System for carbonizing organic material

Abstract

A system for carbonizing organic material is disclosed. A method for carbonizing organic material is also disclosed. Finally, a carbonization product comprising biocarbon formed in the disclosed system or using the disclosed method is further disclosed.

Description

[Technical field]

[0001] The present disclosure relates to a system for carbonizing organic material. The present disclosure further relates to a method for carbonizing organic material. Finally, the present disclosure also relates to a carbonized product comprising biocarbon formed in the system or using the method of the present disclosure. [Background technology]

[0002] Conventionally, various types of organic materials are known to be converted into charcoal or biocarbon using various processes, in which the organic material is heated in an oxygen-deficient or anaerobic atmosphere and the organic material is converted into charcoal in a pyrolysis process.

[0003] However, conducting pyrolysis on an industrial scale in an inert atmosphere to prevent combustion presents many technical challenges, including heat transfer limitations and the production of undesirable tar and liquid products. The requirement to operate in an inert atmosphere adds significant mechanical complexity and limits the overall reaction rate. Summary of the Invention [Means for solving the problem]

[0004] A system for carbonizing organic material is disclosed, the system comprising: a. a means for adding organic feedstock to the carbonization reactor; b. a means for adding an oxygen-containing gas to the carbonization reactor; c. a means for removing oxygen-deficient gas from the carbonization reactor; d. a means for initiating an exothermic reaction within the carbonization reactor; and e. means for removing the carbonized product from the carbonization reactor.

[0005] A method for carbonizing organic material is also disclosed. The method comprises: a. providing an organic feedstock to a carbonization reactor; b. supplying a gas comprising oxygen to a carbonization reactor; c. initiating an exothermic reaction in the carbonization reactor; and d. removing the carbonized product from the carbonization reactor.

[0006] Such systems and methods may be configured for a carbonization reaction to occur in the biomass during the time it traverses the reactor, for example by passing from the top of the reactor to the bottom, for example to a perforated cone therein. In this manner, the biomass enters the carbonization reactor as an organic feedstock or portion thereof and can be removed as a carbonized product.

[0007] At least two temperature sensors may be mounted at different heights of the carbonization reactor, or so-called carbonization reactor canister, in order to monitor the temperature, in particular in the biomass bed. This mounting of temperature sensors may be done in order to monitor the progress of the carbonization reaction. In one embodiment, the sensors are thermocouples. In one embodiment, there are at least four temperature sensors at different heights. In one embodiment, there are at least two temperature sensors, for example four or five or more temperature sensors, at each height. The sensors may be arranged to surround the interior of the carbonization reactor. In one embodiment, one or more of the sensors are arranged as upper sensors above a designated position of the reaction interface, and one or more of the sensors are arranged as lower sensors below a designated position of the reaction interface. Thus, the system and method may be configured to keep the reaction interface at least relatively stationary, in the vertical direction of the reactor, in particular by monitoring the temperature of the upper and lower sensors. At least two temperature sensors mounted at different heights of the carbonization reactor may be utilized to obtain repeated and / or continuous temperature measurements, in particular from the carbonization reactor.

[0008] Further disclosed is a carbonized product comprising biocarbon formed in the disclosed system or using the disclosed method. [Brief description of the drawings]

[0009] The accompanying drawings, which are included to provide a further understanding of the embodiments and are incorporated in and constitute a part of this specification, illustrate various embodiments. [Figure 1] FIG. 1 is a block diagram of the main components of a system for carbonizing organic material according to the present disclosure. [Diagram 2] FIG. 1 illustrates a system for carbonizing organic material according to one embodiment of the present disclosure. [Diagram 3] FIG. 1 illustrates a system for carbonizing organic material according to one embodiment of the present disclosure. [Figure 4] FIG. 1 illustrates temperature measurements over time in a system for carbonizing organic material according to one embodiment of the present disclosure. [Diagram 5] FIG. 2 illustrates reactant weight loss over time in a system for carbonizing organic material according to one embodiment of the present disclosure. [Figure 6] FIG. 1 illustrates a system for carbonizing organic material according to one embodiment of the present disclosure. [Figure 7] FIG. 1 illustrates another system for carbonizing organic material according to an embodiment of the present disclosure. [Figure 8] FIG. 1 illustrates a system for carbonizing organic material, particularly for energy recovery, according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] A system for carbonizing organic material is disclosed, the system comprising: a. a means for adding organic feedstock to the carbonization reactor; b. a means for adding an oxygen-containing gas to the carbonization reactor; c. a means for removing oxygen-deficient gas from the carbonization reactor; d. a means for initiating an exothermic reaction within the carbonization reactor; and e. means for removing the carbonized product from the carbonization reactor.

[0011] As used herein, the term "carbonization" refers to increasing the carbon to oxygen ratio in a product compared to the starting organic feedstock. In certain embodiments, the term carbonization may refer to converting an organic feedstock into a material that consists essentially of pure carbon. In certain embodiments, the term carbonization may refer to converting an organic feedstock into charcoal, biochar, or biocarbon.

[0012] In certain embodiments, the system may be configured to operate in a continuous or semi-batch mode.

[0013] In certain embodiments, the interior volume of the carbonization reactor is under greater than atmospheric pressure during the carbonization reaction.

[0014] In certain embodiments, the addition of the feedstock to the carbonization reactor is carried out at greater than atmospheric pressure.

[0015] As used herein, "greater than atmospheric pressure" refers to an absolute pressure greater than 1.01325 bar.

[0016] In certain embodiments, the pressure in the carbonization reactor may be between 3 and 20 bar.

[0017] In certain embodiments, the organic feedstock is added to the carbonization reactor in a continuous manner.

[0018] As used herein, the term "continuous" refers to the addition of feedstock while the exothermic reaction is proceeding. Similarly, as used herein, the term "semi-batch" refers to the addition of feedstock prior to the initiation of the exothermic reaction. In certain embodiments, the carbonized product is removed from the carbonization reactor in a continuous or semi-batch manner.

[0019] In certain embodiments, the oxygen-depleted gas exiting the reactor is composed of: Nitrogen 0~60% CO2 10-50% ·H20~50% CO 10-50% CH40~20% Ethane 0~5% Ethylene 0~5% Heavier Hydrocarbons 0-5%

[0020] In certain embodiments, the oxygen-depleted gas contains less than 5% O2.

[0021] As used herein, the term "heavier hydrocarbons" refers to hydrocarbons consisting of 3 or 4 or more carbon atoms. Non-limiting examples of heavier hydrocarbons are propane, butane, propene, and butene.

[0022] As used herein, all percentages refer to mole percentages of the composition unless expressly stated otherwise.

[0023] In certain embodiments, the oxygen-containing gas is added to the carbonization reactor at a pressure higher than atmospheric pressure. In certain embodiments, the oxygen-containing gas may be air. In certain embodiments, the oxygen-containing gas may be a gas containing more than 21% oxygen.

[0024] In certain embodiments, the oxygen-containing gas contains less than 21% oxygen. In certain embodiments, the oxygen-containing gas may be a gas, at least a portion of which originates from an oxygen-deficient gas outlet of the carbonization reactor.

[0025] In certain embodiments, the oxygen-containing gas contains less than 78% nitrogen.

[0026] In certain embodiments, the addition of the organic feedstock is at a rate that maintains a constant level of feedstock in the reactor. In certain embodiments, the rate of feedstock addition can be adjusted during the process to maintain an efficient carbonization process in the reactor. In one embodiment, the addition of the feedstock is under pressure. In one embodiment, the reactor is maintained at a pressure greater than atmospheric pressure when the feedstock is added.

[0027] In certain embodiments, the organic feedstock may be derived from biological processes such as photosynthesis or chemosynthesis, hi other embodiments, the organic feedstock is derived from fossil fuels, such as plastics or rubber.

[0028] In certain embodiments, the organic feedstock is mixed with the inorganic material prior to addition to the reactor. In one embodiment, the feedstock is wet-impregnated with an aqueous solution of an inorganic salt prior to addition to the reactor. In one embodiment, the feedstock is wet-impregnated with an aqueous solution containing a metal salt prior to addition to the reactor.

[0029] In certain embodiments, the means for initiating an exothermic reaction within the carbonization reactor is located at an opposite end of the carbonization reactor relative to the inlet for the oxygen-containing gas.

[0030] In certain embodiments, the means for initiating an exothermic reaction in the carbonization reactor is an electric heat source. In certain embodiments, the means for initiating an exothermic reaction in the carbonization reactor may be any other means suitable for initiating a reaction. A non-limiting example of a suitable means is a burner that burns a liquid or gaseous fuel.

[0031] In one embodiment, the energy required to initiate the exothermic reaction in the reactor is provided by leaving a remainder of the hot product at the bottom of the vessel.

[0032] In certain embodiments, the carbonized product is continuously removed from the carbonization reactor. In one embodiment, the reactor is maintained at a pressure greater than atmospheric pressure when the carbonized product is removed. In one embodiment, the carbonized product is cooled or quenched with water while being removed.

[0033] In certain embodiments, the reactor pressure is maintained by controlling the flow rate of the oxygen-containing gas relative to the flow rate of the oxygen-depleted gas.

[0034] In certain embodiments, the flow rate of the oxygen-containing gas is controlled by adjusting the pressure of the oxygen-containing gas relative to the pressure of the carbonization reactor.

[0035] In one embodiment, the biomass to be carbonized is fed to the carbonization reactor from a means for adding organic feedstock to the carbonization reactor, such as a biomass hopper at the top of the carbonization reactor, and the biomass entering and leaving the means for adding organic feedstock to the carbonization reactor is controlled by isolation valves mounted above and below the means for adding organic feedstock to the carbonization reactor, which allow the biomass to be fed to the reactor at a pressure higher than atmospheric pressure. Such valves can be used to prevent pressure leakage from the carbonization pressure reactor. The means for adding organic feedstock to the carbonization reactor can be provided as a feedstock feed line, which can include a feed screw and / or a feed conveyor belt for moving the feedstock to the reactor. In a system in continuous operation, the means for adding organic feedstock to the carbonization reactor, or in particular the feedstock feed line, can be exposed to the carbonization reactor during operation, e.g., all the time.

[0036] In one embodiment, the means for removing the carbonized product from the carbonization reactor transports the carbonized product to a storage vessel, and the flow of the carbonized product to the storage vessel is controlled by an isolation valve.

[0037] In one example, the carbonization reactor is equipped with a perforated cone, for example at the bottom, to collect the biomass and prevent it from falling to the bottom of the reactor. A feeding means can remove the carbonized product from the reactor, for example from the bottom of the perforated cone, and transport the carbonized product to a storage vessel. The flow of the carbonized product into the storage vessel can be controlled by an isolation valve. An isolation valve at the outlet of the product storage vessel allows the carbonized product to be removed from the pressurized system.

[0038] The use of isolation valves allows for rapid loading and / or unloading of the reactor, which in particular facilitates continuous operation. One or more isolation valves may be configured for pressure isolation for adding organic feedstock to the carbonization reactor and / or for removing the carbonized product from the carbonization reactor. One or more isolation valves may be configured for temperature isolation, in particular for removing the carbonized product from the carbonization reactor.

[0039] In one embodiment, the system is configured to maintain the reaction interface at least relatively stationary in the vertical direction of the reactor, for example at a specified position (for example at a specified height or in a specified area, for example between a minimum and a maximum height). To this end, the system may be configured to monitor the progress of the carbonization reaction, in particular by temperature monitoring. To monitor the progress of the carbonization reaction, at least two temperature sensors can be mounted at different heights in the carbonization reactor to monitor the temperature in the reactor, in particular in the biomass bed.

[0040] In one embodiment, the system comprises at least two temperature sensors, such as thermocouples (hereinafter also referred to as "sensors"), which can be mounted at different heights of the carbonization reactor to monitor the progress of the carbonization reaction. A first one of the sensors can be mounted above a designated position of the reaction interface, for example as defined above. A second one of the sensors can be mounted below a designated position of the reaction interface, for example as defined above. The sensors may be utilized to determine one or more estimated temperatures for the carbonization reaction, for example as an average of the temperature values ​​determined by the sensors. The one or more estimated temperatures may also simply include a first estimated temperature as the measured temperature of the first temperature sensor and a second estimated temperature as the measured temperature of the second temperature sensor. If the reaction gas is provided to the reactor from above, the temperature may decrease monotonically downwards in the reactor, so that the two existing sensors can be utilized to monitor the progress of the carbonization reaction and determine the limits of operation. However, three or more temperature sensors may be used to monitor the progress in more detail.

[0041] In one embodiment, the system is configured to provide a control command to remove the carbonized product from the reactor, for example when the estimated temperature of the carbonization reaction defined above exceeds a first threshold temperature, which may be done, for example, when the temperature measured by the first or second temperature sensor, or their average, is higher than a second threshold temperature.

[0042] In one embodiment, the system is configured to provide a control command to add organic feedstock to the reactor, for example when the estimated temperature of the carbonization reaction as defined above is below a second threshold temperature. This may be done, for example, when the temperature measured by the first or second temperature sensor, or an average thereof, is lower than the second threshold temperature.

[0043] The first threshold temperature may be higher than the second threshold temperature. In one embodiment, the first threshold temperature may be 600 to 700 degrees Celsius. In one embodiment, the second threshold temperature may be 500 to 600 degrees Celsius.

[0044] The system may be configured to automatically add organic feedstock and / or remove carbonized product based on control instructions, which may occur under continuous operation of the system.

[0045] In one embodiment, the system is configured to be cooled or quenched with water while the carbonized product is removed.

[0046] In one embodiment, the system is configured for cooling the carbonized product in the carbonization reactor and / or in the means for removing the carbonized product from the carbonization reactor, for example in the feed means, for example in a product outlet for removing the carbonized product from the reactor. For this purpose, the system may comprise a cooler configured for applying a cooling fluid, in particular water, to the carbonized product in the carbonization reactor and / or in the means for removing the carbonized product from the carbonization reactor. The cooling fluid can be delivered to the carbonization reactor and / or to the means for removing the carbonized product from the carbonization reactor, for example in a product outlet. The cooler may for example be a spray cooler configured to spray the cooling fluid on the carbonized product. The system may also comprise means for removing steam from the cooling. These means may comprise piping for removing steam from the cooling, connected to the carbonization and / or to the means for removing the carbonized product from the carbonization reactor.

[0047] One embodiment of a system for carbonizing organic material is depicted diagrammatically in Figure 1. The system according to Figure 1 comprises: 1. A pressure rated reactor, 2. Inlet for compressed gas containing oxygen, 3. Biomass feedstock inlet, 4. An energy input means for initiating an exothermic reaction in the reactor; 5. An outlet for carbonized products, and 6. Equipped with an outlet for oxygen-deficient gas.

[0048] One embodiment of a system for carbonizing organic material is depicted in Figure 2. The system according to Figure 2 comprises a stationary reactor, the reactor walls of which comprise thermal insulation. The reactor is open at the top and, prior to operation, is closed with a sealable airtight lid, which, when closed, is capable of withstanding an internal pressure higher than atmospheric pressure. The lid of the reactor comprises an inlet for a gas comprising oxygen.

[0049] The biomass to be carbonized is fed into the reactor from a feed container at the top of the reactor using a suitable feeding means such as a screw or an auger, which feeds the biomass into the center of the reactor so that it falls onto the top of the existing mass in the reactor.

[0050] The reactor is equipped with a perforated cone at the bottom, which collects the biomass and prevents it from falling to the bottom of the reactor. The holes in the cone allow the oxygen-depleted gas to pass but collect the carbonized product. At the bottom of the perforated cone, a feeding means removes the carbonized product from the reactor and transports it to a storage vessel. The feeding means may be any suitable feeding means known to those skilled in the art, such as a screw feeder or an auger. The oxygen-depleted gas collected from the bottom of the reactor may be combusted for energy or used as a feedstock for a secondary process.

[0051] In one embodiment, the carbonization reaction occurs in the biomass during the time it passes from the top of the reactor to the perforated cone. In one embodiment, the reaction interface remains relatively stationary in the vertical direction of the reactor, and the biomass feedstock moves downward as the reaction progresses. In one embodiment, the reaction interface is the thermal flame front of an exothermic reaction.

[0052] One embodiment of a system for carbonizing organic material is depicted in Figure 3. The system according to Figure 3 comprises a stationary reactor, the reactor walls of which comprise thermal insulation. The reactor is open at the top and, prior to operation, is closed with a sealable airtight lid, which, when closed, is capable of withstanding an internal pressure higher than atmospheric pressure. The reactor comprises an inlet for an oxygen-containing gas and a means for monitoring the height of the biomass layer. The reactor also comprises a pressure sensor mounted through the wall of the reactor at the top end of the reactor above the surface of the biomass layer.

[0053] The biomass to be carbonized is fed into the reactor from a biomass hopper at the top of the reactor using a suitable feeding means such as a screw or auger. The entry and exit of the biomass into the biomass hopper is controlled by isolation valves mounted above and below the biomass hopper, which allow the biomass to be fed into the reactor at a pressure higher than atmospheric pressure. The feeding means feeds the biomass into the center of the reactor so that it falls onto the existing mass in the reactor.

[0054] The reactor is equipped with a perforated cone at the bottom, which collects the biomass and prevents it from falling to the bottom of the reactor. The holes in the cone allow the oxygen-depleted gas to pass but collect the carbonized product. At the bottom of the perforated cone, a feeding means removes the carbonized product from the reactor and transports it to a storage vessel. The feeding means may be any suitable feeding means known to those skilled in the art, such as a screw feeder or an auger. The flow of the carbonized product into the storage vessel is controlled by an isolation valve. An isolation valve at the outlet of the product storage vessel allows the carbonized product to be removed from the pressurized system. The oxygen-depleted gas collected from the bottom of the reactor may be burned for energy or used as a feedstock for a secondary process.

[0055] In one embodiment, the carbonization reaction occurs in the biomass during the time it passes from the top of the reactor to the bottom perforated cone. To monitor the progress of the carbonization reaction, at least two temperature sensors are mounted at different heights in the carbonization reactor canister to monitor the temperature within the biomass bed. In one embodiment, the reaction front remains relatively stationary in the vertical direction of the reactor, and the biomass feedstock moves downward as the reaction progresses. In one embodiment, the reaction front is a thermal front created by the flame front of an exothermic reaction.

[0056] In certain embodiments, the removal of the oxygen-depleted gas is controlled by a control valve.

[0057] In certain embodiments, mechanical energy is recovered from the oxygen-depleted gas as it is depressurized. In one embodiment, mechanical energy is recovered from the oxygen-depleted gas and used to increase the pressure of an oxygen-containing gas.

[0058] Energy recovery can be accomplished by passing the oxygen-depleted gas, which may be at high pressure, to a turbine in a system for recovering energy. In general, energy recovery can be accomplished by any means available to one skilled in the art of energy recovery.

[0059] The system described herein has the additional utility of having properties suitable for continuous or semi-batch carbonization of organic materials. By operating the system in a continuous or semi-batch mode, the need for frequent loading and unloading of the carbonized product as well as the material to be carbonized is eliminated. By eliminating the need for frequent loading and unloading of the carbonized product as well as the material to be carbonized, carbonization can be carried out for longer continuous periods of time without the need to stop the process to load or unload material.

[0060] Carbonization in the disclosed system occurs in an oxygen-containing atmosphere, eliminating the need to evacuate the system prior to use or to introduce an inert gas into the system.

[0061] A method for carbonizing organic material is disclosed, the method comprising: a. providing an organic feedstock to a carbonization reactor; b. supplying a gas comprising oxygen to a carbonization reactor; c. initiating an exothermic reaction in the carbonization reactor; d. Removing the carbonized product from the carbonization reactor; and e. removing the oxygen-depleted gas from the carbonization reactor.

[0062] In certain embodiments, the carbonization is carried out in a continuous or semi-batch mode.

[0063] In certain embodiments, the organic feedstock is fed to the carbonization reactor at greater than atmospheric pressure.

[0064] In certain embodiments, the oxygen-depleted gas comprises: Nitrogen 0~60% CO2 10-50% ·H20~50% CO 10-50% CH40~20% Ethane 0~5% Ethylene 0~5% Heavier Hydrocarbons 0-5%

[0065] In certain embodiments, the oxygen-depleted gas contains less than 5% oxygen.

[0066] In certain embodiments, the oxygen-containing gas is added to the carbonization reactor at a pressure greater than atmospheric pressure.

[0067] In certain embodiments, the oxygen-containing gas may be air. In certain embodiments, the oxygen-containing gas may be a gas containing more than 21% oxygen. In certain embodiments, the organic feedstock is added to the carbonization reactor in a continuous manner.

[0068] In certain embodiments, the organic feedstock is mixed with the inorganic material prior to addition to the reactor.

[0069] In certain embodiments, the carbonized product is removed from the carbonization reactor in a continuous or semi-batch manner.

[0070] In certain embodiments, the addition of the organic feedstock is at a rate that maintains a constant level of the feedstock in the reactor.

[0071] In certain embodiments, the carbonized product is continuously removed from the carbonization reactor.

[0072] Disclosed are carbonized products produced in the disclosed systems or using the disclosed methods.

[0073] In certain embodiments, the carbonized product is biochar or biocarbon. In certain embodiments, the carbonized product is electrically conductive. In certain embodiments, the carbonized product may be activated carbon or activated biocarbon. In certain embodiments, the carbonized product may be subjected to activation using any suitable activation process known to one of skill in the art to form activated carbon or activated biocarbon.

[0074] In certain embodiments, the carbonized product may be further enhanced by including inorganic compounds or compositions in the product.

[0075] The methods described herein have the added utility of having properties that make them suitable for continuous or semi-batch carbonization of organic materials. By operating the methods in a continuous or semi-batch mode, the need for frequent loading and unloading of the material being carbonized as well as the carbonized product is eliminated.

[0076] Carbonization in the disclosed method occurs in an oxygen-containing atmosphere, eliminating the need to evacuate the system prior to use or to introduce an inert gas into the system.

[0077] Also disclosed herein are carbonized products comprising biocarbon formed in the systems or using the methods of the present disclosure.

[0078] The continuous operation of the system may be supported in various ways. In particular, a feed seal arrangement may be provided as an airtight seal arrangement for continuous, e.g., constant, feeding of material in the reactor. The feeding may be performed without lowering the pressure and / or temperature in the reactor, allowing for a continuous process for producing a carbonized product such as biochar. The feed seal arrangement may comprise a double dump valve and / or a pressure-resistant (and may be heat-resistant) special airlock rotary valve. The feed seal arrangement may also comprise a plug screw feeder. Alternatively or additionally, a discharge seal arrangement may be provided as an airtight seal arrangement for continuous, e.g., constant, discharging of material from the reactor without lowering the pressure and / or temperature in the reactor, allowing for a continuous process for producing a carbonized product such as biochar. The discharge seal arrangement may comprise a double dump valve and / or a pressure-resistant (and may be heat-resistant) special airlock rotary valve. The discharge seal arrangement may also comprise a plug screw feeder. FIG. 6 illustrates one embodiment of a system 200 for carbonizing organic material. The system may include any or all of the above features. The system comprises a reactor 210, which may be provided as a pressure rated vessel. The reactor may be fitted with one or more load cells 211, or any appropriate attachment, for measuring the mass of the reactor and / or contents.

[0079] The system may comprise (first) feeding means for feeding the biomass to be carbonized to the reactor. These means may comprise a feedstock feed line 215, e.g. a feedstock feed tube, which may be attached to the reactor 210, preferably at a position above the midpoint of the reactor volume. The feeding means may be configured to pass through the reactor wall, which may be pressurized, allowing material to be moved from the outside of the reactor 210 to the inside of the reactor 210, allowing operation at high pressure. The feedstock feed line 215 may comprise a feed screw 216 and / or a feed conveyor belt for moving the feedstock to the reactor. The feeding means may also comprise one or more feed motors 219 for rotating the feed screw 216 and / or for propelling the feed conveyor belt. The feeding means may comprise a feed feed port 217 and a feed outlet port 218. These feeding means may also comprise a feedstock storage vessel 220, which may further comprise a feedstock bottom isolation valve 221 and / or a feedstock top isolation valve 222. Either or both of these are preferably gate valves that allow solids to pass easily across the valve when the valve is in the open position.

[0080] The system may also comprise (second) feeding means for removing the carbonized product from the reactor. These means may comprise a product discharge 230, e.g. a product discharge pipe 230, which may be attached to the reactor 210, preferably at a position below the midpoint of the reactor volume. The feeding means may be configured to pass through the reactor wall, which may be pressurized, allowing material to be moved from inside the reactor 210 to the outside of the reactor 210, allowing operation at high pressure and temperature. The product discharge 230 may comprise a discharge screw 231 and / or a discharge conveyor belt for moving the carbonized product from the reactor. The feeding means may also comprise one or more discharge motors 234 for rotating the discharge screw 231 and / or for propelling the discharge conveyor belt. The feeding means may comprise a discharge feed port 232 and a discharge outlet port 233. These delivery means may also include a product storage vessel 235, which may further include a first product isolation valve 236 and / or a second isolation valve 237. Either or both of these are preferably gate valves that allow solids to pass easily across the valve when the valve is in the open position.

[0081] In one embodiment, the first isolation valve 236 and the second isolation valve 237 are used during operation to continuously remove carbonized product and allow it to fill the product storage vessel 235 by initially placing both the first isolation valve 236 and the second isolation valve 237 in an open position. Thereafter, for example after the product storage vessel 235 has been filled to a predetermined volume, the second isolation valve 237 is closed and remains closed while the product storage vessel 235 is emptied and resealed. The second isolation valve 237 is then reopened to allow the product filling the volume between the valves to move into the product storage vessel 235. Preferably, the product storage vessel 235 is lower than the discharge outlet port 233 so that gravity can be used to move the product from the discharge outlet port 233 to the product storage vessel 235.

[0082] 7 illustrates one embodiment of a system 400 for carbonizing organic material. The system may include any or all of the features described above. A detailed embodiment of a (first) feeding means 405 for feeding the biomass to be carbonized to the reactor is disclosed, for example as an auger feed system.

[0083] The system 400, or its feeding means 405, includes a main feed channel 410, e.g., a feed pipe, that contains a feed inlet port 412 and a feed outlet port 413. The system may also include a feed transporter 411, e.g., a feed screw and / or a feed conveyor belt, for moving the feed material to the reactor. The system may include one or more feed motors 414 for rotating the feed screw and / or propelling the feed conveyor belt. The system may include a feed storage vessel 415.

[0084] The main feed 410 may be a seamless pipe. The main feed 410 may be constructed of a metallic material. The main feed 410 may be thick enough to withstand expected operating pressures and maintain operating stability at high temperatures with an appropriate safety margin. The supply feed port 412 may be connected to a raw material storage vessel 415. The supply feed port 412 may be configured so that the raw material is drawn into the main feed 410 by gravity. A vibration system may be included to aid in the flow of material from the raw material storage vessel 415 to the main feed pipe 410. Mechanical fingers and / or other features may be included to encourage the flow of material without binding jams or other events that would prevent the free flow of material.

[0085] In one embodiment, the feedstock storage vessel 415 has a feed isolation valve 416, for example at its bottom, between the feedstock storage vessel 415 and the feed feed port 412. The vessel may also have an openable feedstock hopper lid 417, which allows for isolating the feedstock storage vessel 415. The feedstock storage vessel 415 may be configured to allow for the delivery of feedstock to the reactor at high operating pressures while providing a pneumatic seal to prevent gas leakage from the reactor during operation. The feedstock hopper lid 417 may be mounted on a hinge. The feedstock hopper lid 417 may be connected to one or more actuators, such as hydraulic or pneumatic cylinders, so that it can be opened and closed on demand, for example remotely.

[0086] The feedstock storage vessel 415 can be designed to a limited size, provided that the method used to fill the feedstock storage vessel 415 is faster than the time to drain the contents of the main feed line 410, to maintain continuous operation. The feed motor 414 can be configured to operate at variable speeds to allow the feed transporter 411 to be rapidly actuated to rapidly move the newly filled feedstock to the feed outlet port 413, to maintain continuous operation.

[0087] 7 also shows an embodiment of a (second) feeding means 450 for removing the carbonized product from the reactor, for example as an auger product discharge system. The means 450 includes a main discharge channel 460, e.g., a discharge pipe, containing a discharge feed port 462 and a discharge outlet port 463. The means 450 may also include a discharge transporter 461, e.g., a discharge screw and / or a discharge conveyor belt, for moving the carbonized product from the reactor. The means 450 may include one or more discharge motors 464 for rotating the discharge screw and / or for propelling the discharge conveyor belt. The means 450 may include a product storage container 465, e.g., a product hopper.

[0088] In one embodiment, the main discharge 460 is of similar construction to the main feed 410. In some embodiments, the main discharge 460 may be configured to process products at high temperatures and therefore hot solids. The discharge outlet port 463 may be connected to a product storage vessel 465. The feeding means may be configured to draw the product into the product storage vessel by gravity.

[0089] In one embodiment, product storage vessel 465 has an isolation valve at its open port, for example between product storage vessel 465 and discharge outlet port 463. The product storage vessel may have a product hopper lid 466 that can be opened and closed to isolate product storage vessel 465. Product storage vessel 465 may be configured to allow product to be discharged at high reactor operating pressures while providing a pneumatic seal to prevent gas leakage from the reactor during operation.

[0090] The product hopper lid 466 may be attached to a hinge. The product hopper lid 466 may be connected to one or more actuators, such as hydraulic or pneumatic cylinders, so that it can be opened and closed on demand, for example remotely. The product hopper lid 466 may be configured to open downwards such that when the product hopper lid 466 is opened, the product in the product storage vessel 465 falls by gravity. The discharge screw motor 464 may be configured for variable speed operation so that the discharge transporter 461 can be operated at a speed that maintains the level in the reactor substantially constant during operation to maintain continuous operation.

[0091] In one embodiment, the feed systems, i.e. the first and / or second feed systems, are made of all metal components to allow high temperature operation. The first and / or second feed systems can be passively and / or actively cooled, for example by gas and / or fluid, e.g. water. In one embodiment, the internal shaft and blades of the screw are provided with closed channels through which a cooling fluid is circulated to provide cooling. In one embodiment, only the discharge system, i.e. the second feed system, is actively cooled.

[0092] For cooling, a cooling fluid can be applied to the product to reduce the product temperature and the probability of reaction with the atmosphere after exposure to air or other oxygen-containing gases. For this purpose, water can be used as the cooling fluid for cooling the product. The cooling fluid may contain one or more types of minerals to control the amount of minerals that adhere to the product when the water is evaporated.

[0093] A fluid such as water can be applied to minimize the mass of fluid present in the product after the cooling process. The fluid may be sprayed onto the product while the cooling gas may be optionally directed to flow over the product. The mass of fluid and cooling gas can be controlled so that most of the fluid evaporates and is carried away by the cooling gas so that no moisture condenses on the product. In one embodiment, purified water with a mineral content of less than 100 ppm is used so that only a small amount of minerals adhere to the product. Preferably, after cooling the product, there will be less than 200 grams of added water for every kilogram of dry durable carbon product after exposing the product to the atmosphere. More preferably, there will be less than 100 grams of added water for every kilogram of dry durable carbon after exposing the product to the atmosphere. Most preferably, there will be less than 50 grams of added water for every kilogram of dry durable carbon after exposing the product to the atmosphere. Added water is defined as the mass of water present in the product compared to the product taken without the application of water.

[0094] The cooling fluid can be introduced via direct fluid flow and / or as an aerosol. In one embodiment, a liquid delivery device is used to deliver the fluid directly onto the solid product. A pipe, such as a metal pipe, may be placed in the reactor at the bottom of the reactor where the product is formed and the reaction is complete or nearly complete. Aerosol nozzles, nebulizers, and / or other aerosolization devices may be used to generate fluid droplets to be applied to the product, either alone or in combination with direct fluid application. Nitrogen or other inert gases may be used to generate aerosolized fluid droplets using gas aerosolization nozzles. Air may be used as the aerosolization gas, but there is a risk of reaction with the hot product, which may cause the product to react and reduce the solid mass.

[0095] At temperatures where solid carbon is at risk of significant oxidation, thermal radiation, alone or in combination with the application of a cooling fluid, can provide an exemplary mode of heat transfer.

[0096] In selected embodiments, a cooling fluid, such as water, is used to cool the reactor and / or piping holding the product prior to exposure to air. Cooling the reactor can reduce the temperature of the product as heat is transferred from the hot product to the reactor or other containment walls, primarily through radiative and conductive heat transfer. In certain embodiments, a fixed flow rate of cooling fluid is used to flow over the reactor exterior walls at least in the lower portion of the reactor, while monitoring the temperature of the cooling fluid, which is withdrawn immediately after contacting the containment walls. Changes in the temperature of the fluid can be used to estimate the temperature of the product and / or the rate of heat transfer from the product. The changes can be used to determine when the product can be safely removed from the reactor.

[0097] It is further noted that there may be significant energy stored in the oxygen-depleted gas exiting the reactor, e.g., in chemical bonds, but also in mechanical and / or thermal form. In one embodiment, the thermal and / or mechanical energy is recovered in a first process, leaving the oxygen-depleted gas with a lower pressure and / or lower temperature than before it exited the reactor. In some embodiments, more than 20% of this thermomechanical energy may be recovered after it leaves the reactor, or the main part of the reactor.

[0098] 8 illustrates one embodiment of a system 500 for carbonizing organic material. The system may include any or all of the features described above.

[0099] The system 500 may include a thermomechanical energy recovery system. The system may include, for example, a carbonization reactor 501 as a reaction vessel, a means for adding organic feedstock to the carbonization reactor, including a feedstock inlet port 502 and an optional feedstock inlet port isolation valve 503, a means for adding an oxygen-containing gas to the carbonization reactor, including a gas inlet port 510 and an optional gas inlet port isolation valve 511, a means for removing oxygen-depleted gas from the carbonization reactor, including a gas exhaust port 506 and an optional gas exhaust port isolation valve 507, and a means for removing the carbonized product from the carbonization reactor, including a solids exhaust port 504 and an optional solids exhaust port isolation valve 505. Additionally, the system may include a gas auxiliary port 508 and an optional gas auxiliary port isolation valve 509.

[0100] The system 500 may include a turbocharger assembly 520. The turbocharger assembly 520 may include an expander section 521 and a compressor section 522, the two sections may be connected by, for example, a mechanical linkage 523. In operation, the expander section 521 may be configured to receive high pressure and high temperature oxygen depleted gas from the gas exhaust port 506, for example, through a gas line. Within the expander section 521 of the turbocharger assembly 520, thermomechanical energy in the exhaust gas may be converted to kinetic energy, for example, rotational kinetic energy of the expander rotating blades. The kinetic energy may cause movement, such as rotation, of the connected mechanical linkage 523 to provide power to compress the inlet gas, as is known in the art of turbocharging systems. The compressor section 522 may be configured to receive power from the mechanical linkage 523 to rotate the blades within the section. An oxygen-rich fluid, such as atmospheric air and / or other fluid from a storage tank or other storage means, may be provided to the compressor section inlet port 524. In one embodiment, ambient air may be used and dried, for example, using a gas dryer to a controlled dew point, for example, less than -20 degrees Celsius, before entering the turbocharger inlet port. After entering the compressor section 522, the gas may be configured to contact rotating blades and increase in pressure and / or temperature. In some embodiments, the pressure of the oxygen-rich gas is first increased by a compressor (not shown) before entering the compressor section 522, such that the pressure of the fluid entering the reactor may be greater than the pressure that can be provided by the turbocharger assembly 520 functioning alone.

[0101] The oxygen-depleted gas may be configured to enter the compressor section 522 and, after providing the energy for compression, exit the compressor section exhaust port 525 of the compressor section 522 at a lower pressure and temperature than when it entered. The oxygen-depleted gas can then be further processed for energy recovery. In one embodiment, the residual thermal energy is recovered through a heat exchanger. The heat exchanger can then be used, for example, to provide heat for drying the reactor feedstock. In another embodiment, no further direct recovery of the residual thermomechanical energy is attempted. However, the residual thermomechanical energy can also be indirectly recovered as part of a chemical energy recovery process.

[0102] Recovery of the chemical energy of the oxygen-deficient gas can be accomplished immediately after it leaves the reactor or after the thermomechanical energy has been extracted to a planned level. The oxygen-deficient gas has a large amount of energy stored in the form of chemical bonds, which can be released by reacting in a chemical process. In one embodiment, energy is released by combusting the oxygen-deficient gas with oxygen contained in the atmosphere.

[0103] The chemical energy content of the oxygen-deficient gas on a dry basis may be at least 4 megajoules per kilogram (MJ / kg), or preferably at least 5.5 MJ / kg. In one embodiment, air may be used as the reactant gas. Coexisting nitrogen may continue to be present in the oxygen-deficient gas. The nitrogen concentration in the oxygen-deficient gas may be less than 60% by volume, and preferably less than 50% by volume.

[0104] In one embodiment, wood pellets are used as the feedstock. The wood pellets may have a moisture content of less than 20%. On a dry basis, the oxygen-depleted gas leaving the reactor may consist of: Nitrogen less than 50% CO2 15-25% ·H210~20% CO 10-20% Less than 10% CH4 Ethane less than 5% Ethylene less than 2% All heavier hydrocarbons less than 5%

[0105] The amount of residual oxygen contained in the oxygen-deficient gas may be small as it is consumed during the reaction, in one embodiment, oxygen (O2) may comprise less than 5% by volume of the dry oxygen-deficient gas, preferably less than 2% by volume O2, and more preferably less than 0.5% by volume O2.

[0106] In one embodiment, the oxygen-deficient gas is combined with an oxygen-rich fluid, such as atmospheric air. These fluids can be fed through blowers, pumps, compressors, and / or other devices to increase the pressure to allow for feed streams and / or other fluids from storage tanks or other storage means. In one embodiment, atmospheric air is used. In one embodiment, the oxygen-deficient gas is combined with atmospheric air inside a boiler combustion chamber in a boiler heat transfer system to increase the temperature and / or pressure of the boiler working fluid to provide heat for a building or other facility or purpose, as is known in the art of boiler systems. Other types of heat transfer systems can also be used, provided they are compatible with the oxygen-deficient gas provided by the reaction process. [Example]

[0107] Reference will now be made in detail to the various embodiments.

[0108] The following description discloses some embodiments in detail so that a person skilled in the art can utilize the embodiments based on the present disclosure. Not all steps or features of the embodiments are discussed in detail because many of the steps or features are obvious to a person skilled in the art based on this specification.

[0109] Working Example 693 kg of olive pits with a moisture content of 8.5 wt. % containing approximately 332 kg of organic carbon were added to the carbonization reactor. The reactor was pressurized to 400 kPa with compressed air from a pressure regulated source. The reactor was checked for leaks and the outlet valve was opened to allow approximately 8 m 3 1000 ml / h of air was allowed to flow through the reactor. An electric heating coil at the bottom of the reactor was turned on for 5 minutes. The start of the carbonization reaction was evidenced by a sudden increase in reactor pressure, which prevented the inflow of air from the regulated feed. The outlet valve was then opened to reduce the pressure in the reactor. When the reactor pressure dropped below 400 kPa, a controlled flow of air was added to the reactor to maintain a steady flow of air into the reactor while maintaining the pressure in the reactor at 400 kPa. Using the outlet valve and air control valve, the air flow rate was reduced to 68 m3 while maintaining 400 kPa in the reactor. 3 / h. The carbonization reaction is characterized by an exothermic heat wave propagating from the bottom to the top of the reactor over a period of 289 minutes, as evidenced by four rows of thermocouples evenly spaced from the bottom to the top of the reactor (Figure 4). Further evidence of the linear nature of the reaction is evidenced by the steady weight loss, measured by a load cell mounted below the reactor (Figure 5). The yield of carbon product was 165 kg. Independent analysis of the product revealed a carbon content of 91.7%, an atomic H:C ratio of 0.19%, and an atomic O:C ratio of 0.024%.

[0110] It is obvious to those skilled in the art that the basic idea can be implemented in various forms as technology advances, so the embodiments are not limited to the above examples, and may vary within the scope of the claims.

[0111] The embodiments described hereinabove may be used in any combination with each other. Some embodiments may be combined together to form further embodiments. The method or system disclosed herein may include at least one of the embodiments described hereinabove. It will be understood that the benefits and advantages described above may relate to one or more embodiments. The embodiments are not limited to those that solve any or all of the problems stated or those that have any or all of the benefits and advantages stated. It will be further understood that reference to "an" item refers to one or more of those items. In this specification, the term "comprising" is used to mean including the features or acts that follow it without excluding the presence of one or more additional features or acts.

Claims

1. 1. A system for carbonizing organic material, the system comprising: a. a means for adding organic feedstock to the carbonization reactor; b. means for adding an oxygen-containing gas to the carbonization reactor; c) means for removing oxygen-deficient gas from said carbonization reactor; d. a means for initiating an exothermic reaction within said carbonization reactor; and e. Means for removing the carbonized product from said carbonization reactor. Equipped with the system comprising at least two temperature sensors mounted at different heights of the carbonization reactor; the system comprises a turbocharger assembly including an expander section and a compressor section, the expander section configured to receive high pressure and high temperature oxygen-depleted gas from the carbonization reactor via a gas exhaust port; the system comprising: a means for adding the organic feedstock to the carbonization reactor; the carbonization reactor is provided with a perforated cone at its lower end; and / or The system further comprising a heat exchanger whereby residual thermal energy is recovered from the oxygen-deficient gas removed from the carbonization reactor.

2. 10. The system of claim 1 configured to operate in a continuous or semi-batch mode.

3. 10. The system of claim 1, wherein the means for initiating an exothermic reaction within the carbonization reactor is located at an opposite end of the carbonization reactor relative to the oxygen-containing gas inlet.

4. 10. The system of claim 1, wherein the means for initiating an exothermic reaction in the carbonization reactor is an electric heat source.

5. 10. The system of claim 1, further comprising: a first pressure recovery unit configured to recover mechanical energy from the decompressed oxygen-depleted gas; and a second pressure recovery unit configured to recover mechanical energy from the decompressed oxygen-depleted gas and to increase the pressure of the oxygen-containing gas using the recovered mechanical energy.

6. The system described in claim 1, wherein the turbocharger is configured to supply oxygen-rich fluid to the compressor section via an inlet port to increase the pressure and / or temperature of the oxygen-rich fluid.

7. The system described in claim 1, wherein the raw material supply path includes a supply screw and / or a supply conveyor belt for moving the raw material to the reactor.

8. 1. A method for carbonizing organic material, said method comprising: a. providing an organic feedstock to a carbonization reactor; b. providing a gas comprising oxygen to the carbonization reactor; c. initiating an exothermic reaction in the carbonization reactor; d. Removing the carbonized product from the carbonization reactor Including, the method utilizing at least two temperature sensors mounted at different heights of the carbonization reactor; the carbonization reactor comprises a turbocharger assembly having an expander section and a compressor section, wherein during operation, the expander section receives high pressure and high temperature oxygen-depleted gas from the carbonization reactor via a gas exhaust port; the carbonization reactor comprises a means for adding the organic feedstock to the carbonization reactor; the carbonization reactor having a perforated cone at its lower end; the interior volume of the carbonization reactor is under a pressure greater than atmospheric pressure during the carbonization reaction; the organic feedstock is mixed with inorganic materials prior to addition to the reactor; Residual heat energy is recovered from the oxygen-deficient gas removed from the carbonization reactor through a heat exchanger; and / or the carbonized product removed from the reactor is electrically conductive and / or is activated carbon or activated biochar; The method.

9. recovering mechanical energy from the oxygen-depleted gas as it is depressurized; 9. The method of claim 8, wherein the recovered mechanical energy may be used to increase the pressure of the oxygen-containing gas.

10. The method of claim 9, wherein an oxygen-rich fluid is supplied to a compressor section via an inlet port, and the pressure and / or temperature of the oxygen-rich fluid is increased.

11. The method of claim 8, wherein the raw material supply path comprises a supply screw and / or a supply conveyor belt for moving the raw material to the reactor.

12. The method of claim 8, wherein the feedstock is wet-impregnated with an aqueous solution of inorganic salts prior to addition to the reactor.

13. The method of claim 8, wherein the feedstock is wet-impregnated with an aqueous solution containing a metal salt prior to addition to the reactor.

14. A carbonized product comprising biocarbon formed in the system of any one of claims 1 to 7 or using the method of any one of claims 8 to 13.

15. The carbonized product of claim 14, wherein the carbonized product is biochar or biocarbon, and may be activated carbon or activated biocarbon, and / or may be electrically conductive.

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