perforated spacers, where the heat is transferred to the outer side of the coil. Previously, the cold water entering into the boiler gets pre-heated at the economiser using the residual heat from flue gas vented out after supplying necessary heat to water for steam conversion and air for pre-heating. Post heating, the cooled flue gas is vented out of the boiler towards the chimney through pipe displacement.
Particulars Units 500 KPH 700 KPH
Steam generation kg/h 500 700
Steam pressure kg/cm2 10.54 @ 185 OC
17.5 @ 207 OC 10.54 @ 185 OC
17.5 @ 207 OC
Steam temperature 0C
185 @ 10.54 kg/cm2
207 @ 17.5 kg/cm2 185 @ 10.54 kg/cm2
207 @ 17.5 kg/cm2
Feed water temperature 0C
80-100 80-100
GCV of fuel kcal/kg 4300-4500 4300-4500
Fuel consumption kg/h 100-110 130-140
Boiler efficiency % 75 75

This optimal mixing ratio range between base material, oil absorbent and burn stabiliser offered numerous benefits both to the boiler and also to the environment:
(i) The optimized addition of oil absorbents and burn stabilizers ensures uniform oil absorption, preventing fuel clumping and enabling better ignition and sustained combustion.
(ii) The controlled ratio of oil absorbents (5-10%) and burn stabilizers (10-15%) retains absorbed oils efficiently, minimizing energy losses while maintaining a superior calorific value (>4200 kcal/kg).
(iii) The presence of 10-15% burn stabilizers ensures steady combustion, preventing fuel accumulation and flame fluctuations while enhancing uniform heat distribution and reducing unburnt residues.
(iv) The biofuel’s lower ash content minimizes clinker formation and boiler fouling, while burn stabilizers ensure controlled combustion, reducing slag formation in high-temperature zones.
(v) The customizable composition allows flexibility in oil absorbent (5-10%) and burn stabilizer (10-15%) proportions, optimizing combustion efficiency for different boiler configurations.
(vi) The utilization of agricultural residues (groundnut shell, mustard straw, palm kernel shell) and industrial by-products (deoiled cashew nut shell cake, spent coffee grounds) reduces waste, lowers fossil fuel dependency, and ensures high sustainability.

Another embodiment shows the calorific value of biomass composition of deoiled cashew nut shell cake-85%, spent coffee ground-5%, torrefied mustard straw-10%. This biofuel composition, with a superior calorific value of 4430 kcal/kg and an SFR (Steam-to-Fuel Ratio) greater than 5.24, significantly enhances boiler efficiency, reducing fuel consumption per unit steam generation. The torrefied mustard straw ensures stable combustion, preventing flame fluctuations and fuel accumulation, while its low ash content (3.26%) minimizes clinker formation, thereby reducing boiler fouling and maintenance requirements. Additionally, spent coffee grounds optimize oil retention, promoting efficient ignition and sustained combustion. Engineered for high-efficiency boilers, this formulation delivers consistent high heat output with minimal slag formation, ensuring optimal performance, longevity, and operational reliability.

Another embodiment shows that the calorific value of the biomass composition of deoiled cashew nut shell cake-85%, wood chips-10%, crushed palm kernel shell-10%, saw dust- 5%. This biofuel blend, with a calorific value of 4285 kcal/kg and an SFR (Steam-to-Fuel Ratio) greater than 5.1, offers a cost-effective and sustainable solution by utilizing locally available biomass such as wood chips, sawdust, and crushed palm kernel shell (PKS). These components act as burn stabilizers, ensuring stable combustion, steady heat release, and uniform flame distribution, making it a viable alternative to expensive pellets or crushed briquettes. With a moderate ash content (3.6%), it remains low enough to prevent excessive clinker formation, ensuring smooth boiler operation while maintaining high efficiency. Despite a slightly lower CV (compared to Example 1), this formulation ensures reliable steam generation while remaining adaptable to different boiler configurations, allowing flexibility in biomass selection based on local availability. This low-cost fuel option is well-suited for customers looking for good performance, a CV above 4100 kcal/kg, and low ash content, making it a viable, economical, and efficient biofuel solution.
, Claims:We claim:
1. A biofuel composition for use in BioCoil boilers, comprising:
i. 75–85% deoiled cashew nut shell cake as the base material,
ii. 5–10% oil absorbent, selected from the group consisting of sawdust, spent coffee grounds, and crushed groundnut shell dust, and
iii. 10–15% burn stabilizer, selected from the group consisting of torrefied biomass (mustard straw, groundnut shell), wood chips, and crushed palm kernel shell,
wherein the optimized composition achieves a calorific value greater than 4200 kcal/kg, an ash content of less than 4%, and a steam-to-fuel ratio exceeding 5, ensuring stable combustion, uniform heat distribution, minimal clinker formation, and reduced boiler fouling.
2. The biofuel composition of claim 1, wherein the oil absorbent enhances oil retention and uniform combustion, preventing fuel clumping, enabling better ignition, and ensuring sustained combustion.
3. The biofuel composition of claim 1, wherein the burn stabilizer functions to:
i. Maintain flame stability,
ii. Prevent fuel accumulation and bridging,
iii. Moderate flame temperature,
iv. Optimize heat distribution, and
v. Minimize slag formation in high-temperature boiler zones.
4. A high-calorific biofuel composition for superior energy efficiency, comprising:
i. 85% deoiled cashew nut shell cake,
ii. 5% spent coffee grounds, and
iii. 10% torrefied mustard straw,
wherein the fuel achieves a calorific value of 4430 kcal/kg and an ash content of 3.26%, resulting in enhanced combustion efficiency, reduced slag formation, and improved boiler performance with minimal unburnt residues.
5. The biofuel composition of claim 4, wherein torrefied mustard straw acts as a burn stabilizer, providing sustained and steady combustion, ensuring efficient heat transfer, and reducing thermal fluctuations.
6. A balanced biofuel composition optimized for cost-effectiveness and local biomass availability, comprising:
i. 85% deoiled cashew nut shell cake,
ii. 10% wood chips,
iii. 10% crushed palm kernel shell, and
iv. 5% sawdust,
wherein the fuel achieves a calorific value of 4285 kcal/kg, an ash content of 3.6%, and a steam-to-fuel ratio greater than 5.1, ensuring cost-effective and sustainable combustion while maintaining fuel performance comparable to high-energy biofuels. This low-cost fuel option is well-suited for customers looking for good performance, a CV above 4100 kcal/kg, and low ash content, making it a viable, economical, and efficient biofuel solution.
7. The biofuel composition of claim 6, wherein the combined use of wood chips, crushed palm kernel shell, and sawdust optimizes:
i. Fuel blending to accommodate variable biomass availability,
ii. Flame stability to prevent fluctuations,
iii. Uniform heat release for better heat distribution, and
iv. Reduced unburnt residues to enhance combustion efficiency.
8. A method for optimizing biofuel composition for BioCoil boilers, comprising the steps of:
i. Selecting a base material with high calorific value,
ii. Incorporating an oil absorbent to improve fuel ignition, stability, and oil retention,
iii. Adding a burn stabilizer to prevent flame fluctuations, unburnt residues, and fuel bridging,
iv. Adjusting the composition to maintain higher steam-to-fuel ratio (greater than 5), ensuring sustained and efficient energy output, and
v. Reducing clinker formation and slag build-up for prolonged boiler operational efficiency.
9. The method of claim 8, wherein the biofuel composition is tailored to different boiler configurations by:
i. Modifying oil absorbent levels (5–10%) to optimize fuel handling,
ii. Adjusting burn stabilizer levels (10–15%) to enhance flame stability, and
iii. Ensuring the final biofuel formulation has low ash content (<4%) to minimize boiler maintenance and improve efficiency.
10. The biofuel composition of claim 1, wherein the utilization of agricultural residues (such as groundnut shell, mustard straw, palm kernel shell) and industrial by-products (such as deoiled cashew nut shell cake, spent coffee grounds) contributes to:
i. Reduced waste generation,
ii. Lower dependence on fossil fuels, and
iii. Increased sustainability in biomass energy production.

Dated this 31st March ‘2025