processes to produce carbon-rich biogenic reagents

专利摘要:
processes for producing carbon-rich biogenic reagents This invention provides processes and systems for converting biomass into carbon-rich biogenic reagents that are suitable for a variety of commercial applications. some modalities employ pyrolysis in the presence of an inert gas to generate hot solid pyrolysates, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of hot pyrolyzed solids in the presence of the inert gas. additives can be introduced during processing or combined with the reagent, or both. the biogenic reagent can include at least 70% by weight, 80% by weight, 90% by weight, 95% by weight or more of total carbon in a dry form. the biogenic reagent can have an energy content of at least 12,000 btu / lb, 13,000 btu / lb, 14,000 btu / lb, or 14,500 btu / lb in a dry form. the biogenic reagent can be formed into fine powders or structural objects. Structural objects can have a structure and / or strength that are derived from the input, heat rate, and additives.
公开号:BR112013026553B1
申请号:R112013026553
申请日:2012-04-13
公开日:2020-01-28
发明作者:J Despen Daniel；A Mennell James
申请人:Biogenic Reagents LLC；
IPC主号:

专利说明:

“PROCESSES TO PRODUCE CARBON-RICH BIOGENIC REAGENTS.”
Field of the invention [001] The present invention generally relates to processes, systems and apparatus for the production of high carbon biogenic reagents and compositions, products and uses related thereto.
Fundamentals of the invention [002] Carbon is a platform element in a wide variety of industries and has a wide range of uses for chemicals, materials and fuels. Carbon is a good fuel for producing energy, including electricity. Carbon also has great chemical value for several commodities and advanced materials, including metals, metal alloys, composites, carbon fibers, electrodes and catalyst supports. For metal fabrication, carbon is useful as a reagent for reducing metal oxides to metals during processing; as fuel, to provide heat for processing; and as an alloy component of the final metal. Carbon is a very important element in steel, as it allows steel to be hardened by heat treatment.
[003] Carbon reagents can be produced, in principle, from almost any material containing carbon. Carbonaceous materials commonly include fossil resources, such as natural gas, oil, coal and lignite, and renewable resources, such as lignocellulosic biomass and various carbon-rich waste materials.
[004] Biomass is a term used to describe any biologically produced substance, or biogenic substance. The chemical energy contained in biomass is derived from solar energy, using the natural process of photosynthesis. This is the process by which plants obtain carbon dioxide and water from their surroundings and, using the energy of sunlight, convert them into sugars, starches,
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2/160 cellulose, hemicellulose and lignin. Of all renewable energy sources, biomass is unique because it is effectively stored solar energy. In addition, biomass is the only renewable carbon source.
[005] Using biogenic carbon for fuel, CO2 emissions associated with combustion do not contribute to carbon emissions from the net life cycle because carbon is recycled to grow more biomass. Also, using biogenic carbon as a fuel will normally cause less emissions of sulfur dioxide and mercury, compared to using coal or other solid fossil fuels for energy production.
[006] For chemical and material applications where the carbon will not be immediately burned, using biogenic carbon, the carbon can be effectively isolated for long periods of time (for example, when carbon is added to steel for permanent structures). In this way, liquid carbon emissions are really negative - CO2 in the atmosphere is used to grow biogenic raw materials and then the carbon is sequestered in biogenic products.
[007] The conversion of biomass into high carbon reagents, however, presents both technical and economic challenges, resulting from variations in raw materials, operational difficulties and capital intensity. There are a variety of conversion technologies to transform biomass into high carbon materials. Most known conversion technologies use some form of pyrolysis.
[008] Pyrolysis is a process of thermal conversion of solid materials in the complete absence of the oxidizing agent (air or oxygen) or with such limited supply that oxidation does not occur appreciably. Depending on process conditions and additives, biomass pyrolysis can be adjusted to produce vastly different amounts of gas, liquid and solid. Low temperature
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3/160 process and longer steam residence times favor the production of solids. High temperatures and longer residence times increase the conversion of biomass to synthesis gas, while moderate temperatures and shorter steam residence times are generally ideal for the production of liquids. Recently, much attention has been paid to pyrolysis and processes related to the conversion of biomass into high-quality synthesis gas and / or liquids as precursors to liquid fuels.
[009] On the other hand, there has been less focus on improving pyrolysis processes specifically to optimize the yield and quality of solids as high-carbon reagents. Historically, slow wood pyrolysis was carried out in large piles, in a simple batch process, with no emission control. Traditional charcoal making technologies are energy inefficient as well as highly polluting. Clearly, there are economic and practical challenges to expanding such a process for the continuous commercial scale production of high quality carbon, while managing the energy balance and the control of emissions.
Summary [010] In some embodiments, the present invention provides a process for the production of a high carbon biogenic reagent, the process comprising:
(a) supplying a raw material containing carbon composed of biomass;
(b) optionally, dry the raw material to remove at least part of the moisture contained within the raw material;
(c) optionally, de-trim the raw material or the dry raw material to remove at least a portion of interstitial oxygen, if any, contained in the raw material;
(d) in a pyrolysis zone, pyrolyze the raw material in the presence of a gas
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4/160 substantially inert for at least 10 minutes and with a pyrolysis temperature selected from about 250 ° C to about 700 ° C, to generate hot pyrolyzed solids, condensable vapors and non-condensable gases;
(e) separating at least a part of the condensable vapors and at least a part of the non-condensable gases from the hot pyrolyzed solids;
(f) in a refrigeration zone, cool the hot pyrolyzed solids, in the presence of substantially inert gas for at least 5 minutes and with a refrigeration zone temperature lower than the pyrolysis temperature to generate warm pyrolyzed solids;
(g) in an optional refrigerator that is separated from the refrigeration zone, still cool warm pyrolyzed solids to generate cold pyrolyzed solids; and (h) recovering a high carbon biogenic reagent composed of at least a portion of the warm or cold pyrolyzed solids.
[011] The term reactor in this document refers to a unit apart from which atmospheric and temperature conditions can be controlled and in which a physical and / or chemical reaction can take place. The term zone, in the present context, refers to an area within a reactor in which temperature and atmospheric conditions can be controlled in relation to other zones within the reactor.
[012] The term biomass processing unit here refers to a reactor that includes a plurality of zones as discussed in more detail below. In various modalities, the biomass processing unit (BPU) includes a plurality of outlet passages configured to transfer the raw material or raw material at different stages of processing, gases, condensed by-products and heat from various reactors and zones to a or more of the other reactors or zones, the material supply system, the carbon recovery unit and any other components of the system described herein contemplated. In a
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5/160 modality, after the raw material has passed through each of the BPU zones, the raw material is carbonized.
[013] The term carbonization here means increasing the carbon content by a certain amount of biomass. Carbonization can, for the purposes of embodiment, be accomplished by reducing carbon-free material from the biomass, adding carbon atoms to the biomass, or both to form a high carbon biogenic reagent.
[014] As discussed below, several multizone BPU modalities include a single reactor and several multizone BPU modalities may also include more than one separate reactor. It should be noted that other modalities discussed below include separate multiple reactors, each reactor with at least one zone. For the purposes of this disclosure, the properties, principles, processes, alternatives and modalities discussed in relation to single reactor multizone BPU modalities apply equally to all the various separate multiple reactor modalities and vice versa.
[015] In some modalities, the process consists of drying the raw material to remove at least part of the moisture contained within the raw material. In these or other modalities, the process comprises disarming the raw material to remove at least a portion of interstitial oxygen contained in the raw material.
[016] The process may also include preheating the raw material, before step (d), in a preheating zone in the presence of substantially inert gas for at least 5 minutes and with a selected preheating temperature from about 80 ° C to about 500 ° C, or about 300 ° C to about 400 ° C.
[017] In some embodiments, the pyrolysis temperature is selected from about 400 ° C to about 600 ° C. In some embodiments, the pyrolysis in step (d) is performed for at least 20 minutes. The zone cooling temperature can be
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6/160 selected from about 150 ° C to about 350 ° C, for example.
[018] Pyrolysis conditions can be selected to maintain the structural integrity or the mechanical strength of the high carbon biogenic reagent in relation to the raw material, when it is desired to do it for a given product application.
[019] In some modalities, each zone is located within a single reactor or a BPU. In other modalities, each zone is located in separate BPUs or reactors. It should be noted that some modalities include one or more BPUs, each including at least one zone.
[020] Substantially inert gas can be selected from the group consisting of CO, N2, Ar, CO2, H2, CH4 and their combinations. Some of the substantially inert gases may include one or more species of non-condensable gases (for example, CO and CO2) recycled from step (e). In some embodiments, the pyrolysis zone and the refrigeration zone comprise a gas phase containing less than 5% by weight of oxygen, such as about 1% by weight of oxygen or less.
[021] The process can be continuous, semi-continuous or batch. In some continuous or semi-continuous modes, the substantially inert gas flows countercurrently in relation to the direction of the flow of solids. In other continuous or semi-continuous modes, the substantially inert gas flows in currents parallel to the direction of the flow of solids.
[022] In some embodiments, the process includes monitoring and controlling the process with at least one reaction gas probe, such as two or more reaction gas probes. Monitoring and controlling the process can improve the energy efficiency of the process. Monitoring and controlling the process can also improve a product attribute associated with the high carbon biogenic reagent, such as (but not limited to) carbon content, energy content, structural integrity or mechanical strength.
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7/160 [023] The process may also include thermal oxidation (ie combustion) of at least part of the condensable and non-condensable vapors with an oxygen-containing gas. Thermal oxidation can be assisted with the combustion of natural gas. The heat produced from thermal oxidation can be used, at least in part, for drying the raw material. In addition, the heat produced from thermal oxidation can be used, at least in part, to heat the substantially inert gas before entering one of the zones or reactors, such as the pyrolysis zone.
[024] The process may also include combining at least part of the vapors with the cooled pyrolyzed solids to increase the carbon content of the high-carbon biogenic reagent. As an alternative, or in addition, the process may also include combining at least part of the condensable vapors with the warm pyrolyzed solids to increase the carbon content of the high carbon biogenic reagent.
[025] Condensable vapors, therefore, can be used for any energy in the process (such as thermal oxidation) or in carbon enrichment, to increase the carbon content of the high carbon biogenic reagent. Certain non-condensable gases, such as CO or CH4, can be used for energy in the process or as part of the gas substantially inert for the pyrolysis step.
[026] In some modalities, the process also includes the introduction of at least one additive selected from its acids, bases or salts. The additive can be selected from (but not limited to) the group consisting of sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, potassium permanganate and their combinations.
[027] In some modalities, the process also includes the introduction of at least one additive selected from the group consisting of a metal, a metal oxide, a metal hydroxide, a metal halide and their combinations. The additive can
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8/160 be selected from (but not limited to) the group consisting of magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, fluorite, bentonite, calcium oxide, lime and their combinations.
[028] Additives can be added before, during or after any one or more stages of the process, including in the raw material itself at any time, before or after being harvested. Additives can be introduced before or during step (b), before or during step (d), during step (f), during step (g), between steps (f) and (g), or after step (g), for example. An additive can be introduced for warm pyrolyzed solids. For example, an additive can be introduced into an aqueous, steam or aerosol solution to assist in cooling the warm pyrolyzed solids in step (g). In these or other embodiments, an additive is introduced for the cold pyrolyzed solids to form the high carbon biogenic reagent containing the additive.
[029] In some embodiments, the process further comprises the introduction of at least a part of the cold pyrolyzed solids to a separate unit for additional pyrolysis, in the presence of a substantially inert gas for at least 30 minutes and with a pyrolysis temperature selected from about 200 ° C to about 600 ° C to generate a solid product, with a higher carbon content than cold pyrolyzed solids.
[030] In some modalities, the process also includes operating a refrigerator to cool the warm pyrolyzed solids with steam, thus generating the cold pyrolyzed solids and superheated steam; where drying is carried out, at least in part, with the superheated steam derived from the external refrigerator. Optionally, the refrigerator can be operated to cool the warm pyrolysed solids with steam first to reach a first refrigerator temperature and then, with air, to reach a second refrigerator temperature, where the second
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9/160 refrigerator temperature is lower than the first refrigerator temperature and is associated with a reduced risk of combustion for warm pyrolyzed solids in the presence of air.
[031] In some variations, the invention provides a process for the production of a high carbon biogenic reagent, the process comprising:
(a) supply a raw material containing carbon composed of biomass (optionally with some or all of the moisture removed);
(b) in a pyrolysis zone, pyrolyze the raw material in the presence of a substantially inert gas for at least 10 minutes and with a pyrolysis temperature selected from about 250 ° C to about 700 ° C, to generate hot pyrolysed solids, condensable vapors and non-condensable gases;
(c) separating at least a part of the condensable vapors and at least a part of the non-condensable gases from the hot pyrolyzed solids;
(d) in a refrigeration zone, cool the hot pyrolyzed solids, in the presence of the substantially inert gas for at least 5 minutes and with a refrigeration temperature lower than the pyrolysis temperature to generate warm pyrolyzed solids;
[032] (g) in an optional refrigerator that is separated from the refrigeration zone, still cool warm pyrolyzed solids to generate cold pyrolyzed solids; and [033] (h) recovering a high carbon biogenic reagent composed of at least a portion of the warm or cold pyrolyzed solids.
[034] In some variations, the invention provides a process for the production of a high carbon biogenic reagent, the process comprising:
(a) supplying a raw material containing carbon composed of biomass;
(b) optionally, dry the raw material to remove at least part of the moisture, if any, contained within the raw material;
(c) optionally, unravel the raw material to remove at least one
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10/160 portion of interstitial oxygen, if any, contained in the raw material;
(d) in a preheating zone, preheat the raw material in the presence of a substantially inert gas for at least 5 minutes and with a selected preheat temperature of about 80 ° C to about 500 ° Ç;
(e) in a pyrolysis zone, pyrolyze the raw material in the presence of a substantially inert gas for at least 10 minutes and with a pyrolysis temperature selected from about 250 ° C to about 700 ° C, to generate hot pyrolysed solids, condensable vapors and non-condensable gases;
(f) separating at least a part of the condensable vapors and at least a part of the non-condensable gases from the hot pyrolyzed solids;
(g) in a refrigeration zone, cool the hot pyrolyzed solids, in the presence of a substantially inert gas for at least 5 minutes and with a refrigeration temperature lower than the pyrolysis temperature to generate warm pyrolyzed solids;
(h) in an optional refrigerator that is separated from the refrigeration zone, cool the warm pyrolyzed solids to generate cold pyrolyzed solids; and (i) recovering a high carbon biogenic reagent composed of at least a portion of the warm or cold pyrolyzed solids.
[035] the process still comprising introducing at least one additive somewhere in the process (that is, in one or more positions or moments).
[036] In some variations, the invention provides a process for the production of a high carbon biogenic reagent, the process comprising:
(a) supplying a raw material containing carbon composed of biomass;
(b) optionally, drying said raw material to remove at least part of the moisture contained within said raw material;
(c) optionally, disarming said raw material to remove at least a portion of interstitial oxygen, if any, contained in said raw material, or
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11/160 dry raw material;
(d) in a pyrolysis zone, pyrolyze said raw material in the presence of a substantially inert gas for at least 10 minutes and with a pyrolysis temperature selected from about 250 ° C to about 700 ° C, to generate hot pyrolysed solids, condensable vapors and non-condensable gases;
(e) separating at least a part of said condensable vapors and at least a part of said non-condensable gases from said hot pyrolyzed solids;
(f) in an optional refrigeration zone, still cooling said hot pyrolysed solids, in the presence of said inert gas substantially for at least 5 minutes and with a cooling zone temperature lower than said pyrolysis temperature to generate warm pyrolysed solids ;
(g) in an optional refrigerator that is separated from the said refrigeration zone, to cool said warm pyrolyzed solids to generate cold pyrolyzed solids; and (h) recovering a high carbon biogenic reagent composed of at least a portion of said cold pyrolyzed solids; and (i) forming a fine powder of said high carbon biogenic reagent, [037] where the process optionally includes the introduction of at least one additive to the process before step (i), during step (i) or after step (i).
[038] The high carbon biogenic reagent can contain at least 35% of the carbon contained in the raw material, as at least 50% or at least 70% of the carbon contained in the raw material. In some embodiments, the high carbon biogenic reagent contains between about 40% and about 70% of the carbon contained in the raw material.
[039] In certain modalities, an additive is introduced into the dry raw materials before or during step (d), and where the presence of the additive in the process
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12/160 increases the carbon content of a high carbon biogenic reagent compared to an identical process without introducing the additive.
[040] The high carbon biogenic reagent may contain at least 55% by weight of dry carbon, such as at least 55% by weight, 60% by weight, 65% by weight, 70% by weight, 75% by weight , 80% by weight, 90% by weight, 95% by weight or more of dry carbon. The total carbon includes fixed carbon and can also include the carbon of the volatile substance. In some embodiments, the high carbon biogenic reagent contains at least 90% by weight or at least 95% by weight of fixed carbon on a dry basis.
[041] The high carbon biogenic reagent can have an energy content of at least 25,586 kJ / kg (11,000 Btu / lb) on a dry basis, such as at least 27,912 kJ / kg (12,000 Btu / lb), at least 30,238 kJ / kg (13,000 Btu / lb), at least 32,564 kJ / kg (14,000 Btu / lb), at least 33,727 kJ / kg (14,500 Btu / lb) or at least 34,192 kJ / kg (14,700 Btu / lb) on a dry basis.
[042] The high carbon biogenic reagent can be formed into a fine powder by reducing particle size. Alternatively, or sequentially, a high carbon biogenic reagent can be formed into a structural object by pressure, bonding, pelletizing or agglomeration. In some embodiments, the high carbon biogenic reagent is in the form of structural objects whose structure and / or strength are substantially derived from the raw material. In certain embodiments, the high carbon biogenic reagent is in substantially the same structural form as the raw material.
[043] Other variations of the present invention provide a high carbon biogenic reagent production system, the system comprising:
(a) a material feeding system configured to introduce a raw material containing carbon;
(b) an optional dryer, placed in operable communication with the system
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13/160 material feed, configured to remove moisture contained within a carbon-containing raw material;
(c) a biomass processing unit, placed in operable communication with the material feeding system or with the dryer (if present), where the biomass processing unit contains at least one pyrolysis zone placed in operable communication with a spatially separated cooling zone, and where the biomass processing unit is configured with an outlet to remove condensable vapors and non-condensable gases from solids;
(d) a refrigerator, placed in operable communication with the biomass processing unit; and (e) a high carbon biogenic reagent recovery unit, placed in operable communication with the refrigerator.
[044] The dryer, if present, can be configured as a drying zone inside the BPU. In some modalities, the system also comprises a purge system to remove oxygen from the system. The purge system can comprise one or more inlets to introduce a substantially inert gas and one or more outlets to remove the substantially inert gas and displaced oxygen from the system. The purge system can be a deflector placed between the material feed system (or the dryer, if present) and the BPU.
[045] Optionally, the system can include a preheating zone, placed in operable communication with the pyrolysis zone.
[046] Each of at least one pyrolysis zone, cooling zone and preheating zone (if present) can be located within a single unit or in separate units. The material feeding system can be physically integrated with the BPU. In some embodiments, the refrigerator is placed inside the BPU.
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14/160 [047] The system can also include one or more additive feeders for the introduction of additive (s) in the system, like any of the additives described above. In some embodiments, an additive feeder is configured to combine the additive with the carbon-containing raw material. An additive feeder can be interposed between the material feed system (for biomass) and the BPU. An additive feeder can be placed in operable communication with the BPU. An additive feeder can be placed in operable communication with the refrigerator. An additive feeder can be interposed between the refrigerator and the carbon recovery unit. An additive feeder can be placed in operable communication with the carbon recovery unit, including downstream of the recovery unit itself.
[048] The BPU can be configured with a first gas inlet and a first gas outlet. The first gas inlet and the first gas outlet can be placed in communication with different zones or with the same zone. In various embodiments, the BPU is configured with any one or more of a second gas inlet, a second gas outlet, a third gas inlet, a third gas outlet, a fourth gas inlet and a fourth gas outlet. Optionally, each zone in the BPU is configured with a gas inlet and a gas outlet. Gas inlets and outlets allow not only the introduction and removal of steam or gas, but also allow precise monitoring and control processes throughout the various stages of the process, resulting in improvements in efficiency and throughput.
[049] In some embodiments, the refrigeration zone is configured with a gas inlet and the pyrolysis zone is configured with a gas outlet to generate a substantially countercurrent flow of the gas phase in relation to the solid phase (for example, matter -cousin). In other modalities, the cooling zone is configured with a gas inlet and the preheating zone is configured with
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15/160 a gas outlet to generate substantially countercurrent flow of the gas phase in relation to the solid phase. In these or other modalities, the cooling zone is configured with a gas inlet and the drying zone is configured with a gas outlet to generate a substantially countercurrent flow of the gas phase in relation to the solid phase.
[050] The system may also include a first reaction gas probe placed in operable communication with the pyrolysis zone and with a gas monitoring device, such as (but not limited to) MS, GC, GC-MS or FTIR . In some modalities, the system also comprises a second reaction gas probe placed in operable communication with the refrigeration zone and with the gas monitoring device or a second gas monitoring device that can be a different type of instrument. . The system may include additional reaction gas probes placed in operable communication with the drying zone (if any) and / or with the preheating zone (if present) and with a gas monitoring device. When reaction gas probes are included, the system can also include at least one executable computer programmed controller to use the gas monitoring device output to adjust a system set point (such as pyrolysis temperature or flow rate inert gas).
[051] In some embodiments, the system also comprises a process gas heater placed in operable communication with the outlet to remove condensable vapors and non-condensable gases, in which the process gas heater is configured to introduce a separate fuel and an oxidizer in a combustion chamber, adapted for combustion of the fuel and at least part of the condensable vapors.
[052] The system may include a heat exchanger placed between the process gas heater and the dryer, configured to use at least some of the
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16/160 combustion heat for the dryer. Alternatively, or in addition, the system may include a heat exchanger placed between the process gas heater and a gas inlet for the BPU, configured to use at least some of the combustion heat to substantially preheat a gas inert before introduction into the BPU.
[053] In some modalities, the system also consists of a carbon enrichment unit, placed in operable communication with the refrigerator or with the BPU, configured for combining vapors, including non-condensable vapors and / or condensable vapors in a fully or at least partially condensed, with the solids to increase the carbon content of the high carbon biogenic reagent obtained from the carbon recovery unit.
[054] In several modalities, the system is configured to extract and reuse gases from the BPU and / or extract and reuse gases from the carbon recovery unit.
[055] In some embodiments, the system also comprises a separate pyrolysis unit adapted for later pyrolysis of the high-carbon biogenic reagent to further increase its carbon content.
[056] Other variations provide a high carbon biogenic reagent production system, the system comprising:
(a) a material feeding system configured to introduce a raw material containing carbon;
(b) an optional dryer, placed in operable communication with the material feeding system, configured to remove the moisture contained within a carbon-containing raw material;
(c) a preheater, placed in operable communication with the material feeding system or the dryer (if present), configured to heat and / or
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17/160 lightly pyrolyze the raw material;
(d) a pyrolysis reactor, placed in operable communication with the preheater, configured to pyrolyze the raw material;
(e) a refrigerator, placed in operable communication with the pyrolysis reactor, configured to cool pyrolyzed solids; and (f) a high carbon biogenic reagent recovery unit, placed in operable communication with the refrigerator, [057] in which the system is configured with at least one gas inlet for the introduction of a substantially inert gas into the reactor and at least one gas outlet to remove condensable vapors and non-condensable gases from the reactor.
[058] This system may include a deflector placed between the material feeding system or the dryer (if present) and the preheater. The system can be configured with at least two gas inlets and at least two gas outlets, if desired.
[059] In some modalities, the pyrolysis reactor and / or the refrigerator is configured with gas inlet (s) and the dryer (if present) and / or the preheater is configured with gas outlet (s) to generate substantially countercurrent flow of the gas phase in relation to the solid phase.
[060] The system also includes a process gas heater, in some modalities, placed in operable communication with at least one gas outlet to remove condensable vapors and non-condensable gases. The process gas heater can be configured to introduce a separate fuel and an oxidizer into a combustion chamber, adapted for combustion of the fuel and at least part of the condensable vapors.
[061] The system may include a heat exchanger placed between the process gas heater and the dryer, configured to use at least some of the
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18/160 combustion heat for the dryer. The system may include a heat exchanger placed between the process gas heater and a gas inlet for the BPU, configured to use at least some of the heat of combustion to preheat a substantially inert gas prior to introduction into the pyrolysis reactor.
[062] Certain variations provide a continuous biomass pyrolysis reactor, consisting of a raw material inlet, a plurality of spatially separate reactors configured to separately control the temperature and mix within each of the reactors, and an output of carbonaceous solids , where one of the reactors is configured with a first gas inlet for introducing a substantially inert gas into the reactor, and where one of the reactors is configured with a first gas outlet.
[063] In some modalities, the BPU includes at least two, three or four zones. Each zone can be placed in communication with separately adjustable indirect heating means, each independently selected from the group consisting of electric heat transfer, steam heat transfer, hot oil heat transfer, waste heat transfer and their combinations.
[064] The BPU can be configured to separately adjust the composition of the gas phase and the residence time of the gas phase of at least two zones. Some modalities, the BPU is configured to separately adjust the composition of the gas phase and residence time of the gas phase of all zones present in the BPU.
[065] Some modalities, the BPU is configured with a second gas inlet and / or a second gas outlet. In certain modes, the BPU is configured with a gas inlet in each zone and / or a gas outlet in each zone. In some embodiments, the BPU is a countercurrent reactor.
[066] The material feeding system may comprise a mechanism
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19/160 feed selected from the group consisting of a screw, an auger, a drop chamber and a drum material feeding system. The output of carbonaceous solids may include an output mechanism selected from the group consisting of a screw, an auger, a drop chamber, and a material feeding system from the drum. The BPU may include a single auger arranged along each of the zones.
[067] In some modalities, each of the reactors is configured with steps placed on the inner walls to provide the agitation of solids. The steps can be adjusted separately in each zone. The BPU is an axially rotating BPU in some embodiments.
[068] Other variations of the invention provide a process for the production of a high carbon biogenic reagent, the process comprising:
(a) supplying a raw material containing carbon composed of biomass;
(b) optionally, dry the raw material to remove at least part of the moisture contained within the raw material;
(c) optionally, desear the raw material to remove at least a portion of interstitial oxygen, if any, contained in the raw material;
(d) in a pyrolysis zone, pyrolyze the raw material in the presence of an inert gas substantially for at least 10 minutes and with a pyrolysis temperature selected from about 250 ° C to about 700 ° C, to generate hot pyrolysed solids, condensable vapors and non-condensable gases;
(e) separating at least a part of the condensable vapors and at least a part of the non-condensable gases from the hot pyrolyzed solids;
(f) in a refrigeration zone, cool the hot pyrolyzed solids, in the presence of substantially inert gas for at least 5 minutes and with a refrigeration temperature lower than the pyrolysis temperature to generate warm pyrolyzed solids;
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20/160 (g) optionally, cool the warm pyrolyzed solids in a separate refrigerator to generate cold pyrolyzed solids;
(h) then pass at least a part of the condensable vapors and / or at least a part of the non-condensable gases from step (e) through the warm pyrolyzed solids and / or the cold pyrolyzed solids to form carbon-enriched pyrolyzed solids increased; and (i) recovering a high carbon biogenic reagent composed of at least a portion of the enriched pyrolyzed solids.
[069] In some embodiments, step (h) includes passing at least a portion of the condensable vapors from step (e) vaporized and / or condensed through warm pyrolyzed solids to produce pyrolyzed solids enriched with increased carbon and / or energy content . In these or other embodiments, step (h) includes passing at least a portion of the non-condensable gases from step (e) through warm pyrolyzed solids to produce pyrolyzed solids enriched with increased carbon and / or energy content.
[070] In some embodiments, step (h) includes passing at least part of the condensable vapors from step (e) vapor and / or condensed through cold pyrolyzed solids to produce pyrolyzed solids enriched with increased carbon and / or content energetic. In these or other embodiments, step (h) includes passing at least a portion of the non-condensable gases from step (e) through warm pyrolyzed solids to produce pyrolyzed solids enriched with increased carbon and / or energy content.
[071] In certain embodiments, step (h) includes passing substantially all condensable vapors from step (e) in the form of vapor and / or condensed through cold pyrolyzed solids to produce pyrolyzed solids enriched with increased carbon and / or content energetic. In these or other modalities, step (h) includes passing substantially all of the gases not
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21/160 condensable from step (e) by cold pyrolyzed solids to produce pyrolyzed solids enriched with increased carbon content.
[072] Energy can be recovered from condensable vapors, non-condensable gases or both for use in the process. Energy can be recovered by exchanging heat with these currents. Optionally, one or both condensable vapors and non-condensable gases can be burned and the heat of combustion can be recovered for use in the process.
[073] The process may also include presenting an intermediate supply current consisting of at least a part of the condensable vapors and at least a part of the non-condensable gases, obtained from step (e) for a separation unit configured to generate at least the first and second output current. The intermediate supply stream may include all condensable vapors and / or all non-condensable gases, in certain embodiments. A portion of the second outlet stream can be recycled to step (d) for use as a substantially inert gas in the pyrolysis unit, alone or in combination with another source of inert gas (for example, N2).
[074] The first and second output streams can be separated based on relative volatility, for example. In some embodiments, the first outlet stream comprises condensable vapors (eg, terpenes, alcohols, acids, aldehydes or ketones), and the second outlet stream comprises non-condensable gases (eg, carbon monoxide, carbon dioxide and methane).
[075] The first and second output currents can be separated based on the relative polarity. In these embodiments, the first output stream is composed of polar compounds (for example, methanol, furfural and acetic acid) and the second output stream is composed of nonpolar compounds (for example, carbon monoxide, carbon dioxide, methane, terpenes and derivatives of terpenes).
[076] In some modalities, step (h) increases the total carbon content,
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22/160 the fixed carbon content and / or the energy content of the high carbon biogenic reagent in relation to an identical opposite process without step (h). In some embodiments, step (h) increases the fixed carbon content of the high carbon biogenic reagent in relation to an identical opposite process without step (h).
[077] This invention also provides a continuous or joint process to increase the carbon and / or energy content of any carbon-containing material. In some variations, a process for producing a high carbon biogenic reagent comprises:
(a) providing a solid stream comprising a starting material containing carbon;
(b) supplying a gas stream composed of condensable vapors containing carbon, non-condensing gases containing carbon, or a mixture of condensable vapors containing carbon and non-condensing gases containing carbon; and (c) passing the gas stream through the solid stream under appropriate conditions to form a product containing carbon with increased carbon and / or energy content in relation to the carbon containing material.
[078] In some embodiments, the starting material containing carbon is pyrolysed biomass or roasted biomass. The gas stream can be obtained during an integrated process that supplies the carbon-containing material. Or the gas stream can be obtained by processing separately from the carbon-containing material. The gas stream, or a part of it, can be obtained from an external source. Mixtures of gas streams, as well as mixtures of carbon-containing materials, from a variety of sources, are possible.
[079] In some embodiments, the process also comprises recycling or reusing the gas stream to repeat the process to further increase the carbon and / or energy content of the carbon-containing product. In some modalities, the
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The process further comprises recycling or reusing the gas stream to carry out the process to increase the carbon and / or energy content of another raw material other than the carbon-containing material.
[080] This process may include introducing the gas stream into a separation unit configured to generate at least the first and the second outlet stream, where the gas stream is composed of a mixture of condensable vapors containing carbon and non-carbon gases condensables containing carbon. The first and second output currents can be separated based on relative volatility or relative polarity, for example.
[081] In some embodiments, the product containing carbon has a higher total carbon content and / or fixed carbon content and / or volatile carbon content than the material containing carbon. In some embodiments, the product containing carbon has a higher energy content than the material containing carbon.
[082] A high carbon biogenic reagent production system is also provided, the system comprises:
(a) a material feeding system configured to introduce a raw material containing carbon;
(b) an optional dryer, placed in operable communication with the material feeding system, configured to remove the moisture contained within a carbon-containing raw material;
(c) a BPU, placed in operable communication with the material feeding system or with the dryer (if present), where the BPU contains at least one pyrolysis zone placed in operable communication with a spatially separate cooling zone, and where the BPU is configured with an outlet to remove condensable vapors and non-condensable gases from solids;
(d) an optional refrigerator, placed in operable communication with the BPU;
(e) a material enrichment unit, placed in communication
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24/160 operable with the BPU or the refrigerator (if present), configured to pass condensable vapors and / or non-condensable gases between the solids, to form enriched solids with increased carbon content; and (f) a carbon recovery unit, placed in operable communication with the material enrichment unit.
[083] In some modalities, the system also comprises a pre-heating zone, placed in operable communication with the pyrolysis zone. Each pyrolysis zone, refrigeration zone and preheat zone (if present) can be located within a single unit or in separate units. The dryer, if present, can be configured as a drying zone within the BPU.
[084] The refrigeration zone can be configured with a gas inlet and the pyrolysis zone can be configured with a gas outlet to generate a substantially countercurrent flow of the gas phase in relation to the solid phase. The refrigeration zone can be configured with a gas inlet and the preheat zone and / or drying zone can be configured with a gas outlet to generate substantially countercurrent flow of the gas phase in relation to the solid phase.
[085] In certain modalities, the material enrichment unit comprises:
a housing with an upper and lower part;
(ii) an entrance to a bottom of the bottom of the housing configured to transport condensable vapors and non-condensable gases;
(iii) an outlet at the top of the upper part of the frame configured to carry a concentrated gas stream derived from condensable vapors and non-condensable gases;
(iv) a defined path between the upper and lower part of the housing; and (v) a transportation system following the path, the transportation system
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25/160 configured to transport the solids, where the housing is shaped so that the solids absorb at least some of the condensable vapors and / or at least some of the non-condensable gases.
[086] This invention also provides several products and compositions. In some variations, a high carbon biogenic reagent produced by a process comprising the steps of:
(a) supplying a raw material containing carbon composed of biomass;
(b) optionally, dry the raw material to remove at least part of the moisture contained within the raw material;
(c) optionally, desear the raw material to remove at least a portion of interstitial oxygen, if any, contained in the raw material;
(d) in a pyrolysis zone, pyrolyze the raw material in the presence of an inert gas substantially for at least 10 minutes and with a pyrolysis temperature selected from about 250 ° C to about 700 ° C, to generate hot pyrolysed solids, condensable vapors and non-condensable gases;
(e) separating at least a part of the condensable vapors and at least a part of the non-condensable gases from the hot pyrolyzed solids;
(f) in a refrigeration zone, cool the hot pyrolyzed solids, in the presence of substantially inert gas for at least 5 minutes and with a refrigeration zone temperature lower than the pyrolysis temperature to generate warm pyrolyzed solids;
(g) in an optional refrigerator that is separated from the refrigeration zone, to cool warm pyrolyzed solids to generate cold pyrolyzed solids; and (h) recovering a high carbon biogenic reagent composed of at least a portion of the warm or cold pyrolyzed solids.
[087] The high carbon biogenic reagent may also include at least one
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26/160 process additive incorporated during the process. As an alternative, or in addition, the high carbon biogenic reagent may further include at least one product additive introduced to the reagent following the process.
[088] In some modalities, the process additive and / or product additive is selected to increase the carbon content and / or the energy content of the high carbon biogenic reagent. In some embodiments, the process additive and / or the product additive is selected to maintain the structural integrity or mechanical strength of the high carbon biogenic reagent with respect to such raw material. Additives can be useful to help maintain structural shape before using the biogenic reagent.
[089] In some embodiments, the high carbon biogenic reagent comprises at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 80% by weight at least 90% by weight or at least 95% by weight of the total dry carbon. Total carbon includes fixed carbon and carbon of the volatile substance. In some embodiments, the carbon of the volatile substance is at least 5%, at least 20% or at least 40% of the total carbon.
[090] In some embodiments, the high-carbon biogenic reagent consists of about 10% by weight or less of hydrogen, such as about 5% by weight or less of hydrogen on a dry basis. In some embodiments, the reagent comprises about 20% by weight or less of oxygen, such as between about 1% by weight and about 10% by weight of dry oxygen. In some embodiments, the high carbon biogenic reagent consists of about 1% by weight or less of nitrogen, such as about 0.5% by weight or less of nitrogen on a dry basis. In some embodiments, the high-carbon biogenic reagent is composed of about 0.5% by weight or less of phosphorus, such as about 0.2% by weight or less of phosphorus on a dry basis. In some embodiments, the reagent
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27/160 high carbon biogenic is composed of about 0.2% by weight or less of sulfur, like about 0.1% by weight or less of sulfur on a dry basis.
[091] In some embodiments, the high carbon biogenic reagent is composed of about 10% by weight or less of non-combustible substance (eg ash) on a dry basis. In certain embodiments, the high carbon biogenic reagent consists of about 5% by weight or less or about 1% or less of non-combustible substance on a dry basis. The high-carbon biogenic reagent may also contain moisture at varying levels.
[092] The high carbon biogenic reagent can have an energy content of at least 25,586 kJ / kg (11,000 Btu / lb) on a dry basis, at least 30,238 kJ / kg (13,000 Btu / lb), at least 32,564 kJ / kg (14,000 Btu / lb), at least 33,727 kJ / kg (14,500 Btu / lb) on a dry basis. In exemplary embodiments, the high carbon biogenic reagent has an energy content of at least 34,192 kJ / kg (14,700 Btu / lb) and a fixed carbon content of at least 95% by weight on a dry basis.
[093] In some embodiments, a high carbon biogenic reagent comprises, on a dry basis:
55% by weight or more of total carbon;
5% by weight or less of hydrogen;
1% by weight or less of nitrogen;
0.5% by weight or less of phosphorus;
0.2% by weight or less of sulfur; and an additive selected from a metal, a metal oxide, a metal hydroxide, a metal halide or a combination thereof.
[094] The additive can be selected from the group consisting of magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, fluorite, bentonite, calcium oxide, lime and their
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28/160 combinations.
[095] In some embodiments, a high carbon biogenic reagent comprises, on a dry basis:
55% by weight or more of total carbon;
5% by weight or less of hydrogen;
1% by weight or less of nitrogen;
0.5% by weight or less of phosphorus;
0.2% by weight or less of sulfur; and an additive selected from an acid, a base or a salt thereof.
[096] The additive can be selected from the group consisting of sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, potassium permanganate and their combinations.
[097] In certain embodiments, a high carbon biogenic reagent comprises, on a dry basis:
55% by weight or more of total carbon;
5% by weight or less of hydrogen;
1% by weight or less of nitrogen;
0.5% by weight or less of phosphorus;
0.2% by weight or less of sulfur;
a first additive selected from a metal, a metal oxide, a metal hydroxide, a metal halide or a combination thereof; and a second additive selected from an acid, a base or a salt thereof.
where the first additive is different from the second additive.
[098] The first additive can be selected from the group consisting of magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, oxide in
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29/160 magnesium, dolomite, dolomitic lime, fluorite, bentonite, calcium oxide, lime and combinations thereof, and the second additive can be independently selected from the group consisting of sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide , hydrogen chloride, sodium silicate, potassium permanganate and their combinations.
[099] The high carbon biogenic reagent can include about 55% by weight, 60% by weight, 65% by weight, 70% by weight, 75% by weight, 80% by weight, 85% by weight, 90% by weight, 95% by weight or more of total carbon on a dry basis (total carbon includes fixed carbon and carbon associated with volatile substances).
[0100] In some embodiments, the reagent consists of about 8% by weight or less of non-combustible substance on a dry basis, such as about 4% by weight or less of non-combustible substance on a dry basis.
[0101] A high-carbon biogenic reagent may consist essentially of, on a dry basis, carbon, hydrogen, oxygen, nitrogen, phosphorus, sulfur, non-combustible substance, and an additive selected from the group consisting of magnesium, manganese, aluminum, nickel, chromium , silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, fluorite, bentonite, calcium oxide, lime and their combinations. Moisture may be present or absent.
[0102] A high carbon biogenic reagent may consist essentially of, on a dry basis, carbon, hydrogen, nitrogen, phosphorus, sulfur, non-combustible matter, and an additive selected from the group consisting of sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, potassium permanganate and their combinations. Moisture may be present or absent.
[0103] The high carbon biogenic reagent may have an energy content of at least 25,586 kJ / kg (11,000 Btu / lb), at least 27,912 kJ / kg (12,000 Btu / lb),
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30/160 at least 30,238 kJ / kg (13,000 Btu / lb), at least 32,564 kJ / kg (14,000 Btu / lb) or at least 33,727 kJ / kg (14,500 Btu / lb) on a dry basis.
[0104] The high carbon biogenic reagent can be a fine powder or it can be in the form of structural objects. Structural objects can be derived from pressure, binding, pelletizing or particle agglomeration. In some embodiments, structural objects have a structure and / or strength that substantially derive from the carbon raw material source. In certain embodiments, structural objects have substantially the same structural shape as the carbon raw material source.
[0105] In some embodiments of the high carbon biogenic reagent, most carbons are classified as renewable carbon. Substantially all of the carbon contained in certain high-carbon biogenic reagents can be classified as renewable carbons.
[0106] The present invention also provides a wide variety of carbonaceous products, comprising high carbon biogenic reagents. Such carbonaceous products include, among others, blast furnace addition products, taconite pelletizing process addition products, taconite pellets, coal replacement products, carbon coke products, carbon fines products, fluidized bed, blast furnace addition products, injectable carbon products, pan addition carbon products, metallurgical coke products, pulverized carbon products, automatic carbon furnace products, carbon electrodes and activated carbon products. These and other modalities are described in more detail below.
Brief description of the figures [0107] FIG. 1 depicts a multi-reactor modality of a system of the invention.
[0108] FIG. 2 depicts a single multi-zone reactor
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31/160 system of the invention.
[0109] FIG. 3 depicts an embodiment of a zero oxygen continuous feed mechanism suitable for use in connection with the present invention.
[0110] FIG. 4 depicts another embodiment of a biomass processing unit in a single multizone reactor suitable for use in connection with the present invention.
[0111] FIG. 5 depicts an embodiment of a carbon recovery unit suitable for use in connection with the present invention.
[0112] FIG. 6 depicts a modality of a biomass processing unit modality of a single reactor of the present invention with an optional dryer.
[0113] FIG. 7 depicts an embodiment of the pyrolysis reactor system of the invention with an optional dryer and a gas inlet.
[0114] FIG. 8 depicts an embodiment of a single reactor biomass processing unit of the invention with a gas inlet and an optional refrigerator.
[0115] FIG. 9 depicts a modality of the single reactor biomass processing unit system of the invention with an optional dryer and deaerator and an inert gas inlet.
[0116] FIG. 10 depicts a modality of the multiple reactor system of the invention with an optional dryer and deaerator and an inert gas inlet.
[0117] FIG. 11 depicts a modality of the multiple reactor system of the invention with an optional dryer and refrigerator and a material enrichment unit.
[0118] FIG. 12 depicts a modality of the multiple reactor system of the invention with an optional dryer and a deaerator, a refrigerator and an inert gas inlet.
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32/160 [0119] FIG. 13 depicts a modality of the multiple reactor system of the invention with an optional dryer and deaerator, an inert gas inlet and a refrigerator.
[0120] FIG. 14 depicts a graph illustrating the effect of retention time on the fixed carbon content of a biogenic reagent produced according to one embodiment of the present disclosure.
[0121] FIG. 15 depicts a graph illustrating the effect of pyrolysis temperature on the fixed carbon content of a biogenic reagent produced according to one embodiment of the present disclosure.
[0122] FIG. 16 depicts a graph illustrating the effect of the biomass particle size on the fixed carbon content of a biogenic reagent produced according to one embodiment of the present disclosure.
Detailed description of the modalities of the invention [0123] This description will allow one skilled in the art to make and use the invention and describes various modalities, adaptations, variations, alternatives and uses of the invention. These and other modalities, characteristics and advantages of the present invention will become more evident to those skilled in the art when considered with reference to the detailed description after the invention in conjunction with the accompanying drawings.
[0124] As used in this specification and the added claims, the singular forms one (a) and the (a) include the plural forms unless the context clearly indicates otherwise. Unless otherwise defined, all technical and scientific terms used in this document have the same meaning, as is commonly understood by those skilled in the art to which this invention belongs.
[0125] Unless otherwise stated, all numbers expressing reaction conditions, stoichiometries, component concentrations and so on
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33/160 onwards used in the specification and in the claims are to be understood as being modified in all instances by the term about. In this sense, unless otherwise indicated, the numerical parameters set out in the specification to follow and attached claims are approximations that may vary depending on at least one specific analytical technique.
[0126] The term understand, which is synonymous with include, contain, or characterized by, is inclusive or unlimited and does not exclude additional elements, steps of the elements or unreported method. Understanding is a term of the technique used in the claim language that means that the elements named in the claim are essential, but other elements of the claim can be added and still form a construction within the scope of the claim.
[0127] As used in this document, the term consisting of excludes any element, step or ingredient not specified in the claim. When the expression consists of (or its variations) it appears in a clause in the body of a claim, instead of immediately after the preamble, it limits only the element established in that clause; other elements are not excluded from the claim as a whole. As used here, the term compound essentially limits the scope of a claim to the specified elements or steps of the method and those that do not materially affect the underlying and original feature (s) of the subject matter in question.
[0128] With respect to the terms understand, composed of and essentially consist of where one of these three terms is used in this document, the subject matter currently disclosed and claimed may include the use of either of the other two terms. Thus, in some modalities not otherwise explicitly reported, any instance of understanding can be replaced by constituting of, alternatively, by consisting essentially of.
[0129] For the current purposes, biogenic intends to mean a material
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34/160 (a raw material, product or intermediate) that contains an element, such as carbon, which is renewable over time scales of months, years or decades. Non-biogenic materials can be non-renewable or can be renewable over time scales of centuries, thousands of years, millions of years or even larger geological time scales. Note that a biogenic material can include a mixture of biogenic and non-biogenic sources.
[0130] For current purposes, reagent intends to mean a material in its broadest sense; a reagent can be a fuel, a chemical, a material, a compound, an additive, a mixing component, a solvent and so on. A reagent is not necessarily a chemical reagent that causes or participates in a chemical reaction. A reagent may or may not be a chemical reagent; it may or may not be consumed in a reaction. A reagent can be a chemical catalyst for a given reaction. A reagent can cause or participate in adjusting a mechanical, physical or hydrodynamic property of a material to which the reagent can be added. For example, a reagent can be introduced to a metal to give certain properties of resistance to the metal. A reagent can be a substance of sufficient purity (which, in the current context, is typically carbon purity) for use in chemical analysis or physical testing.
[0131] By high carbon, as used in this application to describe biogenic reagents, it simply means that the biogenic reagent has a relatively high carbon content compared to the starting raw material used to produce the high carbon biogenic reagent. Typically, a high carbon biogenic reagent will contain at least about half of its weight in carbon. More typically, a high carbon biogenic reagent will contain at least 55% by weight, 60% by weight, 65% by weight, 70% by weight, 80% by weight, 90% by weight or more of carbon.
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35/160 [0132] Notwithstanding the above, the term biogenic reagent and high carbon is used in this document for practical purposes to consistently describe materials that can be produced by processes and systems of the invention, in various modalities. Limitations on carbon content or any other concentrations will not be imputed from the term itself, but only by reference to specific and equivalent modalities thereof. For example, it will be noted that a starting material with a very low carbon content, subject to the disclosed processes, can produce a high carbon biogenic reagent that is highly enriched in carbon compared to the starting material (high carbon yield), but , however, it is relatively low in carbon (low carbon purity), including less than 50% by weight of carbon.
[0133] Pyrolysis generally refers to the thermal decomposition of a carbonaceous material. In pyrolysis, less oxygen is present than is needed for complete combustion of the material, such as less than 10%, 5%, 1%, 0.5%, 0.1%> or 0.01% of the oxygen that is needed for complete combustion. In some modalities, pyrolysis is performed in the absence of oxygen.
[0134] Exemplary changes that may occur during pyrolysis include any of the following: (i) heat transfer from a heat source increases the temperature inside the raw material; (ii) the initiation of primary pyrolysis reactions at this higher temperature releases volatile compounds and forms a coal; (iii) the flow of hot volatile compounds for cooler solid results in heat transfer between hot volatile compounds and colder non-pyrolysed raw material; (iv) condensation of some of the volatile compounds in the coldest parts of the raw material, followed by secondary reactions, can produce tar; (v) autocatalytic secondary pyrolysis reactions take place while primary pyrolysis reactions occur simultaneously in competition; and (vi) thermal decomposition, reform, water-gas displacement reactions, radical recombination can also occur
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36/160 free and / or dehydration, which are a function of the pressure profile, temperature and residence time.
[0135] Pyrolysis can at least partially dehydrate the raw material. In various modalities, pyrolysis removes more than about 50%, 75%, 90%>, 95%, 99% or more of the water from the raw material.
[0136] As discussed above, some variations of the invention are based, at least in part, on the discovery that multiple reactors or multiple zones within a single reactor can be designed and operated in a way that optimizes carbon yield and quality of the pyrolysis product, while maintaining flexibility and adaptability to variations in raw material and product requirements.
[0137] In general, residence times and temperatures are selected to achieve relatively slow pyrolysis chemistry. The benefit is potentially the substantial preservation of cell walls contained in the biomass structure, which means that the final product can retain some, most or all of the shape and strength of the initial biomass. In order to maximize the potential benefit, an apparatus that does not mechanically destroy the cell walls or otherwise convert the biomass particles into small pieces can be used. Several reactor configurations are discussed after the process description below.
[0138] In addition, if the raw material is a milled or dimensioned raw material, such as wood chips or pellets, it may be desirable for the raw material to be carefully milled or dimensioned. Careful initial treatment will tend to preserve the integrity of the cell wall strength that is present in the source of the native raw material (for example, trees). This can also be important when the final product must maintain some, most or all of the shape and strength of the initial biomass.
[0139] In several modalities, measures are taken to preserve the
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37/160 vascular structure of the wood raw material to create greater resistance in biogenic reagents. For example, and without limitation, in various modalities, the raw material is prepared by the drying raw material over an extended period of time, for example over a period of not less than 1 hour, not less than 2 hours, less than 3 hours, not less than 4 hours, not less than 5 hours, not less than 6 hours, not less than 7 hours, not less than 8 hours, not less than 9 hours, less than 10 hours, less than 11 hours , not less than 12 hours, not less than 13 hours, not less than 14 hours, not less than 15 hours, not less than 16 hours, not less than 17 hours, not less than 18 hours, not less than 19 hours, not less than 20 hours, not less than 21 hours, not less than 22 hours, not less than 23 hours or not less than 24 hours, to allow water and gases to leave biomass without destroying the vascular structure of the raw material. In various embodiments, the use of a slow progressive heat rate during pyrolysis (for example, in contrast to rapid pyrolysis) over minutes or hours is used to allow water and gases to escape from biomass without destroying the structure of the raw material. For example, and without limitation, a rate of temperature increase during the pyrolysis step can vary from about 1 ° C per minute to about 40 ° C per minute, for example, about 1 ° C per minute, about 2 ° C. per minute, about 4 ° C. per minute, about 5 ° C per minute, about 10 ° C per minute, about 15 ° C per minute, about 20 ° C per minute, about 25 ° C per minute, about 30 ° C per minute , about 35 ° C per minute or about 40 ° C per minute. In some embodiments, the temperature rise occurs in a preheating zone to produce the preheated raw material. In some embodiments, the temperature rise occurs predominantly or entirely in a preheating zone to produce the preheated raw material. In some embodiments, the temperature of the preheated raw material is increased in a pre-pyrolysis zone. In some modalities, the temperature rise occurs
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38/160 at least in part, in a carbonization zone or a pyrolysis zone. In some embodiments, the temperature rise occurs predominantly or entirely in a carbonization zone or in a pyrolysis zone. In some embodiments, a preheating zone, a pre-pyrolysis zone, a carbonization zone or a pyrolysis zone is configured to increase the temperature during pyrolysis from a low initial temperature to a higher final temperature over time. In some embodiments, the temperature rise is linear or substantially linear over time. In some embodiments, the rate of temperature increase increases or decreases over time, so that the temperature during preheating, pre-pyrolysis and / or carbonization or pyrolysis is at least partially non-linear, for example, logarithmic or substantially logarithmic by at least part of the preheating, pre-pyrolysis and / or carbonization or pyrolysis step. In various embodiments, an additive is used before drying or pyrolysis to reduce the formation of gas that can damage the vascular structure of the raw material during pyrolysis. In various modalities, before pyrolysis, the dry raw material is dimensioned using a saw or other cutting device designed to be less destructive to the vascular structure of the wood than other types of dimensioning such as sculpting or shearing wet wood that fractures the wood. and decreases its strength. In such embodiments, a biogenic reagent has a higher strength index (for example, CSR value) than a comparable biogenic reagent not prepared in such a way.
[0140] In various modalities, the raw material is prepared by the milling biomass to form a plurality of parts of biomass that are dimensioned substantially uniform and with a substantially uniform shape. For example and without limitation, biomass can be processed to produce sawdust of approximately uniform grain size (eg mesh size). Alternatively, biomass can be processed to produce chips with dimensions
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39/160 substantially uniform (for example, parts of approximately 1 inch by approximately 1/2 inch by approximately 1/8 inch). In other modalities, the raw material can be prepared by grinding the biomass to form material lengths with substantially uniform width and depth dimensions or diameters (for example, wooden bars, plates or pins). In related embodiments, material lengths of substantially uniform width and depth or diameter can still be milled to produce parts of raw material of substantially uniform lengths, resulting in a material of substantially uniform size and shape. For example, wooden pins with uniform diameter (for example, about 1-1 / 8 inch) can be cut into pieces of substantially uniform length (for example, about 1.5 inch). The resulting pieces of raw material have a substantially uniform shape (cylinders) and a substantially uniform size (about 1-1 / 8 inch in diameter by about 1.5 inch in length). In some embodiments, a biogenic reagent prepared from a raw material consists of pieces of substantially uniform size and shape produced in greater mass yield than a comparable biogenic reagent prepared from pieces of raw material of form and / or substantially non-uniform size.
[0141] With general reference to FIGURES 1 to 13, the block flow diagrams of several exemplary multi-reactor modalities of the present disclosure are illustrated. Each figure is discussed in turn below. It should be noted that FIGURES 1 to 13 represent some modalities of the example, but not all modalities contemplated in the current disclosure. As discussed below, several additional non-illustrated modalities and combinations of various components and features discussed in this document are also contemplated. As will be understood in the discussion below, any of the plurality of reactors
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40/160 discussed in this document can be independent reactors or alternatively within a single reactor BPU it can include a plurality of zones or a combination of these. It should be noted that, although each figure illustrates a different alternative modality, all other discussions in this disclosure may apply to each of the illustrated and non-illustrated modalities.
[0142] Now with general reference to FIG. 1, a block flow diagram of a multi-reactor embodiment of the present disclosure is illustrated. This modality can use two to a plurality of different reactors. Three reactors are shown in the illustrative mode, however, any different number of reactors could be employed. In one embodiment, each reactor is connected to at least one other reactor via a material transport unit 304 (shown in FIG. 3). In one embodiment, the material transport unit 304 controls temperature and atmospheric conditions.
[0143] In the illustrated modality, raw material 109, such as biomass, is optionally dried and dimensioned outside the system and introduced into the first reactor 100 in an oxygen-poor environment through the use of a material feeding system 108. As discussed in more detail below and as illustrated in FIG. 3, material feeding system 108 reduces the oxygen level in the ambient air in the system to no more than about 3%. The raw material 109 enters the first reactor 112 through the included material transport unit 304 after oxygen levels have decreased in the first reactor. In one embodiment, the raw material transport unit will include a wrapped sleeve or jacket through which reactor steam and exhaust gases are sent and used to preheat biomass directly or sent to a process gas heater and / or exchanger heat and then sent and used to preheat or pyrolyze the biomass.
[0144] In the illustrated modality, raw material 109 goes first from the
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41/160 material feed 108 to material transport unit 304 in the first reactor of BPU 112.
[0145] As discussed in more detail below, in one embodiment, the first reactor 112 is configured to be connected to any other reactor in the system to recover dissipated heat 132 and conserves energy through a suitable dissipated heat recovery system. In one embodiment, the heat dissipated in the first reactor 112 is used to operate a steam compartment or other suitable heating mechanism configured to dry raw material 109 inside or outside the system. In various embodiments, other by-products of the dissipated heat, such as a substantially heated inert gas or the like, can be used elsewhere in the system to further enrich the material at any point throughout the process.
[0146] In the illustrated embodiment, biomass 109 enters the first reactor 112, where the temperature rises from the ambient temperature range of about 150 ° C to a temperature of about 100 ° C to about 200 ° C. In one embodiment, the temperature does not exceed 200 ° C in the first reactor 112. As discussed in more detail below, the first reactor 112 may include an outlet mechanism for capturing and expelling exhaust gases 120 from biomass 123 while it is being heated. In one embodiment, the exhaust gases 120 are extracted for optional later use. In various embodiments, the heating source used for multiple zones in the BPU 102 is electric or gas. In one embodiment, the heating source used for the various reactors in BPU 102 is the gas dissipated from other reactors in unit 102 or from external sources. In several modalities, the heat is indirect.
[0147] After preheating in the first reactor 112, the material transport unit 304 passes the preheated material 123 in the optional second reactor 114. In the mode of a reactor 1 14 it is the same as reactor 112. In a mode
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42/160 where reactor 114 is different from reactor 112, the transport of material from unit 304 penetrates the second reactor 114 through a high temperature vapor seal system (for example, a vacuum chamber), which allows the transport of unit 304 material penetrate the second reactor, preventing gas escape. In one embodiment, the interior of the second reactor 114 is heated to a temperature of about 100 ° C to about 600 ° C or about 200 ° C to about 600 ° C. In another embodiment, the second reactor 114 includes an outlet port similar to the first reactor 102 for capturing and expelling the gases 122 released from the preheated material 123 while it is being carbonized. In one embodiment, gases 122 are extracted for optional later use. In an illustrative embodiment, the exhaust gases 120 from the first reactor 112 and the exhaust gases 122 from the second reactor 114 are combined in a gas stream 124. Once carbonized, the carbonized biomass 125 leaves the second reactor 114 and enters the third reactor 116 for refrigeration. Again, the third reactor can be the same reactor 112 or 114 or a different one.
[0148] In one embodiment, when biogenic reagent 125 enters third reactor 116, carbonized biomass 125 can cool (actively or passively) to a specified temperature range to form carbonized biomass 126, as discussed above. In one embodiment, the temperature of the carbonized biomass 125 is reduced in the third reactor under substantially inert atmospheric conditions. In another embodiment, the third reactor cools the carbonized biomass 125 with an additional water cooling mechanism. It should be noted that the carbonized biomass 126 can cool in the third reactor 116 to the point where it will not spontaneously burn if exposed to oxygenated air. In such an embodiment, the third reactor 116 reduces the temperature of the carbonized biomass to below 200 ° C. In one embodiment, the third reactor includes a mixer (not shown) to uniformly stir and cool the carbonized biomass. It should be noted that
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43/160 this cooling can occur directly or indirectly with water or other liquids; refrigeration can also occur directly or indirectly with air or other cooled gases or any combination above.
[0149] It should be noted that in several modalities (not shown) one or more additional refrigerators or cooling mechanisms are employed to further reduce the temperature of the carbonized biomass. In several of these modalities, the refrigerator is separated from the other reactors 112, 114, 116 along the material transport system. In some embodiments, the refrigerator follows the reactors. In some embodiments, the refrigerator may be the same as reactors 112, 114, 116. In other embodiments, the refrigerator is, for example, a screw, auger, conveyor (specifically, a conveyor belt in one embodiment), drum, screen , pan, countercurrent bed, vertical turret, coated shovel, cooling screw or combination of these that cools directly or indirectly with water or other liquids or directly or indirectly with other gases or the combination of the above options. In various embodiments, refrigerators can include water spray, refrigerant inert gas streams, liquid nitrogen or ambient air if below the ignition temperature. It should be noted that heat can be recovered from this step by capturing the rapid steam generated by the water spray or the superheated steam generated when the saturated steam is introduced and heated by carbonized biomass.
[0150] As illustrated in FIGURES 1 and 5, the gas phase separator unit 200 includes at least one input and a plurality of outputs. At least one inlet is connected to the exhaust ports on the first reactor 112 and the second reactor 114 of BPU 102. One of the outlets is connected to the carbon recovery unit 104 and another outlet is connected to the collection equipment or more processing equipment , such as a distillation column or an acid hydrogenation unit 106. In several embodiments, the phase separator
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44/160 of gas processes the exhaust gases 120, 122 of the first reactor 112 and the second reactor 114 to produce a condensate 128 and an enriched gas 204. In various embodiments, condensables can be used for energy recovery (134) ( for example in the dryer, reactor or gas heater process) or for other carbon enrichment. In various embodiments, non-condensables (for example CO) can be used for energy recovery (134) (for example, in a dryer, reactor or process gas heater), as an inert gas in the process (for example, in the de-aeration, reactor, BPU or refrigerator discussed in more detail below) or for carbon enrichment.
[0151] In several modalities, condensate 128 includes polar compounds, such as acetic acid, methanol and furfural. In another embodiment, the enrichment gas 204 produced by the gas phase separator 200 includes at least nonpolar gases, for example, carbon monoxide, terpenes, methane, carbon dioxide, etc. In one embodiment, the gas phase separator comprises a fractionation column. In one embodiment, acetic acid is sent via line 128 to an optional acid hydrogenation unit. In another embodiment, methanol and / or furfural are sent via optional additional lines 136 to a processing / distillation unit 138 [0152] In various modalities, as discussed in more detail below, the carbon recovery unit itself has the facility to enrich the material. In several other embodiments, the material is enriched in a material enrichment unit separate from the carbon recovery unit. It should be noted that, in some of these embodiments, the carbon recovery unit is a container for storing the carbonized material, and the separate material enrichment unit is the unit into which gases are introduced to enrich the material.
[0153] In the illustrated modality, the carbon recovery unit 500
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45/160 also enriches carbonized biomass 126. Carbonized biomass 126 leaves the third reactor along the material transport unit 304 and enters the carbon recovery unit 500. In several modalities, as illustrated in more detail in figure 5 and as discussed above, the carbon recovery unit 500 also includes an inlet 524 connected to the gas phase separator 200. In one embodiment, the enrichment gas 204 is directed to the carbon recovery unit to be combined with the biogenic reagent 126 to create a high carbon biogenic reagent 136. In another embodiment, a carbon-enriched gas from an external source can also be directed to the carbon recovery unit to be combined with carbonized biomass 126 to add additional carbon to the biogenic reagent high carbon produced. In several embodiments, carbonized biomass 126 is low temperature carbonized biomass. Illustratively, system 100 can be colocalized near a wood processing unit and the carbon enriched gas from the wood processing unit can be used as gas from an external source.
[0154] Referring now to Figure 2, a block flow chart of a single reactor, the multizone modality of the present disclosure is illustrated. In the illustrated embodiment, crude matter 209, such as biomass, is introduced into reactor 200 in a low oxygen atmosphere, optionally, through the use of a material feeding system 108 already described. As discussed in more detail below, the material feeding system 108 reduces the level of oxygen in the ambient air in the system by no more than about 3%. The raw material 209 enters the BPU 202 in a closed material transport unit 304 after the oxygen levels have been lowered. In one embodiment, the material transport unit will include an encapsulated jacket or glove through which steam and exhaust gases from reactor 200 are sent and used to preheat biomass.
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46/160 [0155] In the illustrated mode, the raw material first travels from the material feeding system 108 in the material transport unit 304 through an optional drying zone 210 of BPU 202. In one mode, the optional drying 210 heats the raw material to remove water and other moisture before being directed to the preheating zone 212. In one embodiment, the interior of the optional drying zone 210 is heated to a temperature of about room temperature to about 150 ° C. Water 238 or other moisture removed from crude 209 can be dissipated, for example, from the optional drying zone 210. In another embodiment, the optional drying zone is adapted to allow vapors and steam to be extracted. In another mode, vapors and steam from the optional drying zone are extracted for optional later use. As discussed below, vapors or steam extracted from the optional drying zone can be used in a suitable waste heat recovery system with the material feed system. In one embodiment, vapors and steam used in the material feed system preheat raw materials while oxygen levels are being purged in the material feed system. In another embodiment, the biomass is dried outside the reactor and the reactor does not include a drying zone.
[0156] As discussed in more detail below, in one embodiment, the optional drying zone 210 is configured to be connected to cooling zone 216 to recover waste heat 232 and conserve energy through an appropriate waste heat recovery system . In one embodiment, the residual heat emitted in the cooling zone 216 is used to operate a heating mechanism configured to dry raw materials 209 in the optional drying zone 210. After being dried for a desired period of time, dry biomass 221 comes out the optional drying zone 210 and enters the preheating zone 212.
[0157] In the illustrated mode, dry biomass 221 enters the first zone
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47/160 (preheating) 212, wherein the temperature is raised from the range of about room temperature to about 150 ° C to a temperature range of about 100 ° C to about 200 ° C. In one embodiment, the temperature does not exceed 200 ° C, in the first / preheating zone 212. It should be appreciated that if the preheating zone 212 is too hot or not hot enough, dry biomass 221 may process incorrectly before entering the second zone 214. As discussed in more detail below, the preheat zone 212 may include an outlet mechanism for capturing and dissipating exhaust gases 220 from dry biomass 221 while being preheated. In another embodiment, the exhaust gases 220 are extracted for optional later use. In several ways, the heating source used for different zones in the BPU 202 is electric or gas. In one embodiment, the heating source used for the various zones of BPU 202 is waste gas from other zones of unit 202 or from external sources. In several modalities, the heating is indirect.
[0158] After the preheating zone 212, the material transport unit 304 passes the preheated material 223 into the second zone (pyrolysis) 214. In one embodiment, the material transport unit 304 enters the second zone / pyrolysis system via a high temperature steam seal system (such as an air lock, not shown), which allows the material transport unit 304 to penetrate the high temperature pyrolysis zone, preventing (or minimizing) the exhaust gas. In one embodiment, the interior of the pyrolysis zone 214 is heated to a temperature of about 100 ° C to about 600 ° C or 200 ° C to about 500 ° C. In another embodiment, the pyrolysis zone 214 includes an outlet orifice similar to the preheating zone 212 to capture and dissipate the gases 222 emitted from the preheated biomass 223 while being carbonized. In one embodiment, gases 222 are extracted for optional later use. In an illustrative embodiment, the exhaust gases 220 from the preheating zone 212 and the
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48/160 exhaust gases 222 from the pyrolysis zone 214 are combined into a gas stream 224. Once carbonized, the carbonized biomass 225 leaves the second / pyrolysis zone 214 and enters the third / cooling or cooling zone 216.
[0159] In one embodiment, when carbonized biomass 225 enters cooling zone 216, carbonized biomass 225 is allowed to cool to a specified temperature range of about 20 ° C to 25 ° C (from about room temperature) to become the reduced temperature carbonized biomass 226, as discussed above. In several embodiments, BPU 202 includes a plurality of cooling zones. In one embodiment, the cooling zone 216 cools the carbonized biomass to below 200 ° C. In one embodiment, the cooling zone includes a mixer to uniformly stir and cool the materials. In several modalities, one or more of the plurality of cooling zones are outside the BPU 202.
[0160] As shown in figures 2 and 5, the gas phase separator unit 200 includes at least one input and a plurality of outputs. In this illustrative embodiment, at least one inlet is connected to the exhaust holes in the first / preheating zone 212 and in the second / pyrolysis zone 214 of BPU 202. One of the outlets is connected to the carbon recovery unit 500 (which is configured to enrich the material), and another outlet is connected to the collection equipment or additional processing equipment such as an acid hydrogenation unit 206 or distillation column. In several embodiments, the gas phase separator processes the exhaust gases 220, 222 from the first / preheating zone 212 and from the second / pyrolysis zone 214 to produce a condensate 228 and an enrichment gas 204. In one embodiment , condensate 228 includes polar compounds, such as acetic acid, methanol and furfural. In one embodiment, the enrichment gas 204 produced by the separator
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49/160 gas phase 200 includes at least non-polar gases. In one embodiment, the gas phase separator comprises a fractionation column. In one embodiment, acetic acid is sent via line 228 to an optional acid hydrogenation unit 206. In another embodiment, methanol and / or furfural are sent via the optional additional line (s) ) 236 for a distillation / processing unit 238.
[0161] In the illustrated modalities, the carbonized biomass leaves the reactor / cooling zone along the material transfer unit 304 and enters the carbon recovery unit 500. In several modalities, as illustrated in more detail in figure 5 and as discussed above, the carbon recovery unit 500 also includes an inlet 524 connected to the gas phase separator 200. In one embodiment, the enrichment gas 204 is directed to the carbon recovery unit 500 to be combined with the biogenic reagent 226 to create a high carbon biogenic reagent 136. In another embodiment, a carbon-enriched gas from an external source can also be directed to the carbon recovery unit 500 to be combined with biogenic reagent 226 to add additional carbon to the reagent biogenic. In various embodiments, the gases taken from the carbon recovery unit 500 in reference 234 are optionally used in energy recovery systems and / or systems for additional carbon enrichment. Illustratively, in various modalities, gases taken from one or more zones of the BPU 202 are optionally used in energy recovery systems and / or systems for additional carbon enrichment. Illustratively, system 200 can be colocalized near a wood processing unit and the carbon enriched gas from the wood processing unit can be used as gas from an external source.
[0162] Now referring in general to figure 3, a modality of
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50/160 material feeding system of the present disclosure is illustrated. As discussed above, high levels of oxygen in the ambient air around the raw material when it processes can result in undesired combustion or oxidation of the raw material, which reduces the quantity and quality of the final product. In one embodiment, the material feeding system is a closed system and includes one or more collectors configured to purge oxygen from the air around the raw material. In one embodiment, the oxygen level of about 0.5% to about 1.0% is used to preheat, pyrolyze / carbonize and cool. It should be appreciated that a primary objective of the closed material feeding system is to reduce oxygen levels to no more than about 3%, no more than about 2%, no more than about 1% or no more than about 0.5%. After the oxygen level is reduced, the biomass is transferred along the material feeding system at the BPU. It should be appreciated that in several modalities, the preheating of inert gases, through the energy recovered from the process and the subsequent introduction of preheated inert gases in the BPU, in the reactor or in the cutting reactor makes the system more efficient.
[0163] In some embodiments, a cutting reactor is included in the system. In a shear reactor mode, the BPU pyrolysed material is fed into a separate additional reactor for additional pyrolysis where inert gas is introduced to create a product with higher fixed carbon levels. In several embodiments, the secondary process can be carried out in a container such as a drum, tank, barrel, receptacle, closed container, pipe, bag, press, or cargo box. In several modalities, the final container can also be used to transport carbonized biomass. In some embodiments, the inert gas is heated through the heat exchanger that derives heat from gases extracted from the BPU and burned in a process gas heater.
[0164] As can be seen in figure 3, the material feeding system
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Closed 51/160 108 includes a raw material feed hopper 300, a material transport unit 304 and an oxygen purge manifold 302.
[0165] In one embodiment, the raw material feed hopper 300 is any suitable outdoor or closed air container configured to receive 109/209 crude or dimensioned / dry biomass. The raw material feed hopper 300 is operationally connected to the material transport unit 304, which, in one embodiment, is a screw or helical thread system operationally rotated by a drive source. In one embodiment, the raw material 109/209 is fed into the material transport unit 304 by a gravity feed system. It should be appreciated that the material transport unit 304 of figure 3 is shaped so that the screw or helical thread 305 is contained in a suitable housing 307. In one embodiment, housing 307 is substantially cylindrical. In various embodiments, material feeding systems include a screw, helical thread, conveyor, drum, screen, chute, drop chamber, pneumatic conveying device, including a rotating air lock or a double or triple flap chamber.
[0166] As the raw material 109/209 is fed from the raw material feed hopper 300 to the material transport unit 304, the helical thread or screw 305 is rotated, moving the raw material 109/209 towards to the oxygen purge manifold 302. It should be appreciated that when the raw material 109/209 reaches the oxygen purge manifold 302, the ambient air between the raw material 109/209 in the material transport unit 304 includes about 20 , 9% oxygen. In various embodiments, an oxygen purge manifold 302 is disposed adjacent to or near the material transport unit 304. Within the oxygen fold manifold of one embodiment, the housing 307 of the material transport unit 304 includes a plurality of holes gas inlet 310a, 310b, 310c
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52/160 and a plurality of gas outlet holes 308a, 308b, 308c.
[0167] The oxygen purge manifold 302 has at least one gas inlet line 312 and at least one gas outlet line 314. In several embodiments, at least one gas inlet line 312 from the purge manifold. oxygen 302 is in operable communication with each of the plurality of gas inlet orifices 310a, 310b, 310c. Similarly, in several embodiments, the at least one gas outlet line 314 of the oxygen purge manifold 302 is in operable communication with each of the plurality of gas outlet orifices 308a, 308b, 308c. It should be appreciated that, in one embodiment, the gas inlet line 312 is configured to pump inert gas into the gas inlet ports 310a, 310b, 310c. In such an embodiment, the inert gas is nitrogen and contains substantially no oxygen. In one embodiment, the inert gas will flow countercurrent to the biomass.
[0168] As will be understood, the introduction of inert gas 312 into the closed material transport unit 304 will force the ambient air out of the closed system. In operation, when inert gas 312 is introduced into the first gas inlet orifice 310a of an embodiment, an amount of oxygen-rich ambient air is forced out of outlet orifice 308a. It should be appreciated that, at this point, the desired level of no more than about 2% oxygen, no more than about 1% oxygen, no more than about 0.5% oxygen or no more than that 0.2% oxygen may not be achieved. Therefore, in several modalities, additional infusions of inert gas 312 must be made to eliminate the necessary amount of oxygen from the air around the crude matter 109 in the closed system. In one embodiment, the second gas inlet orifice 310b pumps inert gas 312 into the closed system shortly after infusion into the first gas inlet orifice 310a, thus purging more of the remaining oxygen from the closed system. It should be appreciated that, after one or two infusions of inert gas 312 to purge oxygen 314, the level
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Desired 53/160 of less oxygen can be achieved. If, in one embodiment, the desired oxygen levels are still not reached after two infusions of inert gas, a third infusion of inert gas 312 at gas inlet 310c will purge remaining undesirable amounts of oxygen 314 from the closed system at the gas outlet 308c. Additional inputs / outputs can also be incorporated, if desired. In several modalities, oxygen levels are monitored throughout the material feeding system to allow calibration of the quantity and location of infusions of inert gas.
[0169] In an alternative mode, heat, steam and gases recovered from the reactor are directed to the feed system, where they are placed in the jacket and separated from direct contact with the feed material, but indirectly heat the material before introduction into the reactor.
[0170] In an alternative mode, heat, steam and gases recovered from the reactor's drying zone are directed to the feed system, where they are placed in the jacket and separated from direct contact with the feed material, but indirectly heat the material before feeding into the reactor.
[0171] It should be appreciated that the gas inlet holes 310a, 310b, 310c and the corresponding gas outlet holes 308a, 308b, 308c, respectively, in one embodiment are slightly offset from each other in relation to a bifurcation plane vertical through the material transport unit 304. For example, in one embodiment, the inlet port 310a and the corresponding outlet port 308 are displaced in the material transport unit 304 by an amount that approximately corresponds to the peak of the helical thread 305 in the material transport unit 304. In several modalities, after the atmosphere surrounding the raw material 109/209 is satisfactorily deoxygenated, it is fed from the
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54/160 material feeding system 108 in BPU 102. In several modalities, oxygen levels are monitored throughout the material feeding system to allow the calibration of the quantity and location of inert gas infusions.
[0172] It must be appreciated that, in one modality, the raw material 109/209 and subsequently dry biomass 221, preheated biomass 123/223, carbonized biomass 125/225 and carbonized biomass 126/226, travels through reactor 102 (or reactors) along a continuous material transport unit 304. In another embodiment, the material transport unit that transports the material differs at different stages of the process. In one embodiment, the process of moving material through the reactor, zones or reactors is continuous. In such an embodiment, the speed of the material transport unit 304 is properly calibrated and calculated by a processor and associated controller so that the operation of the material transport unit 304 does not require interruption when the material moves through the reactor or reactors .
[0173] In another mode, the controller associated with reactor 102 or reactors (112/114/116) is configured to adjust the speed of the material transport unit 304 based on one or more feedback sensors, detected gas (for example , from optional FTIR), measured parameters, temperature meters or other suitable variables in the reactor process. It should be appreciated that, in several modalities, any suitable humidity sensors, temperature sensors or gas sensors in operable communication with the controller and the processor could be integrated in or between each of the zones / reactors or in any suitable position along material transport unit 304. In one embodiment, the controller and processor use information from sensors or gauges to optimize the speed and efficiency of the BPU 100/200. In one embodiment, the controller associated with reactor 102 or reactors (112/114/116) is configured to operate the material transport unit
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55/160
304. In one embodiment, the controller associated with reactor 102 or reactors (112/114/116) is configured to monitor the concentration, temperature and humidity of the gas inside the material transport unit 304 or any of the reactors. In one embodiment, the controller is configured to adjust the speed of the material handling unit 304, the entry of gases into the material handling unit and the heat applied to the material in the material handling unit based on one or more readings taken by the various sensors.
[0174] Referring now to FIGURES 2 and 4, a modality of BPU 102 is illustrated. It should be appreciated that the graphical representation of BPU 202 in figure 4 corresponds substantially to BPU 202 in figure 2. It should also be appreciated that, in several embodiments, BPU 202 is closed at the furnace ferrule to control and manipulate high amounts of heat necessary for the reactor process. As can be seen in figure 4, in one embodiment, the ferrule of the BPU furnace 202 includes several isolation chambers (416, 418) around four zones, 210, 212, 214 and 216. In one embodiment, the furnace includes four separate zones. In various embodiments, each of the four zones 210, 212, 214 and 216 of the BPU 202 includes at least one entrance step and at least one exit step. As discussed in more detail below, within each zone of such modality, the entry and exit steps are configured to be adjustable to control the flow of feed material, gas, and heat inside and outside the zone. A supply of inert air can be introduced into the inlet step and the purged air can be extracted from the corresponding outlet step. In various embodiments, one or more of the exit steps of a zone on the BPU 202 are connected to one or more of the other entry or exit steps on the BPU.
[0175] In one embodiment, after the raw material 209 is deoxygenated in the material feeding system 108, the optional drying zone 210 is introduced in BPU 202, and specifically in the first of four zones. As can be seen
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56/160 in figure 4, the drying zone includes entrance step 422b and exit step 420a. In one embodiment, the drying zone is heated to a temperature of about 80 ° C to about 150 ° C to remove water or other moisture from raw materials 209. The biomass is then moved to the second or pre- heating 212 where the biomass is preheated as described above.
[0176] In another mode, the material that has been optionally dried and preheated is moved to the third zone or carbonization. In one embodiment, carbonization occurs at a temperature of about 200 ° C to about 700 ° C, for example about 200 ° C, about 210 ° C, about 220 ° C, about 230 ° C, about 240 ° C, about 250 ° C, about 260 ° C, about 270 ° C, about 280 ° C, about
290 ° C, about 300 ° C, about 310 ° C, about 320 ° C, about 330 ° C, about
340 ° C, about 350 ° C, about 360 ° C, about 370 ° C, about 380 ° C, about
390 ° C, about 400 ° C, about 410 ° C, about 420 ° C, about 430 ° C, about
440 ° C, about 450 ° C, about 460 ° C, about 470 ° C, about 480 ° C, about
490 ° C, about 500 ° C, about 510 ° C, about 520 ° C, about 530 ° C, about
540 ° C, about 550 ° C, about 560 ° C, about 570 ° C, about 580 ° C, about
590 ° C, about 600 ° C, about 610 ° C, about 620 ° C, about 630 ° C, about
640 ° C, about 650 ° C, about 660 ° C, about 670 ° C, about 680 ° C, about
690 ° C, or about 700 ° C. In another embodiment, a carbonization zone of a 421 reactor is adapted to allow the gases produced during carbonization to be extracted. In another embodiment, the gases produced during carbonization are extracted for optional later use. In one embodiment, a carbonization temperature is selected to minimize or eliminate the production of methane (CH4) and maximize the carbon content of the carbonized biomass.
[0177] In another modality, the carbonized biomass is moved to a cooling or temperature reduction zone (third zone) and is allowed to cool passively or is actively cooled. In one embodiment, the solids of the
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57/160 carbonized biomass is cooled to a temperature of ± 10, 20, 30 or 40 ° C from room temperature.
[0178] In several modalities, the BPU includes a plurality of gas introduction probes and gas extraction probes. In the BPU modality illustrated in figure 4, the BPU additionally includes a plurality of gas introduction probes: 408, 410, 412 and 414, and a plurality of gas extraction probes: 400, 402, 404 and 406. It must be appreciated that, in different modalities, one of each of the introduction probes and one of each of the gas extraction probes corresponds to a different one from the plurality of zones 210, 212, 214 and 216. Furthermore, it should be appreciated that, in various alternative modalities, BPU 202 includes any suitable number of gas introduction probes and gas extraction probes, including more than one gas introduction probe and more than one gas extraction probe for each of the plurality of zones.
[0179] In the illustrated embodiment, the drying zone 210 is associated with the gas introduction probe 412 and the gas extraction probe 402. In one embodiment, the gas introduction probe 412 introduces nitrogen into the drying zone 210 and the probe gas extraction 402 extracts gas from drying zone 210. It should be appreciated that, in several modalities, the gas introduction probe 412 is configured to introduce a gas mixture into drying zone 210. In one embodiment, the extracted gas it's oxygen. It should be appreciated that, in various embodiments, the gas extraction probe 402 extracts gases from drying zone 210 to be reused in a heat or energy recovery system, as described in more detail above.
[0180] In the illustrated embodiment, the preheating zone 212 is associated with the gas introduction probe 414 and the gas extraction probe 400. In one embodiment, the gas introduction probe 414 introduces nitrogen to the preheating zone 212 and the gas extraction probe 400 extracts gas from the pre zone
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58/160 heating 212. It should be appreciated that, in several modalities, the gas introduction probe 414 is configured to introduce a gas mixture in the preheating zone 212. In several modalities, the gas extracted in the extraction probe gas 400 includes carbon-enriched exhaust gases. It should be appreciated that in one embodiment, as discussed above, the gases extracted from the preheat zone 212 and the pyrolysis zone 214 are reintroduced into the material at a later stage in the process, for example, in the carbon recovery unit. In various modalities, the gases extracted from any of the reactor zones are used for energy recovery in the process gas dryer or heater, for additional pyrolysis in a cutting reactor, or in the carbon enrichment unit.
[0181] In the illustrated embodiment, the pyrolysis zone 214 is associated with the gas introduction probe 410 and the gas extraction probe 404. In one embodiment, the gas introduction probe 410 introduces nitrogen into the pyrolysis zone 214 and the gas extraction probe 404 extracts gas from the pyrolysis zone 214. It should be appreciated that, in several modalities, the gas introduction probe 410 is configured to introduce a gas mixture into the pyrolysis zone, 214. In several modalities, the gas extracted in the 404 gas extraction probe includes carbon-enriched exhaust gases. It should be appreciated that in one embodiment, as discussed above, the carbon-enriched gases extracted from the pyrolysis zone 214 are used and reintroduced into the material at a later stage in the process. In various embodiments, as described in more detail below, the gas extracted 400 from the preheating zone 212 and the gas extracted 404 from the pyrolysis zone 214 are combined before being reintroduced into the material.
[0182] In the illustrated mode, the cooling zone 116 is associated with the gas introduction probe 408 and the gas extraction probe 406. In one embodiment, the gas introduction probe 408 introduces nitrogen into the
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59/160 cooling 116 and the gas extraction probe 406 extracts gas from the cooling zone 16. It should be appreciated that, in several modalities, the gas introduction probe 408 is configured to introduce a gas mixture into the cooling zone 116 It should be appreciated that, in several modalities, the gas extraction probe 406 extracts gases from the cooling zone 116 to be reused in a heat or energy recovery system, as described in more detail above.
[0183] It should be appreciated that the gas introduction probes and the gas extraction probes of different modalities described above are configured to operate with the controller and the plurality of sensors discussed above to adjust the levels and concentrations of gas that is being introduced and gas that is extracted from each zone.
[0184] In several modalities, the gas introduction probes and the gas extraction probes are made of a suitable piping configured to withstand high temperature fluctuations. In one embodiment, the gas introduction probe and the gas extraction probe include a plurality of openings through which the gas is introduced or extracted. In several embodiments, the plurality of openings are arranged on the underside of the inlet and gas extraction probes. In various embodiments, each of the plurality of openings extends a substantial length within the respective zone.
[0185] In one embodiment, the gas introduction probes extend from one side of the BPU 202 through each zone. In such an embodiment, each of the four gas introduction probes extends from a single side of the BPU to each of the respective zones. In several embodiments, gaseous catalysts are added that enrich fixed carbon levels. It should be appreciated that, in such an embodiment, the plurality of openings for each of the four gas introduction probes is arranged only in the respective zone associated with that specific gas introduction probe.
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60/160 [0186] For example, see figure 4, if each of the gas introduction probes extends from the left side of the drying zone, in each zone, all four gas introduction probes would go through through the drying zone, with the gas insertion probes of the drying zone delimiting in the drying zone. The remaining three gas introduction probes would travel through the preheating zone, with the gas introduction probe from the preheating zone delimiting the preheating zone. The remaining two gas introduction probes would run through the pyrolysis zone, with the gas introduction probe from the pyrolysis zone delimiting the pyrolysis zone. The gas introduction probe in the cooling zone would be the only gas introduction probe to travel and delimit in the cooling zone. It should be appreciated that, in several modalities, the gas extraction probes are configured similar to the gas introduction probes described in this example. In addition, it should be appreciated that the gas introduction probes and the gas extraction probes can each start on both sides of the BPU.
[0187] In several modalities, the gas introduction probes are arranged concentric with each other to save the space used by the multiple orifice configuration described in the example above. In such an embodiment, each of the four inlet probes / orifices would have a smaller diameter than the previous inlet probe / orifice. For example, in one embodiment, the probe for introducing gas in the drying zone has the largest inner diameter, and the probe for introducing gas in the preheating zone is located within the inner diameter of the probe / orifice in the drying zone. , the gas introduction probe from the pyrolysis zone is then located inside the inside diameter of the gas introduction probe from the preheating zone and the gas introduction probe from the cooling zone is located inside the gas introduction probe. of the pyrolysis zone. In an example of the modality, a suitable connector is attached to each of the
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61/160 gas introduction probes outside BPU 102 to control the air infused in each of the four gas introduction probes individually.
[0188] In such a modality, similar to the example above, the gas introduction probe from the drying zone would delimit in the drying zone, and the three other gas introduction probes would remain in the preheating zone. However, with a concentric or substantially concentric arrangement, only the outermost gas introduction probe is exposed in each zone before being delimited. Therefore, in such a modality, the gas introductions from the individual zone are effectively controlled independently of each other, requiring only a continuous gas introduction probe line. It should be appreciated that a concentric or substantially similar concentric configuration is suitably used for gas extraction probes in one embodiment.
[0189] In one embodiment, each zone or reactor is adapted to extract and collect exhaust gases from one or more of the individual zones or reactors. In another mode, exhaust gases from each zone / reactor remain separate for disposal, analysis and / or later use. In different modalities, each reactor / zone contains a gas detection system such as an FTIR that can monitor the formation of gas within the zone / reactor. In another embodiment, exhaust gases from a plurality of zones / reactors are combined for disposal, analysis and / or later use in various modalities, exhaust gases from one or more zones / reactors are fed to a process gas heater. In another embodiment, exhaust gases from one or more zones / reactors are fed into a carbon recovery unit. In another embodiment, exhaust gases from one or more zones / reactors are fed to a gas phase separator prior to the introduction of the carbon recovery unit. In one embodiment, a gas phase separator comprises a fractionation column. Any fractionation column, known to those skilled in the art, can be used. In
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62/160 one embodiment, exhaust gases are separated into non-polar and polar compounds, using a standard fractionation column heated to an appropriate temperature, or a packed column. In another embodiment, non-polar compounds or enriched gases from a gas phase separator are extracted for optional later use and in several embodiments, exhaust gases from one or more zones / reactors are fed to a process gas heater. In one embodiment, gases extracted from the pre-heating zone / reactor, the pyrolysis zone / reactor and, optionally, the cooling zone / reactor are extracted in a combined stream and fed into the gas phase separator. In several modalities, one or more zones / reactors are configured to control whether and how much gas is introduced into the combined stream.
[0190] As discussed above and generally illustrated in figure 5, exhaust gases 124/224 from BPU 102/202 are directed to the gas phase separator 200. In several embodiments, exhaust gases 124/224 include gases 120 extracted from the first zone / reactor / preheating 112/212 combined with the gases extracted 122/222 from the second zone / reactor / pyrolysis 114/214 or from any gas stream alone. When the exhaust gases 124/224 enter the gas phase separator 200, the exhaust gases 124/224 are separated into polar compounds 128/228/136/236 and non-polar compounds 204, such as non-polar gases. In several embodiments, the gas phase separator 200 is a known fractionation column.
[0191] In several embodiments, the enriched gases 204 extracted from the combined exhaust gases 124/224 are directed from the gas phase separator 200 in the carbon recovery unit 500 through the inlet 524, which enriches the material. As discussed above and as illustrated in figures 8 and 11, it should be appreciated that in several modalities, the extracted gases are first introduced in a material enrichment unit, and then in a
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63/160 separate carbon recovery unit. In the embodiment illustrated in figure 5, the enrichment of the material occurs in the carbon recovery unit 500. In one embodiment (figure 5), the gas phase separator 200 includes a plurality of outlets. In several embodiments, an output of the gas phase separator 200 is connected to the carbon recovery unit 500 to introduce an enriched gas stream to the carbon recovery unit 500. In one embodiment, a portion of the enriched gas stream is directed for the carbon recovery unit 500 and another portion is directed to a purifier, or other purification apparatus suitable for purification and elimination of unwanted gas. In several embodiments, the exhaust gases that are not sent to the carbon recovery unit can be used for any energy recovery (for example, in a process gas heater) or as an inert gas (for example, in the de-aeration, reactor, BPU, or refrigerator). Similarly, in several embodiments, exhaust gases from the carbon recovery unit can be used for any energy recovery (for example, in a process gas heater), as an inert gas (for example, in the de-aeration unit) , reactor, BPU, or refrigerator), or in a secondary recovery unit.
[0192] In one embodiment, another outlet of the gas phase separator extracts polar compounds, optionally, condensing them into a liquid component, including a plurality of different liquid parts. In several modalities, the liquid includes water, acetic acid, methanol and furfural. In several ways, the liquid emitted is stored, disposed of, further processed, or reused. For example, it should be appreciated that the water emitted in one mode can be reused to heat or cool another portion of a system. In another mode, the water is drained. In addition, it should be appreciated that acetic acid, methanol and furfural emitted in one modality can be sent to
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64/160 storage for reuse, resale, distillation or refinement.
[0193] As can be seen in figure 5, the carbon recovery unit 500 of one embodiment comprises a housing with an upper portion and a lower portion. It should be appreciated that, in several modalities in which a material enrichment unit is separated from the carbon recovery unit, the material enrichment unit includes characteristics similar to those discussed with respect to the carbon recovery unit 500 in figure 5. In one embodiment, the carbon recovery unit, comprises: a housing 502 with an upper portion 502a and a lower portion 502b; an inlet 524 in a bottom of the lower portion of the housing configured to carry exhaust gas from the reactor; an outlet 534 at an upper portion of the upper portion of the housing configured to carry a concentrated gas stream; a path 504 defined between the upper portion and the lower portion of the housing; and a conveying system 528 following the path, the conveying system configured for conveying reagent, in which the housing is shaped so that the reagent adsorbed at least part of the reactor exhaust gas. In various embodiments, the upper portion includes a plurality of outlets and the lower portion includes a plurality of inlets.
[0194] In one embodiment, housing 502 is substantially free of corners having an angle of 110 degrees or less, 90 degrees or less, 80 degrees or less or 70 degrees or less. In one embodiment, housing 502 is substantially free of convex corners. In another embodiment, housing 502 is substantially free of convex corners capable of producing swirls or trapping the air. In another embodiment, frame 502 is substantially shaped as a cube, rectangular prism, ellipsoid, stereographic ellipsoid, spheroid, two cones affixed base to base, two regular tetrahedra affixed base to base, two rectangular pyramids affixed base to base or two isosceles triangular prisms affixed
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65/160 base to base.
[0195] In one embodiment, the upper portion 502a and the lower portion 502b of housing 502 are each substantially shaped as an ellipsoid half, a rectangular half prism, stereographic ellipsoid half, a spheroidal half, a cone, a tetrahedron regular, a rectangular pyramid, an isosceles triangular prism or a round-to-rectangular duct transition.
[0196] In another embodiment, the inlet 524 at the bottom of the lower portion of the housing 502b and the outlet 534 at the top of the upper portion of the housing 502a are configured to connect with a pipe. In another embodiment, the upper portion of the lower portion of the housing 502b and the lower portion of the upper portion of the housing 502a are substantially rectangular, circular or elliptical. In another embodiment, the width between the upper portion of the lower portion of the housing 502b and the lower portion of the upper portion of the housing 502a is greater than the width of the transport system 528. In one embodiment, the width of the transportation system 528 is your Height.
[0197] In one embodiment, the carbon recovery unit 500 comprises a path 504 defined between the upper and lower portions, an inlet opening 506 and an outlet opening 508. In one embodiment, the inlet opening and the outlet opening are configured to receive the transport system. In one embodiment, the transport system 528 is at least semi-permeable or permeable to the enrichment gas.
[0198] In one embodiment, the inlet opening 506 includes a sealing mechanism of the inlet opening to reduce the gas leak and the outlet opening 508 includes a sealing mechanism of the outlet opening to reduce the gas leak. In one embodiment, the sealing mechanisms of the inlet and outlet openings comprise an air lock.
[0199] In several embodiments, the lower portion 502b of the unit housing
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66/160 carbon recovery has a narrow round bottom connection opening, which is connected to the gas phase separator 200 for transporting gas stream 204. In several embodiments, the upper part of the lower portion 502b of the housing carbon recovery unit 500 is substantially rectangular in shape and substantially larger than the narrow round bottom connection port. It should be appreciated that in one embodiment, the lower portion makes the transition from a round bottom opening to an opening at the rectangular top. In one embodiment, the opening of the upper rectangular portion of the lower portion is about six feet wide (along the direction of the conveyor system). In various embodiments, the upper portion of the carbon recovery unit 500 is shaped substantially in a similar manner to the lower portion. In one embodiment, the lower opening of the upper portion is wider than the upper opening of the lower portion. In one embodiment, the lower rectangular opening of the upper portion is about six feet wide (along the direction of the conveyor system). In one embodiment, the upper portion is configured to capture all gases passed through the carbon recovery unit 500 that are not adsorbed by the activated materials.
[0200] It should be appreciated that, in various modalities, the shape of the lower portion of the carbon recovery unit helps to reduce and disperse gases 204 across a larger surface area of the carrier that carries the 126/226 biogenic reagent. In various embodiments, the exact shape of the lower 502b and upper 502a portions of the carbon recovery unit 500 depends on the angle of dispersion of gas from the gas phase separator tubing. It should be appreciated that in several modalities, natural gas will tend to expand when it is pumped in an extended range between 5 and 30 degrees in relation to the vertical. In one embodiment, the magnified angle is approximately 15 degrees. It should be appreciated that the bottom portion of the carbon recovery unit is
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67/160 built with as few bends and corners as possible to prevent air capture or swirling.
[0201] In one embodiment, the carbon recovery unit 500 is configured to connect to the gas phase separator 200 as discussed above, as well as the BPU 102/202. In several modalities, the carbon recovery unit 500 is connected to the outlet of the reactor / cooling zone 216/116, or to the last cooling zone of the BPU 102/202 or outside the BPU. In one embodiment, the 116/216 reactor / cooling zone outlet includes biogenic reagent that was processed in BPU 102/202. In one embodiment, the 126/226 biogenic reagent enters the carbon recovery unit 500 along a suitable transport system. In several embodiments, the upper and lower portions of the carbon recovery unit are connected to each other, and define a path through which a transport system passes. In one embodiment, the transport system is constructed with a mesh or porous material configured to allow gas to pass through it. It should be appreciated that the transport system is configured to pass through an opening in the carbon recovery unit 500 and then through an exit opening in the carbon recovery. In some embodiments, the inlet and outlet inside and outside the carbon recovery unit are properly sealed with an air lock or other suitable sealing mechanism to prevent gases from escaping through the conveyor opening. In several embodiments, the exhaust gases that are not sent to the carbon recovery unit can be used for any energy recovery (for example, in a process gas heater) or as an inert gas (for example, in the de-aeration, reactor, BPU or refrigerator). Similarly, in several embodiments, the exhaust gases from the carbon recovery unit can be used for any energy recovery (for example, in a process gas heater), as an inert gas
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68/160 (for example, in the de-aeration unit, reactor, BPU or refrigerator), or in a secondary recovery unit.
[0202] In several modalities, the process operates the 126/226 biogenic reagent from the 116/216 cooling zone on the transport system for the first exit using a suitable discharge mechanism from the reactor / cooling zone 116/216. In one embodiment, the 126/216 biogenic reagents are spread over the entire width of the transport system, to minimize material stacking or group and maximize the surface area for gaseous adsorption. At the point where biogenic reagents 126/216 are deposited and adequately spread in the transport system, in different modalities, the transport system transports biogenic reagent 126/216 through the opening in the carbon recovery unit 104 defined between the lower portion and the upper portion discussed above. In the carbon recovery unit 104, the biogenic reagent 126/216 adsorb channeled gases in the lower portion of the carbon recovery unit 104 of the gas phase separator 200. After the biogenic reagent is enriched with non-polar gases, it should be appreciated that the biogenic reagent becomes a high carbon biogenic reagent. In several embodiments, the high-carbon biogenic reagent is an end product of the process disclosed in this document and is transported away from the carbon recovery unit 104 in suitable storage or post-processing apparatus.
[0203] In one embodiment, after the enriched gases 204 pass through the carrier and the 126/216 biogenic reagent, the resulting gas is extracted in the upper portion of the carbon recovery unit 104. In several embodiments, the gases 134 are taken to an adequate purification, stacking or recovery system. In some embodiments, the exhaust gases are exploited for any reusable qualities in the system, including use in a secondary carbon recovery unit or for energy. In
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69/160 In various modalities, exhaust gases that are not sent to the carbon recovery unit can be used for any energy recovery (for example, in a process gas heater) or as an inert gas (for example, in de-aeration unit, reactor, BPU or refrigerator). Similarly, in several embodiments, the exhaust gases from the carbon recovery unit can be used for any energy recovery (for example, in a process gas heater), as an inert gas (for example, in the de-aeration, reactor, BPU or refrigerator), or in a secondary recovery unit.
[0204] It should be appreciated that biogenic reagents 126/216 include a high amount of carbon, and carbon has a high preference for adsorption of non-polar gases. In addition, it should be appreciated that the enriched gas stream 204 includes mainly non-polar gases such as terpenes, carbon monoxide, carbon dioxide and methane. In several modalities, when the enriched gases are directed from the gas phase separator in the carbon recovery unit, the gas flow rate and the conveyor speed are monitored and controlled to ensure maximum absorption of non-polar gases in the biogenic reagent 126/216. In another embodiment, the high energy organic compounds comprise at least a portion of the enriched gases 204 eluted during the carbonization of the biomass, and emitted from the gas phase separator 200 to the carbon recovery unit 104. In several embodiments, the enriched gases 204 are additionally enriched with additional additives before being introduced into the carbon recovery unit or material enrichment unit.
[0205] As discussed in more detail below, in various modalities, the residence time of the biogenic reagent 126/216 in the carbon recovery unit is controlled and varies based on the composition of the biogenic reagent 126/216
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70/160 and gas flow and composition. In one embodiment, biogenic reagents are passed through one or more carbon recovery units more than once. In several embodiments, the outlet of the dissipated air from the gas phase separator and the outlet of the dissipated air from the carbon recovery unit 104 can be bypassed or forked into an additional or even more refined carbon recovery unit or used for energy or inert gas for use in the process.
[0206] Referring generally to figures 6 to 13, several modalities of the present disclosure are illustrated and discussed. It should be appreciated that the various modalities and alternatives discussed below with respect to figures 6 to 13 apply to the modalities of figures 1 to 5 discussed above, and vice versa.
[0207] Referring now specifically to figure 6, this modality can use a BPU including a single reactor having two for a greater plurality of different zones. The two zones are shown in the illustrative mode, however, any different number of zones could be used. In one embodiment, each zone is connected to at least one other zone, through a material transport unit (not shown). In one embodiment, the material transport unit controls the temperature and atmosphere conditions.
[0208] Specifically in an embodiment illustrated in figure 6, system 600 includes a material feeding system 602, a BPU 606, including a pyrolysis zone 608 and a cooling zone 610, a refrigerator 614 and a recovery unit carbon 616. It should be appreciated that the refrigerator 614 of figure 6 is outside the BPU 606, and is, furthermore, in the cooling zone 610 that resides inside the BPU 606.
[0209] In several embodiments, the 600 system includes an optional dryer between the material feed system 602 and the BPU 606. In several embodiments, the BPU 606 includes a plurality of zones. In figure 6, BPU 606
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71/160 includes a pyrolysis zone 608 and a cooling zone 610. BPU 606 also includes at least a plurality of inlets and outlets for adding substances and removing various substances from the plurality of zones 608, 610, including at least condensable vapors and non-condensable gases 612. It should be appreciated that in several modalities discussed below, one or more of the plurality of zones 608 or 610 are bounded by BPU 606.
[0210] Referring now to figure 7, a system 700 of a modality is illustrated and discussed. The 700 system includes a single reactor system, including a material feed system 702, a preheater 706, a pyrolysis reactor 708, a refrigerator 714 and a carbon recovery unit 716. In several embodiments, the 700 system includes an optional dryer 704 between the material feed system 702 and the preheater 706. As can be seen in figure 7, the pyrolysis reactor 708 of one embodiment includes at least one gas inlet 710 and at least one outlet 712 to emit substances from the pyrolysis reactor 708. In several embodiments, the substances emitted by outlet 712 include condensable vapors and / or non-condensable gases. It should be appreciated that the 708 pyrolysis reactor may include one or more zones, not discussed in detail in this document. In several modalities, the 700 system includes one or more reactors, in addition to the 708 pyrolysis reactor.
[0211] Referring now to Figure 8, a single reactor, a multi-zone BPU system 800 of a modality is illustrated and discussed. System 800 includes a material feeding system 802, a BPU 808 having a pyrolysis zone 810 and a cooling zone 812, a material enrichment unit 818, and a carbon recovery unit 820. Similar to the modalities discussed above , figure 8 also includes an optional dryer 804 located between the material feed system 802 and the BPU 808. It should be appreciated that moisture 806 from dryer 804 is removed during the drying process. Figure 8
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72/160 also includes an optional cooler 816 outside BPU 808 and before material enrichment unit 818. As discussed in more detail below, material enrichment unit 818 is in communication with a gas outlet 814 from BPU 808, which carries condensable vapors and non-condensable gases from the BPU. It should be appreciated that several embodiments illustrated in figure 8 include a separate carbon recovery unit 820 from material enrichment unit 818. As discussed above, in several embodiments, the carbon recovery unit 820 in figure 8 is an appropriate vessel in the which the enriched material is stored after the material enrichment unit 818, and the carbon recovery unit 820 does not further enrich the material.
[0212] It should be appreciated that, in several modalities, an optional process gas heater 824 is arranged in the system and fixed in the BPU 808. In several modalities, vapors or other exhaust gases from the BPU 808 are introduced in the gas heater. optional 824 process, along with an external source of any one or more of air, natural gas, and nitrogen. As discussed below, in various embodiments, the air emissions from the process gas heater 824 are introduced into the dryer 804 as a heat or energy recovery system.
[0213] Referring now to Figure 9, a BPU 908 of a 900 system of a modality is illustrated and discussed. BPU 908 includes a plurality of zones: the preheating zone 904, the pyrolysis zone 910 and the cooling zone 914. The BPU 908 of one embodiment also includes a material feeding system 902 in communication with one of the zones of at least one gas inlet 906 in communication with one or more of zones 904, 910, 914. In several embodiments, as discussed below, one of the zones also includes at least one outlet 912 to emit substances, in one embodiment, condensable vapors and / or non-condensable gases. In several modalities, one of the zones also includes an outlet for advanced carbon emission from the 900 system.
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73/160 [0214] It should be appreciated that, although figure 9 shows the gas inlet 906 being connected to the preheating zone 904, several modalities include inlets in any combination of the three zones. Similarly, it should be appreciated that, while the 912 gas outlet comes from the pyrolysis zone 910, several modalities include outlets outside one or more of any combination of the three zones. As discussed below, several modalities contemplated include entrances and exits within the BPU: for example, an exit from the pyrolysis zone 910 next is the entrance to the preheating zone 904. It should be appreciated that, in the illustrated mode, each of the reactors in the BPU are connected to another through the material supply system, as discussed above.
[0215] In various modalities, the preheating zone 904 of BPU 908 is configured to feed biomass 902 (or other raw material containing carbon) in a way that does not impact biomass, which could break through cell walls and start the rapid decomposition of the solid phase into vapors and gases. In one embodiment, the preheat zone 904 can be considered as mild pyrolysis.
[0216] In several modalities, the pyrolysis zone 910 of BPU 908 is configured as the primary reaction zone, in which the preheated material undergoes pyrolysis chemistry to release condensable gases and vapors, resulting in a solid material, which is a high carbon reaction intermediate. The components of biomass (mainly cellulose, hemicellulose and lignin) decompose and create vapors, which escape by penetrating through pores or creating new nanopores. The latter effect contributes to the creation of porosity and surface area.
[0217] In several modalities, the cooling zone 914 of the BPU 908 is configured to receive high carbon reaction intermediate and to cool the solids, that is, the cooling zone 914 will have a lower temperature than the pyrolysis zone 910 In cooling zone 914, chemistry and mass transport
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74/160 can be complex. In several embodiments, secondary reactions occur in the cooling zone 914. It should be appreciated that carbon-containing components that are in the gas phase can decompose to form additional fixed carbon and / or become adsorbed to the carbon. In this way, advanced carbon 916 is not simply the devolatilized, solid waste from the processing steps, but instead includes additional carbon that has been deposited from the gas phase, such as by decomposing organic vapors (for example, tar ) that can form carbon.
[0218] Referring now to figures 10 to 13, several modalities of the system's reactor are illustrated and discussed. Similar to each of the modalities, the systems include an optional deaerator and an optional dryer, as discussed in more detail below. Referring to figure 10, system 1000 includes a material feed system 1002, a pyrolysis reactor 1012, a cooling reactor 1018, a refrigerator 1020 and a carbon recovery unit 1022. As further discussed below, a source gas 1016 is configured to inlet gas into one or both of the pyrolysis reactor 1012 and the cooling reactor 1018. In several embodiments, the pyrolysis reactor includes an outlet to emit at least condensable vapors and / or non-condensable gases. In several embodiments, the carbon recovery unit 1022 includes an outlet 1024 to emit activated carbon from the 1000 system [0219] It should be appreciated that, in several embodiments illustrated at least in figures 10 to 13, the illustrated systems include a deaerator optional and an optional dryer. As can be seen in figure 10, for example, represented by dashed lines, the optional deaerator 1004 is connected to the system 1000 between the material feed system 1002 and the pyrolysis reactor 1002. Similarly, dryer 1006 is connected to the system 1000 between the material feeding system 1002 and the pyrolysis reactor 1012. In several modalities, the dryer
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1006 and de-aerator 1004 are also connected to each other so that the material of the material feed system can follow any number of different paths through the material feed system, de-aerator, dryer, and to the pyrolysis reactor. It should be appreciated that, in some embodiments, the material only passes through an optional deaerator 1004 and dryer 1006.
[0220] In some embodiments, with reference to figure 10, a process for producing a high carbon biogenic reagent comprises the following steps:
(a) supplying a carbon-containing raw material comprising biomass;
(b) optionally drying the raw material to remove at least a portion of the moisture contained within the raw material;
(c) optionally de-aerating the raw material to remove at least a portion of interstitial oxygen, if any, contained in the raw material;
(d) pyrolyze the raw material in the presence of an inert gas phase substantially at least 10 minutes and at least a selected temperature of about 250 ° C to about 700 ° C, to generate pyrolysed solids, condensable vapors, and gases non-condensable;
(e) separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids;
(f) cooling hot pyrolyzed solids to generate cooled pyrolyzed solids; and (g) recovering a high carbon biogenic reagent comprising at least a portion of the cooled pyrolyzed solids.
[0221] Referring now to figure 11, a system of multiple reactors 1100 of a modality is illustrated. Similar to the modality discussed above and illustrated in figure 10, this modality includes a material feeding system 1102, reactor
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76/160 pyrolysis 1112, cooler reactor 1118, and carbon recovery unit 1124. In the embodiment illustrated in figure 11, cooler 1120 is optional, and a material enrichment unit 1122 is arranged between the cooler 1120 and the carbon recovery unit 1124. It should be appreciated that, in various embodiments, the material enrichment unit 1122 enriches the material before proceeding to the carbon recovery unit 1124, which may or may not further enrich the material. In several embodiments, an optional deaerator 1104 and an optional dryer 1106 are arranged between the material feed system 1102 and the pyrolysis reactor 1112. In the illustrated embodiment, the pyrolysis reactor 1112 also includes an outlet 1114 configured to remove substances such as condensable vapors and non-condensable gases, and direct the removed substances to the material enrichment unit 1122.
[0222] Several modalities extend the concept of additional carbon formation, including a separate material enrichment unit 818, 1122 in which the cooled carbon is subjected to an environment including carbon-containing species, to enrich the carbon content of the final product. When the temperature of this unit is below pyrolysis temperatures, the additional carbon should be in the form of an adsorbed carbonaceous species, rather than additional fixed carbon.
[0223] As will be described in detail below, there are a large number of options such as to intermediate input and output currents (purge or probe) of one or more phases present in any specific reactor, several mass and energy recycling schemes, several additives that can be introduced anywhere in the process, adjust process conditions, including reaction and separation conditions for the purpose of adapting product distributions, and so on. Inlet and outlet currents from reactor or specific zone allow good monitoring and control of the process, such as through sampling by
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FTIR and dynamic process adjustments.
[0224] The present disclosure is different from rapid pyrolysis, and is different from conventional slow pyrolysis. High quality carbon materials in the present disclosure, including compositions with high fractions of fixed carbon, can be obtained from the disclosed processes and systems.
[0225] Biomass, for purposes of dissemination, must be interpreted as any biogenic raw material or mixture of biogenic and non-biogenic raw material. Basically, biomass includes at least carbon, hydrogen and oxygen. The methods and apparatus of the invention can accommodate a wide range of raw materials of various types, sizes and moisture content.
[0226] Biomass includes, for example, plant and plant material, vegetation, agricultural waste, forest waste, wood waste, paper waste, animal waste, poultry waste and solid urban waste. In various embodiments of the invention when using biomass, the raw material of the biomass can include one or more materials selected from: wood harvest residues, soft wood shavings, hard wood shavings, tree branches, tree stumps, knots , leaves, bark, sawdust, out-of-specification paper pulp, cellulose, corn, corn straw, wheat straw, rice straw, cane bagasse, yellow millet, miscellaneous, animal manure, municipal waste, municipal sewage, commercial waste , grape, pumice, almond shells, pecan shells, coconut shells, coffee grounds, grass pellets, hay pellets, wood pellets, cardboard, paper, carbohydrates, plastic, and fabric. A person skilled in the art will understand that the options for raw materials are virtually unlimited [0227] Various modalities of this disclosure should also be used for raw materials containing carbon other than biomass, such as a fossil fuel (for example, coal coke or oil), or any mixtures of biomass and fossil fuels (such as mixtures of
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78/160 biomass / coal). In some embodiments, a biogenic raw material is, or includes, coal, bitumen, crude oil, asphalt, or crude oil processing solids (such as coke). Raw materials can include waste tires, recycled plastics, recycled paper and other waste or recycled materials. Any method, apparatus or system described in this document can be used with any carbonaceous raw material. Carbon-containing raw materials can be transported by all known means, such as by truck, train, ship, barge, tractor trailer, or any other vehicle or means of transport.
[0228] The selection of a specific raw material or raw materials is not considered technically critical, but is carried out in a way that tends to favor an economic process. Normally, regardless of the raw materials chosen, there may be (in some modalities) sieving to remove undesirable materials. The raw material can optionally be dried before processing.
[0229] The raw material used can be supplied or processed in a wide variety of particle sizes or formats. For example, the feed material can be a fine powder, or a mixture of fine and coarse particles. The feed material can be in the form of large pieces of material, such as wood chips or other forms of wood (for example, round, cylindrical, square, etc.). In some embodiments, the feed material comprises pellets or other agglomerated forms of particles that have been compressed together or otherwise bonded, such as with a binder.
[0230] Note that size reduction is an energy-intensive and costly process. The pyrolysed material can be sized with significantly less energy input, that is, it can be more energy efficient to reduce the particle size of the product, not the raw material. This is an option in the present disclosure, because the process does not require starting material
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79/160 fine, and there is not necessarily any reduction in particle size during processing. The present disclosure provides the ability to process large pieces of raw material. Notably, many applications in the high carbon product market do require large sizes (for example, in the order of centimeters), so that in some embodiments, large pieces are fed, produced and sold. It should be appreciated that, although not necessary in all disclosure modalities, the smaller design resulted in higher numbers of fixed carbon under similar process conditions and may be preferred in some modalities.
[0231] When it is desired to produce a final carbonaceous biogenic reagent that has structural integrity, such as in the form of cylinders, there are at least two options in the context of the present invention. First, the material produced from the process is collected, and then mechanically processed in the desired way. For example, the product is compressed or pelleted, with a binder. The second option is to use feed materials that generally have the desired size and / or shape for the final product and employ processing steps that do not destroy the basic structure of the feed material. In some embodiments, the feed material and the product have similar geometric shapes, such as spheres, cylinders or cube.
[0232] The ability to maintain the approximate shape of feed material throughout the process is beneficial when product strength is important. In addition, this control avoids the difficulty and cost of pelletizing high-carbon fixed materials.
[0233] The starting feed material in various modalities is supplied with a variety of humidity levels, which will be appreciated. In some embodiments, the feed material is already sufficiently dry that it does not need to be dried further before pyrolysis. Normally, it would be desirable to use fonts
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80/160 commercial biomass, which generally contains moisture, and feed the biomass through a drying step before introduction into the pyrolysis reactor. However, in some embodiments the dry raw material is used. It should be appreciated that, in several modalities, although any biomass works, the following factors can affect the process and its products: how the material is cultivated, harvested, irrigated, selection of material species and carbon content. In particular, in several modalities, low fertilizer and low phosphorus used in cultivation result in better properties for producing metal. In several modalities, low impact shear during harvest results in greater strength. In several modalities, less irrigation and smaller growth rings can result in greater strength.
[0234] It should be appreciated that, in various modalities, catalysts and / or additives are included in the BPU, and temperature profiles within the BPU are selected to promote the production of carbon dioxide in carbon monoxide, leading to greater fixed carbon in the final product.
[0235] It is desirable to provide a relatively low oxygen environment in the pyrolysis reactor, such as about 10% by weight, 5% by weight, 3% by weight, or 1% by weight of O2 in the gas phase. First, uncontrolled combustion should be avoided in the pyrolysis reactor, for safety reasons. Some amount of oxidation from total carbon to CO2 can occur, and the heat released from exothermic oxidation can aid in endothermic pyrolysis chemistry. Large amounts of carbon oxidation, including partial oxidation of synthesis gas, will reduce the carbon yield for solids.
[0236] Practically speaking, it can be difficult to achieve a strictly oxygen-free environment in each of the reactor (s) or in the BPU. This limit can be addressed, and in some embodiments, the reactor (s) or the BPU is substantially free of molecular oxygen in the gas phase. To ensure that little
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81/160 or no oxygen is present in the reactor (s) or in the BPU, it may be desirable to remove the air from the feed material prior to its introduction into the reactor (s) or in the BPU. There are several ways to eliminate or reduce the air in the raw material.
[0237] In some modalities, as seen in figures 10, 11, 12 and 13, a de-aeration unit is used in such raw materials, before or after drying, it is transported in the presence of another gas that can remove adsorbed oxygen and penetrate the pores of the raw material to remove oxygen from the pores. Most gases that have less than 21% by volume of O2 can be used, varying in effectiveness. In some embodiments, nitrogen is used. In some modalities, CO and / or CO2 is used. Mixtures can be used, such as a mixture of nitrogen and a small amount of oxygen. Steam may be present in the de-aeration gas, although the addition of significant moisture to the feed should be avoided. The effluent from the de-aeration unit can be purged (to the atmosphere or to an emissions treatment unit) or recycled.
[0238] In principle, the effluent (or a portion of it) from the de-aeration unit could be introduced into the pyrolysis reactor itself since the oxygen removed from the solids will now be highly diluted. In the present modality, it may be advantageous to introduce the effluent deaeration gas in the last zone of the reactor, when it is operated in a countercurrent configuration.
[0239] Various types of deaeration units can be used. In one embodiment, if drying were performed, de-aeration after drying would prevent the step of purifying soluble oxygen out of the present moisture. In certain embodiments, the drying and de-aeration steps are combined into a single unit, or a certain amount of de-aeration is achieved during drying.
[0240] The feed material, optionally de-aerated and optionally dried, is introduced into a pyrolysis reactor or multiple reactors in series or parallel.
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The material feeding system in various modalities introduces the raw material using any known means, including screw material feeding systems or locking funnels, for example. In some embodiments, a material feeding system incorporates an air lock.
[0241] When a single reactor is used (as in figure 6, 3 or 4), several zones can be present. Several zones, such as two, three, four or more zones, can allow separate control of temperature, solids residence time, gas residence time, gas composition, flow pattern, and / or pressure to adjust the overall performance of the process.
[0242] As discussed above, references to zones should be interpreted broadly to include regions of space within a single physical unit (as in figures 6, 8 or 9), physically separate units (as in figures 7 and 10 to 13) or any combination of these. For a BPU, the demarcation of zones where the BPU may be related to the structure, such as the presence of steps inside the BPU or different heating elements to provide heat to separate the zones. Alternatively, or, moreover, in different modalities, the demarcation of zones in a BPU refers to the function, such as, at least: different temperatures, fluid flow patterns, solid flow patterns and the extent of the reaction. In a single batch reactor, the zones are operating in time rather than space. Several modalities include the use of multiple batch BPUs.
[0243] It will be appreciated that there are not necessarily abrupt transitions from one area to another. For example, the boundary between the preheating zone and the pyrolysis zone can be somewhat arbitrary; some amount of pyrolysis may occur in a portion of the preheat zone, and some amount of preheat may continue to occur in the pyrolysis zone. The temperature profile in the BPU is generally continuous, including at the limits of the zone within the zone.
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83/160 [0244] Some modalities, as seen, for example, in figure 9, employ a preheating zone 304 that is operated under conditions of preheating and / or light pyrolysis. In various embodiments, the temperature of the preheat zone 304 is about 80 ° C to about 500 ° C, such as about 300 ° C to about 400 ° C. In several modalities, the temperature of the preheat zone 304 is not so high as to impact the biomass material that breaks the cell walls and initiates rapid decomposition of the solid phase into gases and vapors. Pyrolysis commonly known as rapid or instant pyrolysis is avoided in the present disclosure.
[0245] All references to zone temperatures in this specification should be constructed in a non-limiting manner to include temperatures that can be applied to the present bulk solids, or gas phase, or the reactor or BPU walls (on the process). It will be understood that there will be a temperature gradient in each zone, both axially and radially, as well as temporally (that is, in the starting sequence or due to transients). In this way, references to zone temperatures can be references to average temperatures or other effective temperatures that can influence actual kinetics. Temperatures can be directly measured by thermocouples or other temperature probes, or indirectly measured or estimated by other means.
[0246] The second zone, or the primary pyrolysis zone, is operated under pyrolysis or carbonization conditions. The temperature of the pyrolysis zone can be selected from about 250 ° C to about 700 ° C, such as about 300 ° C, 350 ° C, about 400 ° C, 450 ° C, 500 ° C, 550 ° C, about 600 ° C or 650 ° C. Within this zone, the preheated biomass undergoes pyrolysis chemistry to release condensable gases and vapors, leaving a significant amount of solid material as an intermediate in the high carbon reaction. The components of biomass (mainly cellulose, hemicellulose and lignin) decompose and create vapors, which
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84/160 escape by penetrating through pores or creating new pores. The temperature will depend, at least on the residence time of the pyrolysis zone, as well as the nature of the raw material and product properties.
[0247] The cooling zone is operated to cool the intermediate of the high carbon reaction to varying degrees. In several embodiments, the temperature of the cooling zone is a lower temperature than the pyrolysis zone. In various embodiments, the temperature of the cooling zone is selected from about 100 ° C to about 550 ° C, such as about 150 ° C to about 350 ° C.
[0248] In several modalities, chemical reactions continue to occur in the cooling zone. It should be appreciated that, in several modalities, secondary pyrolysis reactions are initiated in the cooling zone. Carbon-containing components that are in the gas phase may condense (due to the reduced temperature of the cooling zone). The temperature remains high enough, however, to promote reactions that can form additional fixed carbon from the condensed liquids (secondary pyrolysis) or at least form bonds between the adsorbed species and the fixed carbon. An exemplary reaction that can occur is the conversion of carbon monoxide into carbon dioxide plus fixed carbon (Boudouard reaction).
[0249] Zone residence times may vary. For a desired amount of pyrolysis, higher temperatures may allow for shorter reaction times, and vice versa. The residence time in a continuous BPU (reactor) is the volume divided by the volumetric flow rate. The residence time in a batch reactor is the batch reaction time, after heating to the reaction temperature.
[0250] It should be recognized that, in multiphase BPUs, there are different residence times. In the present context, in each zone, there will be a residence time (and residence time distribution) of the solids phase and the vapor phase.
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For a given appliance that employs multiple zones, and with a given yield, residence times across zones will generally be coupled on the solids side, but residence times can be decoupled on the vapor side when several inlet and outlet holes are used in individual areas, in different modalities, the residence times of solids and steam are decoupled.
[0251] The residence time of the preheating zone solids can be selected from about 5 min to 60 min, as about 10 min, depending on the temperature and the time required to reach a preheating temperature . The rate of heat transfer, which will depend on the type and size of the particle, the physical apparatus and the heating parameters, will dictate the minimum residence time necessary to allow the solids to reach a predetermined preheating temperature.
[0252] The residence time of the pyrolysis zone solids can be selected from about 10 min to about 120 min, such as about 20 min, 30 min or 45 min. Depending on the pyrolysis temperature in this zone, there should be enough time to allow carbonization chemistry to occur, after the necessary heat transfer. For times below about 10 min, in order to remove large amounts of non-carbon elements, the temperature would need to be quite high, such as above 700 ° C. This temperature would promote rapid pyrolysis and its generation of vapors and gases derived from the carbon itself, which must be avoided when the desired product is a solid carbon.
[0253] In a static system of several modalities, an equilibrium conversion is achieved at a given time. When, as in certain embodiments, steam is continuously flowing over the solids with continuous removal of volatile compounds, the balance constraint can be removed to allow pyrolysis and devolatilization to continue until reaction rates approach
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86/160 of zero. Longer times do not tend to substantially alter the remaining recalcitrant solids.
[0254] The residence time of the cooling zone solids in various modalities can be selected from about 5 min to about 60 min, such as about 30 min. depending on the cooling temperature in this zone, there should be enough time to allow the carbon solids to cool to the desired temperature. The cooling rate and temperature will dictate the minimum residence time required to allow the carbon to be cooled. Additional time may not be desirable, unless some amount of secondary pyrolysis is desired.
[0255] As discussed above, the residence time of the vapor phase can be selected and controlled separately. The residence time of the steam in the preheating zone can be selected from about 0.1 min to about 10 min, such as about 1 min. The residence time of the steam in the pyrolysis zone can be selected from about 0.1 min to about 20 min, such as about 2 min. The residence time of the steam in the cooling zone can be selected from about 0.1 min to about 15 min, such as about 1.5 min. Short vapor residence times promote rapid sweep of volatile compounds out of the system, while longer vapor residence times promote reactions of components in the vapor phase with the continuous solid phase.
[0256] The operation mode of the reactor and the global system can be continuous, semi-continuous, batch, or any combination or variation of these. In some embodiments, the BPU is a continuous, countercurrent reactor, in which the solids and steam flow substantially in opposite directions. The BPU can also be operated in batch, but with a simulated countercurrent vapor flow, as through periodic and removal of the gas phases from the batch vessel.
[0257] Various flow patterns can be desired or observed. With
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87/160 chemical reactions and simultaneous separations involving multiple phases in multiple zones, fluid dynamics can be quite complex. Normally, the flow of solids can approach the flow of the piston (well mixed in the radial dimension) while the flow of steam can approach the flow of fully mixed (fast transport in the radial and axial dimensions). Multiple steam inlet and outlet holes can contribute to the total mix.
[0258] The pressure in each zone can be separately selected and controlled. The pressure in each zone can be independently selected from about 1 kPa to about 3000 kPa, such as about 101.3 kPa (normal atmospheric pressure). Independent control of the pressure zone is possible when multiple gas inlets and outlets are used, including vacuum holes to remove the gas when less than atmospheric zone pressure is desired. Similarly, in a multiple reactor system, the pressure in each reactor can be independently selected and controlled.
[0259] The process can conveniently be operated at atmospheric pressure, in some modalities. There are many advantages associated with operating at atmospheric pressure, ranging from mechanical simplicity to enhanced safety. In certain embodiments, the pyrolysis zone is operated at a pressure of about 90 kPa, 95 kPa, 100 kPa, 101 kPa, 102 kPa, 105 kPa or 110 kPa (absolute pressures).
[0260] The vacuum operation (for example, 10-100 kPa) would promote the rapid sweep of volatile compounds out of the system. Higher pressures (for example, 100-1000 kPa) can be useful when the exhaust gases are fed in a high pressure operation. High pressures can also be useful to promote heat transfer, chemistry or separations.
[0261] The step of separating at least a portion of the condensable vapors and at least one potion of the non-condensable gases from the
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88/160 hot pyrolysed solids can be carried out in the reactor itself, or using a separate separation unit. A substantially inert scanning gas can be introduced into one or more zones. Condensable vapors and non-condensable gases are then transported away from the zone (s) in the scan gases and out of the BPU.
[0262] The sweep gas can be N2, Ar, CO, CO2, H2, H2O, CH4, other light hydrocarbons or combinations of these, for example. The scan gas can first be preheated before introduction, or possibly cooled, if it comes from a heated source.
[0263] The sweep gas removes volatile compounds more completely, taking them out of the system before they can condense or further react later. The sweep gas allows volatile compounds to be removed at higher rates than could be obtained only from volatilization at a given process temperature. Or, the use of the sweep gas allows more moderate temperatures to be used to remove a certain amount of volatile compounds. The reason that the scanning gas improves the removal of volatile compounds is that the separation mechanism is not only related to volatility, but also the removal of the liquid / vapor phase aided by the scanning gas. The scanning gas can reduce the volatilization mass transfer limitations, as well as reduce the thermodynamic limitations, by continually depleting a given volatile species, to cause more of that to evaporate to achieve thermodynamic equilibrium.
[0264] It is important to remove gases loaded with volatile organic carbon from subsequent processing stages in order to produce a product with a high fixed carbon. Without removal, volatile carbon can be adsorbed or absorbed into pyrolysed solids, thus requiring additional energy (cost) to achieve a purer form of carbon, which can be desired. Removing vapors
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89/160 quickly, it is also speculated that porosity can be improved in pyrolysis solids. In several embodiments, higher porosity is desirable, as are activated carbon products.
[0265] In certain embodiments, the sweep gas, in conjunction with a relatively low process pressure, such as atmospheric pressure, provides rapid removal of steam, without the large amounts of inert gas required.
[0266] In some embodiments, the scanning gas flows countercurrently to the direction of the flow of the raw material. In other embodiments, the scanning gas flows countercurrently to the direction of the flow of the raw material. In some embodiments, the flow pattern of the solids approximates the flow in the piston, while the flow pattern of the sweeping gas, and the gas phase generally, approach the flow fully mixed in one or more zones.
[0267] The scan can be performed in any one or more zones. In some embodiments, the sweep gas is introduced into the cooling zone and extracted (together with the volatile compounds produced) from the cooling and / or pyrolysis zones. In some embodiments, the scanning gas is introduced into the pyrolysis zone and extracted from the pyrolysis and / or preheating zones. In some embodiments, the sweep gas is introduced into the preheating zone and extracted from the pyrolysis zone. In this or other modalities, the sweep gas can be introduced in each of the preheating, pyrolysis and cooling zones and also extracted from each zone.
[0268] In some embodiments, the zone or zones in which the separation is carried out is a unit physically separated from the BPU. The separation unit or zone can be arranged between zones, if desired. For example, there may be a separation unit placed between the pyrolysis and cooling zones.
[0269] The sweep gas can be introduced continuously, especially
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90/160 when the flow of solids is continuous. When the pyrolysis reaction is operated as a batch process, the scan gas can be introduced after a certain period of time, or periodically, to remove volatile compounds. Even when the pyrolysis reaction is operated continuously, the scan gas can be introduced semi-continuously or periodically, if desired, with suitable controls and valves.
[0270] The sweep gas containing volatile compounds can leave one or more zones and can be combined if obtained from multiple zones. The resulting gas stream, containing several vapors, can then be fed to a process gas heater for controlling air emissions, as discussed above and illustrated in FIG. 8. Any known thermal oxidation unit can be used. In some embodiments, the process gas heater is fed with natural gas and air, to reach temperatures sufficient for the substantial destruction of the volatile compounds contained therein.
[0271] The effluent from the process gas heater will be a flow of hot gas comprising water, carbon dioxide and nitrogen. This effluent flow can be purged directly for air emissions, if desired. In some embodiments, the energy content of the effluents from the process gas heater is recovered, as a unit for recovering the dissipated heat. The energy content can also be recovered by exchanging heat with another flow (such as the sweep gas). The energy content can be used for direct or indirect heating, or heating aid, a unit elsewhere in the process, such as the dryer or reactor. In some modalities, essentially all the effluents from the process gas heater are used for indirect heating (utility side) of the dryer. The process gas heater can use fuels other than natural gas.
[0272] The yield of the carbonaceous material may vary, depending on the
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91/160 factors described above, including the type of raw material and process conditions. In some embodiments, the net yield of the solids as a percentage of the starting raw material, on a dry basis, is at least 25%, 30%, 35%, 40%, 45%), 50% or higher. The rest will be divided between condensable vapors, such as terpenes, tars, alcohols, acids, aldehydes or ketones; and non-condensable gases, such as carbon monoxide, hydrogen, carbon dioxide and methane. The relative amounts of condensable vapors compared to non-condensable gases will also depend on the conditions of the process, including the water present.
[0273] In terms of the carbon balance, in some modalities, the net carbon yield, as a percentage of the initial carbon in the raw material, is at least 25%, 30%, 40%, 50%, 60%, 70% or higher. For example, in some embodiments, the carbonaceous material contains between about 40% and about 70% of the carbon contained in the initial raw material. The rest of the carbon results in the formation of methane, carbon monoxide, carbon dioxide, light, aromatic hydrocarbons, tars, terpenes, alcohols, acids, aldehydes or ketones, in varying lengths.
[0274] In alternative modalities, a portion of these compounds are combined with carbon-rich solids to enrich the product's carbon and energy content. In these modalities, some or all of the gas flow resulting from the reactor, containing several vapors, can be condensed, at least in part, and then cooled pyrolyzed solids derived from the cooling zone and / or from the separate refrigerator are passed. These modalities are described in more detail below.
[0275] After the reaction and cooling within the cooling zone (if present), the carbonaceous solids can be introduced into a refrigerator. In some embodiments, solids are collected and simply allowed to cool at slow rates. If the carbonaceous solids are reactive or unstable in the air, it may be desirable to maintain an inert atmosphere and / or rapidly cool the solids, for example
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92/160 example, for a temperature below 40 ° C, such as room temperature. In some embodiments, a water cooler is employed for rapid cooling. In some embodiments, a fluidized bed refrigerator is employed. A “refrigerator” should be largely built to also include containers, tanks, pipes or portions thereof. It should be appreciated that, in several modalities, the refrigerator is different from the cooling unit or the cooling reactor.
[0276] In some modalities, the process also includes the operation of the refrigerator to cool the warm pyrolyzed solids with steam, thus generating the cold pyrolyzed solids and the superheated steam; where drying is carried out, at least in part, with the superheated steam derived from the refrigerator. Optionally, the refrigerator can be operated to first cool the warm pyrolysed solids with steam to reach a first refrigerator temperature and then with air to reach a second refrigerator temperature, where the second refrigerator temperature is lower than first refrigerator temperature and is associated with a reduced combustion risk for warm pyrolyzed solids in the presence of air.
[0277] After cooling to ambient conditions, carbonaceous solids can be recovered and stored, transported to another location of operation, transported to another location, or, on the other hand, discarded, traded or sold. The solids can be fed to a unit to reduce the particle size. A variety of size reduction units are known in the art, including crushers, shredders, grinders, sprayers, jet mills, pin mills and ball mills.
[0278] Sieving or other means of separation based on particle size can be included. The screening can be upstream or downstream of the grinding, if present. A portion of the sieved material (for example, large
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93/160 pieces) can be returned to the grinding unit. Small and large particles can be recovered for separate uses downstream. In some embodiments, the cooled pyrolyzed solids are ground into a fine powder, such as a powdered carbon or activated carbon product or increased strength.
[0279] Various additives can be introduced throughout the process, before, during or after any step disclosed in this document. Additives can be broadly classified as process additives, selected to improve process performance, such as carbon yield or pyrolysis time / temperature to achieve a desired carbon purity; and product additives, selected to improve one or more properties of the biogenic altocarbon reagent, or a downstream product incorporating the reagent. Certain additives can provide enhanced process and product characteristics, such as the overall yield of the biogenic reagent, compared to the quantity of the biomass feedstock.
[0280] Additives can be added before, during or after any one or more of the process steps, including in the raw material itself, at any time, before or after it is harvested. Additive treatment can be incorporated before, during or after dimensioning, drying or other preparation of the raw material. Additives can be incorporated into or on top of raw material supply facilities, discharge equipment, storage receptacles, conveyors (including open or closed conveyors), dryers, process heaters or any other units. Additives can be added anywhere in the pyrolysis process itself, using suitable means for introducing the additives. Additives can be added after carbonization, or even after spraying, if desired.
[0281] In some embodiments, an additive is selected from a metal, a metal oxide, a metal hydroxide or a combination of these. For example, a
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94/160 additive can be selected from, but is not limited to, magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide , magnesium oxide, dolomite, dolomitic lime, fluorite, fluorite, bentonite, calcium oxide, lime and combinations thereof.
[0282] In some embodiments, an additive is selected from an acid, base or salt. For example, an additive can be selected from, but not limited to, sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, potassium permanganate or combinations thereof.
[0283] In some embodiments, an additive is selected from a metal halide. Metal halides are composed of metals and halogens (fluorine, chlorine, bromine, iodine and astate). Halogens can form many compounds with metals. Metal halides are generally obtained by directly combining, or more commonly, neutralizing the base metal salt with a hydroalogenic acid. In some modalities, an additive is selected from iron halide (FeX2 and / or FeXs), iron chloride (FeCl2 and / or FeCl3), iron bromide (FeBr2 and / or FeBr3) or its hydrates and any combinations thereof.
[0284] Additives can result in a final product with a higher energy content (energy density). An increase in energy content can result from an increase in total carbon, fixed carbon, volatile carbon or even hydrogen. Alternatively or additionally, the increase in energy content may result from the removal of non-combustible material or material with an energy density lower than carbon. In some embodiments, additives reduce the extent of liquid formation, in favor of solid and gas formation, or in favor of solid formation.
[0285] In several modalities, additives chemically modify the initial biomass, or the biomass treated before pyrolysis, to reduce the rupture of
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95/160 cell walls for greater strength / integrity. In some embodiments, additives can increase the fixed carbon content of the biomass raw material before pyrolysis.
[0286] Additives can result in a final biogenic reagent with improved mechanical properties, such as yield strength, compressive strength, tensile stress, fatigue stress, impact resistance, elasticity module, compressibility module or shear module . Additives can improve mechanical properties simply because they are present (for example, the additive itself gives resistance to the mixture) or due to a transformation that takes place in the additive phase or within the resulting mixture. For example, reactions, such as vitrification, can occur within a portion of the biogenic reagent that includes the additive, thereby improving the final resistance.
[0287] Chemical additives can be applied to wet or dry the raw material of biomass. Additives can be applied as a solid powder, a spray, a mist, a liquid or a vapor. In some embodiments, additives can be introduced by spraying a liquid solution (such as an aqueous solution or in a solvent), or by immersion in tanks, receptacles, bags or other containers.
[0288] In certain modalities, immersion pretreatment is employed, in which the solid raw material is dipped in a bath comprising the additive, discontinuously or continuously, for a time sufficient to allow the additive to penetrate the feed material. solid.
[0289] In some embodiments, additives applied to the raw material can reduce the energy requirements for pyrolysis, and / or increase the yield of the carbonaceous product. In this or other modalities, the additives applied to the raw material can provide the functionality that is desired for the intended use of the carbonaceous product, as will be described further below on the compositions.
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96/160 [0290] Productivity, or process capacity, can vary widely from small laboratory scale units to full commercial scale biorefineries, including any pilot, demonstration or semi-commercial scale. In various modalities, the process capacity is at least about 1 kg / day, 10 kg / day, 100 kg / day, 1 ton / day (all tons are metric tons), 10 tons / day, 100 tons / day, 500 tonnes / day, 1000 tonnes / day, 2000 tonnes / day, or more.
[0291] In some embodiments, a portion of the solids produced can be recycled to the front end of the process, that is, to the drying or de-aerating unit or directly to the BPU or reactor. Returning to the front end and passing through the process again, the treated solids can become higher in fixed carbon. The solid, liquid and gaseous flows produced or existing within the process can be recycled independently, passed on to subsequent steps, or removed / purged from the process at any point.
[0292] In some embodiments, the pyrolysed material is recovered and then fed to a separate reactor for additional pyrolysis, to create a product with greater carbon purity. In some embodiments, the secondary process can be carried out in a simple container, such as a steel drum, through which a heated inert gas (for example, heated N2) passes through. Other containers useful for this purpose include process tanks, barrels, receptacles, closed containers, bags and cargo boxes. This secondary sweep gas with volatile compounds can be sent to the process gas heater, or back to the main BPU, for example. To cool the final product, another flow of inert gas, which is initially at room temperature, for example, can be passed through the solids to cool the solids, and then returned to a pre-heating system for the inert gas. In several modalities, the
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97/160 secondary process takes place in a separate carbonization or pyrolysis reactor, in which the substantially preheated inert gas is introduced to pyrolyze the material and conduct carbonization.
[0293] Some embodiments of the invention provide a high carbon biogenic reagent production system comprising:
(a) a material feeding system configured to introduce a raw material containing carbon;
(b) an optional dryer, arranged in operable communication with the material feeding system, configured to remove the moisture contained within a carbon-containing raw material;
(c) a biomass processing unit, including a plurality of zones, arranged in operable communication with the dryer, wherein the biomass processing unit contains at least one pyrolysis zone arranged in operable communication with a spatially separate cooling zone , and where the biomass processing unit is configured with an outlet to remove condensable vapors and non-condensable gases from the solids;
(d) an external refrigerator, arranged in operable communication with the biomass processing unit; and (e) a carbon recovery unit, arranged in operable communication with the refrigerator.
[0294] Some variations provide a high carbon biogenic reagent production system that comprises:
(a) a material feeding system configured to introduce a raw material containing carbon;
(b) an optional dryer, arranged in operable communication with the material feeding system, configured to remove the moisture contained within a carbon-containing raw material;
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98/160 (c) an optional preheater, arranged in operable communication with the dryer, configured to slightly heat and / or pyrolyze the raw material;
(d) a pyrolysis reactor, arranged in communication operable with a preheater, configured to pyrolyze the raw material;
(e) a refrigerator, arranged in operable communication with the pyrolysis reactor, configured to cool the pyrolyzed solids; and (f) a carbon recovery unit, arranged in operable communication with the chiller, in which the system is configured with at least one gas outlet to remove condensable vapors and non-condensable gases from the solids.
[0295] The material feeding system can be physically integrated with the BPU, as through the use of a screw material feeding system or helical thread mechanism to introduce feed solids in one of the reactors or zones.
[0296] In some modalities, the system also includes a preheating zone, arranged in operable communication with the pyrolysis zone. Each of the pyrolysis zone, cooling zone and preheating zone (if present) can be located within a single BPU, or can be located in separate BPUs.
[0297] Optionally, the dryer can be configured as a drying zone within the BPU. Optionally, the cooler can be arranged within the BPU (ie, configured as an additional cooling zone or integrated with the cooling zone discussed above).
[0298] The system may include a purging means for removing oxygen from the system. For example, the purging means may comprise one or more inlets to introduce a substantially inert gas, and one or more outlets to remove the substantially inert gas and displaced oxygen from the system. In
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99/160 some modalities, the purging means is a deaerator disposed in operable communication between the dryer and the BPU.
[0299] The BPU can be configured with at least one first gas inlet and one first gas outlet.
[0300] The first gas inlet and the first gas outlet can be arranged in communication with different zones, or with the same zones.
[0301] In some embodiments, the BPU is configured with a second gas inlet and / or a second gas outlet. In some embodiments, the BPU is configured with a third gas inlet and / or a third gas outlet. In some embodiments, the BPU is configured with a fourth gas inlet and / or a fourth gas outlet. In some modalities, each zone present in the BPU is configured with a gas inlet and a gas outlet.
[0302] The gas inlets and outlets allow not only the introduction and removal of steam, but the gas outlets (probes), in particular, allow for accurate monitoring and control of the process through various stages of the process, up to and potentially including all stages of the process. Accurate process monitoring would be expected to result in improvements in performance and efficiency, both dynamically, as well as for a period of time when the operational history can be used to adjust process conditions.
[0303] In some embodiments (see, in general, FIG. 4), a reaction gas probe is arranged in operable communication with the pyrolysis zone. Such a reaction gas probe can be useful for extracting gases and analyzing them in order to determine the extent of the reaction, the selectivity of pyrolysis or other monitoring of the process. Then, based on the measurement, the process can be controlled or adjusted in a number of ways, such as adjusting the feed rate, inert gas scan rate, temperature (of one or more zones), pressure (of one or more zones ), additives, and so on.
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100/160 [0304] As intended in this document, monitoring and control via reaction gas probes must be interpreted to include any one or more sample extractions via reaction gas probes and, optionally, make adjustments to the process or equipment based on measurements, if deemed necessary or desirable, using well-known principles of process control (feedback, feedforward, proportional-integral-derivative logic, etc.).
[0305] A reaction gas probe can be configured to extract gas samples in a number of ways. For example, a sampling line may have a lower pressure than the pressure of the pyrolysis reactor, so that when the sampling line is opened, a quantity of gas can easily be extracted from the pyrolysis zone. The sampling line may be under vacuum, as when the pyrolysis zone is close to atmospheric pressure. Typically, a reaction gas probe will be associated with a gas outlet, or a portion thereof (for example, a line divided from a gas outlet line).
[0306] In some embodiments, a gas inlet and a gas outlet are used as a reaction gas probe by periodically introducing an inert gas into a zone, and pulling the inert gas with a sample of the process out of the outlet gas (sample sweep). Such an arrangement can be used in a zone that, on the other hand, has no gas inlet / outlet for substantially inert gas for processing, or the reaction gas probe can be associated with a separate gas inlet / outlet present, in addition to the process inputs and outputs. An inert sampling gas that is introduced and extracted periodically for sampling (in modalities that use sample sweeps) could even be different from the inert gas of the process, if desired, both for reasons of precision in the analysis and to introduce an analytical marker.
[0307] For example, the concentration of acetic acid in the gas phase of the pyrolysis zone can be measured using a gas probe to extract a sample, which
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101/160 is then analyzed using a suitable technique (such as gas chromatography, GC; mass spectroscopy, MS; GC-MS, or Fourier Transformed Infrared Spectroscopy, FTIR). The concentration of CO and / or CO2 in the gas phase could be measured and used as an indication of the selectivity of pyrolysis for gases / vapors, for example. The concentration of terpene in the gas phase could be measured and used as an indication of the selectivity of pyrolysis for liquids, and so on.
[0308] In some modalities, the system also comprises at least one additional gas probe arranged in operable communication with the cooling zone, or with the drying zone (if present) or with the preheating zone (if present).
[0309] A gas probe for the cooling zone can be useful to determine the extent of any additional chemicals occurring in the cooling zone, for example. A gas probe in the cooling zone can also be useful as an independent temperature measurement (in addition, for example, to a thermocouple disposed in the cooling zone). This independent measurement can be a correlation of the cooling temperature with a measured quantity of a given species. The correlation could be developed separately, or it could be established after a period of operation of the process.
[0310] A gas probe for the drying zone can be useful to determine the degree of drying, measuring the water content, for example. A gas probe in the preheating zone could be useful to determine the degree of any mild pyrolysis occurring, for example.
[0311] In certain embodiments, the cooling zone is configured with a gas inlet, and the pyrolysis zone is configured with a gas outlet, to generate a substantially countercurrent flow of the gas phase in relation to the solid phase. Alternatively, or in addition, the preheating zone (when
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102/160 is present) can be configured with a gas outlet, to generate a substantially countercurrent flow of the gas phase in relation to the solid phase. Alternatively, or in addition, the drying zone can be configured with a gas outlet, to generate a substantially countercurrent flow.
[0312] The pyrolysis reactor or reactors can be selected from any suitable reactor configuration that is capable of carrying out the pyrolysis process. Exemplary reactor configurations include, but are not limited to, fixed bed reactors, fluidized bed reactors, entrained flow reactors, helical threads, rotary cones, rotary drum furnaces, calciners, roasters, moving bed reactors, bed reactors transported, ablative reactors, spinning cones or microwave assisted pyrolysis reactors.
[0313] In some embodiments, in which a helical thread is used, sand or another heat carrier can optionally be used. For example, the raw material and sand can be fed at one end of a screw. The screw mixes sand and raw material and transports them through the reactor. The screw can provide good control of the residence time of the raw material and not dilute the pyrolyzed products with a carrier or fluidizing gas. The sand can be reheated in a separate vessel.
[0314] In some modalities, in which an ablative process is used, the raw material is moved at high speed against a hot metal surface. The ablation of any coal forming on surfaces can maintain a high rate of heat transfer. Such devices can prevent product dilution. As an alternative, the particles of the raw material can be suspended in a carrier gas and introduced at a high speed through a cyclone, whose wall is heated.
[0315] In some embodiments, in which a fluidized bed reactor is used, the raw material can be introduced into a bed of hot fluidized sand
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103/160 by a gas, which is normally a recirculated product gas. The reference in this document to sand should also include similar materials, substantially inert, such as glass particles, recovered ash particles and the like. High rates of heat transfer from fluidized sand can result in rapid heating of the raw material. There may be a little bit of ablation by friction with the sand particles. Heat is generally supplied by heat exchange tubes, through which hot combustion gas flows.
[0316] Circulating fluidized bed reactors can be used, in which gas, sand and raw material move together. Exemplary transport gases include recirculated product gases and flue gases. High rates of heat transfer from the sand ensure rapid heating of the raw material, and the ablation is expected to be stronger than with regular fluidized beds. A separator can be used to separate the product gases from the sand and coal particles. The sand particles can be reheated in a fluidized burner vessel and recycled to the reactor.
[0317] In some embodiments, the BPU is a continuous reactor comprising an input of the raw material, a plurality of spatially separate zones configured to separately control the temperature and mixture within each zone, and an output of carbonaceous solids, in which one of the zones is configured with a first gas inlet to introduce a substantially inert gas into the BPU, and in which one of the zones is configured with a first gas outlet.
[0318] In various modalities, the reactor includes at least two, three, four or more zones. Each of the zones is arranged in communication with the separately adjustable heating medium selected independently from the group consisting of electric heat transfer, steam heat transfer, hot oil heat transfer, phase change heat transfer,
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104/160 dissipated heat transfer and combinations thereof. In some embodiments, at least one zone is heated with an effluent flow from the process gas heater, if present.
[0319] The BPU can be configured to separately adjust the composition of the gas phase and residence time of the gas phase of at least two zones, up to and including all zones present in the BPU.
[0320] The BPU can be equipped with a second gas inlet and / or a second gas outlet. In some modalities, the BPU is configured with a gas inlet in each zone. In these or other modalities, the BPU is configured with a gas outlet in each zone. The BPU can be a co-current or counter-current reactor.
[0321] In some embodiments, the material feeding system comprises a screw or helical thread mechanism. In some embodiments, the outlet of carbonaceous solids comprises a screw or helical thread outlet mechanism.
[0322] Certain modalities use a rotary calciner with a screw material feeding system. In these modalities, a part or all of the BPU is axially rotating, that is, it rotates on its axis of axis. The speed of rotation will impact the solid flow pattern and the heat and mass transport. Each of the zones can be configured with steps arranged on the inner walls, to provide agitation of the solids. The steps can be separately adjustable in each zone.
[0323] Other means of stirring the solids can be used, such as helical threads, screws or conveyors with paddles. In some embodiments, the BPU includes a single, continuous helical thread, arranged along each of the zones. In other modalities, the reactor includes twin screws arranged along each of the zones.
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105/160 [0324] Some systems are specifically designed with the ability to maintain the approximate size of the feed material throughout the process - that is, to process the biomass raw material without significantly destroying or damaging its structure. In some embodiments, the pyrolysis zone does not contain helical threads, screws or squeegees that would tend to significantly reduce the size of the feed material being pyrolyzed.
[0325] In some embodiments of the invention, the system also includes a process gas heater arranged in operable communication with the outlet, by which condensable vapors and non-condensable gases are removed. The process gas heater can be configured to receive a separate fuel (like natural gas) and an oxidizer (like air) in a combustion chamber, adapted for combustion of the fuel and at least a portion of the condensable vapors. Certain non-condensable gases can also be oxidized, such as CO or CH4, to CO2.
[0326] When a process gas heater is employed, the system may include a heat exchanger disposed between the process gas heater and the dryer, configured to use at least part of the combustion heat for the dryer. This modality can contribute significantly to the overall energy efficiency of the process.
[0327] In some modalities, the system also includes a material enrichment unit, arranged in operable communication with the refrigerator, configured to combine the condensable vapors, in a form at least partially condensed, with the solids. The material enrichment unit can increase the carbon content of the high carbon biogenic reagent obtained from the carbon recovery unit.
[0328] The system may also include a separate pyrolysis zone adapted to further pyrolyze the high carbon biogenic reagent to further increase
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106/160 plus its carbon content. The separate pyrolysis zone can be a relatively simple container, unit or device, such as a tank, barrel, receptacle, drum, closed container, bag or cargo box.
[0329] The total system can be in a fixed location, or it can be made portable. The system can be built using modules that can simply be duplicated for a practical, proportional increase. The system can also be built using economies of scale, as is well known in the process industry.
[0330] Some variations regarding the carbon enrichment of solids will now be described. In some embodiments, a process for producing a high carbon biogenic reagent comprises:
(a) the supply of a carbon-containing raw material comprising a biomass;
(b) optionally, drying the raw material to remove at least a portion of the moisture contained within the raw material;
(c) optionally, deaerating the raw material to remove at least a portion of the interstitial oxygen, if any, contained in the raw material;
(d) in a pyrolysis zone, the pyrolysis of the raw material in the presence of a substantially inert gas for at least 10 minutes and with a pyrolysis temperature, selected from about 250 ° C to about 700 ° C, to generate heat-pyrolyzed solids, condensable vapors and non-condensable gases;
(e) separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids;
(f) in a cooling zone, the cooling of the hot pyrolysed solids, in the presence of substantially inert gas for at least 5 minutes and with a cooling temperature below the pyrolysis temperature, to generate the
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107/160 warm pyrolyzed solids;
[0331] (g), optionally, cooling the warm pyrolyzed solids in a refrigerator to generate the cold pyrolyzed solids;
[0332] (h) the subsequent passage of at least a portion of the condensable vapors and / or at least a portion of the non-condensable gases from step (e) through the warm pyrolyzed solids and / or cold pyrolyzed solids, to form the enriched pyrolyzed solids with increased carbon content; and in a carbon recovery unit, the recovery of a high carbon biogenic reagent comprising at least a portion of the enriched pyrolyzed solids.
[0333] In some embodiments, step (h) includes passing at least a portion of the condensable vapors from step (e), in the form of vapor and / or condensate, through the warm pyrolyzed solids, to produce the pyrolyzed solids enriched with increased carbon content. In some embodiments, step (h) includes passing at least a portion of the non-condensable gases from step (e) through the warm pyrolyzed solids to produce the enriched pyrolyzed solids with an increased carbon content.
[0334] It should be appreciated that in several modalities, carbon enrichment increases the carbon content, the energy content, as well as the mass yield.
[0335] Alternatively, or in addition, vapors or gases may come in contact with cold pyrolyzed solids. In some embodiments, step (h) includes passing at least a portion of the condensable vapors from step (e), in the form of vapor and / or condensate, through the cold pyrolyzed solids, to produce the pyrolyzed solids enriched with carbon content increased. In some embodiments, step (h) includes the passage of at least a portion of the non-condensable gases from step (e) through cold pyrolyzed solids, to produce the solids
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108/160 pyrolysates enriched with increased carbon content.
[0336] In certain embodiments, step (h) includes the substantial passage of all condensable vapors from step (e), in the form of vapor and / or condensate, through cold pyrolyzed solids, to produce the pyrolyzed solids enriched with increased carbon. In certain embodiments, step (h) includes the substantial passage of all non-condensable gases from step (e) through the cold pyrolyzed solids, to produce the enriched pyrolyzed solids with increased carbon content.
[0337] The process may include various methods of treating or separating vapors or gases before using them for carbon enrichment. For example, an intermediate feed stream consisting of at least a portion of the condensable vapors and at least a portion of the non-condensable gases, obtained from step (e), can be fed to a separation unit, configured to generate at least a first and a second outflow. In certain embodiments, the intermediate supply flow comprises all condensable vapors, all non-condensable gases, or both.
[0338] Separation techniques may include or use distillation columns, flash vessels, centrifuges, cyclones, membranes, filters, filled beds, capillary columns and so on. The separation can be mainly based, for example, on distillation, absorption, adsorption or diffusion and can use differences in vapor pressure, activity, molecular weight, density, viscosity, polarity, chemical functionality, affinity to a stationary phase and any combinations of these.
[0339] In some embodiments, the first and second output streams are separated from the intermediate feed stream based on relative volatility. For example, the separation unit can be a distillation column, a tank
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109/160 flash or a condenser.
[0340] Thus, in some embodiments, the first outflow comprises condensable vapors and the second outflow comprises non-condensable gases. Condensable vapors may include at least one carbon-containing compound, selected from terpenes, alcohols, acids, aldehydes or ketones. Pyrolysis vapors can include aromatic compounds, such as benzene, toluene, ethylbenzene and xylenes. Heavier aromatic compounds, such as refractory tars, may be present in the vapor. Non-condensable gases can include at least one carbon-containing molecule selected from the group consisting of carbon monoxide, carbon dioxide and methane.
[0341] In some embodiments, the first and second output streams are separate intermediate feed streams based on relative polarity. For example, the separation unit can be an emptying column, a full bed, a chromatography column or membranes.
[0342] Thus, in some embodiments, the first outflow comprises polar compounds, and the second outflow comprises non-polar compounds. Polar compounds can include at least one carbon-containing molecule selected from the group consisting of methanol, furfural and acetic acid. Non-polar compounds can include at least one carbon-containing molecule selected from the group consisting of carbon monoxide, carbon dioxide, methane, a terpene and a terpene derivative.
[0343] Step (h) can increase the total carbon content of the high carbon biogenic reagent, compared to an otherwise identical process without step (h). The degree of increase in carbon content can be, for example, about 1%, 2%, 5%, 10%, 15%, 25% or even greater, in various modalities.
[0344] In some embodiments, step (h) increases the fixed carbon content of the high carbon biogenic reagent. In these or other modalities, step (h)
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110/160 increases the volatile carbon content of the high carbon biogenic reagent. The volatile carbon content is the carbon assigned to the volatile matter in the reagent. The volatile matter can be, but is not limited to, hydrocarbons, including aliphatic or aromatic compounds (for example, terpenes); oxygenates, including alcohols, aldehydes or ketones; and several tars. The volatile carbon will usually remain bound or adsorbed to the solids under ambient conditions, but after heating, it will be released before the fixed carbon is oxidized, aerated or otherwise released as a vapor.
[0345] Depending on the conditions associated with step (h), it is possible for an amount of volatile carbon to become fixed carbon (for example, through Boudouard carbon formation from CO). Normally, volatile matter is expected to enter the fixed carbon micropores and be present as condensed / adsorbed species, but still relatively volatile. This residual volatility may be more advantageous for fuel applications, compared to product applications that require high surface area and porosity.
[0346] Step (h) can increase the energy content (ie energy density) of the high carbon biogenic reagent. The increase in energy content may result from an increase in total carbon, fixed carbon, volatile carbon or even hydrogen. The degree of increase in energy content can be, for example, about 1%, 2%, 5%, 10%, 15%, 25% or even greater, in various modalities.
[0347] Other separations can be used to recover one or more non-condensable gases or condensable vapors, for use within the process or further processing. For example, additional processing can be included to produce refined CO or syngas.
[0348] As another example, separation of acetic acid can be performed, followed by the reduction of acetic acid in ethanol. The reduction of acetic acid can
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111/160 be carried out, at least in part, using hydrogen derived from the non-condensable gases produced.
[0349] Condensable vapors can be used for energy in the process (such as thermal oxidation) or for carbon enrichment, to increase the carbon content of the high carbon biogenic reagent. Certain non-condensable gases, such as CO or CH4, can be used both for energy in the process and as part of the gas substantially inert for the pyrolysis step. Combinations of any of the above are also possible.
[0350] A potential benefit of including step (h) is that the gas flow is purified, with the resulting gas flow being enriched in CO and CO2. The resulting gas stream can be used for energy recovery, recycled for the carbon enrichment of solids, and / or used as an inert gas in the reactor. Similarly, the separation of non-condensable gases from condensable vapors, the CO / CO2 flow is prepared for use as the inert gas in the reactor system or in the cooling system, for example.
[0351] Other variations of the invention are established as a premise in realizing that the principles of the carbon enrichment stage can be applied to any raw material, in which one wishes to add carbon.
[0352] In some embodiments, a batch or continuous process for the production of a high carbon biogenic reagent comprises:
(a) providing a solid flow comprising a carbon-containing material;
(b) providing a gas stream comprising carbon-containing condensable vapors, carbon-containing non-condensable gases or a mixture of carbon-containing condensable vapors and carbon-containing non-condensable gases; and (c) passing the gas flow through the solid flow under suitable conditions
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112/160 to form a carbon containing product with an increased carbon content compared to the carbon containing material.
[0353] In some embodiments, the starting material containing carbon is pyrolysed biomass or roasted biomass. The gas flow can be obtained during an integrated process that supplies the material containing carbon. Or, the gas flow can be obtained from separate processing of the carbon-containing material. The gas flow, or a portion of it, can be obtained from an external source (for example, an oven at a sawmill). Mixtures of gas flows, as well as mixtures of carbon-containing materials, from a variety of sources, are possible.
[0354] In some embodiments, the process further comprises recycling or reusing the gas flow to repeat the process to further increase the carbon and / or energy content of the carbon-containing product. In some embodiments, the process further comprises recycling or reusing the gas stream to carry out the process to increase the carbon and / or energy content of another raw material other than the material containing carbon.
[0355] In some embodiments, the process also includes the introduction of the gas flow in a separation unit, configured to generate at least the first and the second outlet flows, in which the gas flow comprises a mixture of condensable vapors containing carbon and non-condensable gases containing carbon. The first and second output streams can be separated based on relative volatility, relative polarity or any other property. The gas flow can be obtained by processing separately from the carbon-containing material.
[0356] In some embodiments, the process also comprises recycling or reusing the gas flow to repeat the process to further increase the carbon content of the carbon-containing product. In some modalities, the process also includes recycling or reusing the gas flow to carry out the
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113/160 process to increase the carbon content of another raw material.
[0357] The product containing carbon may have an increased total carbon content, a higher fixed carbon content, a higher volatile carbon content, a higher energy content or any combination of these, in relation to the starting material containing carbon.
[0358] In related variations, the high carbon biogenic reagent production system comprises:
(a) a material feeding system configured to introduce a raw material containing carbon;
(b) an optional dryer, arranged in operable communication with the material feeding system, configured to remove the moisture contained within a carbon-containing raw material;
(c) a BPU, arranged in operable communication with the dryer, in which the BPU contains at least one pyrolysis zone arranged in operable communication with a spatially separate cooling zone, and in which the BPU is configured with an outlet to remove condensable vapors and non-condensable gases from solids;
(d) a refrigerator, arranged in operable communication with the BPU;
(e) a material enrichment unit, arranged in operable communication with the refrigerator, configured to pass condensable vapors and / or non-condensable gases through solids, to form enriched solids with increased carbon content; and (f) a carbon recovery unit, arranged in operable communication with the material enrichment unit.
[0359] The system can also comprise a pre-heating zone, arranged in operable communication with the pyrolysis zone. In some embodiments, the dryer is configured as a drying zone within the BPU. Each of the
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114/160 zones can be located within a single BPU or in separate BPUs. In addition, the refrigerator can be disposed within the BPU.
[0360] In some embodiments, the cooling zone is configured with a gas inlet, and the pyrolysis zone is configured with a gas outlet, to generate a substantially countercurrent flow of the gas phase in relation to the solid phase. In these or other modalities, the preheating zone and / or the drying zone (or dryer) is configured with a gas outlet, to generate a substantially countercurrent flow of the gas phase in relation to the solid phase.
[0361] In specific modalities, the system incorporates a material enrichment unit that comprises:
a carcass with an upper portion and a lower portion;
(ii) an entrance to a bottom of the lower portion of the housing, configured to transport condensable vapors and non-condensable gases;
(iii) an outlet at the top of the upper portion of the housing, configured to carry a flow of concentrated gas derived from condensable vapors and non-condensable gases;
(iv) a defined path between the upper and lower portions of the carcass; and (v) a material transport system, following the path, the material transport system configured to transport the solids, in which the carcass is molded, such that the solids adsorb at least some of the condensable vapors and / or at least some of the non-condensable gases.
[0362] The present invention is capable of producing a variety of compositions useful as high carbon biogenic reagents and products that incorporate these reagents. In some variations, a high carbon biogenic reagent is produced by any process disclosed in this document, as a process comprising the steps of:
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115/160 (a) supply of a carbon-containing raw material comprising a biomass;
(b) optionally, drying the raw material to remove at least a portion of the moisture contained within the raw material;
(c) optionally, deaerating the raw material to remove at least a portion of the interstitial oxygen, if any, contained with the raw material;
(d) in a pyrolysis zone, the pyrolysis of the raw material in the presence of a substantially inert gas for at least 10 minutes and with a selected pyrolysis temperature of about 250 ° C to about 700 ° C, to generate solids hot pyrolysates, condensable vapors and non-condensable gases;
(e) separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids;
(f) in a cooling zone, the cooling of the hot pyrolyzed solids, in the presence of substantially inert gas for at least 5 minutes and with a cooling temperature below the pyrolysis temperature, to generate the warm pyrolyzed solids;
(g) cooling the warm pyrolyzed solids to generate the cold pyrolyzed solids; and (h) recovering a high carbon biogenic reagent comprising at least a portion of the cold pyrolyzed solids.
[0363] In some embodiments, the reagent comprises at least about 55% by weight, for example at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight or at least 95% by weight of the total dry carbon. Total carbon includes at least fixed carbon, and may also include carbon from volatile matter. In some embodiments, the carbon in the volatile matter is at least 5%, at least
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10%, at least 25% or at least 50% of the total carbon present in the high carbon biogenic reagent. The fixed carbon can be measured, using ASTM D3172, while the volatile carbon can be estimated, using ASTM D3175, for example.
[0364] The high carbon biogenic reagent can comprise about 10% by weight or less, like about 5% by weight or less, of hydrogen on a dry basis. The biogenic reagent may comprise about 1% by weight or less, such as about 0.5% by weight or less, dry nitrogen. The biogenic reagent can comprise about 0.5% by weight or less, such as about 0.2% by weight or less, dry phosphorus. The biogenic reagent may comprise about 0.2% by weight or less, such as about 0.1% by weight or less, sulfur on a dry basis.
[0365] Carbon, hydrogen and nitrogen can be measured, using ASTM D5373 for final analysis, for example. Oxygen can be estimated, using ASTM D3176, for example. Sulfur can be measured, using ASTM D3177, for example.
[0366] Certain modalities provide reagents with little or essentially no hydrogen (except for any moisture that may be present), nitrogen, phosphorus or sulfur and are substantially carbon plus any ash and moisture present. Therefore, some modalities provide a material with up to and including 100% carbon, on a dry ash free basis (DAF).
[0367] In general, raw materials, such as biomass, contain non-volatile species, including silica and various metals, which are not easily released during pyrolysis. Naturally, it is possible to use raw materials without ash, in which case there should be no substantial amounts of ash in the pyrolysed solids. The ashes can be measured, using ASTM D3174, for example.
[0368] Different amounts of non-combustible material, such as ash, may be present. The high carbon biogenic reagent can comprise about
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10% by weight or less, such as about 5% by weight, about 2% by weight, about 1% by weight or less of non-combustible dry matter. In certain embodiments, the reagent contains a little ash, or even essentially no ash or other non-combustible material. Therefore, some modalities essentially supply pure carbon, including 100% carbon, on a dry basis.
[0369] Different amounts of moisture may be present. On a total mass basis, the high carbon biogenic reagent may comprise at least 1% by weight, 2% by weight, 5% by weight, 10% by weight, 15% by weight, 25% by weight, 35% by weight. weight, 50% by weight or more moisture. As intended in this document, moisture should be interpreted as including any form of water present in the biogenic reagent, including absorbed moisture, adsorbed water molecules, chemical hydrates and physical hydrates. The equilibrium moisture content may vary at least with the local environment, such as relative humidity. In addition, humidity can vary during transportation, preparation for use and other logistics. Humidity can be measured, using ASTM D3173, for example.
[0370] The high carbon biogenic reagent can have several energy levels which, for the present purposes, means the energy density based on the highest heating value, associated with the total combustion of the totally dry reagent. For example, the high carbon biogenic reagent may have an energy content of about at least 25,586 kJ / kg (11,000 Btu / lb), at least 27,912 kJ / kg (12,000 Btu / lb), at least 30,238 kJ / kg ( 13,000 Btu / lb), at least 32,564 kJ / kg (14,000 Btu / lb) or at least 34,890 kJ / kg (15,000 Btu / lb). In certain embodiments, the energy content is between about 32,564-34,890 kJ / kg (14,000-15,000 Btu / lb). The energy content can be measured, using ASTM D5865, for example.
[0371] The high carbon biogenic reagent can be formed into a powder,
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118/160 as a coarse powder or a fine powder. For example, the reagent can be formed into a powder with an average mesh size of about 200 mesh, about 100 mesh, about 50 mesh, about 10 mesh, about 6 mesh, about 4 mesh mesh or about 2 mesh, in modalities.
[0372] In some embodiments, the high-carbon biogenic reagent is formed into structural objects comprising pressed, bonded or agglomerated particles. A starting material for forming these objects can be a powder form of the reagent, as an intermediate obtained by reducing the particle size. Objects can be formed by mechanical pressing or other forces, optionally with a binder or other means of agglomerating particles.
[0373] In some embodiments, the high carbon biogenic reagent is produced in the form of structural objects whose structure is substantially derived from the raw material. For example, pieces of the raw material can produce pieces of the high-carbon biogenic reagent. Or, cylinders of the raw material can produce cylinders of the high-carbon biogenic reagent, which may be slightly smaller, but on the other hand, retain the basic structure and geometry of the starting material.
[0374] A high carbon biogenic reagent according to the present invention can be produced as, or formed into, an object that has a minimum dimension of at least about 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, 6 cm, 7 cm, 8 cm, 9 cm, 10 cm, or larger. In various embodiments, the minimum or maximum dimension can be a length, width or diameter.
[0375] Other variations of the invention refer to the modality of the additives in the process, in the product, or both. In some embodiments, the biogenic high carbon reagent includes at least one process additive incorporated during the process. In these or other embodiments, the reagent includes at least one product additive, introduced into the reagent after the process.
[0376] In some embodiments, a high carbon biogenic reagent
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119/160 comprises, on a dry basis:
55% by weight or more of total carbon;
5% by weight or less of hydrogen;
1% by weight or less of nitrogen;
0.5% by weight or less of phosphorus;
0.2% by weight or less of sulfur; and an additive selected from a metal, a metal oxide, a metal hydroxide, a metal halide or a combination thereof.
[0377] The additive can be selected from, but is not limited to, magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, fluorite, fluorite, bentonite, calcium oxide, lime and combinations thereof.
[0378] In some embodiments, a high carbon biogenic reagent comprising, on a dry basis:
55% by weight or more of total carbon;
5% by weight or less of hydrogen;
1% by weight or less of nitrogen;
0.5% by weight or less of phosphorus;
0.2% by weight or less of sulfur; and an additive selected from an acid, base or salt thereof.
[0379] The additive can be selected from, but is not limited to, sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, potassium permanganate or combinations thereof.
[0380] In certain embodiments, a high carbon biogenic reagent comprises, on a dry basis:
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120/160
55% by weight or more of total carbon;
5% by weight or less of hydrogen;
1% by weight or less of nitrogen;
0.5% by weight or less of phosphorus;
0.2% by weight or less of sulfur;
a first additive selected from a metal, metal oxide, metal hydroxide, metal halide or a combination thereof; and a second additive selected from an acid, a base or a salt thereof, wherein the first additive is different from the second additive.
[0381] The first additive can be selected from magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, oxide magnesium, dolomite, dolomitic lime, fluorite, fluorite, bentonite, calcium oxide, lime and combinations of these, while the second additive can be selected independently from sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, chloride hydrogen, sodium silicate, potassium permanganate, or combinations thereof.
[0382] A given high carbon biogenic reagent consists essentially of, on a dry basis, carbon, hydrogen, nitrogen, phosphorus, sulfur, non-combustible matter and an additive selected from the group consisting of magnesium, manganese, aluminum, nickel, chromium , silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, fluorite, fluorite, bentonite, calcium oxide, lime and combinations thereof .
[0383] A given high carbon biogenic reagent consists essentially of, on a dry basis, carbon, hydrogen, nitrogen, phosphorus, sulfur,
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121/160 non-combustible material and an additive selected from the group consisting of sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate and combinations thereof.
[0384] The amount of additive (or total additives) can vary widely, from about 0.01% by weight to about 25% by weight, including about 0.1% by weight, about 1% by weight , about 5% by weight, about 10% by weight, or about 20% by weight. It will be appreciated, then, when relatively large amounts of additives are incorporated, as greater than about 1% by weight, there will be a reduction in the energy content calculated based on the total weight of the reagent (including the additives). Also, in several modalities, the high carbon biogenic reagent with additive (s) can have an energy content of about at least 25,586 kJ / kg (11,000 Btu / lb), at least 27,912 kJ / kg (12,000 Btu / lb) , at least 30,238 kJ / kg (13,000 Btu / lb), at least 32,564 kJ / kg (14,000 Btu / lb) or at least 34,890 kJ / kg (15,000 Btu / lb).
[0385] The above discussion about the shape of the product also applies to the modalities that incorporate additives. In fact, certain modalities incorporate additives as binders or other modifiers to enrich the final properties for a specific application.
[0386] In some embodiments, most of the carbon contained in the high carbon biogenic reagent is classified as renewable carbon. In some modalities, substantially all carbon is classified as renewable carbon. There may be certain market mechanisms (for example, Renewable Identification Numbers, tax credits, etc.) in which the value is assigned to the renewable carbon content within the high carbon biogenic reagent.
[0387] In certain embodiments, the fixed carbon can be classified as non-renewable carbon (eg from coal), while the volatile carbon, which can be added separately, can be the renewable carbon for
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122/160 increase not only the energy content, but also the value of renewable carbon.
[0388] High carbon biogenic reagents produced as described in this document as useful for a wide variety of carbonaceous products. The high carbon biogenic reagent may be a desirable market product in itself. High-carbon biogenic reagents, as provided in this document, are associated with lower levels of impurities, reduced process emissions and improved sustainability (including higher renewable carbon content) compared to the state of the art.
[0389] In variations, a product includes any of the biogenic high carbon reagents that can be obtained by the disclosed processes, or that are described in the compositions presented in this document, or any portions, combinations or derivatives thereof.
[0390] In general, high carbon biogenic reagents can be burned to produce energy (including electricity and heat); partially oxidized or reformed by steam to produce synthesis gas; used for their adsorption or absorption properties; used for their reactive properties during metal refining (such as metal oxide reduction) or other industrial processing; or used for their material properties in carbon steel and various other metal alloys. Essentially, high carbon biogenic reagents can be used for any market application for carbon based goods or advanced materials, including special uses to be developed.
[0391] Prior to suitability or actual use in any product application, the disclosed high-carbon biogenic reagents can be analyzed, measured and optionally modified (as by means of additives) in several ways. Some properties of potential interest, other than chemical composition and energy content, include density, particle size, surface area,
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123/160 microporosity, absorbency, adsorption, binding capacity, reactivity, desulfurization activity and basicity, to name a few properties.
[0392] Products or materials that may incorporate these high carbon biogenic reagents include, but are not limited to, carbon based blast furnace addition products, carbon based taconite pellet addition products, carbon based cooker, carbon based metallurgical coke products, coal substitute products, carbon based coke products, carbon fines products, carbon based fluidized bed raw materials, carbon-based blast furnace, carbon-based injectable products, carbon-based powder products, carbon-based automatic furnace products, carbon electrodes or activated carbon products.
[0393] The use of disclosed high-carbon biogenic reagents in the production of metals can reduce slag, increase overall efficiency and reduce the environmental impacts of the life cycle. Therefore, the modalities of this invention are particularly suitable for processing and fabricating metal.
[0394] Some variations of the invention use high carbon biogenic reagents as carbon based blast furnace addition products. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, such as (but not limited to) iron. Foundry is a form of extractive metallurgy; its main use is to produce a metal from its ore. The smelter uses heat and a chemical reducing agent to break down the ore. Carbon and / or carbon monoxide derived from carbon removes oxygen from the ore, leaving the elemental metal behind.
[0395] The reducing agent may consist of, or comprise, a high carbon biogenic reagent. In a blast furnace, the high carbon biogenic reagent, the ore, and normally the limestone can be continuously supplied from the top of the furnace, while the air (optionally with oxygen enrichment) is
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124/160 blown to the bottom of the chamber, so that chemical reactions take place throughout the oven, as the material moves downwards. The end products are usually molten metal and slag phases taken from the bottom and flue gases coming out of the top of the oven. The downward flow of the ore in contact with an upward flow of hot gases, rich in carbon monoxide is a countercurrent process.
[0396] The quality of carbon in the blast furnace is measured by its resistance to degradation. The role of carbon as a permeable medium is crucial in the economical operation of the blast furnace. Carbon degradation varies with the position in the blast furnace and involves combining the reaction with CO2, H2O or O2 and the abrasion of carbon particles against each other and other components of the load. Degraded carbon particles can cause clogging and poor performance.
[0397] The Coke Reactivity test is a reputable measure of carbon performance in a blast furnace. This test has two components: the Coke Reactivity Index (CRI) and the Coke Resistance after Reaction (CSR). A carbon-based material with a low CRI (high reactivity) value and a high CSR value can provide improved blast furnace performance. The CRI can be determined, according to any suitable method known in the art, for example, by the ASTM DS341 Method on a received basis.
[0398] In some embodiments, the high carbon biogenic reagent, when mixed with another carbon source, for example, up to about 10% by weight or more, provides a final carbon product having properties suitable for combustion at a high -oven.
[0399] The resistance of the high carbon biogenic reagent can be determined by any suitable method, known in the art, for example, by a drop-break test, or a CSR test. In some embodiments, the high carbon biogenic reagent, when mixed with another carbon source,
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125/160 provides a final carbon product having a CSR of at least about 50%, 60% or 70%. A combination product can also provide a final coke product having adequate reactivity for combustion in a blast furnace. In some embodiments, the product has a CRI, such that the high carbon biogenic reagent is suitable for use as an additive or as a replacement for metallurgical coal, metallurgical coke, coke fines, foundry coke or injectable coal.
[0400] Some modalities employ one or more additives in an amount sufficient to provide a high carbon biogenic reagent that, when added to another carbon source (for example, coke) having an insufficient CRI or CSR for use as a blast furnace, provides a composite product with a CRI and / or CSR sufficient for use in a blast furnace. In some embodiments, one or more additives are present in an amount sufficient to provide a high carbon biogenic reagent having a CRI of no more than about 40%, 30% or 20%.
[0401] In some embodiments, one or more additives selected from alkaline earth metals, or oxides or carbonates of these, are introduced during or after the process of producing a high carbon biogenic reagent. For example, calcium, calcium oxide, calcium carbonate, magnesium oxide or magnesium carbonate can be introduced as additives. The addition of these compounds before, during or after pyrolysis can increase or decrease the reactivity of high carbon biogenic reagent in a blast furnace. These compounds can lead to stronger materials, that is, higher CSR, thus improving the efficiency of the blast furnace. In addition, additives, such as those selected from alkaline earth metals, or oxides or carbonates of these, can lead to lower emissions (for example, SO2).
[0402] In some embodiments, a high carbon biogenic reagent contains not only a high content of fixed carbon, but also a very small fraction
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126/160 high volatile carbon as described above. Volatile matter may be desirable for the reduction of metal oxide because it is expected to have the best mass transport in metal oxide at lower temperatures. Compared to fossil-based products, such as coke, high-carbon biogenic reagents can have sufficient strength and more fixed and volatile carbon, which leads to greater reactivity.
[0403] In some embodiments, a blast furnace replacement product is a high carbon biogenic reagent according to the present invention, comprising at least about 55% by weight of carbon, no more than about 0.5 % by weight of sulfur, not more than about 8% by weight of non-combustible material, and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, the blast furnace replacement product still comprises no more than about 0.035% by weight of phosphorus, about 0.5% by weight to about 50% by weight of volatile matter and, optionally, one or more more additives. In some embodiments, the blast furnace replacement product comprises about 2% by weight to about 15% by weight of dolomite, about 2% by weight to about 15% by weight of dolomite lime, about 2% by weight to about 15% by weight of bentonite and / or about 2% by weight to about 15% by weight of calcium oxide. In some embodiments, the blast furnace replacement product has dimensions substantially in the range of about 1 cm to about 10 cm.
[0404] In some embodiments, a high carbon biogenic reagent according to the present invention is useful as a substitute for the foundry coke. Foundry coke is generally characterized as having a carbon content of at least about 85% by weight, a sulfur content of about 0.6% by weight, no more than about 1.5% by weight of matter volatile, no more than about 13% by weight of ash, no more than about 8% by weight of moisture, about 0.035% by weight of phosphorus, a CRI value of about 30, and dimensions varying
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127/160 from about 5 cm to about 25 cm.
[0405] Some variations of the invention use high carbon biogenic reagents as products of addition of carbon-based taconite pellets. The ores used in the production of iron and steel are iron oxides. The main iron oxide ores are hematite, limonite (also called brown ore), taconite and magnetite, a black ore. Taconite is a low quality but important ore that contains magnetite and hematite. The iron content of taconite is generally 25% by weight to 30% by weight. Blast furnaces typically require at least 50% by weight of iron content ore for efficient operation. Iron ores can be processed, including crushing, screening, tumbling, flotation and magnetic separation. Refined ore is enriched to more than 60% iron and is often formed into pellets before dispatch.
[0406] For example, taconite can be ground into a fine powder and combined with a binder such as bentonite clay and limestone. Pellets about a centimeter in diameter can be formed, containing approximately 65% iron, for example. The pellets are burned, oxidizing magnetite to hematite. The pellets are durable, which ensures that the blast furnace charge remains porous enough to allow the heated gas to pass and react with the pelleted ore.
[0407] Taconite pellets can be fed to a blast furnace to produce iron, as described above with reference to blast furnace addition products. In some embodiments, a high carbon biogenic reagent is introduced into the blast furnace. In these or other modalities, a high carbon biogenic reagent is incorporated into the taconite pellet itself. For example, the taconite ore powder, after beneficiation, can be mixed with a high carbon biogenic reagent and a binder and rolled into small objects, and then hardened. In such modalities, the taconite-carbon pellets with the appropriate composition
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128/160 can be conveniently placed in a blast furnace without the need for a separate carbon source.
[0408] Some variations of the invention use high carbon biogenic reagents as carbon based pan addition products. A pan is a vessel used to transport and pour molten metals. Smelting pans are used to pour molten metal into molds to produce the melt. Pan transfers are used to transfer a large amount of molten metal from one process to another. The treatment pots are used for a process to take place inside the pot to change some aspect of the molten metal, such as converting cast iron to a ductile iron by adding various elements to the pot.
[0409] High carbon biogenic reagents can be introduced into any type of pot, but normally the carbon will be added to treatment pots in appropriate quantities based on the target carbon content. The carbon injected into the pans can be in the form of a fine powder, for a good mass transport of the carbon in the final composition. In some embodiments, a high carbon biogenic reagent according to the present invention, when used as a pan addition product, has a minimum dimension of about 0.5 cm, such as about 0.75 cm, about 1 cm, about 1.5 cm, or larger.
[0410] In some embodiments, a high carbon biogenic reagent according to the present invention is useful as a carbon addition additive to a pan in, for example, a basic oxygen oven or electric arc furnace installations, in anywhere where the carbon pan addition would be used (for example, added to the carbon pan during steelmaking). In some embodiments, the pan addition carbon additive is a high carbon biogenic reagent comprising at least about 55% by weight of carbon, no more than about 0.4% by weight of sulfur, no more than about 0.035% by weight
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129/160 phosphorus, and a heating value of at least about 25,586 kJ / kg (11,000 BTU per pound).
[0411] In some embodiments, the pan addition carbon additive comprises up to about 5% by weight of manganese, up to about 5% by weight of calcium oxide and / or up to about 5% by weight of dolomitic lime . In some embodiments, the pan addition carbon additive has a minimum dimension of about 1/4 inch. In some embodiments, the pan addition carbon product has a maximum dimension of about 1/2 inch. In some embodiments, the pan addition carbon additive has a minimum dimension of about 1/4 inch and a maximum dimension of about 1/2 inch. In some embodiments, the pan addition carbon product is substantially free of fossil fuel.
[0412] Direct reduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron ore (in the form of pieces, pellets or fines) by a reducing gas, produced from gas natural or coal. The reducing gas is usually a synthesis gas, a mixture of hydrogen and carbon monoxide, which acts as a reducing agent. The high carbon biogenic reagent, as provided in this document, can be converted into a gas stream comprising CO, to act as a reducing agent to produce the reduced direct iron.
[0413] Iron nuggets are a production of high quality steel and iron foundry feed material. Iron nuggets are essentially all iron and carbon, with almost no gangue (slag) and low levels of metal residues. They are a premium grade pig iron product with superior transport and handling characteristics. The carbon contained in iron nuggets, or any portion of it, may be the high carbon biogenic reagent provided in this document. Iron nuggets can be produced by reducing ore
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130/160 iron in a rotary furnace furnace, using a high carbon biogenic reagent as the reducer and energy source.
[0414] Some variations of the invention use high carbon biogenic reagents as carbon-based metallurgical coke products. Metallurgical coke, also known as met coke, is a carbon material normally manufactured by the destructive distillation of various mixtures of bituminous coal. The final solid is a non-smelting carbon called metallurgical coke. As a result of the loss of volatile gases and partial smelting, coke met has an open, porous morphology. Met coke has a very low volatile content. However, the ash constituents, which were part of the original raw material for bituminous coal, remain encapsulated in the resulting coke. Met coke raw materials are available in a wide range of sizes from fine powder to pieces the size of a basketball. Typical purities range from 86-92% by weight of fixed carbon.
[0415] Metallurgical coke is used where a high quality, hard, resilient wear carbon is needed. Applications include, but are not limited to, conductive paving, friction materials (eg, carbon coatings), foundry coatings, foundry carbon producer, corrosion materials, drilling applications, reducing agents, treatment agents thermal, ceramic packaging media, electrolytic processes and oxygen exclusion.
[0416] Metallurgical coke can be characterized as having a heating value of about 23,260 to 32,564 kJ / kg (10,000 to 14,000 Btu per pound) and an ash content of about 10% by weight or more. Thus, in some embodiments, a metallurgical coke replacement product comprises a high carbon biogenic reagent according to the present invention, comprising at least about 80% by weight, 85% by weight or 90% by weight of carbon, no more than
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131/160 about 0.8% by weight of sulfur, no more than about 3% by weight of volatile matter, no more than about 15% by weight of ash, no more than about 13% by weight moisture weight, and no more than about 0.035% phosphorus weight. In some embodiments, the metallurgical coke replacement product comprises about 55% by weight of carbon, no more than about 0.4% by weight of sulfur, no more than about 0.035% by weight of phosphorus, and a heating value of at least about 25,586 kJ / kg (11,000 BTU per pound). In some embodiments, a metallurgical coke replacement product further comprises about 2% by weight to about 15% by weight of dolomite, for example, about 1% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, about 10% by weight, about 11% by weight. weight, about 12% by weight, about 13% by weight, about 14% by weight, or about 15% by weight of dolomite. In some embodiments, a metallurgical coke replacement product further comprises about 2% by weight to about 15% by weight of bentonite, for example, about 1% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, about 10% by weight, about 11% by weight. weight, about 12% by weight, about 13% by weight, about 14% by weight, or about 15% by weight of bentonite. In some embodiments, a metallurgical coke replacement product further comprises about 2% by weight to about 15% by weight of calcium oxide, for example, about 1% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, about 10% by weight, about 11 % by weight, about 12% by weight, about 13% by weight, about 14% by weight, or about 15% by weight of calcium oxide. In some embodiments, a metallurgical coke substitute product also comprises about 2% by weight to about 15% by weight of dolomitic lime
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132/160 for example, about 1% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, about 10% by weight, about 11% by weight, about 12% by weight, about 13% by weight, about 14% by weight, or about 15% by weight of dolomitic lime. In some embodiments, a metallurgical coke replacement product comprises any combination of about 2% by weight to about 15% by weight of dolomite, about 2% by weight to about 15% by weight of bentonite, about 2 % by weight to about 15% by weight of calcium oxide, and / or about 2% by weight to about 15% by weight of dolomitic lime. A high carbon biogenic reagent according to the present invention, when used as a metallurgical coke replacement product, can have a size range of about 2 cm to about 15 cm, for example. In some embodiments, a metallurgical coke replacement product has a minimum size of about 3/4 inch. In some embodiments, a metallurgical coke replacement product has a maximum dimension of about 4 inches. In some embodiments, a metallurgical coke replacement product has a minimum size of about 3/4 inch and a maximum size of about 4 inches. In some embodiments, a metallurgical coke replacement product is substantially free of fossil fuel.
[0417] In some embodiments, the metallurgical coke replacement product also includes an additive, such as chromium, nickel, manganese, magnesium oxide, silicon, aluminum, dolomite, fluorite, calcium oxide, lime, dolomitic lime, bentonite and combinations of these.
[0418] Some variations of the invention use high carbon biogenic reagents as coal substitute products. Any process or system using coal can, in principle, be adapted to use a high carbon biogenic reagent.
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133/160 [0419] In some embodiments, a high carbon biogenic reagent is combined with one or more coal-based products to form a compound, having a higher category than the carbon-based product (s) coal and / or having less emissions, when burned, than the pure coal-based product.
[0420] For example, a low grade coal, such as subbetuminous coal can be used in applications that normally require a higher grade coal product, such as bituminous coal, combining a selected amount of a high carbon biogenic reagent, according to the present invention, with the low grade coal product. In other embodiments, the category of a mixed coal product (for example, a combination of a plurality of coals from different categories) can be improved by combining the mixed coal with some amount of the high carbon biogenic reagent. The amount of a high carbon biogenic reagent to be mixed with the coal product (s) may vary, depending on the category of the coal product (s), the characteristics of the high carbon biogenic reagent (for example). carbon content, heating value, etc.) and the desired category of the combined final product.
[0421] For example, anthracite coal is generally characterized as having at least about 80% by weight of carbon, about 0.6% by weight of sulfur, about 5% by weight of volatile matter, up to about 15 % by weight of ash, up to about 10% by weight of moisture, and a heating value of about 29 MJ / kg (approximately 12,494 Btu / lb). In some embodiments, an anthracite coal substitute product is a high carbon biogenic reagent according to the present invention, comprising at least about 80% by weight, no more than about 0.6% by weight of sulfur, no more than about 15% ash weight and a heating value of at least about 27,912 kJ / kg (12,000 Btu / lb).
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134/160 [0422] In some embodiments, a high carbon biogenic reagent according to the present invention is useful as a thermal coal replacement product. Thermal coal products are generally characterized as having high levels of sulfur, high levels of phosphorus, high ash content and heating values of up to about 34,890 kJ / kg (15,000 Btu / lb). In some embodiments, a thermal coal replacement product is a biogenic high carbon reagent comprising no more than about 0.5% by weight of sulfur, no more than about 4% by weight of ash and a heating value of at least about 27,912 kJ / kg (12,000 Btu / lb).
[0423] Some variations of the invention use high carbon biogenic reagents as carbon based coke products. Any coking process or system can be adapted to use high carbon biogenic reagents to produce the coke, or use them as a raw material for coke.
[0424] In some embodiments, a high carbon biogenic reagent according to the present invention is useful as a replacement product for coal or thermal coke. For example, a coal or thermal coke replacement product may consist of a high carbon biogenic reagent comprising at least about 50% by weight of carbon, no more than about 8% by weight of ash, no more than about 0.5% by weight of sulfur and a heating value of at least about 25,586 kJ / kg (11,000 Btu / lb). In other embodiments, the thermal coke replacement product further comprises about 0.5% by weight to about 50% by weight of volatile matter. The replacement product for coal or thermal coke may include about 0.4% by weight to about 15% by weight of moisture.
[0425] In some embodiments, a high carbon biogenic reagent, according to the present invention, is useful as a petroleum coke (pet) or a calcination petroleum coke replacement product. Calcination petroleum coke is generally characterized as having at least about 66% by weight
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135/160 carbon, up to 4.6% by weight of sulfur, up to about 5.5% by weight of volatile matter, up to about 19.5% by weight of ash and up to about 2% by weight of moisture , and is usually sized in about 3 meshes or less. In some embodiments, the calcination petroleum coke replacement product is a high carbon biogenic reagent comprising at least about 66% by weight of carbon, no more than about 4.6% by weight of sulfur, no more than about 19.5% by weight of ash, no more than 2% by weight of moisture, and is sized in about 3 meshes or less.
[0426] In some embodiments, a high carbon biogenic reagent in accordance with the present invention is useful as a replacement carbon for coking carbon (for example, burned together with metallurgical coal in a coking oven). In one embodiment, a coke carbon replacement product is a high carbon biogenic reagent comprising at least about 55% by weight of carbon, no more than about 0.5% by weight of sulfur, no more than about 8% by weight of non-combustible material, and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, a coke carbon replacement product is a high carbon biogenic reagent comprising at least about 55% by weight of carbon, no more than about 0.4% by weight of sulfur, no more than about 0.035% by weight of phosphorus, and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, the coke carbon replacement product has a minimum size of about 3/4 inch. In some embodiments, the coke carbon replacement product is substantially free of fossil fuel. In some embodiments, the coke carbon replacement product comprises about 0.5% by weight to about 50% by weight of volatile matter, and / or one or more additives.
[0427] Some variations of the invention use biogenic reagents from
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136/160 high carbon as fine carbon products, which normally have very fine particle sizes, such as 6 mm, 3 mm, 2 mm, 1 mm, or smaller. In some embodiments, a high carbon biogenic reagent according to the present invention is useful as a substitute for coke fines. Coke fines are generally characterized as having a maximum dimension of no more than about 6 mm, a carbon content of at least about 80% by weight, 0.6 to 0.8% by weight of sulfur, 1% to 20% by weight of volatile matter, up to about 13% of ash, up to about 13% by weight of moisture. In some embodiments, a coke fines replacement product is a high carbon biogenic reagent according to the present invention, comprising at least about 80% by weight of carbon, no more than about 0.8% by weight sulfur, no more than about 20% by weight of volatile matter, no more than about 13% by weight of ash, no more than about 13% by weight of moisture, and a maximum dimension of about 6 mm.
[0428] In some embodiments, a high-carbon biogenic reagent in accordance with the present invention is useful as a replacement product for carbon fines during, for example, the production of taconite pellets or in a manufacturing process. iron. In some embodiments, a carbon fines replacement product is a high carbon biogenic reagent comprising at least about 55% by weight of carbon, no more than about 0.4% by weight of sulfur, no more than about 0.035% by weight of phosphorus, and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, the carbon fines replacement product has a minimum size of about 1/8 inch. In some embodiments, the carbon fines replacement product is substantially free of fossil fuel.
[0429] Some variations of the invention use high carbon biogenic reagents as raw materials for various fluidized beds, or as products
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137/160 replacement of raw material based on fluidized carbon. Carbon can be used in fluidized beds for total combustion, partial oxidation, gasification, steam reform or the like. Carbon can be primarily converted into synthesis gas for a number of downstream uses, including energy production (for example, combined heat and energy), or liquid fuels (for example, methanol or Fischer-Tropsch diesel fuels).
[0430] In some embodiments, a high carbon biogenic reagent according to the present invention is useful as a fluidized bed replacement product in, for example, fluidized bed ovens, wherever the coal was used (for example, for process heating or energy production). In some embodiments, a fluidized bed replacement product is a high carbon biogenic reagent that comprises at least about 55% by weight of carbon, no more than about 0.4% by weight of sulfur, no more than about 0.035% by weight of phosphorus, and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, the fluidized bed replacement product has a minimum size of about 1/4 inch. In some embodiments, the fluidized bed replacement product has a maximum dimension of about 2 inches. In some embodiments, the fluidized bed replacement product has a minimum dimension of about 1/4 inch and a maximum dimension of about 2 inches. In some embodiments, the fluidized bed replacement product is substantially free of fossil fuel. Some variations of the invention use high carbon biogenic reagents as carbon based oven addition products. Coal-based furnace addition products are generally characterized as having high levels of sulfur, high levels of phosphorus and high ash content, which contributes to the degradation of the metal product and creates air pollution. In some embodiments, a carbon furnace replacement replacement product comprising a biogenic reagent
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138/160 high carbon comprises no more than about 0.5% by weight of sulfur, no more than about 4% by weight of ash, no more than about 0.03% by weight of phosphorus, and a dimension maximum of about 7.5 cm. In some embodiments, the oven addition replacement product comprises about 0.5% by weight to about 50% by weight of volatile matter and about 0.4% by weight to about 15% by weight of moisture . In some embodiments, the oven addition replacement product is a high carbon biogenic reagent comprising at least about 80% by weight of carbon, no more than about 0.4% by weight or less than sulfur, no more than about 0.035% by weight of phosphorus, no more than about 5% by weight of manganese, no more than about 5% by weight of fluorite, and a heating value of at least about 25,586 kJ / kg (11,000 Btu / lb). In some embodiments, the oven addition replacement product further comprises about 5% by weight to about 10% by weight of dolomite, for example, about 5% by weight, about 6% by weight, about 7 % by weight, about 8% by weight, about 9% by weight, or about 10% by weight of dolomite. In some embodiments, the oven addition replacement product further comprises about 5% by weight to about 10% by weight of dolomitic lime, for example, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, or about 10% by weight of dolomitic lime. In some embodiments, the oven addition replacement product further comprises about 5% by weight to about 10% by weight of calcium oxide, for example, about 5% by weight, about 6% by weight, about of 7% by weight, about 8% by weight, about 9% by weight, or about 10% by weight of calcium oxide. In some embodiments, the oven addition replacement product further comprises about 5% by weight to about 10% by weight of dolomitic lime and about 5% by weight to about 10% by weight of calcium oxide. In some embodiments, the furnace replacement product further comprises about 5% by weight to about 10% by weight of dolomite,
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139/160 about 5% by weight to about 10% by weight of dolomitic lime and about 5% by weight to about 10% by weight of calcium oxide. In some embodiments, the oven addition replacement product has a minimum size of about 3/4 inch. In some embodiments, the oven addition replacement product has a maximum dimension of about 2 inches. In some embodiments, the addition of the oven has a minimum dimension of about 3/4 inch and a maximum dimension of about 2 inches. In some embodiments, the furnace replacement replacement product is substantially free of fossil fuel.
[0431] In some embodiments, a high carbon biogenic reagent according to the present invention is useful as an oven addition carbon additive in, for example, basic oxygen furnaces or electric arc furnaces, where an oven addition carbon could be used. For example, furnace addition carbon can be added to steel scraps during steelmaking, in electric arc furnace installations). For electric arc furnace applications, high-purity carbon is desired so that impurities are not introduced back into the process after previous removal of impurities.
[0432] In some embodiments, an oven addition carbon additive is a high carbon biogenic reagent according to the present invention, comprising at least about 80% by weight of carbon, no more than about 0.5 % by weight of sulfur, not more than about 8% by weight of non-combustible material, and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, the oven-added carbon additive further comprises up to about 5% by weight of manganese, up to about 5% by weight of fluorite, about 5% by weight to about 10% by weight of dolomite, about 5% by weight to about 10% by weight of dolomitic lime, and / or about 5% by weight to about 10% by weight of calcium oxide.
[0433] Some variations of the invention use biogenic reagents from
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140/160 high carbon as carbon based products from automatic furnace. In some embodiments, a high carbon biogenic reagent according to the present invention is useful as an automatic furnace coal replacement product in, for example, automatic furnace installations, where the coal would be used (for example, for process heating or energy production). In some embodiments, an automatic furnace carbon replacement product is a high carbon biogenic substitute comprising at least about 55% by weight of carbon, no more than about 0.4% by weight of sulfur, no more than about 0.035% by weight of phosphorus, and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, the automatic furnace carbon replacement product has a minimum size of about 1 inch. In some embodiments, the automatic furnace carbon replacement product has a maximum dimension of about 3 inches. In some embodiments, the automatic furnace carbon replacement product has a minimum dimension of about 1 inch and a maximum dimension of about 3 inches. In some embodiments, the automatic furnace carbon replacement product is substantially free of fossil fuel.
[0434] Some variations of the invention use high carbon biogenic reagents as injectable carbon-based materials (eg, sprayed). In some embodiments, a high-carbon biogenic reagent in accordance with the present invention is useful as a replacement for the injection grade calcination petroleum coke. Injection grade calcination petroleum coke is generally characterized as having at least about 66% by weight of carbon, about 0.55 to about 3% by weight of sulfur, up to about 5.5% by weight of volatile matter, up to about 10% by weight of ash, up to about 2% by weight of moisture, and is dimensioned in about 6 meshes or less. In some embodiments, a calcination petroleum substitute product is a
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141/160 high carbon biogenic reagent comprising at least about 66% by weight of carbon, no more than about 3% by weight of sulfur, no more than about 10% by weight of ash, no more than about 2 % by weight of moisture, and is sized in about 6 meshes or less. In several embodiments, injectable carbon is also known as pulverized carbon, pulverized carbon for injection, or PCI. In several embodiments, injectable carbon is used as a direct energy source, a reagent, or both.
[0435] In some embodiments, a high carbon biogenic reagent in accordance with the present invention is useful as an injectable carbon replacement product in, for example, basic oxygen furnaces or electric arc furnace installations in any application where injectable carbon would be used (for example, injected into slag or pot during steelmaking). In some embodiments, an injectable carbon replacement product is a high carbon biogenic substitute composed of at least 55% by weight of carbon, no more than about 0.4% sulfur, no more than about 0.035% phosphorus and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, the injectable carbon replacement product also comprises up to about 10% by weight of dolomitic lime. In some embodiments, the injectable carbon replacement product also comprises up to about 10% by weight of calcium oxide. In some embodiments, the injectable carbon replacement product also comprises up to about 10% by weight of dolomitic lime and up to about 10% by weight of calcium oxide. In some embodiments, the injectable carbon replacement product has a maximum dimension of about 1/8 inch. In some embodiments, the injectable carbon replacement product is substantially free of fossil fuels.
[0436] In some embodiments, a high carbon biogenic reagent according to the present invention is useful as a carbon replacement product
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142/160 pulverized, for example, where pulverized coal would be used (for example, for heating process or energy production). In some embodiments, the pulverized coal substitute product is composed of up to about 10% calcium oxide. In some embodiments, a pulverized coal substitute product is a high carbon biogenic substitute composed of at least 55% carbon weight, no more than about 0.4% sulfur and a heating value of at least about 25,586 kJ / kg (11,000 Btu per pound). In some embodiments, the pulverized coal replacement product has a maximum dimension of about 1/8 inch. In some embodiments, the pulverized coal substitute product is substantially free of fossil fuels.
[0437] Some variations of the invention use high carbon biogenic reagents as a carbon addition product for the production of metals. In some embodiments, a high carbon biogenic reagent, in accordance with the present invention, is useful as a carbon addition product for the production of carbon steel or another metal alloy composed of carbon. Advanced phase carbon addition products derived from coal are generally characterized by high levels of phosphorus, high levels of sulfur and high ash content and high levels of mercury that degrade the quality of the metal and contribute to air pollution. In some embodiments of the present invention, the carbon addition product is composed of not more than about 0.5% by weight of sulfur, not more than about 4% by weight of ash, not more than about 0.03% by weight of phosphorus, a minimum dimension of about 1 to 5 mm and a maximum dimension of about 8 to 12 mm.
[0438] Some variations of the invention use high carbon biogenic reagents as carbon electrodes. In some embodiments, a high carbon biogenic reagent according to the present invention is useful as an electrode material (eg, anode) suitable for use, for example, in
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143/160 production of aluminum. In some embodiments, an electrode material is composed of a high carbon biogenic reagent according to the present invention, in some embodiment. In some embodiments, a carbon electrode comprises a high carbon biogenic reagent composed of at least 55% by weight of carbon and no more than about 0.5% by weight of sulfur. In some embodiments, the carbon electrode is substantially free of fossil fuels.
[0439] Other uses of the high carbon biogenic reagent on carbon electrodes include applications in batteries, fuel cells, capacitors and other energy storage or energy supply devices. For example, in a lithium-ion battery, the high-carbon biogenic reagent can be used on the anode side to intercalate the lithium. In these applications, the purity of carbon and low ash can be very important. In some embodiments, a metal fabrication method consists of a stage in which a carbon electrode is consumed. In some embodiments, the carbon electrode comprises a high carbon biogenic reagent composed of at least 55% by weight of carbon and no more than about 0.5% by weight of sulfur. In some embodiments, the carbon electrode is substantially free of fossil fuels.
[0440] Some variations of the invention use high carbon biogenic reagents as catalyst supports. Carbon is a catalyst support known in a wide range of catalyzed chemical reactions, such as synthesis of mixed alcohol from the synthesis gas using cobalt and molybdenum sulfur metal catalysts supported in a carbon phase, or supported iron-derived catalysts in carbon for the Fischer-Tropsch synthesis of high hydrocarbons from the synthesis gas.
[0441] Some variations of the invention use high carbon biogenic reagents as activated carbon products. Activated carbon is used in a wide variety of gas and liquid phase applications, including water treatment,
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144/160 air purification, vapor solvent recovery, food and beverage and pharmaceutical processing. For activated carbon, the porosity and surface area of the material are generally important. The high carbon biogenic reagent provided here can provide a superior activated carbon product, in various modalities, due to (i) a larger surface area than fossil fuels based on activated carbon; (ii) carbon renewability; (iii) vascular nature of the biomass raw materials together with additives allows for better penetration / distribution of additives that improve the control of pollutants; and (iv) the less inert material (gray) leads to greater reactivity.
[0442] In some embodiments, the amounts of various components of high carbon biogenic reagent compositions disclosed in this document are determined on a dry basis. In some embodiments, the amounts of various components of high carbon biogenic reagent compositions disclosed in this document are determined on an ash-free basis. In some embodiments, the amounts of various components of high carbon biogenic reagent compositions disclosed in this document are determined on a dry, ash-free basis.
[0443] It should be recognized that in the above description of the market applications of high carbon biogenic reagents, the applications described are not exclusive, nor are they exhaustive. Thus, a high-carbon biogenic reagent that is described as being suitable for a type of carbon product may be suitable for any other application described, in various modalities. These applications are exemplary only, and there are other applications of high-carbon biogenic reagents. In several embodiments, injectable carbon is used as a direct energy source, as a reagent, or both.
[0444] In addition, in some modalities, the same physical material can be used in various market processes, either in an integrated manner or in sequence.
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So, for example, a high carbon biogenic reagent that is used as a carbon electrode or activated carbon can, at the end of its useful life as a performance material, then be introduced to a combustion process for energy value or for a metal process etc.
[0445] Some modalities may employ activated carbon, both for its reactive / adsorptive properties and also as a fuel. For example, an activated carbon injected into an emissions stream may be suitable for removing contaminants, followed by combustion of activated carbon particles and possibly contaminants, to produce energy and to thermally destroy or chemically oxidize the contaminants.
[0446] Significant product and environmental benefits can be associated with high carbon biogenic reagents, compared to conventional fossil fuel products. High carbon biogenic reagents can be not only environmentally superior, but also functionally superior from a processing point of view because of the higher purity, for example.
[0447] Regarding the production of metals, the production of biogenic reagents with the disclosed process can result in significantly lower emissions of CO, CO2, NOx, SO2 and dangerous air pollutants compared to the producer coke derived from coal needed to prepare them for use in the production of metals.
[0448] The use of high carbon biogenic reagents in place of coal or coke also significantly reduces environmental emissions of SO2, dangerous air pollutants, and mercury.
[0449] Also, due to the purity of these high carbon biogenic reagents (including low ash content), biogenic reagents have the potential to reduce slag and increase production capacity in metal fabrication processes.
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Examples
Example 1. Preparation of the Biogenic Reagent - General Method.
[0450] Large splinters of red pine wood substrate, Douglas fir cylinders (1.25 inch diameter pieces) and Douglas fir pieces (approximately 2 inches by 2 inches), were loaded into a hopper. with an optionally heated nitrogen gas flow. Optionally, a 1% aqueous solution of an additive (for example, NaOH or KOH) was applied by spraying to the wooden substrate while in the funnel or by immersing the biomass in the aqueous additive solution. Regardless of the application method, the additive solution was allowed to penetrate the biomass for 30 minutes before the biomass was dried. Once the reactor reached the desired temperature, the rotation of the reactor was started and the wooden substrate was fed slowly by activating the material feeding system. Average residence times in the heated part of the reactor for each batch are shown in Table 1. After leaving the heated part of the reactor, the pyrolysed material collected in a discharge funnel. A carrier removed the biogenic reagent from the discharge funnel for further analysis.
[0451] The biogenic reagent was prepared according to the General Method above using various sizes of raw material, varying the reactor temperatures, heated or nitrogen environments, additive and residence times. Table 1 summarizes the pyrolysis parameters for each batch.
OK bela 1. Preparation of the Biogenic Reagent. Sample Substrate size Temp. ofreactor Temp. of nitrogen Additive Residence time THE Large splinters 371 ° C Environment(20-25 ° C) none 0.5 hour B Large splinters 350 ° C Environment none 0.5 hour Ç Large splinters 350 ° C 300 ° C none 0.5 hour D 1.25 inch cylinders 600 ° C 300 ° C none 2 hours
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AND 2 x 2 inches 600 ° C 300 ° C none 2 hours F Large splinters 480 ° C Environment none 4 hours G Large splinters 480 ° C Environment KOH 4 hours H Large splinters 370 ° C Environment KOH 2.5 hours I Large splinters 370 ° C Environment KOH 2 hours J1 Treated Entry AT AT NaOH AT J2 Output J1 370 ° C Environment NaOH 2 hours
Example 2. Analysis of the Biogenic Reagent.
[0452] Parameters of biogenic reagents prepared according to
General Method of Example 1 were analyzed according to Table 2 below.
Table 2. Methods Used to Analyze Biogenic Reagents.
Parameter Method Humidity (total) ASTM D3173 Ash content ASTM D3174 Volatile substance content ASTM D3175 Fixed carbon content (by content) ASTM D3172 Sulphur content ASTM D3177 Heating value (BTU per pound) ASTM D5865 Carbon content ASTM D5373 Hydrogen content ASTM D5373 Nitrogen content ASTM D5373 Oxygen content (by calculation) ASTM D3176
[0453] Results for Samples A to F, which were prepared without the use of additives, are shown in Table 3 below.
Table 3. Characteristics of Biogenic Reagents from A to F.
Sample THE B Ç D AND F Humidity (% by weight) 2.42 3.02 3.51 0.478 0.864 4.25 Gray (% by weight) 1.16 0.917 0.839 1.03 1.06 1.43 Volatile Matter (% by weight) 38.7 46.4 42.8 2.8 17.0 18.4
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Fixed carbon (% by weight) 57.7 49.4 52.9 95.7 81.0 76.0 Sulfur (% by weight) NDt ND ND ND ND ND Heating value(BTU / lb) 12,807 12,452 12,346 14,700 13,983 13,313 Carbon (% by weight) 73.3 71.2 71.0 * NT NT 84.1 Hydrogen (% by weight) 4.47 4.85 4.63 NT NT 2.78 Nitrogen (% by weight) 0.251 0.227 0.353 NT NT 0.259 Oxygen (% by weight) 18.3 19.7 19.6 NT NT 7.13
^f ND: less than 0.05% by weight of sulfur content.
* NT: Not Tested.
[0454] Results for Samples from G to J2, which were prepared without the use of additives, are shown in Table 4 below.
Table 4. Characteristics of Biogenic Reagents G to J2
Sample G H I J1 J2 Humidity (% by weight) 3.78 5.43 1.71 15.2 4.05 Gray (% by weight) 5.97 12.6 15.8 7.9 20.2 Volatile Matter (% by weight) 17.8 30.2 19.7 59.1 25.3 Fixed carbon (% by weight) 72.5 51.7 62.8 17.8 50.5 Sulfur (% by weight) NDt ND ND ND ND Heating value (BTU / lb) 12,936 10,530 11,997 6,968 9,639 Carbon (% by weight) 81.1 64.4 69.6 41.9 67.2 Hydrogen (% by weight) 2.6 3.73 3.82 4.64 3.78 Nitrogen (% by weight) 0.20 0.144 0.155 0.145 0.110 Oxygen (% by weight) 6.31 13.6 8.91 30.2 4.6
tND: less than 0.05% by weight of sulfur content.
Example 3. Production of a High Heat Value Biogenic Reagent.
[0455] This example demonstrates the production of a biogenic reagent with a
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149/160 high heat value.
[0456] A raw material composed of cylindrical pieces of Douglas fir (1 -1 / 8 in diameter, about 1.5 inches long) was pyrolyzed according to the General Method of Example 1. The reactor was heated to 600 ° C. and the raw material was pyrolyzed with a residence time of 30 minutes. After cooling, the resulting biogenic reagent was analyzed according to the methods described in Example 2. The results are shown in Table 5.
Table 5. Analysis of the High Heat Value Biogenic Reagent.
Approximate analysis Parameter MethodASTM As received Moisture free Free of ash and moisture Humidity (total) D3173 1.45% by weight - - Grey D3174 0.829% inWeight 0.841% inWeight - Volatile substance D3175 7.15% by weight 7.26% by weight 7.32% by weight Fixed carbon D3172 90.6% by weight 91.9% by weight 92.7% by weight Sulfur D3177 NDt ND ND Heating value D5865 14,942 BTU / lb 15,162 BTU / lb 15,291 BTU / lb Final analises Parameter MethodASTM As received Moisture free Free of ash and moisture Moisture(total) D3173 1.45% by weight - - Grey D3174 0.829% inWeight 0.841% inWeight -
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Sulfur D3177 ND ND ND Carbon D5373 88.3% by weight 89.6% by weight 90.4% by weight Hydrogen* D5373 1.97% by weight 2.00% by weight 2.01% by weight Nitrogen D5373 0.209% inWeight 0.212% inWeight 0.214% inWeight Oxygen* D3176 7.19% by weight 7.30% by weight 7.36% by weight
^f ND: The sulfur content was less than 0.050% by weight (as received), less than 0.051% by weight (free of moisture) or less than 0.052% by weight (free of ash and moisture).
* Excluding water.
Example 4. Production of a High Heat Value Biogenic Reagent.
[0457] This example demonstrates the production of a biogenic reagent with a high heat value.
[0458] A raw material composed of red pine chips with an average particle size of approximately 1 inch by 1/2 inch by 1/8 inch was pyrolyzed according to the General Method of Example 1. The reactor was heated to 550 ° C. and the raw material was pyrolyzed with a residence time of 30 minutes. After cooling, the resulting biogenic reagent was analyzed according to the methods described in Example 2. The results are shown in Table 6.
Table 6. Analysis of the High Heat Value Biogenic Reagent.
Approximate analysis Parameter MethodASTM As received Moisture free Free of ash and moisture Humidity (total) D3173 2.55% by weight - - Grey D3174 1.52% by weight 1.56% by weight - Volatile substance D3175 10.1% by weight 10.4% by weight 10.5% by weight Fixed carbon D3172 85.8% by weight 88.1% by weight 89.5% inWeight Sulfur D3177 ND * ND ND
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Heating value D5865 14,792 BTU / lb 15,179 BTU / lb 15,420 BTU / lb Final analises Parameter MethodASTM As received Moisture free Free of ash and moisture Humidity (total) D3173 2.55% by weight - - Grey D3174 1.52% by weight 1.56% by weight - Sulfur D3177 ND ND ND Carbon D5373 88.9% by weight 91.2% by weight 92.7% by weight Hydrogen* D5373 2.36% by weight 2.42% by weight 2.45% inWeight Nitrogen D5373 0.400% inWeight 0.410% inWeight 40.417% by weight Oxygen* D3176 4.22% by weight 4.33% by weight 4.40% inWeight
NDU The sulfur content was less than 0.050% by weight (as received), less than 0.051% by weight (free of moisture) or less than 0.052% by weight (free of ash and moisture).
* Excluding water.
Example 5. Production of a Biogenic Coke Replacement Product for Mixing with Metallurgical Coke.
[0459] The biogenic reagent was prepared from fixation by pins of kiln-dried wood substantially in accordance with the General Method of Example 1.
[0460] Mixtures of metallurgical coke (Sample ID No. SGS / 427-1 104014001) with 2% and 5% of the biogenic reagent were prepared by mixing metallurgical coke with the appropriate amount of biogenic coke replacement product. The values of strength and reactivity were measured according to ASTM D5341 for mixtures compared to metallurgical coke alone are shown in Table 7 (the values are the average of a minimum of two tests per sample).
Table 7. CSR and CRI of Coke Biogenic Reagent Mixtures
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Metallurgical. Amount of Biogenic Reagent CRI CSR 0% by weight (reference) 24.5% 62.8% 2% by weight 25.7% (+ 1.2%) 62.3% (-0.5%) 5% by weight 28.0% (+ 3.5%) 61.2% (-1.6%)
[0461] This example demonstrates that a biogenic reagent prepared according to the General Method of Example 1, when mixed with metallurgical coke at 2% by weight and 5% by weight, is capable of reaching CRI values below 30% and CSR values above 60%, corresponding to typical specifications for the use of metallurgical coke in large blast furnaces.
Example 6. Production of an Advanced Hot Resistance Biogenic Coke Replacement Product.
[0462] The red pine wood chips dimensioned approximately 1 x /> x 1/8 were pyrolyzed according to the General Method of example 1 at 600 ° C. with a residence time of 30 minutes. The resulting biogenic reagent is known as Sample A.
[0463] Fixing by pins of oven-dried milled wood with a diameter of 1-1 / 8 was cut into segments with a length of about 1.5 inches each. The segments were pyrolyzed according to the General Method of Example 1 at 600 ° C. with a residence time of 2 hours. The resulting biogenic reagent is known as Sample B.
[0464] Samples A and B were placed separately in quartz tubes and heated to 100 ° C in the presence of CO2 gas for one hour. After one hour, Sample A had a CSR value of about 0%. After one hour, Sample B had a CSR value of 64.6%. These results indicate the potential to increase the hot resistance of a biogenic coke replacement product and suitability for use as a substitute for metallurgical coke in
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Example 7. Preparation of the Particularly Dimensioned Biogenic Reagent.
[0465] As shown in Table 8 below, the Biogenic Reagent with a specific shape and medium size was produced according to the General Method of Example 1.
Table 8. Properties of the Biogenic Reagent Particularly
Dimensioned.
Sample Carbonfixed Volumeinitial VolumeFinal Changeinvolume Starting mass PastaFinal Mass change Blocks 90% inWeight 3.15 in ³ 1.51 in ³ -52% 22.7 g 4.91 g -78% Cylinders-1 80% inWeight 1.46 in ³ 0.64 in ³ -56% 14.47 g 3.61 g -75% Cylinders-2 90% inWeight 1.46 in ³ 0.58 in ³ -60% 14.47g 3.60 g -75%
Example 8. Effect of Residence Time on Fixed Carbon Levels.
[0466] The effect of residence time on fixed carbon levels in the biogenic reagent was investigated by dividing a batch of raw material into four groups of approximately equal mass, composed of pieces of raw material of approximately equal particle size. Each of the four groups was subjected to pyrolysis according to the General Method of Example 1 at 350 ° C, with residence times of 0 minutes, 30 minutes, 60 minutes and 120 minutes, respectively. The fixed carbon content of each sample was determined by ASTM D3172. The results are shown in Table 9 and in FIG. 14 corresponding.
Table 9. Effect of Residence Time on Fixed Carbon Levels.
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Sample Residence time Fixed carbon Residence 1 0 minute 17% Residence 2 30 minutes 50% Residence 3 60 minutes 66% Residence 4 120 minutes 72%
Example 9. Effect of Pyrolysis Temperature on Fixed Carbon Levels.
[0467] The effect of pyrolysis temperature on fixed carbon levels in the biogenic reagent was investigated by dividing a batch of raw materials into five groups of approximately equal mass composed of pieces of raw material of approximately equal particle size. Each of the five groups was subjected to pyrolysis according to the General Method of Example 1 with a residence time of 30 minutes. The fixed carbon content of each sample was determined by ASTM D3172. The results are shown in Table 10 and the corresponding figure 15.
Table 10. Effect of Residence Time on Fixed Carbon Levels.
Sample Temp. Pyrolysis Fixed Carbon Temperature-1 310 ° C 38% by weight Temperature-2 370 ° C 58% by weight Temperature-3 400 ° C 64% by weight Temperature-4 500 ° C 77% by weight Temperature-5 600 ° C 83% by weight
Example 10. Effect of Raw Material Particle Size on Levels of
Fixed Carbon.
[0468] The effect of raw material particle size on fixed carbon levels in the biogenic reagent was investigated by pyrolysis of three groups of red pine biomass: sawdust (average particle size of approximately 0.0625 inch), chips ( average particle size of
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1.5 inch). Each of the three groups was subjected to pyrolysis according to the general method of Example 1 at 400 ° C. for 30 minutes. The fixed carbon content of each sample was determined by ASTM D3172. The results are shown in Table 11 and in the corresponding figure 16.
Table 11. Effect of Residence Time on Fixed Carbon Levels.
Sample Average particle size Fixed carbon Sawdust ~ 0.0625 inch 71% inWeight Splinters ~ 1 inch x 1/2 inch x 1/8 inch 64% inWeight Pieces ~ 1.5 ”lengths of cylinders 1-1 / 8” in diameter 62% inWeight
Example 11. Effect of Oxygen Level During Pyrolysis on Mass Yield of Biogenic Reagent.
[0469] This example demonstrates the effect of oxygen levels on the mass yield of the biogenic reagent.
[0470] Two samples of hardwood sawdust (4.0 g) each were placed in a quartz tube. The quartz tube was then placed in a tube oven (Lindberg Model 55035). The gas flow was set at 2,000 ccm. One sample was exposed to a 100% nitrogen atmosphere, while the other sample was subjected to a gas flow comprising 96% nitrogen and 4% oxygen. The oven temperature was set at 290 ° C. Upon reaching 290 ° C (approximately 20 minutes), the temperature was maintained at 290 ° C for 10 minutes, at which point the heat source was turned off, and the tube and oven allowed to cool for 10 minutes. The tubes were removed from the oven (gas still flowing at 2,000 ccm). Once the tubes and
Petition 870190052151, of 6/3/2019, p. 172/185
156/160 the samples were cooled enough for the process, the gases were deactivated, and the pyrolysed material removed and weighed (Table 12).
Table 12. Effect of Oxygen Levels During Pyrolysis on Mass Yield.
Sample Atmosphere Mass Yield Atmosphere-1 (a) 100% Nitrogen 87.5% Atmosphere-2 (a) 96% Nitrogen, 4% Oxygen 50.0%
Example 12. Effect of Oxygen Level During Pyrolysis on the Fixed Content Level and Heat Value of the Biogenic Reagent.
[0471] The increase in the fixed carbon content and heat value of using a Carbon Recovery Unit (“CRU”) is demonstrated.
[0472] The sawdust pyrolysis according to Example 10 was carried out. A standard coconut shell charcoal (CSC) tube (SKC Cat. No. 226-09) was placed in the exhaust gas stream following a standard midget impinger containing 10 mL of HPLC grade water. The increases in fixed carbon levels and heat value were compared with a CSC tube that had not been exposed to any exhaust gases (Table 13, data without ash and humidity).
Table 13. Increase in Fixed Carbon Content and Heat Value as a
Function of Oxygen Content During Pyrolysis.
Sample Atmosphere Increased carbon content Increased heat value Atmosphere-1 (b) 100% Nitrogen + 3.2% +567 BTU / lb(+ 4.0%) Atmosphere-2 (b) 96% Nitrogen, 4% Oxygen + 1.6% +928 BTU / lb(+ 6.5%)
[0473] The results of Examples 11 and 12 demonstrate the benefits of maintaining an oxygen atmosphere close to zero in mass yield and the value
Petition 870190052151, of 6/3/2019, p. 173/185
157/160 commercial of the pyrolysis process disclosed. By using the exhaust gases from these two experiments it was also possible to demonstrate that the BTU-laden gases leaving the process can be captured in order to increase the BTU content and / or the carbon content of a carbon substrate (coal , coke, activated carbon, carbon).
Example 13. Example 13. Effect of heated nitrogen on the fixed carbon content of a biogenic reagent.
[0474] This example demonstrates the effect of introducing heated nitrogen gas to the biomass processing unit.
[0475] The production of the biogenic reagent using a biomass consisting of red pine wood chips having a typical dimension of 1 inch by 12 inches by 18 inches was carried out according to the General Method of Example 1 with a heated pilot scale reactor for four zones at 350 ° C. In the first run, nitrogen was introduced at room temperature. In a second run, which was performed immediately after the first run, in order to minimize the variation in other parameters, the nitrogen was preheated to 300 ° C, before injection in the pyrolysis zone. In each case, the nitrogen flow rate was 1.2 cubic feet per minute, and the biomass was processed for 30 minutes.
[0476] The fixed carbon content was measured on a dry and ash-free basis, according to ASTM D3172 for each run (Table 14).
Table 14. Effect of Nitrogen Temperature on the Fixed Carbon Content of a Biogenic Reagent.
Sample Nitrogen Temperature Fixed carbon content Atmosphere-1 (c) Environment 51.7% Atmosphere-2 (c) 300 ° C 55.3%
[0477] The test results show an increase of 7.0% [(100) (55.3% Petition 870190052151, of 6/3/2019, page 174/185
158/160
51.7%) 55.3%] in the fixed carbon content of the carbonized product of biogenic reagent using pre-heated nitrogen.
Example 14. Improvement of Mass Yield by Pre-treatment of Biomass.
[0478] This example demonstrates the production of a biogenic activated carbon product having an additive, particularly iron (II) bromide.
[0479] An aqueous solution of iron (II) bromide hydrate was created by mixing 72.6 grams of iron (II) bromide hydrate in 1 gallon of water (eg 1.0% aqueous solution of iron bromine). This solution was added to 5.23 pounds (2.37 kg) of air-dried red pine chips (12% moisture content). Each wood chip was approximately 1 x / 2 x 1/8.
[0480] The wood chip and solution container was sealed with a tight water lid. The contents were mixed periodically over approximately four hours by tilting and rolling the container and contents. The wood chips and the solution were kept sealed overnight to allow the wood chips to saturate with the solution.
[0481] Subsequently, the contents were transferred to an open waterproof tank and allowed to air dry for several hours, with periodic mixing until all the free liquid was absorbed by the wood chips or evaporated. The contents were transferred to an air dryer and allowed to dry overnight.
[0482] Pre-treated air-dried wood chips had a moisture content of 12%. The mass of the pre-treated, air-dried wood chips was determined to be 5.25 pounds (2.38 kg). The contents were transferred to a pyrolysis reactor with nitrogen gas preheated to 300 ° C with a gas flow rate of 0.4 cubic feet per minute. Pyrolysis occurred at 370 ° C for 30 minutes.
[0483] The finished product was removed from the reactor at a temperature below 100 ° C. Upon reaching room temperature (approximately 23 ° C), the product
Petition 870190052151, of 6/3/2019, p. 175/185
The finished 159/160 had a mass of 2.5 pounds (1.14 kg), indicating a mass yield of 47.6% based on the mass of the raw material (for example, the mass contribution of the pre- treatment was subtracted) at a moisture content of 12%. On a dry basis (correcting the moisture content of 12% and the mass contribution of the pretreatment additive), the mass yield was 54.1%. As shown in Table 15 below, this represents an 8 to 15% increase in mass yield over untreated wood chips processed under the same conditions.
Table 15. Pre-treatment of Biomass with 1.0% Aqueous Iron (II) Bromide Increases Mass Yield.
Pre-treatment Yield in pasta(12% humidity) Mass yield (dry basis) none 34.3% 39.0% none 35.4% 40.2% none 37.2% 42.2% Medium (without pre-treatment) 35.6% 40.5% Iron Bromide (II) 47.6% 54.1% DIFFERENCE 12.0% 13.6%
[0484] These data indicate a significant improvement in mass yield for wood chips treated with an iron (II) bromide solution prior to pyrolysis processing.
[0485] In this detailed description, reference was made to various modalities of the invention and non-limiting examples related to how the invention can be understood and practiced. Other modalities that do not provide all the established resources and advantages can be used, without departing from the spirit and scope of the present invention. This invention incorporates routine experimentation
Petition 870190052151, of 6/3/2019, p. 176/185
160/160 and optimization of the methods and systems described in this document. Such modifications and variations are considered within the scope of the invention defined by the claims.
[0486] All publications, patents, and patent applications cited in this specification are incorporated into this document by reference in their entirety, as if each publication, patent, or patent application was specifically and individually inserted into this document.
[0487] Where the methods and steps described above indicate certain events that occur in a certain order, those skilled in the art will recognize that the ordering of certain steps can be modified and that such changes are in accordance with the variations of the invention. In addition, some of the steps can be performed simultaneously in a parallel process when possible, as well as performed sequentially.
[0488] Therefore, insofar as there are variations of the invention, which are within the spirit of the disclosure or equivalent to the inventions found in the attached claim, the intention is that this patent covers these variations as well. The present invention is limited only by what is claimed.

权利要求:
Claims (17)
[1]
1. Process to produce a carbon-rich biogenic reagent CHARACTERIZED by the fact that it comprises:
(a) supplying a carbon-containing raw material comprising plant or plant-derived biomass;
(b) drying said raw material to remove at least a portion of the moisture contained within said raw material;
(c) disarming said raw material to remove at least a portion of interstitial oxygen, if any, contained within said raw material or said dry raw material;
(d) preheat said dry raw material in a preheat zone in the presence of an inert gas for at least 5 minutes up to a maximum of 60 minutes and with a selected preheating temperature of 80 ° C to 500 ° C ;
(e) in a pyrolysis zone, pyrolyze said raw material in the presence of an inert gas for at least 10 minutes to a maximum of 120 minutes and, with a selected pyrolysis temperature of at least 250 ° C to a maximum of 700 ° C, to generate hot pyrolyzed solids, condensed vapors, and non-condensable gases, in which the conditions in the pyrolysis stage are selected to maintain the structural integrity or mechanical strength of said carbon-rich biogenic reagent to said raw material;
(f) separating at least a portion of said condensed vapors and at least a portion of said non-condensable gases from said hot pyrolyzed solids;
(g) in a cooling zone, cool said hot pyrolyzed solids in the presence of said inert gas for at least 5 minutes and, with a cooling zone temperature lower than said pyrolysis temperature,
Petition 870190052151, of 6/3/2019, p. 178/185
[2]
2/5 to generate heated pyrolysed solids;
(h) in a cooler that is separated from said cooling zone, to cool said heated pyrolyzed solids to generate cooled pyrolyzed solids; and (i) recovering a carbon rich biogenic reagent comprising at least a portion of said cooled pyrolysed solids, wherein said carbon rich biogenic reagent has an energy content of at least 25,586 kJ / kg (11,000 Btu / lb), of at least least 27,912 kJ / kg (12,000 Btu / lb), at least 30,238 kJ / kg (13,000 Btu / lb), at least 32,564 kJ / kg (14,000 Btu / lb), at least 33,727 kJ / kg (14,500 Btu / lb), or at least 34,192 kJ / kg (14,700 Btu / lb) on a dry basis.
2. Process, according to claim 1, CHARACTERIZED by the fact that each said zone is located within a single reactor.
[3]
3. Process according to claim 1, CHARACTERIZED by the fact that at least part of said inert gas includes at least one or more species separated from the non-condensable gas.
[4]
4. Process according to claim 1, CHARACTERIZED by the fact that each said pyrolysis zone and each said cooling zone comprises a gas phase containing less than 5% by weight of oxygen.
[5]
5. Process according to any one of claims 1 to 4, CHARACTERIZED by the fact that said process is continuous.
[6]
6. Process, according to claim 5, CHARACTERIZED by the fact that said inert gas flows countercurrent in relation to the direction of flow of solids.
[7]
7. Process according to any one of claims 1 to 6, CHARACTERIZED by the fact that said process still comprises monitoring and controlling said process with at least one reaction gas probe.
[8]
8. Process according to any one of claims 1 to 7,
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3/5
CHARACTERIZED by the fact that said process comprises one or more: heating the process gas of at least a part of said condensable vapors with a gas containing oxygen;
using heating of the process gas, at least in part, to dry said raw material to remove at least a portion of the moisture contained in said raw material; and using process gas heating, at least in part, to heat said inert gas.
[9]
Process according to any one of claims 1 to 8, CHARACTERIZED by the fact that said process comprises combining at least a portion of said condensable vapors, at least partially in condensed form, with said cooled and / or pyrolyzed solids or with said hot pyrolyzed solids, to increase the carbon content of said carbon-rich biogenic reagent.
[10]
10. Process according to any one of claims 1 to 9, CHARACTERIZED by the fact that said process comprises:
introduce at least one additive selected from sodium hydroxide, potassium hydroxide, magnesium oxide, hydrobromic acid, hydrochloric acid, sodium silicate, potassium permanganate and combinations thereof; and / or introduce at least one additive selected from magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, fluorite, fluorospar, bentonite, calcium oxide, lime and combinations thereof.
[11]
11. Process, according to claim 10, CHARACTERIZED by the fact that said additive is introduced:
before or during step (b);
before or during step (e);
Petition 870190052151, of 6/3/2019, p. 180/185
4/5 during step (g);
during step (h);
between step (g) and (h);
after step (h);
after step (i);
said pyrolyzed solids heated in an aqueous solution, steam or aerosol to aid in the cooling of said pyrolyzed solids heated in step (h); or said pyrolyzed solids cooled to form said carbon-rich biogenic reagent containing said additive.
[12]
12. Process according to any one of claims 1 to 11, CHARACTERIZED by the fact that said process comprises:
introducing at least a portion of said cold pyrolyzed solids into a separate unit for additional pyrolysis, in the presence of a second inert gas, and optionally including one or more non-condensable gas species recovered from step (f), for at least 30 minutes and with a selected pyrolysis temperature of 200 ° C to 600 ° C, to generate a solid product having a higher carbon content than the said cooled pyrolyzed solids.
[13]
13. Process, according to claim 1 or 8, CHARACTERIZED by the fact that the process comprises operating a chiller:
for cooling said hot pyrolyzed solids with steam to generate cooled pyrolyzed solids and superheated steam and wherein the drying step is carried out, at least in part, with said superheated steam; and / or to cool the hot pyrolysed solids with steam first until reaching a first cooler temperature and then with air to reach a second cooler temperature, where the temperature of the second cooler is lower than the temperature of the first cooler and is associated reduced risk of combustion
Petition 870190052151, of 6/3/2019, p. 181/185
5/5 of said hot pyrolyzed solids in the presence of said air.
[14]
14. Process according to any of claims 1 to 13, CHARACTERIZED by the fact that said carbon-rich biogenic reagent contains at least 35%, at least 50% or at least 70% of carbon contained in said raw material .
[15]
15. Process according to any one of claims 1 to 14, CHARACTERIZED by the fact that said carbon-rich biogenic reagent contains at least 70% by weight, at least 80% by weight, at least 90% by weight or at least minus 95% by weight of dry carbon, wherein said carbon optionally includes fixed carbon and volatile matter carbon.
[16]
16. Process according to any one of claims 1 to 15, CHARACTERIZED by the fact that said carbon-rich biogenic reagent is formed into a fine powder by reducing particle size, or is formed into a structural object by pressing, agglutination, pelletizing or agglomeration.
[17]
17. Process, according to claim 1, CHARACTERIZED by the fact that said raw material is pyrolyzed in step (e) in the presence of an inert gas for 20 minutes, 30 minutes, 45 minutes or 60 minutes.

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法律状态:
2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-03-06| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2019-12-24| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-01-28| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 13/04/2012, OBSERVADAS AS CONDICOES LEGAIS. |

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2020-05-12| B25A| Requested transfer of rights approved|Owner name: CARBON TECHNOLOGY HOLDINGS, LLC (US) |

优先权:

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申请号 | 申请日 | 专利标题

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US201161475968P| true| 2011-04-15|2011-04-15|

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US201161475943P| true| 2011-04-15|2011-04-15|

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US201161475991P| true| 2011-04-15|2011-04-15|

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US201161475996P| true| 2011-04-15|2011-04-15|

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US201161475930P| true| 2011-04-15|2011-04-15|

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US201161475949P| true| 2011-04-15|2011-04-15|

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US201161475959P| true| 2011-04-15|2011-04-15|

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US201161475937P| true| 2011-04-15|2011-04-15|

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US201161475973P| true| 2011-04-15|2011-04-15|

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US201161476025P| true| 2011-04-15|2011-04-15|

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US201161476049P| true| 2011-04-15|2011-04-15|

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US201161475956P| true| 2011-04-15|2011-04-15|

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US201161476043P| true| 2011-04-15|2011-04-15|

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US201161475946P| true| 2011-04-15|2011-04-15|

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US201161475971P| true| 2011-04-15|2011-04-15|

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US201161475977P| true| 2011-04-15|2011-04-15|

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US201161475981P| true| 2011-04-15|2011-04-15|

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