Carbon Technology Holdings, LLC

Biogenic Reagents Ventures, LLC

Biogenic Reagent Ventures, LLC

James A Mennell

Daniel J Despen

Steve Filips

Dustin Slack

Daren Einar Daugaard

David Reamer

This invention provides processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

High-carbon biogenic reagents and uses thereof

In some variations, the invention provides a biocarbon composition comprising a low fixed carbon material with a fixed carbon concentration from 20 wt % to 55 wt %; a high fixed carbon material with a fixed carbon concentration from 50 wt % to 100 wt % (and higher than the fixed carbon concentration of the low fixed carbon material; from 0 to 30 wt % moisture; from 0 to 15 wt % ash; and from 0 to 20 wt % of one or more additives (such as a binder). Some variations provide a process for producing a biocarbon composition, the process comprising: pyrolyzing a first biomass-containing feedstock to generate a low fixed carbon material; separately pyrolyzing a second biomass-containing feedstock to generate a high fixed carbon material; blending the low fixed carbon material with the high fixed carbon material, thereby generating an intermediate material; optionally, blending one or more additives into the intermediate material; optionally, drying the intermediate material; and recovering a biocarbon composition containing the intermediate material or a thermally treated form thereof.

Biocarbon blends with optimized fixed carbon content, and methods for making and using the same

Some variations provide a carbon-negative carbon product that is characterized by a carbon intensity less than 0 kg COe per metric ton of the carbon-negative carbon product, wherein the carbon-negative carbon product contains at least about 50 wt % carbon. In some embodiments, the carbon intensity is less than −500 kg COe per metric ton of the carbon-negative carbon product. Other variations provide a carbon-negative metal product (e.g., a steel product) that is characterized by a carbon intensity less than 0 kg COe per metric ton of the carbon-negative metal product, wherein the metal product contains from 50 wt % to 100 wt % of one or more metals and optionally one or more alloying elements. In some embodiments, the carbon-negative metal product is characterized by a carbon intensity less than −200 kg COe per metric ton of the carbon-negative metal product. The carbon-negative metal product can contain a wide variety of metals.

Carbon-negative metallurgical products

Biomass combustion processes may be controlled to intentionally generate a carbon-containing ash, from which activated carbon is produced according to the methods disclosed. Some variations provide an economically attractive process for producing an activated carbon product, the process comprising combusting a carbon-containing feedstock to generate energy, combustion products, and ash, wherein the ash contains at least 10 wt % carbon; separating and recovering carbon contained in said ash; and further activating or treating the separated carbon, to generate an activated carbon product. Many process variations are disclosed, and uses for the activated carbon product are disclosed.

Methods and apparatus for producing activated carbon from biomass through carbonized ash intermediates

Highly mesoporous activated carbon products are disclosed with mesoporosities characterized by mesopore volumes of 0.7 to 1.0 cubic centimeters per gram or greater. Also disclosed are activated carbon products characterized by a Molasses Number of about 500 to 1000 or greater. Also disclosed are activated carbon products characterized by a Tannin Value of about 100 to 35 or less. The activated carbon products may be further characterized by total pore volumes of at least 0.85 cubic centimeters per gram and BET surface areas of at least about 800 square meters per gram. The activated carbon product may be derived from a renewable feedstock.

Highly mesoporous activated carbon

Processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Pyrolysis in the presence of an inert gas is employed to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

Methods and apparatus for enhancing the energy content of carbonaceous materials from pyrolysis

This invention provides processes and systems for converting biomass into high carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

Process for producing high-carbon biogenic reagents

Some variations provide a composition for reducing a metal ore, the composition comprising a carbon-metal ore particulate, wherein the carbon-metal ore particulate comprises at least about 0.1 wt % to at most about 50 wt % fixed carbon on a moisture-free and ash-free basis, and wherein the carbon is at least 50% renewable carbon as determined from a measurement of theC/C isotopic ratio. Some variations provide a process for reducing a metal ore, comprising: providing a biomass feedstock; pyrolyzing the feedstock to generate a biogenic reagent comprising carbon and a pyrolysis off-gas comprising hydrogen or carbon monoxide; obtaining a metal ore comprising a metal oxide; combining the carbon with the metal ore, to generate a carbon-metal ore particulate; optionally pelletizing the carbon-metal ore particulate; and utilizing the pyrolysis off-gas to chemically reduce the metal oxide to elemental metal, such as iron.

Bio-reduction of metal ores integrated with biomass pyrolysis

Provided are biogenic porous carbon silicon dioxide compositions, as well as related compositions, and methods of making and using such compositions. Exemplary biogenic porous carbon silicon dioxide compositions include a high-carbon biogenic reagent composition that contains at least about 50 wt % total carbon, at most about 5 wt % hydrogen, at most about 1 wt % nitrogen, at most about 0.5 wt % phosphorus, at most about 0.2 wt % sulfur, at most about 0.02 wt % titanium, at most about 0.5% calcium, at most about 0.1% aluminum, and silicon dioxide. The total carbon can be biogenic carbon, and the silicon dioxide can be contained within river rock or silica fume. Also provided are processes for producing such compositions, where the processes can include: preheating a renewable feedstock, pyrolyzing the renewable feedstock, separating certain pyrolysis products, cooling solid pyrolysis products, and introducing silicon dioxide at a certain point in process.

Biogenic porous carbon silicon dioxide compositions

This disclosure provides a halogenated activated carbon composition comprising carbon, a halogenated compound and a salt. In some embodiments, the halogenated compound and the salt comprise a naturally occurring salt mixture, as may be obtained from ocean water, salt lake water, rock salt, salt brine wells, for example. In some embodiments, the naturally occurring salt mixture comprises Dead Sea salt.

Growing community of inventors

Dellwood, MN, United States of America

James A Mennell