Biogenic porous carbon silicon dioxide composition and methods of making and using the same

Abstract

To provide biogenic porous carbon silicon dioxide compositions and methods of making and using the same.SOLUTION: A high-carbon biogenic reagent composition comprises, on a dry basis: 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, where the total carbon comprises biogenic carbon.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] Claiming priority This application is a continuation of U.S. Provisional Patent Application No. 62 / 685,120, filed June 14, 2018. No. 6, the entire contents of which are incorporated herein by reference.

[0002] This disclosure generally relates to Origin Porous carbon silicon dioxide composition and method for making same and how to use it. [Background technology]

[0003] raw Origin The use of porous carbon silicon dioxide compositions reduces the non-renewable energy required for silicon production. Drugs These have the potential to reduce the use and environmental impact of Origin Porous Carbon II The use of the silicon oxide composition also increases throughput and reduces energy usage, Extends electrode life, produces higher purity silicon, and is more durable than typical electric arc and underwater arc welding. Allows the use of small sized silicon dioxide (quartz) in arc furnaces and reduces the regeneration of silica fume Such combinations have the potential to improve silicon manufacturing by enabling the use of The compositions, as well as methods of making and using, are disclosed herein. Summary of the Invention

[0004] This disclosure relates to Origin Porous carbon silicon dioxide compositions and methods of making and using same Provide the law.

[0005] Provided herein is a high carbon composition comprising silicon dioxide. The composition is dried. On a weight basis, at least about 50% total carbon, at most about 5% hydrogen, at most about 1% % nitrogen, up to about 0.5% phosphorus, up to about 0.2% sulfur, up to about 0.0 2% by weight titanium, max. 0.5% calcium, max. 0.1% aluminium, and silicon dioxide.

[0006] The composition has, on a dry basis, at least about 50% by weight total carbon and at most about 5% by weight hydrogen. , up to about 1% by weight of nitrogen, up to about 0.5% by weight of phosphorus, up to about 0.2% by weight of sulfur , maximum of about 0.02% by weight titanium, maximum of about 0.5% by weight calcium, maximum of about 0.1% by weight of aluminum, and silicon dioxide, which is found in river rocks. may be included.

[0007] The composition has, on a dry basis, at least about 50% by weight total carbon and at most about 5% by weight hydrogen. , up to about 1% by weight of nitrogen, up to about 0.5% by weight of phosphorus, up to about 0.2% by weight of sulfur , maximum of about 0.02% by weight titanium, maximum of about 0.5% by weight calcium, maximum of about 0.1% by weight The material may include aluminum, and silicon dioxide, the silicon dioxide being preferably silica fume. It may be included within the

[0008] In some embodiments, the carbon is Origin In some embodiments, the carbon The element is non-living. Origin The composition comprises at least about 55% by weight, at least about 60% by weight, %, at least about 65% by weight, at least about 70% by weight, at least about 75% by weight, At least about 80%, at least about 90%, or at least about 95% by weight of total carbon In some embodiments, the composition comprises at least about 55% by weight of Includes total carbon.

[0009] The composition may comprise at least about 1% by weight, at least about 5% by weight, at least about 10% by weight, At least about 15%, at least about 20%, or at least about 25% by weight It may contain silicon oxide.

[0010] In some embodiments, the silicon dioxide is contained within river rock. In some embodiments, the silicon dioxide includes silica fume.

[0011] In some embodiments, the composition is extruded. The composition is extruded to form pellets. In some embodiments, the composition The composition improves the density of the composition by mixing carbon and silicon dioxide, and the combined product density Improves the ability to "sink" the composition in an electric arc furnace, or to use To improve usage and improve furnace efficiency, the composition is made water-resistant and dust-resistant exterior. The material is extruded to produce

[0012] In some embodiments, the composition is densified.

[0013] In some embodiments, the composition has a size of at least about 0.64 cm (0.25 inches) by 0.75 cm (0.8 inches). Approximately 2.5cm (1.0 inch) to a maximum of approximately 5.1cm (2.0 inch) x approximately 15cm (6 It has dimensions of 1.0 inches.

[0014] In some embodiments, the composition has a viscosity of about 560 kg / m 3 (35 lbs / ft3 ) ~ approx. 720kg / m 3(45 pounds per cubic foot).

[0015] In some embodiments, the composition has an iodine value of at least about 300.

[0016] In some embodiments, the composition has a moisture (H2O) content of about 1% to about 45%. In some embodiments, the composition has a moisture (H2O) content of less than about 1%.

[0017] The composition has, on a dry basis, at least about 50% by weight total carbon and at most about 5% by weight hydrogen. , up to about 1% by weight of nitrogen, up to about 0.5% by weight of phosphorus, up to about 0.2% by weight of sulfur , maximum of about 0.02% by weight titanium, maximum of about 0.5% by weight calcium, maximum of about 0.1% by weight of aluminum, and a high carbon content of at least about 15% by weight of silicon dioxide. Drugs composition The silica may be contained within river rocks, and the composition may be densified. It has dimensions of approximately 0.64 cm (0.25 in) by approximately 2.5 cm (1.0 in). It can be made into pellets and has a capacity of about 560 kg / m 3 (35 lbs / ft3) ~Approx. 720kg / m 3 (45 pounds per cubic foot).

[0018] The composition has, on a dry basis, at least about 50% by weight total carbon and at most about 5% by weight hydrogen. , up to about 1% by weight of nitrogen, up to about 0.5% by weight of phosphorus, up to about 0.2% by weight of sulfur , maximum of about 0.02% by weight titanium, maximum of about 0.5% by weight calcium, maximum of about 0.1% by weight of aluminum, and a high carbon content of at least about 15% by weight of silicon dioxide. Drugs composition The silicon dioxide may be contained within a silica fume, and the composition may comprise a densified It is approximately 0.64cm (0.25 inch) by 2.5cm (1.0 inch) in size. It can be pelletized to a size of about 560 kg / m 3 (35 lbs / cubic ft 720kg / m 3 (45 pounds per cubic foot) Cut.

[0019] Provided herein is a method for producing high carbon Drugs derived from It is a process for producing The process includes providing a carbon-containing feedstock comprising dry biomass, and in a preheating zone, in the presence of a substantially inert gas for at least about 5 minutes and at about 80° C. to about 500° C. Preheating the feedstock at a selected preheat temperature and providing a substantially inert gas in the pyrolysis zone. in the presence of a suitable gas for at least about 10 minutes and at a temperature selected from about 250° C. to about 700° C. At pyrolysis temperatures, the feedstock is pyrolyzed to produce hot pyrolyzed solids, condensable vapors, and non-condensable gases. and generating at least a portion of the condensable vapor and at least a portion of the non-condensable gas. A portion of the pyrolyzed solids is separated from the hot pyrolyzed solids in a cooling zone. In the presence of an active gas, for at least about 5 minutes and at a cooling temperature below the pyrolysis temperature, cooling the hot pyrolyzed solids to produce a hot pyrolyzed solid; In a cooler separate from the condenser, the warm pyrolyzed solids are cooled to produce low temperature pyrolyzed solids. and producing a high carbon product comprising at least a portion of the low temperature pyrolyzed solids. reason Drugs and recovering the silicon dioxide feedstock, The present invention further includes introducing the

[0020] In some embodiments, the process includes drying the feedstock to remove moisture contained within the feedstock. Further comprising removing at least a portion.

[0021] In some embodiments, the process further comprises degassing the feedstock or dry feedstock to remove any residual gases, if present. , while contained in the raw material Inside the gap Further comprising removing at least a portion of the oxygen.

[0022] In some embodiments, the process comprises the steps of: and further cooling the hot pyrolyzed solid to produce a cold pyrolyzed solid. include.

[0023] In some embodiments, the process comprises converting a silicon dioxide feedstock into a low temperature pyrolyzed solid. In some embodiments, the process further comprises introducing carbon dioxide prior to pyrolysis. Further comprising introducing a source of silicon into the feedstock.

[0024] In some embodiments, introducing the silicon dioxide source comprises introducing silica fume. In some embodiments, introducing the silicon dioxide comprises introducing river rock into the soil. In some embodiments, the particle size of the silicon dioxide feedstock is greater than that of river rock. Whether silica fume or silica fume, the size can range from about 0.01 mm to about 12 mm. In this embodiment, the particle size is from about 0.01 mm to about 12 mm in increments of about 0.05 mm. obtain.

[0025] In some embodiments, the process further comprises densification.

[0026] In some embodiments, high density The transformation Additives can be used to improve densification. mixing the additive, carbon, and silicon dioxide; and extruding the mixture through a die. forming the pellets, and optionally drying the pellets. It may include and.

[0027] In some embodiments, densification may be performed using, optionally, an additive, such as bentonite. and improving densification from about 0.5% to about 15% in increments of about 0.5% using any Optionally, for example, adding about 5% to about 50% water and adding additives, carbon, and diacid. and extruding the mixture through a die to form pellets. and optionally heating or cooling the extruder and / or die plate. , improving densification, and optionally degassing the extruder, and optionally pelletizing. and drying the pellet.

[0028] In some embodiments, the process includes a high carbon production Drugs derived from Pressurized, bonded and pelletized , extruding, or agglomerating. [Brief description of the drawings]

[0029] [Figure 1] FIG. 1 illustrates a multiple reactor embodiment of the system of the present invention.

[0030] [Diagram 2] FIG. 1 illustrates a single reactor, multi-zone embodiment of the system of the present invention.

[0031] [Diagram 3]FIG. 1 illustrates one embodiment of a zero oxygen continuous supply mechanism suitable for use in connection with the present invention.

[0032] [Figure 4] FIG. 2 shows another embodiment of a single reactor, multi-zone biomass processing unit suitable for use in connection with the present invention.

[0033] [Diagram 5] FIG. 1 illustrates one embodiment of a carbon recovery unit suitable for use in connection with the present invention.

[0034] [Figure 6] FIG. 1 illustrates an embodiment of an embodiment of a single reactor biomass processing unit of the present invention with an optional dryer.

[0035] [Figure 7] FIG. 1 illustrates an embodiment of the pyrolysis reactor system of the present invention with an optional dryer and gas inlet.

[0036] [Figure 8] FIG. 1 shows an embodiment of a single reactor biomass processing unit of the present invention with a gas inlet and optional cooler.

[0037] [Figure 9] FIG. 1 illustrates an embodiment of a single reactor biomass processing unit system of the present invention with optional dryer and degasifier, and an inert gas inlet.

[0038] [Figure 10] FIG. 1 illustrates an embodiment of a multiple reactor system of the present invention with optional dryers and degassers, and an inert gas inlet.

[0039] [Figure 11] FIG. 1 illustrates an embodiment of a multiple reactor system of the present invention with optional dryers and coolers, and a material concentration unit.

[0040] [Figure 12] FIG. 1 illustrates an embodiment of a multiple reactor system of the present invention with optional dryers, degassers, coolers, and inert gas inlets.

[0041] [Figure 13] FIG. 1 illustrates an embodiment of a multiple reactor system of the present invention with optional dryers and degassers, an inert gas inlet, and a cooler.

[0042] [Figure 14] FIG. 1 illustrates an embodiment of a single reactor biomass processing unit of the present disclosure for producing biogenic activated carbon.

[0043] [Figure 15] FIG. 1 illustrates an embodiment of a dual reactor biomass processing unit of the present disclosure for producing biogenic activated carbon. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] This disclosure relates to Origin Porous carbon silicon dioxide compositions and methods of making and using same Provide the law.

[0045] This description is provided to enable any person skilled in the art to make and use the disclosure, and is not intended to be limiting of the invention. These and other implementations of the present disclosure are described. Aspects, features, and advantages of the present invention may be better understood by reference to the following detailed description of the present disclosure taken in conjunction with the accompanying drawings, in which: , will become more apparent to those skilled in the art.

[0046] definition As used herein, the term "at most" provides a minimum value for "insignificant amount."

[0047] As used herein, the term "carbon" refers to Origin Or non-living Origin Carbon It can mean "life Origin " on time scales of months, years, or decades. means materials (raw materials, products, or intermediates) that contain renewable elements such as carbon. The intention is to Origin Materials may be non-renewable or may last for centuries or thousands of years. They may be renewable over years, millions of years, or even longer geological timescales. Origin The material is raw Origin Source and non-life Origin The source may include a mixture of

[0048] As used herein, the term "biomass" refers to any living Origin Raw materials or raw Origin Raw materials and non-raw materials Origin It is to be understood as a mixture with raw materials. The mass contains at least carbon, hydrogen, and oxygen. It can accommodate a wide range of raw material types, sizes, and moisture contents.

[0049] As used herein, the term "activation" refers to various processes in which the pore structure is strengthened. This refers to one of the processes.

[0050] As used herein, the phrase "porous carbon" refers, in various embodiments, to the porous carbon of the present disclosure. Describes materials that can be produced by the process and system. or any other concentration limitations arise from the term itself and not from the specific embodiment and its Attribution should be made only by reference to equivalents. For example, the disclosed process The starting material, which has a very low initial carbon content, is subjected to a high carbon enrichment step. (high yield of carbon), but still containing less than about 50% by weight carbon. , carbon is relatively low (low purity carbon) Origin It is understood that porous carbon can be produced. Hello.

[0051] As used herein, the term "silicon dioxide" (SiO2) is used interchangeably with "silica." is interchangeable with the term

[0052] As used herein, " Drugs The term "materials" means materials in its broadest sense. It is intended to Drugs For example, fuels, chemicals, materials, compounds, additives, The blend component may be a solvent. Drugs does not necessarily cause or initiate a chemical reaction. Chemistry involved in reactions Drugs It doesn't have to be. Drugs may or may not be a chemical reactant. It may or may not be consumed in the reaction. Drugs is a chemical catalyst for a particular reaction It could be. Drugs teeth, Drugs of the mechanical, physical, or hydrodynamic properties of the material to which it can be added Can cause or be involved in regulation. For example, Drugs is introduced into the metal, It can impart certain strength properties. Drugs is used in chemical analysis or physical testing Sufficient purity ( Context of the Specification In the case of , it can be a material of typically carbon purity.

[0053] As used herein, the terms "pyrolysis" and "pyrolyzing" generally refer to Refers to the thermal decomposition of carbonaceous materials.

[0054] As used herein, the term "reactor" refers to a reactor that controls atmospheric and temperature conditions. refers to a discrete unit capable of undergoing physical and / or chemical reactions.

[0055] As used herein, the term "zone" refers to a zone in a reactor relative to other zones in the reactor. Refers to the area within the reactor where the temperature and atmospheric conditions can be controlled.

[0056] As used herein, the term "biomass processing unit" is defined in more detail below. As discussed in detail, it refers to a reactor that contains multiple zones.

[0057] As used herein, the term "carbonization" refers to the process of carbonizing a given amount of biomass. Carbonization means converting biomass into non-carbon-containing materials. of Reduce "High carbonization" can be achieved by increasing the amount of carbon dioxide produced, adding carbon atoms to the biomass, or both. Carbon Drugs derived from This can be illustratively achieved by forming

[0058] As used herein, the indefinite article "a" or "an" refers to any compound disclosed herein. When used in reference to a statement or description of the existence of a step in a process, the statement or Unless the description explicitly provides the contrary, such indefinite articles refer to steps in a process. It is not intended to be limited to one occurrence. As used herein, the amount, concentration, or other If a value or parameter is expressed as a range, a preferred range, or an upper preferred value and a lower preferred value, When a range is given as one of a list of preferred values, this does not include the ranges disclosed separately. Any upper limit or preference value and any lower limit or preference value, regardless of whether they are All ranges formed from pairs are to be understood as specifically disclosed.

[0059] Where a range of numerical values ​​is recited herein, unless otherwise stated, the ranges include all values ​​not less than the endpoints thereof. It is intended that the scope of the present invention include all integers and fractions within the range. However, it is not intended that the range be limited to the specific values ​​recited when defining a range.

[0060] As used herein, the terms "comprising" and "including" are used interchangeably. The term "luding" or grammatical variations thereof refers to one or more additional features, Without precluding the addition of integers, actions, components, or groups of them , be considered to specify the inclusion of the described feature, integer, action, or component. For example, a composition, mixture, process, method, article, or The device is not necessarily limited to only those elements, but may include any such composition, mixture, Any product, process, method, article, or apparatus that is not expressly listed or inherent in "Comprising" is used in the U.S. Patent and Trademark Office Code. "Consisting of" and "consisting essentially of" are defined in the Patent Examining Procedure Manual of the Patent Office. " is broader than and includes the term "commercial use, trade secrets, and other related terms." "Or" refers to an inclusive or and not an exclusive or.

[0061] Unless otherwise specified, reaction conditions, stoichiometry, etc., used in the specification and claims are All numbers expressing theories, concentrations of ingredients, etc. are expressly assumed in all cases to be preceded by the term "about." Therefore, unless indicated to the contrary, The numerical parameters set forth in the following specification and attached claims are at least These are approximations that may vary depending on the particular analytical technique.

[0062] composition Provided herein is a biocompatible material comprising silicon dioxide. Origin The composition is a carbon composition. , on a dry basis, at least about 50% by weight total carbon, at most about 5% by weight hydrogen, at most about 1% by weight of nitrogen, up to about 0.5% by weight of phosphorus, up to about 0.2% by weight of sulfur, up to about 0.02% by weight titanium, 0.5% maximum calcium, 0.1% maximum aluminum The material may include aluminum, and silicon dioxide.

[0063] The composition comprises, on a dry basis, at least about 55%, at least about 60%, At least about 65% by weight, at least about 70% by weight, at least about 75% by weight, at least about 8 0%, at least about 90%, or at least about 95% by weight of total carbon, up to about 5% by weight hydrogen, a maximum of about 1% by weight nitrogen, a maximum of about 0.5% by weight phosphorus, and a maximum of about 0. 2% by weight of sulfur, a maximum of about 0.02% by weight of titanium, a maximum of about 0.5% by weight of calcium, At most about 0.1% aluminum, and at least about 1% by weight, at least about 5% by weight, At least about 10% by weight, at least about 15% by weight, at least about 20% by weight, or It may contain at least about 25% by weight silicon dioxide.

[0064] The composition has, on a dry basis, at least about 50% by weight total carbon and at most about 5% by weight hydrogen. , up to about 1% by weight of nitrogen, up to about 0.5% by weight of phosphorus, up to about 0.2% by weight of sulfur , up to about 0.02% by weight titanium, up to about 0. 5% of calcium, up to about 0. 1% % by weight of aluminum, and at least about 15% by weight of silicon dioxide, The silicon dioxide is contained within the river rocks and has a densified composition of at least about 0.6 In the form of a pellet with dimensions of 4 cm (0.25 in) by approximately 2.5 cm (1.0 in). and approximately 560 kg / m 3 (35 lbs / ft3) ~ approx. 720 kg / m 3 ( It has a bulk density of 45 pounds per cubic foot.

[0065] The composition has, on a dry basis, at least about 50% by weight total carbon and at most about 5% by weight hydrogen. , up to about 1% by weight of nitrogen, up to about 0.5% by weight of phosphorus, up to about 0.2% by weight of sulfur , up to about 0.02% by weight titanium, up to about 0. 5% of calcium, up to about 0. 1% % by weight of aluminum, and at least about 15% by weight of silicon dioxide, The silicon dioxide is contained in silica fume in rivers, and the composition is densified and at least The paper also has dimensions of approximately 0.64 cm (0.25 in) by approximately 2.5 cm (1.0 in). It is in a slender shape and is approximately 560 kg / m 3 (35 lbs / ft3) ~ approx. 720k g / m 3 (45 pounds per cubic foot).

[0066] The composition may comprise at least about 55% by weight, at least about 60% by weight, at least about 65% by weight %, at least about 70% by weight, at least about 75% by weight, at least about 80% by weight, The carbon nanotube may comprise at least about 90% by weight, or at least about 95% by weight, total carbon.

[0067] The composition may comprise at least about 1% by weight, at least about 5% by weight, at least about 10% by weight, At least about 15%, at least about 20%, or at least about 25% by weight of the diacid It may contain silicon carbide.

[0068] In some embodiments, Origin The starting materials for producing the carbon composition are very low Although the composition has a low initial carbon content, when subjected to the disclosed process, the resulting composition has a high initial carbon content. Although the carbon is highly enriched in the fossil fuel (high carbon yield), it is still about 50% % or less by weight of carbon. Origin carbon Is raw Origin Relatively high carbon content compared to the initial feedstock used to produce carbon The typical carbon content of biomass is about 50% by weight or less. thing Origin Carbon usually contains more than half the weight of carbon. More typically, the raw material Depending on the composition, Origin Carbon is at least about 55% by weight, at least about 60% by weight, at least about 65% by weight, at least about 70% by weight, at least about 75% by weight, at least About 80% by weight, at least about 85% by weight, at least about 90% by weight, at least about 95% by weight %, at least about 96%, at least about 97%, at least about 98%, or or at least about 99% by weight carbon.

[0069] In some embodiments, Origin The carbon composition is activated. This refers to any process that results in enhanced pore size in the carbon. Conventional processes for this purpose require large energy inputs and suffer from low yields.

[0070] Various embodiments of the present disclosure are directed to a process for producing fossil fuels (e.g., coal or petroleum coke) and other biofuels. Any mixture of carbon-containing materials other than biomass and fossil fuels (biomass In some embodiments, raw materials are used. Origin The raw materials are coal, in irrigation shale, crude oil, asphalt, or solids from crude oil processing (such as petroleum coke) The raw materials include waste tires, recycled plastics, recycled paper, and Other waste or recycled materials may be included. The stem can be used with any carbonaceous feedstock. Carbon-containing feedstocks include trucks, trains, , a ship, barge, tractor trailer, or any other vehicle or conveyance. The object may be transported by any means known in the art.

[0071] In some embodiments, the present disclosure Origin The carbon composition is silicon dioxide (SiO2) In some embodiments, the SiO2 can be raw SiO2. In yet another embodiment, SiO2 is contained within river rock or quartz. 2 may be contained within silica fume.

[0072] In some embodiments, the composition comprises: Drugs In some embodiments, the composition is ,raw Origin carbon Drugs In another embodiment, the composition is a high carbon Drugs derived from It is.

[0073] In some embodiments, the composition is extruded. Extrusion can be used to, for example, For example, to increase density, carbon and silicon dioxide are mixed together to increase the density of the combined product. , modifying the particle size of carbon to produce a product that "sinks" in an electric arc furnace, improving its use, and To improve the efficiency of the furnace, a water- and dust-resistant exterior can be made of the extrudate .

[0074] In some embodiments, the composition is densified. These are explained in more detail below.

[0075] In some embodiments, the composition is in pellet form. The composition has a size of at least about 0.25 inches by about 1.0 inches. ) ~Having a maximum dimension of about 5.1 cm (2.0 in) by about 15 cm (6.0 in) For example, the composition can have a particle size as shown in Table 1 below. do. [Table 1]

[0076] In some embodiments, the composition has a viscosity of about 560 kg / m 3 (35 lbs / ft3 ) ~ approx. 720kg / m 3 (45 pounds per cubic foot) In some embodiments, the composition has a bulk density of about 550 kg / m 3 (34 lbs / l ft), approximately 560 kg / m 3 (35 lbs / ft3), approximately 570 kg / m 3 (36 lbs / cu ft), approximately 580 kg / m3 (36 lbs / cu ft), approx. 590kg / m 3 (37 lbs / ft3), approximately 600 kg / m 3 (37 lbs / l ft), approximately 610 kg / m 3 (38 lbs / cu ft), approximately 620 kg / m 3 (39 lbs / cu ft), approximately 630 kg / m 3 (39 lbs / cu ft), approx. 640kg / m 3 (40 lbs / ft3), approximately 650 kg / m 3 (41 lbs / l ft), approximately 660 kg / m 3 (41 lbs / cu ft), approximately 670 kg / m 3 (42 lbs / cu ft), approximately 680 kg / m 3 (42 lbs / cu ft), approx. 690kg / m 3 (43 lbs / ft3), approximately 700 kg / m 3 (44 lbs / l ft), approximately 710 kg / m 3 (44 lb / ft3), approximately 720 kg / m 3 (45 lbs / ft3), approximately 730 kg / m 3 (46 lbs / cu ft), approx. 740kg / m 3 (46 lb / ft3), or about 750 kg / m 3 (47 pon In some embodiments, the bulk density of the composition may be about 56 0kg / m 3 (35 lbs / ft3) ~ approx. 720 kg / m 3 (45 lbs / cu. weight), approx. 650kg / m 3 (41 lbs / ft3) ~ approx. 700 kg / m 3 (4 4 lbs / ft3), approximately 670 kg / m 3 (42 lbs / cu ft) ~ approx. 71 0kg / m 3 (44 lb / ft3), or about 630 kg / m 3 (39 lbs. ft3) ~ approx. 730 kg / m 3 (46 pounds per cubic foot).

[0077] Increasing porosity improves the reactivity of the carbon and facilitates the conversion of the composition to pure silicon. The composition may have an iodine value of at least about 300. The iodine value is determined by the iodine value of the porous carbon. The iodine number is a parameter used to characterize the performance of carbon. It is a measure of the micropore (e.g., 0-20 Å) content. It is In some embodiments, the compositions produced according to the embodiments of the present disclosure are important measurements. The porous carbon product may have a molecular weight of about 300, about 400, about 500, about 600, about 750, about 900, Approx. 1000, Approx. 1100, Approx. 1200, Approx. 1300, Approx. 1500, Approx. 1600, Approx. 175 0, about 1900, about 2000, about 2100, and about 2200 iodine Price Have In some embodiments, the porous carbon products produced according to embodiments of the present disclosure include at least At least about 300, at least about 400, at least about 500, at least about 600, At least about 750, at least about 900, at least about 1000, at least about 1100, At least about 1200, at least about 1300, at least about 1500, at least about 16 00, at least about 1750, at least about 1900, at least about 2000, at least Also about 2100, and at least about 2200 iodine Price In yet another embodiment, The porous carbon products produced according to the embodiments of the present disclosure have a molecular weight of about 300 to about 2200. About 500 to about 1500, about 750 to about 1750, about 900 to about 1300, about 1000 to about 1500, about 1500 to about 2200, or about 1200 to about 1900 iodine Price have .

[0078] process Provided herein is a method for producing high carbon Drugs derived from It is a process for producing In some embodiments, the process includes providing a carbon-containing feedstock comprising dried biomass. and in a preheat zone, in the presence of a substantially inert gas, for at least about 5 minutes. Preheating the raw material at a preheating temperature selected from about 80°C to about 500°C; in the presence of a substantially inert gas for at least about 10 minutes and at about 250°C to The raw material is pyrolyzed at a pyrolysis temperature selected from about 700°C to obtain a high-temperature pyrolyzed solid, generating a condensable vapor and a non-condensable gas; and Separating at least a portion of the non-condensable gas from the hot pyrolyzed solids and cooling the solids. in the presence of a substantially inert gas for at least about 5 minutes and at a pyrolysis temperature Cool the hot pyrolyzed solids at a cooling temperature lower than and cooling the warm pyrolyzed solids in a cooler separate from the cooling zone. Instead, producing a low-temperature pyrolyzed solid and dissolving at least the low-temperature pyrolyzed solid. Some of the high-carbon Drugs derived from and recovering the second Further comprising introducing silicon oxide into the process.

[0079] High carbon Drugs derived from Disclosed herein is a process for producing providing a carbon-containing feedstock comprising biomass; and optionally drying the feedstock; removing at least a portion of the moisture contained within the raw material and, optionally, drying the raw material or The dried ingredients are degassed to remove any residual gases, if any, contained within the ingredients. Inside the gap At least a portion of the oxygen is removed. and in the pyrolysis zone, in the presence of a substantially inert gas, The raw material is pyrolyzed for 10 minutes at a pyrolysis temperature selected from about 250°C to about 700°C. , producing high temperature pyrolyzed solids, condensable vapors, and non-condensable gases; and At least a portion of the steam and at least a portion of the non-condensable gases are reacted with a high temperature pyrolyzed solid. and in a cooling zone, in the presence of a substantially inert gas, Cool the hot pyrolyzed solids for approximately 5 minutes at a cooling zone temperature below the pyrolysis temperature. Instead, it produces a warm pyrolyzed solid and an optional cooling zone separate from the In the cooler, the warm pyrolyzed solids are further cooled to produce cooler pyrolyzed solids. and producing a high carbon product comprising at least a portion of the warm or low temperature pyrolyzed solids. Drugs derived from and recovering the

[0080] In some embodiments, during pyrolysis, an amount of acid less than that required for complete combustion of the material is used. In some embodiments, the oxygen is about 10% or less of the oxygen required for complete combustion. , about 5% or less, about 1% or less, about 0.5% or less, about 0.1% or less, or about 0.01% or less In some embodiments, the pyrolysis is carried out in the absence of oxygen.

[0081] In some embodiments, the high carbon Drugs derived from The process for producing In some embodiments, the reactor can control the temperature and conditions of the atmosphere. In some embodiments, the reaction is carried out in a reactor. In some embodiments, the reactor may include one or more zones. One or more zones have controlled temperature and atmospheric conditions relative to other zones in the reactor. This is the region within the reactor where

[0082] In various embodiments, high carbon Drugs derived from The process for producing the biomass In some embodiments, the BPU includes a processing unit ("BPU") that includes various reactors and The raw materials or The feedstock may be fed to other reactors or zones, the feed system, the carbon recovery unit, and the to any one or more of the other contemplated components of the system described in this document. In one embodiment, the feedstock is a BPU having a plurality of output passages configured to be fed to a zone of the BPU. After passing through each, the raw material is carbonized.

[0083] In some embodiments, the high carbon Drugs derived from The process for producing In some embodiments, carbonization involves removing non-carbon-containing materials from biomass. Reduce To "High carbon biomass" can be achieved by either adding carbon atoms to biomass or both. Drugs derived from This can be illustratively achieved by forming

[0084] As discussed below, various multi-zone BPU embodiments include a single reactor. Various multi-zone BPU embodiments may also include multiple separate reactors. Other embodiments discussed include multiple separate reactors, each reactor comprising at least one It should be understood that for purposes of this disclosure, all single reactor multi-zone Features, principles, processes, alternatives, and implementations discussed with respect to embodiments of the zonal BPU The configuration applies equally to all multiple separate reactor embodiments and vice versa. .

[0085] In some embodiments, the process includes drying the feedstock to remove moisture contained within the feedstock. In these or other embodiments, the process includes removing at least a portion of the starting material. Degas the material and remove the Inside the gap removing at least a portion of the oxygen.

[0086] The process may further comprise, prior to step (d), reacting at least about 1000 ml of toluene in the presence of a substantially inert gas. 5 minutes and a preheating temperature selected from about 80°C to about 500°C or about 300°C to about 400°C The method may further include preheating the feedstock in a preheat zone at 100° C.

[0087] 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 carried out for at least about 20 minutes. The cooling zone temperature can be selected from, for example, about 150°C to about 350°C.

[0088] The pyrolysis conditions may be adjusted to provide high carbon content to the feedstock if desired for a particular product application. raw Drugs derived from The thickness may be selected to maintain the structural integrity or mechanical strength of the material.

[0089] In some embodiments, each of the zones is located within a single reactor or BPU. In other embodiments, each of the zones is located in a separate BPU or reactor. Some embodiments include one or more BPUs, each of which includes at least one zone. Please understand this.

[0090] Substantially inert gases include N2, Ar, CO, CO2, H2, CH4, and their Some of the substantially inert gases may be selected from the group consisting of the following combinations: (e) including one or more non-condensable gas species (e.g., CO and CO2) recycled from In some embodiments, the pyrolysis zone and the cooling zone each contain about 1% by weight. This includes a gas phase containing less than 5% by weight of oxygen, such as:

[0091] The process can be continuous, semi-continuous, or batch. In a continuous embodiment, the inert gas flows substantially countercurrent to the direction of solids flow. In other continuous or semi-continuous embodiments, the inert gas is fed in a direction opposite to the direction of flow of the solids. flow substantially simultaneously.

[0092] In some embodiments, the process includes at least one reactive gas probe, such as two or more reactive gas probes. Includes monitoring and controlling the process with one reactive gas probe. By monitoring and controlling the process, the energy efficiency of the process can be improved. By monitoring and controlling the carbon content, energy content, structural integrity, or mechanical High carbon content, including but not limited to strength Drugs derived from Related product attributes It can also be improved.

[0093] The process comprises the thermal oxidation of at least a portion of the condensable and non-condensable steam with an oxygen-containing gas. (i.e., combustion). Thermal oxidation may be facilitated by the combustion of natural gas. The heat produced from the thermal oxidation may be utilized, at least in part, to dry the feedstock. In addition, the heat produced from the thermal oxidation can be used to heat the fuel in a zone or reactor, such as the pyrolysis zone. is utilized at least in part to heat a substantially inert gas prior to entering one of the obtain.

[0094] The process combines at least a portion of the steam with low temperature pyrolyzed solids to produce a high carbon raw Drugs derived from Alternatively, or in addition, the method may further include increasing the carbon content of The process comprises combining at least a portion of the condensable vapor with the warm pyrolyzed solids, High carbon Drugs derived from The method may further include increasing the carbon content of the

[0095] Condensable vapors can therefore be generated either by processes (such as by thermal oxidation) or by carbon enrichment. of energy, and high carbon production Drugs derived from It can increase the carbon content of CO or Certain non-condensable gases, such as CH4, can be used as energy in processes or through pyrolysis. It may be utilized either as part of the substantially inert gas for the step.

[0096] In some embodiments, the process comprises the step of adding at least one selected from an acid, a base, or a salt thereof. The method further includes introducing at least one additive. The additives include sodium hydroxide, hydroxide Potassium oxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, permanganate potassium, and combinations thereof. cannot be used).

[0097] In some embodiments, the process comprises the step of: At least one additive selected from the group consisting of nitriles, ... The additives may further include magnesium, manganese, aluminum, nickel, etc. Cr, Chromium, Silicon, Boron, Cerium, Molybdenum, Phosphorus, Tungsten, Vanadium iron halide, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, Fluorite, fluorspar, bentonite, calcium oxide The inorganic filler may be selected from the group consisting of (but is not limited to) calcium carbonate, calcium lauryl sulfate, calcium sulfate phosphate, calcium phosphate ... cannot be used).

[0098] Additives containing silicon dioxide or silica fume may be applied at any time before or after harvest. Included in the ingredient itself, or added before, during, or after one or more steps of the process The additive may be added, for example, before or during step (b), before or during step (d), During, during step (f), during step (g), between steps (f) and (g), or during The additive may be introduced after step (g) into the warm pyrolyzed solid. For example, the additive may be to facilitate cooling of the warm pyrolyzed solid in step (g): It may be introduced into an aqueous solution, vapor, or aerosol. In these or other embodiments, the addition The agent is introduced into the low temperature pyrolyzed solids to form a high carbon product containing the additive. Drugs derived from Shape Complete.

[0099] In some embodiments, the process comprises at least about For additional pyrolysis, the mixture is heated for 30 minutes at a pyrolysis temperature selected from about 200° C. to about 600° C. At least a portion of the low temperature pyrolyzed solids is introduced into a separate unit for the purpose of producing low temperature pyrolysis. and producing a solid product having a higher carbon content than the dissolved solid.

[0100] In some embodiments, the process includes operating a cooler to cool the warm pyrolyzed solids. with steam, thereby producing low temperature pyrolyzed solids and superheated steam. The drying may further comprise at least partially cooling the superheated steel obtained from the external cooler. Optionally, a cooler is operated to cool the warm pyrolyzed solids down to First, cool with steam to reach the first cooler temperature, then cool with air to reach the second cooler temperature. The second condenser temperature may reach a temperature lower than the first condenser temperature in the presence of air. It is associated with reduced combustion risks for warm pyrolyzed solids.

[0101] In the process disclosed herein, the introduction of silicon dioxide is in addition to the introduction of silica fume. Silica fume is ultra-fine (generally particles less than 1 μm in diameter) silica from silicon production. (including silica powder by-products, e.g., in the manufacture of silicon metal or ferrosilicon alloys) Silicon metal and alloys are produced in electric furnaces. Silica fume consists primarily of amorphous (non-crystalline) silicon dioxide.

[0102] In the process disclosed herein, the introduction of silicon dioxide is carried out by introducing raw silicon dioxide. For example, the introduction of silicon dioxide may include the introduction of river rock or quartz. Free silica is a multi-crystalline material with a composition very close to that of silicon dioxide. It occurs in the form of, for example, 46.75% by weight silicon and 53.25% oxygen. Quartz is by far the most commonly occurring form. Tridymite, cristobalite, The hydrous silica mineral opal is rare, and vitreous (glassy) silica, cobalt silica, and hydrated silica are also rare. Striga, tephra, and stishovite have been reported from only a few locations.

[0103] Silicon dioxide, whether introduced as silica fume or river rock, First, the process is carried out by adding silicon dioxide to the pyrolyzed solids at low temperature after pyrolysis. Silicon dioxide can be introduced as silica fume or river rock. Silicon dioxide, whether or not it is added, can be introduced prior to pyrolysis, and it is a heat transfer agent. , thereby improving the pyrolysis of biomass.

[0104] The silicon dioxide introduced is contained within the raw material sources such as silica fume or river rock. It contains a much larger alloy than previously used in submerged arc or electric arc furnaces. For example, the particle size of the silicon dioxide raw material can be smaller than that of river rock. Silica fume may range from about 0.01 mm to about 12 mm. For example, the particle size may be It can be from about 0.01 mm to 12 mm in increments of about 0.05 mm.

[0105] The process may include compressing, bonding, pelletizing, extruding, or agglomerating the composition. It can be included in the following:

[0106] The process can further include densification, whereby the powder is densified, for example into pellet form. Other shapes can also be produced, for example spheres. The proximity of carbon and silicon dioxide in the composition allows the composition to more efficiently bond to silicon. Brings about transformation.

[0107] The densification process can create the final composition of the material. The material is mixed and blended in a controlled manner with other particles, including the compositions described herein. The compositions described can be processed and extruded through densification equipment. Such equipment can include commercially available machines. Densification equipment can include forming dies. The composition is extruded through a nozzle, thereby producing, for example, pellets. Base plate temperatures are typically between about 72°C (165°F) and about 85°C (185°F). The pellets are heated at a temperature of about 43°C (110°F) and no more than about 121°C (250°F). As the pellets exit the extruder, they are slightly coated on the outside of the pellets. This coating is a naturally occurring substance in cellulosic materials. The pellets are then transferred to a finished product conveyor / cooler. It is possible.

[0108] Following formation, the pellets are cooled in a range of devices, including but not limited to air coolers, air conditioners, or liquid nitrogen. The pellets can be cooled by any cooling means, including but not limited to the cooling process. The pellet components maintain their integrity as they harden into the shape created by the extruder. In one embodiment, the pellets are then molded into a mold cavity after sufficient cooling and hardening. It is placed through a car screen, which separates the fine particles from the discrete particles. The fine particle output can be separated and recycled again or extruded by an extruder. This allows the pellets to be extruded, which removes any excess particles that may be generated. This can minimize the potential for waste to be generated.

[0109] The densification process involves the use of additives to improve densification and the use of additives, carbon and extruding the mixture through a die, thereby and optionally drying the pellets. can be done.

[0110] The densification process may optionally be carried out using additives, such as bentonite, to reduce the densification rate to approximately 0. Improving densification to about 0.5% to about 15% in 5% increments, and optionally, e.g. Add about 5% to about 50% water and mix the additive, carbon, and silicon dioxide. and extruding the mixture through a die, thereby producing pellets. Optionally, the extruder and / or die plate are heated or cooled to improve densification and optionally venting the extruder and optionally drying the pellets. The present invention can include the steps of:

[0111] Extruders can also be used to shape and mix materials. A process used to create cross-sectional profile objects. The material is The two main advantages of this process over other manufacturing processes are The advantage is that very complex cross sections can be produced and the material only experiences compressive and shear stresses. The advantage of this method is that it can process brittle materials without the need for cutting. This also means that products with excellent surface finishes can be produced. Extrusion can be continuous (theoretically producing an infinitely long piece of material) or semi-continuous (producing multiple The extrusion process can be performed at high or low temperatures. Using a variety of binders, coatings, and extrusion recipes, A variety of pellets are available, ranging from pellets with a pellet durability index of over 99% to dust-free and hydrophobic pellets. The die thickness, die taper, screw speed, etc. can be adjusted to achieve the desired product attributes. Moisture content, pre-compression, product size, and many other variables can affect pellet quality. For example, if a lot of water is used during extrusion and the product is then dried, In this case, it is easier to apply a wax-based coating than if less water was used in the extrusion process. It is easier to do that.

[0112] Referring generally to FIGS. 1-13, several exemplary multiple reactor embodiments of the present disclosure are Block flow diagrams are shown. Each diagram is discussed in turn below. Figures 1-13 are Although they represent some exemplary embodiments, they do not represent all contemplated embodiments of the present disclosure. As discussed below, it should be understood that some of the Various additional non-illustrated embodiments and combinations of some components and features are also contemplated. As will be appreciated in the discussion below, any of the multiple reactors discussed herein may Each of the reactors may be separate or may be in a single reactor, and the BPU may be in multiple Each of the figures shows different alternative implementations. Although an embodiment is shown, all other discussion in this disclosure refers to the illustrated embodiment and It should be understood that this is applicable to each of the embodiments not shown.

[0113] Referring now generally to FIG. 1, a block flow diagram of a multiple reactor embodiment of the present disclosure is shown. A diagram is shown. This embodiment can utilize two or more different reactors. In the illustrative embodiment, three reactors are shown, however, any different number of reactors may be used. In one embodiment, each reactor is connected to a material transport unit 304 (shown in FIG. 3). In one embodiment, the material transport Unit 304 controls the atmospheric and temperature conditions.

[0114] In the illustrated embodiment, a raw material 109 such as biomass is optionally dried and The system is sized externally and, optionally, by using a material feed system 108. and introduced into the first reactor 100 in a low oxygen atmosphere. As shown in FIG. 3, the material supply system 108 is configured to adjust the oxygen level in the ambient air in the system. After the oxygen level is reduced in the first reactor, the raw material 109 is The first reactor 112 enters via an enclosed material transport unit 304. In one embodiment, The raw material transport unit includes an encapsulating jacket or sleeve through which The steam and off-gas from the reactor are then sent to directly preheat the biomass. , used or sent to a process gas heater and / or heat exchanger, and then , which is sent and used to preheat or pyrolyze biomass.

[0115] In the illustrated embodiment, the raw material 109 is first transported to a material supply 304 on a material transport unit 304. From system 108 it passes to the first reactor of BPU 112 .

[0116] As will be discussed in more detail below, in one embodiment, the first reactor 112 is a reactor that converts waste heat into 32 and to save energy through a suitable waste heat recovery system. In one embodiment, the first reactor 1 is configured to be connected to any other reactor in the reactor. The waste heat released at 12 is used to dry the raw material 109 inside or outside the system. The steam bin or other suitable heating mechanism may be used to operate the steam bin. In this form, the by-product of the waste heat, such as the heated inert gas, is essentially used in the system. Can be used elsewhere to further concentrate the material at any point along the process .

[0117] In the illustrated embodiment, biomass 109 enters the first reactor 112 and the temperature is about The temperature is increased from a range of ambient temperature to about 150° C. to a range of about 100° C. to about 200° C. In the first reactor 112, the temperature does not exceed 200° C. As discussed in more detail below, As shown, the first reactor 112 is heated by extracting ethanol from the biomass 123. An output mechanism for capturing and venting the fumes 120 may be included. The off-gas 120 is optionally extracted for later use. The heat source used for the various zones in the BPU 102 is electric or gas. In this configuration, the heat sources used for the various reactors of the BPU 102 are the same as the heat sources used for other reactions in the unit 102. In various embodiments, the heat is indirect. .

[0118] Following preheating in the first reactor 112, the material transport unit 304 transports the preheated material 1 23 is passed to an optional second reactor 114. In one embodiment, reactor 114 is In one embodiment where reactor 114 is different from reactor 112, the material transport unit The unit 304 is connected to the second reactor through a high temperature steam seal system (e.g., an airlock). 114, so that the material transport unit 304 can In one embodiment, the interior of the second reactor 114 is In another embodiment, the mixture is heated to a temperature of about 100° C. to about 600° C. or about 200° C. to about 600° C. In this embodiment, the second reactor 114 is configured to extract the preheated material 123 from the material while it is being carbonized. 1 includes an output port similar to that of the first reactor 102 for capturing and venting the gas 122 that is In one embodiment, the gas 122 is optionally extracted for later use. In one embodiment, the off-gas 120 from the first reactor 112 and the off-gas from the second reactor 114 The off-gases 122 from the refrigerant and the refrigerant exhaust gases are combined into one gas stream 124. The separated biomass 125 exits the second reactor 114 and is passed to a third reactor 116 for cooling. In this case, the third reactor may be the same as 112 or 114, Or it may be different.

[0119] In one embodiment, Drugs derived from When 125 enters the third reactor 116, the carbonized Iomas 125 is a device that is designed to be (actively or passively) cooled to a specific temperature range, as discussed above. The biomass may be cooled to form carbonized biomass 126. The temperature of the oxidized biomass 125 is reduced in a third reactor under substantially inert atmospheric conditions. In another embodiment, the third reactor is a reactor for storing carbonized biomass 12 with additional water cooling. 5 is cooled. The carbonized biomass 126 will self-burn when exposed to oxygenated air. It should be understood that the mixture may be cooled in the third reactor 116 to a point where it will not spontaneously ignite. In one such embodiment, the third reactor 116 is configured to increase the temperature of the carbonized biomass by 2 In one embodiment, the third reactor is agitated and cooled to below 00° C. and a mixer (not shown) for uniform cooling. Cooling is performed by directly adding water or other liquid. Cooling can occur either directly or indirectly, with air or other cooling gases, or with the above mentioned It is to be understood that any combination of the above may occur either directly or indirectly.

[0120] In some embodiments (not shown), a refrigerant is added to further reduce the temperature of the carbonized biomass. It should be understood that one or more additional coolers or cooling mechanisms may be used to cool the air. In such an embodiment, the cooler may be connected to other reactors 112, 113 along the material transport system. 14, 116. In some embodiments, a cooler follows the reactor. In some embodiments, the cooler may be the same as the reactors 112 , 114 , 116 . In other embodiments, the cooler may be, for example, a screw, an auger, a conveyor (particularly In one embodiment, the conveyor belt, drum, screen, pan, countercurrent bed, vertical tower, Jacketed paddles, cooling screws, or a combination of these, which are or other liquids, directly or indirectly, or other gases, directly or indirectly In various embodiments, the cooler is a water spray, a cooled These may include a condensed inert gas stream, liquid nitrogen, or ambient air if below its ignition temperature. The flash steam generated by the above process or saturated steam is introduced to the carbonized By capturing the superheated steam produced when heated by biomass, It should be appreciated that heat can be recovered from this step.

[0121] As shown in FIG. 1 and FIG. 5, the gas phase separator unit 200 includes at least one The BPU 102 includes a first reactor 1 and a plurality of outputs. At least one input is connected to the first reactor 1 of the BPU 102. 12 and an exhaust port on the second reactor 114. One of the outputs is Another of the outputs is connected to a carbon capture unit 104, and the other is connected to a collection device or an oxygen hydrogenation device. The unit 106 is connected to further processing equipment such as a distillation column. In the gas phase separator, off-gas 12 from the first reactor 112 and the second reactor 114 is separated into 0, 122 to produce a condensate 128 and a concentrated gas 204. In this case, the condensate is used for energy recovery (134) (e.g., in a dryer, reactor, or process In some embodiments, the carbon enrichment may be used in a gas heater, or for other carbon enrichment. In the case of the 130-kV reactor, non-condensable species (e.g., CO) can be extracted for energy recovery (134) (e.g., in the dryer, reactor, or process gas heater) and inert gas in the process (e.g., in a degassing unit, reactor, BPU, or cooling It may be used in a refrigerator (in a cooler) or for carbon enrichment.

[0122] In various embodiments, the condensate 128 may be a mixture of acetic acid, methanol, and furfural. In another embodiment, the enriched gas 2 produced by the gas phase separator 200 includes polar compounds. 04 is at least non-polar gases such as carbon monoxide, terpenes, methane, carbon dioxide, etc. In one embodiment, the vapor phase separator comprises a fractionation column. In one embodiment, the acetic acid is The optional acid hydrogenation unit is sent via line 128. Nol and / or furfural may be delivered via optional additional line(s) 136. The condensed effluent is then sent to the distillation / treatment unit 138.

[0123] In various embodiments, as discussed in more detail below, the carbon capture unit itself comprises: In various other embodiments, the material is concentrated in a carbon capture unit. In some such embodiments, the carbon dioxide is concentrated in a material concentration unit separate from the carbon dioxide. The material recovery unit is a container for storing carbonized material and is separated from the material enrichment unit. It should be understood that a gas separator is a unit into which a gas is introduced to concentrate a material.

[0124] In the illustrated embodiment, the carbon recovery unit 500 also converts the carbonized biomass 126 into The carbonized biomass 126 is transported along the material transport unit 304 to the third reaction The wastewater leaves the vessel and enters a carbon recovery unit 500. In various embodiments, the wastewater is As shown and discussed above, the carbon recovery unit 500 is also connected to the gas phase separator 200. In one embodiment, the enriched gas 204 is directed to a carbon recovery unit. Being kicked and living Drugs derived from Combined with 126, it produces high-carbon Drugs derived from Create 136 In another embodiment, carbon enriched gas from an external source is also directed to a carbon recovery unit. This is then combined with carbonized biomass126 to produce the final high-carbon biomass. Drugs derived from Agent Additional carbon can be added to the carbonized biomass. 26 is a carbonized biomass with a reduced temperature. The system may be located in the same location near the wood processing facility and may be configured to extract carbon-enriched gases from the wood processing facility from an external source. It can be used as a gas.

[0125] Referring now generally to FIG. 2, a single reactor, multi-zone embodiment of the present disclosure is A block flow diagram is shown. In the illustrated embodiment, a raw material 20, such as biomass, is 9 can be optionally used to provide low-acid feed to the feedstock 108 already described. As discussed in more detail below, the material feed is The system 108 reduces the oxygen level in the ambient air at the system to approximately 3% or less. After the oxygen level is reduced, the raw material 209 is transported to the BP In one embodiment, the material transport unit is a reactor for preheating the biomass. Steam and off-gas from the reactor 200 are delivered to the encapsulated jacket used. Includes a nut or sleeve.

[0126] In the illustrated embodiment, the raw material is first transferred to the material supply system on the material transport unit 304. From the drum 108, the mixture passes through an optional drying zone 210 of the BPU 202. In this embodiment, an optional drying zone 210 heats the raw material before it is passed to the preheating zone 212. In one embodiment, the optional drying zone 210 The portion is heated to a temperature between about ambient temperature and about 150° C. Water 23 removed from the raw material 209 8 or other moisture can be evacuated, for example, through optional drying zone 210. In another embodiment, the optional drying zone is adapted to extract vapor and steam. In another embodiment, the vapor and steam from the optional drying zone are The extract may be optionally extracted for later use. As discussed below, the extract may be optionally dried in a drying zone. The extracted vapor or steam from the turbine is fed into a suitable waste heat recovery system with a material feed system. In one embodiment, the vapor and steam used in the material delivery system can be used The raw materials are preheated while the oxygen levels are purged in the material feed system. In an embodiment, the biomass is dried outside the reactor and the reactor does not include a drying zone. .

[0127] As will be discussed in more detail below, in one embodiment, the optional drying zone 210 , to recover waste heat 232 and conserve energy through a suitable waste heat recovery system; In one embodiment, the cooling zone 216 is configured to connect to the The discharged waste heat is configured to dry the raw material 209 in an optional drying zone 210. After drying for the desired period, the dried biomass is Mass 221 exits optional drying zone 210 and enters preheat zone 212.

[0128] In the illustrated embodiment, the dried biomass 221 is passed into the first (preheating) zone 212. The temperature range changes from about ambient temperature to about 150°C to about 100°C to about 200°C. In one embodiment, the temperature exceeds 200° C. in the first / preheat zone 212. If the preheat zone 212 is too hot or not hot enough, the dried biomass 221 It should be understood that the erroneous processing may occur before entering the second zone 214. As discussed in more detail in, the preheat zone 212 is used to heat the dried burlap while it is being preheated. An output mechanism can be included to capture and exhaust gas 220 from the biomass 221. In another embodiment, the off-gas 220 is optionally extracted for later use. In various embodiments, the heat source used for the various zones in the BPU 202 may be electrical or In one embodiment, the heat source used for the various zones of the BPU 202 is a unit. In various embodiments, the heat may be from other zones in the reactor 202 or from waste gases from an external source. It is contiguous.

[0129] Following the preheat zone 212, a material transport unit 304 transports the preheated material 223 to a second In one embodiment, the material transport unit 304 is The second / pyrolysis zone is sealed through a high temperature steam seal system (e.g., airlock, not shown). This allows the material transport unit 304 to prevent (or minimize) the escape of gas. ) through the high temperature pyrolysis zone. In one embodiment, the pyrolysis zone 2 The inside of 14 is heated to a temperature of about 100°C to about 600°C or about 200°C to about 500°C. In another embodiment, the pyrolysis zone 214 has an output port similar to that of the preheat zone 212. and captures gases 222 released from the preheated biomass 223 during carbonization. In one embodiment, the gas 222 is optionally extracted for later use. In one illustrative embodiment, the off-gas 220 from the preheating zone 212 and the pyrolysis zone The off-gases 222 from the exhaust 214 are combined into one gas stream 224. The carbonized biomass 225 exits the second / pyrolysis zone 214 and is heated to a third / temperature Enters drop or cooling zone 216.

[0130] In one embodiment, as the carbonized biomass 225 enters the cooling zone 216, the carbonized The biomass 225 was stored at a specified temperature of about 20°C to 25°C (about room temperature), as discussed above. The biomass is cooled to a temperature range selected for the temperature reduction to produce carbonized biomass 226. In an embodiment, the BPU 202 includes multiple cooling zones. 216 cools the carbonized biomass to below 200° C. In one embodiment, the cooling zone The cooling system includes a mixer for mixing and uniformly cooling the material. One or more of the cooling zones are external to the BPU 202.

[0131] As shown in FIG. 2 and FIG. 5, the gas phase separator unit 200 includes at least one In this illustrative embodiment, at least one input is Exhaust ports above the first / preheat zone 212 and the second / pyrolysis zone 214 of the PU 202 One of the outputs is connected to a carbon capture unit 500 (to concentrate the material). Another one of the outputs is connected to a collection device or an acid hydrogenation unit 2 06 or a distillation column. The separator separates the off-gas 2 from the first / preheating zone 212 and the second / pyrolysis zone 214. 20, 222 are processed to produce a condensate 228 and a concentrated gas 204. The condensate 228 contains polar compounds such as acetic acid, methanol, and furfural. In one embodiment, the enriched gas 204 produced by the gas phase separator 200 is at least In one embodiment, the gas phase separator comprises a fractionation column. The acid is sent via line 228 to optional acid hydrogenation unit 206. In this case, methanol and / or furfural may be added via optional additional line(s). The effluent is sent via 236 to a distillation / processing unit 238 .

[0132] In the illustrated embodiment, the carbonized biomass is cooled along the material transfer unit 304. It exits the reactor / zone and enters a carbon recovery unit 500. In various embodiments, as shown in FIG. As shown in further detail below and discussed above, the carbon capture unit 500 also includes a gas phase separator. In one embodiment, the enriched gas 204 is Directed towards Unit 500, Drugs derived from Combined with 226, it produces high-carbon Drugs derived from Agent In another embodiment, carbon enriched gas from an external source is also produced. Drugs derived from Agent Combined with 226 Drugs derived from Carbon capture units to add additional carbon to 500. In various embodiments, the carbon capture unit 50 at reference 234 The gas drawn from the boiler can optionally be fed into an energy recovery system and / or further Similarly, in various embodiments, the BPU 202 may be used in a system for carbon enrichment. The gas withdrawn from one or more of the zones may optionally be fed to an energy recovery system. Illustratively, the system may be used in a system for further carbon enrichment and / or for further carbon enrichment. 200 may be co-located near a wood processing facility and may detect carbon enriched gases from the wood processing facility. can be used as the gas from an external source.

[0133] Referring now generally to FIG. 3, one material delivery system embodiment of the present disclosure is shown. As discussed above, high oxygen levels in the ambient air surrounding the raw material during processing Bell causes undesirable combustion or oxidation of raw materials, which can affect the quantity and quality of the final product. In one embodiment, the material supply system is a closed system, one or more manifolds configured to purge oxygen from the air surrounding the raw material. In one embodiment, an oxygen level of about 0.5% to about 1.0% is used during preheating, pyrolysis / carbonization, and The primary goal of a closed material supply system is to keep oxygen levels below approximately 3%. It is understood that the reduction is to about 2% or less, about 1% or less, or about 0.5% or less. After the oxygen levels are reduced, the biomass is transported along the material feed system to the BPU. In various embodiments, preheating of the inert gas with recovered process energy, and and the subsequent introduction of preheated inert gas into the BPU, reactor, or trimming reactor. , it should be appreciated that this makes the system more efficient.

[0134] In some embodiments, a trimming reactor is included in the system. In one embodiment of the device, the pyrolyzed material from the BPU is fed to a separate It is fed to an additional reactor where heated inert gas is introduced to increase the fixed carbon level. In various embodiments, the secondary process is carried out in drums, tanks, bins, etc. In containers such as barrels, bins, totes, pipes, bags, presses, or roll-off containers In various embodiments, the final container may also be used for transporting the carbonized biomass. In some embodiments, the inert gas is extracted from the BPU and used for transport. , heated via a heat exchanger that draws heat from the gases combusted in the process gas heater .

[0135] As can be seen in FIG. 3, the enclosed material feed system 108 includes a raw material feed hopper 300, a fuel delivery unit 304, and an oxygen purge manifold 302.

[0136] In one embodiment, the raw material feed hopper 300 is a feedstock or sizing / dry bio Any suitable outdoor or enclosed air container configured to receive the mass 109 / 209. The raw material supply hopper 300 is operatively connected to a material transport unit 304. In one embodiment, this may be a screw or an oar that is operatively rotated by a drive source. In one embodiment, the raw material 109 / 209 is fed by a gravity feed system. The material is fed to the material transport unit 304 by a screw. or auger 305 is adapted to be enclosed in a suitable enclosure 307. It should be understood that in one embodiment, the enclosure 307 is substantially cylindrical. In various embodiments, the material feed system may be a screw, an auger, a conveyor, a drum, , screens, chutes, drop chambers, rotary airlocks, or double or triple An air conveying device including a heavy flap airlock.

[0137] Raw materials 109 / 209 are fed from raw material feed hopper 300 to material transport unit 304 When this occurs, the auger or screw 305 rotates, forcing the raw material 109 / 209 through the oxygen permeation. The raw material 109 / 209 flows into the oxygen purge manifold 302. Upon reaching 2, the ambient air between the raw materials 109 / 209 in the material transport unit 304 It should be understood that the oxygen purge manifold contains approximately 20.9% oxygen. The hull 302 is arranged adjacent to or around the material transport unit 304. In the oxygen fold manifold of the embodiment, the enclosure 307 of the material transport unit 304 has a plurality of gas inlet ports 310a, 310b, 310c and a plurality of gas outlet ports 310b, 310c. Includes 08a, 308b, 308c.

[0138] The oxygen purge manifold 302 includes at least one gas inlet line 312 and at least one Each of the oxygen purge manifolds has a gas outlet line 314. In various embodiments, the oxygen purge manifold At least one gas inlet line 312 of 302 includes a plurality of gas inlet ports 310a, 310b, 310c, 310d, 310e, 310f, 310g, 310h, 310i, 310j ... 10b, 310c, respectively. Similarly, in various embodiments, At least one gas outlet line 314 of the oxygen purge manifold 302 includes a plurality of gas outlets. The nozzles 308 a, 308 b, and 308 c are in operative communication with each other. In this embodiment, the gas inlet line 312 supplies the inert gas to the gas inlet ports 310a, 310b, 310c, 310d, 310e, 310f, 310g, 310h, 310i, 310j, 310m .... It should be understood that the present invention is configured to pump the 10c to the 10d. In the present embodiment, the inert gas is nitrogen that is substantially free of oxygen. The gas flows countercurrent to the biomass.

[0139] As will be appreciated, the introduction of the inert gas 312 into the enclosed material transport unit 304 During operation, the inert gas 312 is pumped through the closed system. When introduced into the first gas inlet port 310a, a quantity of oxygen-rich ambient air is introduced into the outlet port 310b. At this point, the mixture is extruded from the port 308a. Desired levels of oxygen below .5%, or about 0.2%, may not be achieved. I want you to understand this. Therefore, in various embodiments, an additional injection of inert gas 312 is performed to ensure a closed system. It is necessary to purge a necessary amount of oxygen from the air surrounding the raw material 109 in the system. In this embodiment, the second gas inlet port 310b is connected to the first gas inlet port 310a. An inert gas 312 is then pumped into the closed system, thereby The inert gas 31 is used to purge more of the remaining oxygen from the It is understood that after one or two injections of 2, the desired level of less oxygen may be achieved. In one embodiment, if the desired oxygen level is not achieved after two inert gas injections, In this case, the third injection of inert gas 312 at gas inlet 310c is densely packed at gas outlet 308c. Purge remaining undesirable amounts of oxygen 314 from the closed system. Inlets / outlets may also be incorporated. In various embodiments, the oxygen level is controlled by the amount of inert gas injection. and is monitored throughout the material delivery system to allow for location calibration.

[0140] In an alternative embodiment, the heat, steam, and gases recovered from the reactor are fed to a jacket. The nozzle is directed into the feed system, which is sealed off and isolated from direct contact with the feed material, but The feed material is indirectly heated before being introduced into the reactor.

[0141] In an alternative embodiment, heat, steam, and gas recovered from the drying zone of the reactor are used to The gas is directed towards a feed system that is sealed in a jacket and isolated from direct contact with the feed material. However, the feedstock is indirectly heated before being introduced into the reactor.

[0142] Gas inlet ports 310a, 310b, 310c and corresponding gas outlets of one embodiment. Ports 308a, 308b, and 308c each extend vertically through material transport unit 304. It should be understood that the two are slightly offset from each other relative to the bisecting plane. In an embodiment, the inlet port 310a and corresponding outlet port 308a are In the material transport unit 304, the pitch of the auger 305 is approximately equal to the pitch of the auger 305. In various embodiments, the feedstock 109 / 209 is offset by an amount that is greater than the amount of the feedstock 109 / 209 that surrounds it. After the atmosphere is sufficiently deoxygenated, it is passed from the material supply system 108 to the BPU 102. In various embodiments, the oxygen level is calibrated to the amount and location of the inert gas injection. The entire material delivery system is monitored to enable

[0143] In one embodiment, the raw material 109 / 209 is mixed with the dried biomass 221, followed by the preheated biomass. Biomass 123 / 223, Carbonized Biomass 125 / 225, and Carbonized Biomass 126 / 226 transports the reactor 102 (or multiple reactors) along a continuous material transport unit 304. It should be understood that the material moves through the reactor. The units are different at different stages in the process. In one embodiment, the reactor, zone, or In one such embodiment, the process of moving material through the reactor is continuous. The velocity of the material transport unit 304 determines the rate at which the material is transported as it moves through one or more reactors. The associated controller and processor are configured to operate the transmission unit 304 without requiring interruption. The input signal is appropriately calibrated and calculated by the processor.

[0144] In another embodiment, the reactor 102 or multiple reactors (112 / 114 / 116) may The associated controller may include one or more feedback sensors, a detected gas (e.g., any from any FTIR), measured parameters, temperature gauges, or reactor processes and configured to adjust the speed of the material transport unit 304 based on other suitable variables in the In various embodiments, any device in operative communication with the controller and processor may be used. Suitable moisture, temperature or gas sensors may be installed in or on each zone / reactor. It will be appreciated that the present invention may be integrated into the material transport unit 304 at any suitable location, such as between, or along the material transport unit 304. In one embodiment, the controller and processor may receive the signal from the sensor or gauge. This information is used to optimize the speed and efficiency of the BPU 100 / 200. The controller associated with the reactor 102 or multiple reactors (112 / 114 / 116) The reactor 1 is configured to operate the material transport unit 304. The controller associated with the reactor or reactors (112 / 114 / 116) controls the material transport. Monitor the gas concentration, temperature, and moisture inside the delivery unit 304 or inside any reactor. In one embodiment, the controller is configured to monitor the The velocity, gas input to the material transport unit, and the gas added to the material in the material transport unit The heat is adjusted based on one or more readings obtained by various sensors. It is done.

[0145] 2 and 4, one embodiment of the BPU 102 is illustrated. The graphical representation of BPU 202 in FIG. 4 corresponds substantially to BPU 202 in FIG. It should be understood that in various embodiments, the BPU 202 is required for the reactor process. It is also understood that the large amount of heat generated is enclosed in a kiln shell to control and manipulate it. As can be seen in FIG. 4, in one embodiment, the kiln shell of the BPU 202 has four Several insulating chambers (41 6, 418). In one embodiment, the kiln includes four separate zones. In one embodiment, the four zones 210, 212, 214, and 216 of the BPU 202 Each includes at least one entrance flight and at least one exit flight. As discussed in more detail below, within each zone of one such embodiment, an inlet and exit flights control the flow of feed material, gas, and heat into and out of the zone. The inlet flight is configured to be adjustable to allow the inert air supply to be introduced into the inlet flight. and the purged air can be extracted from the corresponding exit flight. In an embodiment, one or more of the exit flights of the zones in the BPU 202 are It is connected to one or more of the other entrance or exit flights.

[0146] In one embodiment, the raw material 209 is deoxygenated in the material supply system 108 and then Introduced into U202, specifically the first of the four zones is an optional drying The drying zone is introduced into zone 210. As can be seen in FIG. and exit flight 420a. In one embodiment, the drying zone is heated to a temperature between about 80° C. and about 15 The raw material 209 is then heated to a temperature of 0° C. to remove water or other moisture from the raw material 209. The biomass is then moved to a second or preheat zone 212 where the biomass is heated and cooled as described above. The oven is preheated to .

[0147] In another embodiment, the optionally dried and preheated material is subjected to a third or carbonization zone. In one embodiment, the carbonization is performed at a temperature between about 200° C. and about 700° C., for example, at about 200° C. ℃, about 210℃, about 220℃, about 230℃, about 240℃, about 250℃, about 260℃, about 2 70℃, about 280℃, about 290℃, about 300℃, about 310℃, about 320℃, about 330℃, About 340℃, about 350℃, about 360℃, about 370℃, about 380℃, about 390℃, about 400℃ ℃, 410℃, about 420℃, about 430℃, about 440℃, about 450℃, about 460℃, about 47 0℃, about 480℃, about 490℃, about 500℃, about 510℃, about 520℃, about 530℃, about 540℃, about 550℃, about 560℃, about 570℃, about 580℃, about 590℃, about 600℃ , about 610°C, about 620°C, about 630°C, about 640°C, about 650°C, about 660°C, about 67 The reaction occurs at a temperature of about 0° C., about 680° C., about 690° C., or about 700° C. In another embodiment, The carbonization zone of the reactor 421 is adapted to allow extraction of the gases produced during carbonization. In another embodiment, the gas produced during carbonization is optionally extracted for later use. In one embodiment, the carbonization temperature is set to minimize or eliminate the production of methane (CH4) and to reduce the carbonization temperature. The carbon content of the oxidized biomass is selected to maximize the carbon content of the oxidized biomass.

[0148] In another embodiment, the carbonized biomass is subjected to a temperature reduction or cooling zone (a third zone In one embodiment, the cooling system is moved in a direction parallel to the axis of the cooling medium, and is passively or actively cooled. The carbonized biomass solids were cooled to temperatures within ±10, 20, 30, or 40°C of room temperature. can be.

[0149] In various embodiments, the BPU includes multiple gas introduction probes and gas extraction probes. In the embodiment of the BPU illustrated in FIG. 4, the BPU includes a plurality of gas introduction probes: 8, 410, 412, and 414, as well as a plurality of gas extraction probes: 400, 402 , 404, and 406. In various embodiments, each of the gas introduction probes and one of each gas extraction probe is connected to a plurality of zones 210, 212, 214. , and 216. In one embodiment, the BPU 202 includes two or more gas introduction nozzles for each of a number of zones. Any suitable number of gas introduction probes, including two or more gas extraction probes, It should also be understood to include a gas extraction probe.

[0150] In the illustrated embodiment, the drying zone 210 includes a gas introduction probe 412 and a gas extraction probe 414. In one embodiment, the gas introduction probe 412 is associated with a dry Nitrogen is introduced into zone 210 and a gas extraction probe 402 extracts gas from the drying zone 210. In various embodiments, the gas introduction probe 412 introduces the mixture of gases into the drying zone. It should be understood that the extracted gas is configured to be introduced into 210. In various embodiments, the gas extraction probe 402 is configured as described in more detail above. As will be described, gases can be extracted from the drying zone 210 for use in a heat or energy recovery system. It should be understood that the data is reused across systems.

[0151] In the illustrated embodiment, the preheat zone 212 includes a gas introduction probe 414 and a gas extraction probe 416. In one embodiment, the gas introduction probe 414 is associated with a preheat Nitrogen is introduced into zone 212 and a gas extraction probe 400 extracts gas from preheat zone 212. In various embodiments, the gas introduction probe 414 introduces the mixture of gases into the preheat zone. It should be understood that the gas extraction system is configured to introduce the gas into the gas extractor 212. The gas extracted by the probe 400 includes carbon-enriched off-gas. As mentioned above, the gases extracted from the preheating zone 212 and the pyrolysis zone 214 are It may be reintroduced into the material at a later stage in the process, for example in a carbon capture unit. It should be understood that in various embodiments, gas extracted from any of the reactor zones may be Energy recovery in dryers or process gas heaters, trimming reactors The wastewater is then used either for further pyrolysis in a refrigerated storage tank or in a carbon enrichment unit.

[0152] In the illustrated embodiment, the pyrolysis zone 214 includes a gas introduction probe 410 and a gas extraction probe 420. In one embodiment, the gas introduction probe 410 is associated with a nitrogen The pyrolysis zone 214 is fed with a gas extraction probe 404. In various embodiments, the gas introduction probe 410 extracts the gas by dissolving the mixture of gases in a pyrolyzer. It should be appreciated that the method is configured to introduce the solution zone 214. The gas extracted by the gas extraction probe 404 includes carbon-enriched off-gas. In one embodiment, As discussed above, carbon enriched gas extracted from the pyrolysis zone 214 is used; It should be understood that the material may be reintroduced at a later stage in the process. is a gas mixture comprising extracted gas 400 from the preheat zone 212 and The extracted gases 404 from the pyrolysis zone 214 are combined before being reintroduced into the material.

[0153] In the illustrated embodiment, the cooling zone 116 includes a gas introduction probe 408 and a gas extraction probe 409. In one embodiment, the gas introduction probe 408 is associated with a cooling Nitrogen is introduced into zone 116 and a gas extraction probe 406 extracts gas from cooling zone 116. In various embodiments, the gas introduction probe 408 introduces the mixture of gases into the cooling zone. It should be understood that the gas extraction device is configured to introduce the gas into the gas extraction system. The probe 406 extracts gas from the cooling zone 116, as described in more detail above. It should be understood that the heat generated by the process may be reused in a heat or energy recovery system.

[0154] The gas introduction and extraction probes of the various embodiments described above are introduced into each zone. to adjust the levels and concentrations of gases introduced and extracted from each zone. It will be understood that the present invention is configured to operate with the controller and a number of sensors. sea ​​bream.

[0155] In various embodiments, the gas introduction probe and the gas extraction probe are resistant to high temperature fluctuations. In one embodiment, the gas introduction probe and The gas extraction probe includes a number of openings through which gas is introduced or extracted. In the embodiment, the plurality of openings are disposed below the inlet and the gas extraction probe. In this embodiment, each of the plurality of openings extends a substantial length within the respective zone. do.

[0156] In one embodiment, the gas introduction probe extends from one side of the BPU 202 through each zone. In one such embodiment, each of the four gas introduction probes is located on one side of the BPU. to each of the zones. In various embodiments, the fixed carbon level is enriched A gaseous catalyst is added. In such an embodiment, each of the four gas introduction probes The multiple openings for the respective zones associated with that particular gas introduction probe are Please understand that the

[0157] For example, in Figure 4, each gas introduction probe enters each zone from the left side of the drying zone. When the gas introduction probes extend to the drying zone, all four gas introduction probes move through the drying zone and The first gas inlet probe terminates in the drying zone. The remaining three gas inlet probes all The gas introduction probe of the preheat zone is moved through the preheat zone by a gas introduction probe that terminates in the preheat zone. The remaining two gas introduction probes pass through the pyrolysis zone and are connected to the gas introduction probes of the pyrolysis zone. The lobe terminates in the pyrolysis zone. The gas inlet probe in the cooling zone is In various embodiments, the gas introduction probe is the only one that moves and terminates in the cooling zone. It is understood that the extraction probe is constructed similarly to the gas introduction probe described in this example. It should be understood that the gas introduction probe and the gas extraction probe are each located at either of the BPUs. It should also be understood that it is possible to start from the

[0158] In various embodiments, the gas introduction probe may be configured in a multi-port configuration as described in the examples above. In order to save space, they are arranged concentrically with each other. In one embodiment, each of the four inlet probes / ports is connected to the previous inlet probe / port. For example, in one embodiment, the gas introduction probe in the drying zone has a smaller diameter than the has the largest inner diameter, and the gas inlet probe of the preheating zone is the inlet probe / The gas inlet probe of the pyrolysis zone is then connected to the gas inlet of the preheat zone. The gas introduction probe in the cooling zone is located within the inner diameter of the gas introduction probe in the pyrolysis zone. In one exemplary embodiment, a suitable connector is located on the outside of the BPU 102. Each of the four gas introduction probes is attached to The amount of air injected into each is controlled individually.

[0159] In one such embodiment, similar to the example above, the gas introduction probe in the drying zone is The other three gas introduction probes continue into the preheat zone. In a concentric or substantially concentric arrangement, only the outermost gas introduction probes are In one such embodiment, the gas introduction of the individual zones is therefore The inlets are independent of each other while only requiring one continuous gas introduction probe line. In one embodiment, a similar concentric or substantially concentric configuration is used for gas extraction. It should be understood that the present invention is preferably used in a probe.

[0160] In one embodiment, each zone or reactor comprises one or more individual zones or reactors. In another embodiment, each zone is adapted to extract and collect off-gas from above. The off-gas from the reactor / reactor is separated and stored for disposal, analysis, and / or later use. In various embodiments, each reactor / zone may include a gas supply that monitors gas formation within the zone / reactor. In another embodiment, the gas detection system includes a FTIR that can visualize the Off-gases from several zones / reactors are stored for disposal, analysis, and / or later use. In various embodiments, the off-gas from one or more zones / reactors is In another embodiment, the off-gas from one or more zones / reactors is fed to a process gas heater. The fumes are fed to a carbon recovery unit. In another embodiment, one or more zones / reaction The off-gas from the reactor is fed to a gas phase separator before being introduced into a carbon recovery unit. In an embodiment, the gas phase separator comprises a fractionation tower. Any fractionation tower known to one of ordinary skill in the art may be used. In one embodiment, the off-gas is passed through a standard fractionation tower or packed tower heated to a suitable temperature. In another embodiment, the non-polar and polar compounds are separated using a gas phase separator. The non-polar compounds or concentrated gases from the mixture are extracted for optional later use and are then used in various experiments. In an embodiment, off-gas from one or more zones / reactors is fed to a process gas heater. In one embodiment, a preheat zone / reactor, a pyrolysis zone / reactor, and optionally The gas extracted from the cooling zone / reactor is extracted into a combined stream and gas phase separated. In various embodiments, one or more of the zones / reactors are combined. to control whether and how much gas is introduced into the injected stream. It is composed.

[0161] As discussed above and generally illustrated in FIG. The off-gas 124 / 224 is directed to the gas phase separator 200. The gas extractor 124 / 224 is a gas extractor 124 from the second pyrolysis zone / reactor 114 / 214. Extraction gas from the first / preheat zone / reactor 112 / 212 combined with 2 / 222 120, or either gas stream only. At 0, the off-gas 124 / 224 is divided into polar compounds 128 / 228 / 136 / 236. and non-polar compounds 204, such as non-polar gases. 200 is a known fractionating tower.

[0162] In various embodiments, concentrated gas extracted from the combined off-gas 124 / 224 204 is connected to a carbon capture unit 202 via an input 524 for concentrating the material from the gas phase separator 200. As discussed above and illustrated in FIGS. In this embodiment, the extracted gas is first introduced into a material enrichment unit and then into a separate carbon capture unit. It should be understood that the concentration of the material is introduced into the unit. is performed in the carbon recovery unit 500. In one embodiment (FIG. 5), the gas phase separator 200 , including multiple outputs. In various embodiments, one output from the gas phase separator 200 is a carbon A carbon recovery unit 500 is connected to the enriched gas stream for introduction into the carbon recovery unit 500. In an embodiment, a portion of the enriched gas stream is directed to a carbon recovery unit 500 and another portion is directed to Directed to a scrubber, or another suitable purification device for cleaning and disposing of unwanted gases. In various embodiments, the off-gas that is not sent to the carbon recovery unit is used for energy recovery. (e.g. in process gas heaters) or as an inert gas (e.g. in degassing units) In addition, various embodiments may be used in the same manner. In this mode, the off-gas from the carbon recovery unit is used for energy recovery (e.g., process gas hi as an inert gas (e.g., in a degassing unit, reactor, BPU, or in a cooler), or in a secondary recovery unit.

[0163] In one embodiment, another output from the gas phase separator extracts polar compounds and, optionally, These are condensed into a liquid composition that includes a plurality of distinct liquid portions. In various embodiments, the liquid is In various embodiments, the output liquid may include water, acetic acid, methanol, and furfural. The body may be stored, disposed of, further processed, or reused. It is understood that the water can be reused to heat or cool other parts of the system. In another embodiment, the water is drained. and furfural may be sent to storage tanks for reuse, resale, distillation, or purification. It should also be understood that it is possible to

[0164] As can be seen in FIG. 5, one embodiment of a carbon capture unit 500 has an upper portion and a lower portion. The material enrichment unit is separated from the carbon recovery unit. In the embodiment, the material enrichment unit is the same as that discussed with respect to the carbon recovery unit 500 of FIG. It should be understood that the carbon recovery unit includes features similar to those described above. A housing 502 having a top portion 502a and a bottom portion 502b, and a housing 502 for conveying reactor off-gas. and an inlet 524 at the bottom of the lower portion of the housing configured to convey the enriched gas stream. The outlet 534 is at the top of the upper part of the housing, and the partition between the upper and lower parts of the housing. A route 504 is defined, Drugs a route-following transport system 5 configured to transport 28, and the housing includes: Drugs adsorbs at least a portion of the reactor off-gas. In various embodiments, the upper portion includes multiple outlets and the lower portion includes multiple inlets. Includes.

[0165] In one embodiment, the housing 502 is angled at 110 degrees or less, 90 degrees or less, 80 degrees or less, or In one embodiment, the housing 502 is substantially free of corners having an angle of 70 degrees or less. In another embodiment, the housing 502 is configured to create a vortex or to have no convex corners. The housing is substantially free of convex corners that can trap air. The shape 502 may be a cube, a prism, an ellipsoid, a solid ellipsoid, a spheroid, or a shape of a base pasted together. Two cones glued together, a regular tetrahedron glued together at its base, and two pyramids glued together at their bases. , or two isosceles triangular prisms with their bases glued together.

[0166] In one embodiment, the upper and lower portions 502a, 502b of the housing 502 are Substantially half ellipsoid, half prism, half-cuboid, half ellipsoid, cone, regular tetrahedron, pyramid , an isosceles prism, or a rounded corner duct transition.

[0167] In another embodiment, the inlet 524 at the bottom of the lower portion of the housing 502b and the housing An outlet 534 at the top of the top of the gage 502a is configured to connect to a pipe. In an embodiment, the top of the lower portion of housing 502b and the bottom of the upper portion of housing 502a In another embodiment, the housing 502 is substantially rectangular, circular, or elliptical. The width between the top of the lower portion of b and the bottom of the upper portion of the housing 502a is Wider than wide. In one embodiment, the width of the transport system 528 is its height.

[0168] In one embodiment, the carbon capture unit 500 includes a passage 50 defined between an upper portion and a lower portion. 4, inlet opening 506, and outlet opening 508. In one embodiment, the inlet opening and the exit opening are configured to receive a transport system. The delivery system 528 is at least semi-permeable or permeable to the concentrated gas.

[0169] In one embodiment, the inlet opening 506 includes an inlet opening seal to reduce gas leakage. The outlet opening 508 includes an outlet opening sealing mechanism to reduce gas leakage. In one embodiment, the inlet and outlet opening sealing mechanisms include an airlock. Prepare.

[0170] In various embodiments, the lower portion 502b of the carbon capture unit housing has a narrow rounded bottom connection. The gas phase separator 200 has an opening which is connected to the gas phase separator 200 for transport of the gas stream 204. In various embodiments, the top of the lower portion 502b of the housing of the carbon recovery unit 500 is substantially The opening is generally rectangular in shape and is substantially wider than the narrow round-bottom connection opening. It should be understood that the section transitions from a rounded bottom opening to a rectangular top opening. The rectangular top opening at the bottom is approximately 6 feet wide (along the direction of the conveyor system). In various embodiments, the top of the carbon capture unit 500 is substantially similar in width to the bottom. In one embodiment, the bottom opening of the top portion is wider than the top opening of the bottom portion. In an embodiment, the rectangular bottom opening at the top is approximately 6 In one embodiment, the top is made of carbon that is not adsorbed by the porous material. The primary gas recovery unit 500 is configured to capture all gas passing through it.

[0171] In various embodiments, the shape of the lower portion of the carbon capture unit is Drugs derived from 126 / 226 This helps to slow down and disperse the gas 204 over a larger surface area of ​​the conveyor carrying the gas. It should be understood that in various embodiments, the lower portion 502b of the carbon capture unit 500 and The exact shape of the upper 502a portion depends on the angle of gas dispersion coming from the gas phase separator pipe. In various embodiments, the gas is pumped at a flare ranging from 5 degrees to 30 degrees from vertical. It should be understood that the flare angle has a natural tendency to expand over time. The bottom of the carbon recovery unit is 15 degrees to prevent air trapping or the formation of vortices. It should be understood that in order to achieve this, the substrate is constructed with as few creases and corners as possible.

[0172] In one embodiment, the carbon recovery unit 500 includes a gas phase separator 20, as discussed above. 0, and BPU 102 / 202. The raw material recovery unit 500 is connected to the output of the cooling reactor / zone 216 / 116 or the BPU 10 2 / 202 to the outside of the last cooling zone or BPU. The output of the cooling reactor / zone 116 / 216 is the raw material processed by the BPU 102 / 202. Origin Drugs In one embodiment, Drugs derived from 126 / 226 is based on a preferred transportation system. In various embodiments, the top and bottom of the carbon recovery unit The upper and lower portions are connected to each other and define a path through which the transportation system passes. The transport system is a porous or mesh material configured to allow gas to pass through it. The transport system passes through an opening in the carbon capture unit 500 and then It should be understood that the liquid is configured to pass through an outlet opening in the liquid recovery. In some embodiments, the inlets and outlets to and from the carbon capture unit are configured to allow gas to pass through a conveyor opening. An airlock or other suitable sealing mechanism must be provided to prevent escape through the mouth. In various embodiments, the off-gas that is not sent to the carbon recovery unit is For energy recovery (e.g. in process gas heaters) or as an inert gas (e.g. For example, in a degassing unit, a reactor, a BPU, or a cooler. In various embodiments, the off-gas from the carbon recovery unit is used for energy recovery (e.g., in process gas heaters), as an inert gas (e.g. in degassing units, reactors, The refrigeration system may be used in a secondary recovery unit (e.g., in a BPU, or chiller), or in a secondary recovery unit.

[0173] In various embodiments, the process begins with the cooling reactor / zone 116 / 216 A suitable exhaust mechanism is used to extract the generated heat from the cooling zone 116 / 216 into the transport system. Drugs derived from In one embodiment, the 126 / 226 output is Drugs derived from 126 / 2 2 6 is spread across the width of the conveying system to minimize stacking or bundling of material. This minimizes the surface area for gas absorption. Drugs derived from 126 / 2 2 6 piled up Once suitably dispersed on the transport system, in various embodiments, the transport system ,raw Drugs derived from 126 / 2 2 6, the carbon cycle defined between the upper and lower portions discussed above. The carbon dioxide is transported through an opening in the carbon capture unit 104. raw Drugs derived from 126 / 2 2 6 from the gas phase separator 200 to the bottom of the carbon recovery unit 104 It absorbs the gas piped in. Drugs derived from is condensed with a non-polar gas and then Drugs derived from but High carbon Drugs derived from It should be understood that in various embodiments, Drugs derived from Agent is the end product of the process disclosed herein and is extracted from the carbon recovery unit 104 The mixture is then transported to suitable storage or post-treatment equipment.

[0174] In one embodiment, the concentrated gas 204 is conveyed through a conveyor and Drugs derived from 126 / 2 2 Passing 6 After this, the resulting gas is extracted at the top of the carbon recovery unit 104. The exhaust gas 134 is then transported to a suitable scrubber, stack, or collection system. In some embodiments, the exhaust gas is recycled for use in a secondary carbon capture unit or is utilized for any reusable quality in the system, including for energy. In various embodiments, the off-gas that is not sent to the carbon recovery unit may be used for energy recovery (e.g. in process gas heaters) or as an inert gas (e.g. in degassing units, In various embodiments, the refrigerant may be used in a reactor, a BPU, or a cooler. The off-gas from the carbon recovery unit can be used for energy recovery (e.g., process gas heaters). as an inert gas (e.g., in degassing units, reactors, BPUs, or cooling in a storage vessel), or in a secondary recovery unit.

[0175] raw Drugs derived from 126 / 2 2 6 contains a large amount of carbon, which is used to adsorb non-polar gases. It should be understood that the enriched gas stream 204 has a high priority for the terpenes, It should also be understood to include non-polar gases such as carbon dioxide, carbon dioxide, and methane. In various embodiments, when the enriched gas is directed from the gas phase separator to a carbon recovery unit, the gas The flow rate and conveyor speed are monitored and controlled to Drugs derived from 126 / 2 2 6. Non In another embodiment, the energetic organic compound is a bipolar compound. During carbonization of the omegas, the gas phase separator 200 outputs the gas to the carbon recovery unit 104. At least a portion of the enriched gas 204. In various embodiments, the enriched gas 204 is It is further concentrated with additional additives before being introduced into a recovery unit or material concentration unit. do.

[0176] As discussed in more detail below, in various embodiments, the carbon recovery unit raw Drugs derived from 126 / 2 2 The residence time of 6 is Drugs derived from 126 / 2 2 Composition of 6 and It is controlled and varied based on gas flow and composition. Drugs derived from is 1 In various embodiments, the effluent from the gas phase separator is passed through one or more carbon recovery units two or more times. The enriched air output and the exhaust air output from the carbon capture unit 104 are used for additional carbon capture. Bypass or divert to a unit or use in a process can be further purified or used for inert gases.

[0177]

[0031] Referring more generally to Figures 6-13, various embodiments of the present disclosure are illustrated and discussed. The various embodiments and alternatives discussed below with respect to FIGS. It should be understood that the same applies to the embodiment of Figures 1-5, and vice versa.

[0178] Specifically, referring to FIG. 6, this embodiment includes two or more different A BPU may be utilized that includes a single reactor having a zone comprising: Although two zones are shown, any different number of zones may be used. In one embodiment, each zone is connected to at least one In one embodiment, the material transport unit is connected to atmospheric and temperature conditions. Control the matter.

[0179] Specifically, in one embodiment illustrated in FIG. 6, the system 600 includes a material delivery system. 602, a BPU 606 including a pyrolysis zone 608 and a cooling zone 610, a cooler 614 , as well as a carbon recovery unit 616. The cooler 614 in FIG. It is understood that this is in addition to the cooling zone 610 present in the BPU 606. stomach.

[0180] In various embodiments, the system 600 includes a material supply system 602 and a BPU 606. In various embodiments, the BPU 606 includes multiple zones. In FIG. 6, the BPU 606 includes a pyrolysis zone 608 and a cooling zone 610. The PU 606 also includes a plurality of zones containing at least a condensable vapor and a non-condensable gas 612. At least a plurality of devices for adding and removing various substances from the electrodes 608, 610. In various embodiments discussed below, the multiple zones 608 include multiple inlets and outlets. or 610 is sealed by the BPU 606. stomach.

[0181] Referring now to FIG. 7, one embodiment of a system 700 is illustrated and discussed. The system 700 includes a material supply system 702, a preheater 706, a pyrolysis reactor 708, a cooler 714, and a carbon recovery unit 716. In this embodiment, the system 700 may include an optional feed system 702 between the material feed system 702 and the preheater 706. 7, the pyrolysis reactor 708 in one embodiment includes a dryer 704. At least one gas inlet 710 for outputting material from the reactor 708 and at least In various embodiments, the material output through the outlet 712 is , condensable vapors and / or non-condensable gases. It should be understood that the present invention may include one or more zones not specifically discussed. In an embodiment, the system 700 includes one or more reactors in addition to the pyrolysis reactor 708. nothing.

[0182] Referring now to FIG. 8, one embodiment of a single reactor, multi-zone BPU system 80 8. The system 800 includes a material feed system 802, a pyrolysis zone 804, and a feed system 806. 810 and a BPU 808 having a cooling zone 812, a material concentration unit 818, and Similar to the embodiment discussed above, FIG. 8 also illustrates a carbon capture unit 820 for An optional dryer 804 is located between the feed system 802 and the BPU 808. It should be appreciated that moisture 806 from the dryer 804 is removed during the drying process. Also outside the BPU 808, an optional cooler 816 may be provided prior to the material concentration unit 818. As discussed in more detail below, the material enrichment unit 818 is configured to enrich the material in water from the BPU. It communicates with the gas outlet 814 of the BPU 808, which carries condensable vapors and non-condensable gases. Various embodiments shown in FIG. 8 include a carbon capture unit separate from the material enrichment unit 818. It should be understood that the present invention includes a 820 . As discussed above, in various embodiments, FIG. The carbon recovery unit 820 stores the concentrated material following the material concentration unit 818. and the carbon recovery unit 820 is a suitable vessel that does not further concentrate the material.

[0183] In various embodiments, an optional process gas heater 824 is disposed in the system. , it should be understood that the BPU 808 is attached to the BPU 808. In various embodiments, Steam or other off-gas from 808 may be mixed with one or more of air, natural gas, and nitrogen. Along with the external source above, the optional process gas heater 824 is input. As discussed, in various embodiments, the air discharge from the process gas heater 824 is , is input to the dryer 804 as a heat or energy recovery system.

[0184] Referring now to FIG. 9, there is illustrated a BPU 908 of one embodiment of a system 900, The BPU 908 includes multiple zones: a preheat zone 904, a pyrolysis zone 910, and cooling zone 914. The BPU 908 of one embodiment also includes zones 904, 91 0, 914 of at least one gas inlet 906 in communication with one or more of the In various embodiments, the material supply system 902 is in communication with one of the As discussed, one of the zones, in one embodiment, is a zone that is free of material, condensable vapors, and and / or at least one outlet 912 for outputting non-condensable gases. In the configuration, one of the zones is an outlet for outputting advanced carbon from the system 900. Also includes.

[0185] FIG. 9 shows a gas inlet 906 connected to a preheat zone 904, although various implementations It should be understood that embodiments include entrances to any combination of the three zones. The gaseous outlet 912 comes from the pyrolysis zone 910, although various embodiments may include three zones. It should be understood that this includes exits from one or more of any combination of the above. As will be appreciated, various contemplated embodiments include inputs and outputs within the BPU: For example, the outlet of the pyrolysis zone 910 is then input to the preheat zone 904. In this configuration, each of the reactors in the BPU is provided with a material feed system as discussed above. It should be understood that the signals are connected to each other via

[0186] In various embodiments, the preheat zone 904 of the BPU 908 does not "bombard" the biomass. 902 (or another carbon-containing feedstock) in a manner that The process disrupts the cell walls and initiates the rapid decomposition of the solid phase into steam and gas. The preheat zone 904 can be thought of as a gentle pyrolysis.

[0187] In various embodiments, the pyrolysis zone 910 of the BPU 908 is configured as the primary reaction zone. The formed and preheated material undergoes pyrolysis chemistry to release gases and condensable vapors. It produces solid materials that are high-carbon reaction intermediates. Biomass components (mainly cellulose, hemicellulose, etc.) The enzymes in the fibers (cellulose, cellulose, and lignin) decompose to produce steam, which penetrates the pores or leaks by creating new nanopores. The latter effect is due to the increase in porosity and surface area. Contribute to the creation.

[0188] In various embodiments, the cooling zone 914 of the BPU 908 receives high carbon reaction intermediates. , i.e., the cooling zone 914 is configured to cool the solids in the pyrolysis zone 91 0. In the cooling zone 914, the chemistry and mass transport become complex. In various embodiments, secondary reactions occur in the cooling zone 914. Certain carbon-containing components can form additional fixed carbon and / or be adsorbed onto carbon. Therefore, Advanced Carbon 916 is simply the solid degassed residue of the processing step. rather, by decomposition of organic vapors (e.g., tar) that can form carbon. It contains additional carbon deposited from the gas phase.

[0189] 10-13, various multiple reactor embodiments of the system are illustrated. As with each of the embodiments, the system is discussed in more detail below. With reference to FIG. The system 1000 includes a material supply system 1002, a pyrolysis reactor 1012, a cooling reactor 1014, and a 1018, a cooler 1020, and a carbon recovery unit 1022. As shown, the gas source 1016 is connected to one of the pyrolysis reactor 1012 and the cooling reactor 1018. In various embodiments, the pyrolysis reactor is configured to input gas to the reactor or both. At least one outlet for outputting condensable vapor and / or non-condensable gas. In an embodiment, the carbon recovery unit 1022 outputs the porous carbon from the system 1000. The device includes an outlet 1024 for receiving the signal.

[0190] In at least the various embodiments illustrated in FIGS. 10-13, the illustrated system may include any It should be understood that the present invention includes an optional degasser and an optional dryer. As can be seen in FIG. 10 , an optional degasser 1004 is provided in the material supply system 100. 2 and the pyrolysis reactor 1002. Similarly, the dryer 1006 is a system 100 between the material supply system 1002 and the pyrolysis reactor 1012. 0. In various embodiments, the dryer 1006 and the degasser 1004 may also be In addition, the material from the material supply system is fed through the material supply system, the degasser, the dryer, and the heat separator. are connected to each other so that any number of different paths can be taken through the reactor. In some embodiments, the material is passed through the optional degasser 1004 and dryer 100. Please understand that only one of the six will pass.

[0191] In some embodiments, referring to FIG. Drugs derived from For manufacturing The process includes the steps of providing a carbon-containing feedstock comprising biomass, and optionally, drying the raw material to remove at least a portion of the moisture contained within the raw material; and optionally Optionally, the feedstock may be degassed to remove any residual gases, if any, contained within the feedstock. Inside the gap At least one of the oxygen removing the remaining part and subjecting the mixture to at least about 10 minutes or more in the presence of a substantially inert gas phase. and pyrolyzing the raw material at at least one temperature selected from about 250°C to about 700°C, generating a high temperature pyrolyzed solid, a condensable vapor, and a non-condensable gas; At least a portion of the condensable vapor and at least a portion of the non-condensable gas are converted into a high temperature pyrolyzed solid. and cooling the hot pyrolyzed solids to produce a cold pyrolyzed solid. and producing a high carbon product comprising at least a portion of the low temperature pyrolyzed solids. reason Drugs and recovering the

[0192] Referring now to FIG. 11, an embodiment of a multiple reactor system 1100 is illustrated. Similar to the embodiment discussed above and illustrated in FIG. The feed system 1102, the pyrolysis reactor 1112, the cooling reactor 1118, and the carbon capture unit 1116 are In the illustrated embodiment of FIG. 11, the cooler 1120 is optional. The material enrichment unit 1122 may include an optional cooler 1120 and a carbon recovery unit 112 4. In various embodiments, the material enrichment unit 1122 is a separate The material is concentrated before continuing to the carbon recovery unit 1124, which may further concentrate the material. It should be understood that the optional degasser 1104 may not be required. and an optional dryer 1106 are connected to the material feed system 1102 and the pyrolysis reactor 1112. In the illustrated embodiment, the pyrolysis reactor 1112 also includes a condensable vaporizer. and removing substances such as vapors and non-condensable gases, and transferring the removed substances to a material concentration unit 1122. The output of the input signal is sent to an output port 1114 configured to receive the input signal.

[0193] Various embodiments may further comprise a process for enriching the carbon content of the final product by cooling the carbon. By including a separate material enrichment unit 818, 1122 that is provided to the environment containing the species. , which extends the concept of additional carbon formation. If the temperature of this unit is lower than the pyrolysis temperature, The additional carbon is expected to be in the form of adsorbed carbonaceous species rather than additional fixed carbon. .

[0194] Now referring to FIG. 14, one embodiment of a single reactor biomass processing unit 140 The unit 1400 includes a hopper 1404 into which a raw material 1402 is fed. The hopper 1404 optionally transports the raw material 1402 to the reactor 1412. Prior to this, the reactor off-gas (e.g., vapor stream 1414) and / or additives and / or 14. The feedstock 1402 may be provided with a gas supply 1462 for adding and / or mixing gas from an external source 1462 to the feedstock 1402. The activated carbon 1426 flows through the reactor 1412 before exiting at the opposite end. Steam, nitrogen, carbon dioxide, or a combination thereof 1452 is mechanically transported. The steam flow 1414 is introduced into the reactor 1412 in a countercurrent manner relative to the biomass flow. At least partially removed from the reactor 1412 and optionally fed to a hopper 1404. The oxidizer 1424 then receives the oxidizer gas from the thermal oxidizer discharge. The heat from the gas is used to heat a gas stream 1458, which may include nitrogen and / or carbon dioxide. Gas stream 1458, or a portion thereof, is directed to reactor 14 via path 1460. 12, and / or optionally, feedstock 140 prior to entering reactor 1412 (not shown). The off-gas 1456 is recycled to the septic tank 2 according to standard methods, for example through a stack. It can be disposed of by

[0195] Now referring to FIG. 15, one embodiment of a two reactor biomass processing unit 1500 The unit 1500 is similar to the processing unit 1400 described above with respect to FIG. The first multi-zone reactor unit 1512A is configured substantially similarly to the first multi-zone reactor unit 1512A. However, in this embodiment, the raw material produced by reactor 1512A Origin activated carbon 1 At least a portion of 526A is fed to a hopper 1504 and then fed via a path 1502. The first reactor 1512A, the thermal oxidizer 1524, and a heat exchanger 1554, optionally thermally oxidized and optionally conditioned At least a portion of the evaporated vapor stream 1560 is fed countercurrently to the second reactor 1512B. Optionally, at least a portion of the off-gas from the second reactor 1512B is routed through path 1572. to indirectly heat the second reactor 1512B. In addition, the portion of the off-gas that is not recycled as heat may be passed via path 1556B to, e.g., Can be discarded by the stack. Origin The activated carbon product is and exits the second reactor 1512B.

[0196] As will be described in more detail below, the intermediate addition of one or more of the phases present in any particular reactor may be used. Force and output (purge or probe) flows, various mass and energy recycle schemes the mix, various additives that can be introduced anywhere in the process, and the ability to adjust the product distribution There are numerous options available, including the adjustability of process conditions, including both reaction and separation conditions. Zone or reactor specific input and output flows allow for FTIR sampling. Enables better process monitoring and control through things like pull-out and dynamic process adjustments become.

[0197] The present disclosure differs from fast pyrolysis and also from conventional slow pyrolysis. The high quality carbon materials in the present disclosure, including compositions with high It can be obtained from the stem.

[0198] Exemplary Uses Silicon products are produced using porous carbon and a form of silicon dioxide in a furnace. Generally, the silicon dioxide introduced into a silicon production furnace requires a relatively large amount of (e.g. tennis ball size). Silica fume and raw silicon (river rocks) Both of these have larger carbon atoms that allow the product to "sink" toward the electrode in the furnace. Only when combined with a sintered rod can it be used in a silicon production furnace. , which is essentially river rock. A supply of river rock that is both of sufficient purity and of useful size Disclosed herein are compositions that overcome this problem.

[0199] Surprisingly, the inventors have discovered that (1) the compositions described herein are effective in silicon production furnaces, For example, higher temperatures than previously available in electric arc furnaces and submerged arc furnaces can be achieved. (2) allowing the use of higher purity and / or smaller (cheaper) sources of silicon dioxide; The close proximity of carbon and silicon dioxide in the densified composition allows for more efficient conversion to silicon. (Thus, the closer proximity achieved by densification is an important structural aspect.) (3) the compositions have higher purity (higher purity provides important structural benefits); surface), the overall surface area of ​​any final silicone product produced using the composition. It was found that this improved the quality of the

[0200] The examples and embodiments described herein are for illustrative purposes only and are not intended to be limiting of the scope of the claimed invention. It is understood that the present disclosure is not intended to limit the scope of the invention. Various modifications or changes will be suggested to those skilled in the art in light of the examples and embodiments of the present application. It is understood that the present invention falls within the spirit and scope of the appended claims. All publications, patents, and patent applications cited herein are hereby incorporated by reference in their entirety for all purposes. is incorporated herein by reference.

[0201] All publications, patents, and patent applications cited herein are hereby expressly incorporated by reference in their entirety. Each and every patent or patent application is hereby incorporated by reference in its entirety as if each such patent or patent application was specifically and individually set forth herein. The body is incorporated herein by reference.

[0202] Where the methods and steps described above indicate particular events occurring in a particular order, those skilled in the art will recognize the particular The order of certain steps may be changed and such changes are understood to be in accordance with the scope of the present disclosure. Additionally, certain steps may be performed simultaneously in parallel processes when possible. The operations may be performed in parallel or sequentially.

[0203] Some variations of the present disclosure are based, at least in part, on the use of multiple reactors or a single reactor. The multiple zones optimize the carbon yield and product quality from pyrolysis while simultaneously reducing the feedstock Designed and operated to maintain flexibility and adjustability to fluctuations and product requirements It can be done.

[0204] The above explanation is Origin Limiting in any way the potential uses of porous carbon should not be construed as a Origin Injection of porous carbon into the gas stream is a promising method for reducing the Power plants, biomass-fired power plants, metal processing plants, crude oil refineries, chemical plants, polymer plants, pulp and paper plants, cement plants, waste incinerators, food processing plants In gas or liquid streams originating from plants, gasification plants, and synthesis gas plants This may be useful in controlling pollutant emissions in EXAMPLES

[0205] Example 1. Silicon dioxide Origin Preparation of Porous Carbon Compositions—General Methods. Wood biomass (red pine sawdust) is placed in a hopper and optionally transported to a dryer, where it is The moisture in the wood is reduced to less than 15% by heating, and the biomass is then subjected to a reactor system as described herein. The biomass is then heated to about 650 degrees Celsius for about 30 minutes, using mainly CO2 The porous carbon was then evacuated from the reactor and activated with a gas stream containing N 2 and H20 and conveyed to a mixer where 25% by weight of silicon dioxide was introduced. The mixture was mixed with the porous carbon for about 5 minutes. Origin Porous carbon composition is conveyed to an extruder where it is extruded into pellets of approximately 0.25 inch by 1 inch, and then This was then sent to a dryer where it was dried to less than about 8 percent moisture.

[0206] While specific embodiments have been described herein for purposes of illustration, it is understood that any such modifications may be within the scope of the present invention. It will be understood that various modifications may be made without departing from the spirit and scope of the present invention. It is not intended to be limited except as by the appended claims.

[0207] paragraph A. at least about 50% by weight total carbon and at most about 5% by weight hydrogen on a dry basis; maximum of about 1% by weight nitrogen, maximum of about 0.5% by weight phosphorus, maximum of about 0.2% by weight sulfur; Maximum of about 0.02% by weight of titanium, maximum of about 0.5% of calcium, maximum of about 0.1% of Aluminum, and silicon dioxide, total carbon, Origin Carbon-containing, high-carbon thing Drug of origin composition.

[0208] paragraph B. at least about 50% by weight total carbon and at most about 5% by weight hydrogen on a dry basis; maximum of about 1% by weight nitrogen, maximum of about 0.5% by weight phosphorus, maximum of about 0.2% by weight sulfur; Maximum of about 0.02% by weight of titanium, maximum of about 0.5% of calcium, maximum of about 0.1% of It contains aluminum and silicon dioxide, which is found in river rocks and is the total carbon dioxide. Raw, raw Origin Carbon-containing, high-carbon Drugs derived from composition.

[0209] paragraph C. at least about 50% by weight total carbon and at most about 5% by weight hydrogen on a dry basis; maximum of about 1% by weight nitrogen, maximum of about 0.5% by weight phosphorus, maximum of about 0.2% by weight sulfur; Maximum of about 0.02% by weight of titanium, maximum of about 0.5% of calcium, maximum of about 0.1% of It contains aluminum and silicon dioxide, the silicon dioxide being contained in silica fume. , total carbon, Origin Carbon-containing, high-carbon Drugs derived from composition.

[0210] paragraph D. Silicon dioxide is found in river rocks and is a high-carbon source of Para A. Drugs derived from composition .

[0211] paragraph E. Silicon dioxide is a high carbon product of Para A contained within silica fume. Drugs derived from composition.

[0212] paragraph F. Any one of Paragraphs A to E, containing at least about 65% by weight of total carbon. raw Drugs derived from composition.

[0213] paragraph G. Any one of Para A to F, containing at least about 70% by weight of total carbon. raw Drugs derived from composition.

[0214] paragraph H. Any one of high carbon paras A to G containing at least about 95% by weight of total carbon. raw Drugs derived from composition.

[0215] paragraph I. Any one of Para A to H, containing at least about 15% by weight of silicon dioxide. High carbon Drugs derived from composition.

[0216] paragraph J. Any one of Paragraphs A to J, containing at least about 25% by weight of silicon dioxide. High carbon Drugs derived from composition.

[0217] paragraph K. A high-quality composition according to any one of Paragraphs A to J, containing at least about 1% by weight of silicon dioxide. Carbon Drugs derived from composition.

[0218] paragraph L. high carbon biogenic Drugs derived from Any one of Paragraphs A to K, wherein the composition is extruded. High carbon Drugs derived from composition.

[0219] paragraph M. High carbon raw material Drugs derived from Any one of Para A to L, wherein the composition is densified. High carbon Drugs derived from composition.

[0220] paragraph N. High carbon raw material Drugs derived from Any one of Para A to M, wherein the composition is in the form of pellets. High carbon Drugs derived from composition.

[0221] paragraph O. High carbon raw material Drugs derived from The composition has a thickness of at least about 0.25 inches. x approx. 2.5cm (1.0 inch) ~ Max. approx. 5.1cm (2.0 inch) x approx. 15cm ( 6.0 inches) of any one of Para A to N high carbon raw materials Drugs derived from composition .

[0222] paragraph P. high carbon raw material Drugs derived from The composition has a viscosity of about 560 to about 720 kg / m 3 (35~45 points A high-carbon composite material selected from Para A to O having a bulk density of 1000 mm / cubic foot. Origin Drugs composition.

[0223] paragraph Q.High carbon raw material Drugs derived from The composition has an iodine value of at least about 300. Any one of A to P high carbon Drugs derived from composition.

[0224] paragraph R. at least about 50% by weight total carbon and at most about 5% by weight hydrogen on a dry basis; maximum of about 1% by weight nitrogen, maximum of about 0.5% by weight phosphorus, maximum of about 0.2% by weight sulfur; Maximum of about 0.02% by weight of titanium, maximum of about 0.5% of calcium, maximum of about 0.1% of aluminum, and at least about 15% by weight of silicon dioxide, The total carbon contained in the river rocks is Origin Contains carbon and is high in carbon Drugs derived from The composition , densified and at least 0.25 inches by 2.5 inches 1.0 inch) and is in the form of pellets weighing about 560 to about 720 kg / m 3(3 High carbon fiber with a bulk density of 5 to 45 pounds per cubic foot Drugs derived from composition.

[0225] paragraph S. at least about 50% by weight total carbon and at most about 5% by weight hydrogen on a dry basis; maximum of about 1% by weight nitrogen, maximum of about 0.5% by weight phosphorus, maximum of about 0.2% by weight sulfur; Maximum of about 0.02% by weight of titanium, maximum of about 0.5% of calcium, maximum of about 0.1% of aluminum, and at least about 15% by weight of silicon dioxide, The total carbon contained in silica fume is Origin Contains carbon and is high in carbon Drugs derived from set The composition is densified and has dimensions of at least about 0.25 inches by about 2.5 inches. It is in the form of pellets with dimensions of about 560 to about 720 kg / m 3 High carbon raw material with a bulk density of 35-45 pounds per cubic foot Drugs derived from composition .

[0226] paragraph T. high carbon biogenic Drugs derived from 13. A process for producing a composition comprising: providing a carbon-containing feedstock comprising dried biomass; and in a preheating zone, in the presence of a reactive gas for at least about 5 minutes and at a temperature selected from about 80° C. to about 500° C. preheating the feedstock at a thermal temperature and introducing a substantially inert gas into a pyrolysis zone. for at least about 10 minutes at a pyrolysis temperature selected from about 250° C. to about 700° C. The feedstock is pyrolyzed at 100° C. to produce high temperature pyrolyzed solids, condensable vapors, and non-condensable gases. and dissolving at least a portion of the condensable vapor and at least a portion of the non-condensable gas. and separating at least a portion of the pyrolyzed solid from the hot pyrolyzed solid in a cooling zone. In the presence of the substantially inert gas, for at least about 5 minutes and below the pyrolysis temperature. and cooling the hot pyrolyzed solids at a low cooling temperature to produce a warm pyrolyzed solid. and cooling the warm pyrolyzed solids in a cooler separate from the cooling zone. cooling the mixture to produce a low temperature pyrolyzed solid; and At least some of the high-carbon Drugs derived from and recovering the silicon dioxide. The process further comprises introducing the

[0227] paragraph U. Before preheating the ingredients, dry the ingredients and remove any residual volatile compounds present in the ingredients. The process of Para T, further comprising removing at least a portion of the moisture contained in the

[0228] paragraph V. Prior to preheating the feedstock, degas the feedstock to remove any gases, if any, present in the feedstock. The method of claim 1, further comprising removing at least a portion of the molecular oxygen contained therein. process.

[0229] paragraph W. The introduction of silicon dioxide includes the introduction of silica fume; One of the processes T~V.

[0230] paragraph X. Introducing silica includes introducing river rocks, para T-W Any one of the processes.

[0231] paragraph Y. Any one of the processes paraT through X, further including densification.

[0232] paragraph Z. High carbon raw material Drugs derived from Pressing, bonding, pelletizing, extruding, or agglomerating The process of any one of paras T to Y further comprises:

Claims

1. 1. A densified, high carbon biological reagent composition comprising silicon dioxide, comprising, on a dry basis: at least 50% by weight total carbon; up to 5% by weight hydrogen, maximum 1% by weight of nitrogen, up to 0.5% by weight phosphorus, maximum 0.2% by weight of sulfur, maximum 0.02% by weight titanium, Maximum 0.5% calcium, A maximum of 0.1% aluminum, and Contains silicon dioxide, the total carbon includes biogenic carbon; the silicon dioxide is contained within river rocks; or the silicon dioxide is contained within silica fume; and The densified high carbon biological reagent composition, wherein the high carbon biological reagent composition is densified.

2. 10. The composition of claim 1 comprising at least 65% by weight total carbon.

3. 10. The composition of claim 1 comprising at least 70% by weight total carbon.

4. 10. The composition of claim 1 comprising at least 95% by weight total carbon.

5. The composition according to any one of claims 1 to 4, comprising at least 15% by weight of silicon dioxide.

6. The composition according to any one of claims 1 to 4, comprising at least 25% by weight of silicon dioxide.

7. The composition according to any one of claims 1 to 4, comprising at least 1% by weight of silicon dioxide.

8. The composition of any one of claims 1 to 4, wherein the densified high carbon biological reagent composition is extruded.

9. The composition of any one of claims 1 to 4, wherein the densified high carbon biological reagent composition is in pellet form.

10. 5. The composition of any one of claims 1 to 4, wherein the densified high carbon biological reagent composition has dimensions of at least 0.64 cm (0.25 inches) by 2.5 cm (1.0 inches) and up to 5.1 cm (2.0 inches) by 15 cm (6.0 inches).

11. The densified high carbon biological reagent composition has a carbon content of at least 560 kg / m ３ (35 lbs / ft3) to a maximum of 720 kg / m ３ The composition of any one of claims 1 to 4, having a bulk density of 45 pounds per cubic foot.

12. The composition of any one of claims 1 to 4, wherein the densified high carbon biological reagent composition has an iodine value of at least 300.

13. 1. A densified, high carbon biological reagent composition comprising silicon dioxide, comprising, on a dry basis: at least 50% by weight total carbon; up to 5% by weight hydrogen, maximum 1% by weight of nitrogen, up to 0.5% by weight phosphorus, maximum 0.2% by weight of sulfur, maximum 0.02% by weight titanium, Maximum 0.5% calcium, A maximum of 0.1% aluminum, and Contains at least 15% by weight of silicon dioxide; the silicon dioxide is contained within river rocks; the total carbon includes biogenic carbon; and The high carbon biological reagent composition is densified and in pellet form having dimensions of at least 0.64 cm (0.25 in) by 2.5 cm (1.0 in) and has a strength of at least 560 kg / m ３ (35 lbs / ft3) to a maximum of 720 kg / m ３ (45 pounds per cubic foot) of bulk density of said densified high carbon biological reagent composition.

14. 1. A densified, high carbon biological reagent composition comprising silicon dioxide, comprising, on a dry basis: at least 50% by weight total carbon; up to 5% by weight hydrogen, maximum 1% by weight of nitrogen, up to 0.5% by weight phosphorus, maximum 0.2% by weight of sulfur, maximum 0.02% by weight titanium, Maximum 0.5% calcium, A maximum of 0.1% aluminum, and Contains at least 15% by weight of silicon dioxide; the silicon dioxide is contained within silica fume; the total carbon includes biogenic carbon; and The high carbon biological reagent composition is densified and in pellet form having dimensions of at least 0.64 cm (0.25 in) by 2.5 cm (1.0 in) and has a strength of at least 560 kg / m ３ (35 lbs / ft3) to a maximum of 720 kg / m ３ (45 pounds per cubic foot) of bulk density of said densified high carbon biological reagent composition.

15. 1. A process for producing a densified, high carbon biological reagent composition comprising silicon dioxide, said process comprising: Providing a carbon-containing feedstock comprising dry biomass; preheating the feedstock in a preheat zone in the presence of a substantially inert gas for at least 5 minutes and at a preheat temperature of at least 80° C. and up to 500° C.; pyrolyzing the feedstock in a pyrolysis zone in the presence of a substantially inert gas for at least 10 minutes and at a pyrolysis temperature of at least 250° C. up to 700° C., thereby producing hot pyrolyzed solids, condensable vapors, and non-condensable gases; separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids; cooling said hot pyrolyzed solids in a cooling zone in the presence of said substantially inert gas for at least 5 minutes and at a cooling temperature below said pyrolysis temperature, thereby producing warm pyrolyzed solids; cooling the warm pyrolyzed solids in a cooler separate from the cooling zone, thereby producing cooler pyrolyzed solids; recovering a high carbon biological reagent comprising at least a portion of the low temperature pyrolyzed solids; introducing silicon dioxide into the process, thereby producing a high carbon biological reagent composition comprising silicon dioxide, said silicon dioxide being contained within river rocks or said silicon dioxide being contained within silica fume; and densifying the silicon dioxide-containing high carbon biological reagent composition, thereby producing a densified high carbon biological reagent composition comprising silicon dioxide.

16. 16. The process of claim 15, further comprising drying a carbon-containing feedstock comprising biomass prior to said preheating, thereby removing moisture contained within said feedstock.

17. 16. The process of claim 15, further comprising degassing the carbon-containing feedstock comprising biomass or the dried biomass prior to the preheating, thereby removing molecular oxygen contained within the feedstock.

18. 18. The process of any one of claims 15 to 17, further comprising pressing, bonding, pelletizing, extruding, or agglomerating the high carbon biological reagent composition comprising silicon dioxide or the densified high carbon biological reagent composition comprising silicon dioxide.

19. A densified, high carbon biological reagent composition comprising silicon dioxide produced by the process of any one of claims 15 to 17.

Images