Apparatus and Process for the Production of Dry Durable Carbon

Abstract

A system for producing dry durable carbon from organic substances, and a method for fabricating and using the same. The system can be configured to initiate a combustion reaction for a feedstock having a first portion disposed within a reaction zone of the combustion reaction and a second portion disposed outside the zone. The temperature of the combustion reaction can be raised to a predetermined temperature, and a gas path through the reaction zone can be formed to enable a reactive gas to react with the first portion of the feedstock at the predetermined temperature to produce a first portion of a dry durable carbon product. The system can advantageously enable feedstock volatile components discharged from the second portion of the feedstock to enter the reaction zone and react with the reactive gas to form a reacted gas that excludes bio-oil and tar.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 332,569, filed on April 19, 2022, the entire disclosure of which is incorporated herein by reference for all purposes.

[0002] The disclosed embodiments generally relate to the field of carbon production, and more particularly, but not limited to, methods and apparatuses for producing solid carbonaceous materials from biomass.

Background Art

[0003] Over the centuries, a wide variety of processes have been used to produce carbonaceous materials, including those that use natural biomass as a raw material. With the recent demand for viable carbon sequestration techniques, new interest has emerged in these technologies.

[0004] Systems for converting organic materials into solid carbon forms have existed for centuries. The best - known method is called pyrolysis, in which volatile chemicals are removed from the starting material and the organic (or carbon - containing) material is heated to a high temperature in an inert atmosphere for the purpose of increasing the carbon fraction of the remaining solid, or sometimes liquid, starting material. Removing volatile chemicals from the solid material is an early stage of solid combustion and can be called gasification. Pyrolysis has been used in many industrial processes.

[0005] From simple pyrolysis processes, improved and new systems have been developed, including slow pyrolysis, fast pyrolysis, gasification, and carbonization. These systems can use different operating temperatures, gas flows to the raw material, reactive gases, and other modifications. In recent years, these systems have regarded biomass as a raw material substance. In some cases, the goal is to convert a certain percentage of the carbon contained in the starting biomass into solid carbon as part of a "green economy".

[0006] Biomass includes any type of plant-based material and can be further specified as biomass waste, where politicians and activists will focus on maintaining existing species and will direct carbon capture technology to utilize lost life forms. Usually, in the process, any biomass can be used, optionally after drying, but biomass waste is certainly preferred.

[0007] Biomass waste includes a wide variety of materials including (1) agricultural residues such as corn cobs, olive seeds, walnut shells, sunflower husks and pods, and sugarcane bagasse, (2) wood such as logs, planks, chips and bark, (3) aquatic plants such as water hyacinths and seaweeds, (4) organic municipal solid waste such as tires, sewage sludge or other organic clarification solids, and (5) livestock residues.

[0008] Solid carbonaceous materials produced using various pyrolysis and improved production systems may contain a wide variety of carbon along with ash, moisture, and other substances. Charcoal is a commonly produced material and has a carbon content of about 70% by weight or more. This material is usually produced by pyrolyzing broad-leaved trees as raw materials at a temperature of less than about 500°C in a large kiln or retort. Such a material generally presents a balance between production cost and carbon content when used as a fuel. Increasing the treatment temperature increases the production cost but results in a material with a higher carbon fraction. High treatment temperatures may, in some cases, result in unique products that exceed graphite and coal processed products.

[0009] In view of the above, there is a need for systems and methods for producing dry durable carbon that overcome the above-described obstacles and drawbacks of currently available pyrolysis systems. SUMMARY OF THE INVENTION

[0010] The present disclosure relates to a system for producing a solid product capable of containing carbon from an organic substance, and a method for fabricating and using the same. The system can be configured to convert the organic substance into a carbon product together with energy.

[0011] According to a first aspect disclosed herein, a method for producing dry durable carbon is shown, the method comprising: initiating a combustion reaction for a raw material having a first portion disposed within a reaction zone of the combustion reaction and a second portion disposed outside the reaction zone; raising the temperature of the combustion reaction to a predetermined reaction temperature; forming a gas path through the reaction zone to enable a reactive gas to react with the first portion of the raw material at the predetermined reaction temperature to produce a first portion of a dry durable carbon product, and / or including enabling the raw material volatile components discharged from the second portion of the raw material to enter the reaction zone and react with the reactive gas to form a reacted gas excluding bio-oil and tar.

[0012] In some embodiments of the disclosed method of the first aspect, the method can further include preparing the raw material for the combustion reaction. The raw material can be prepared, for example, by drying the raw material to a predetermined moisture level, rearranging the raw material to achieve a predetermined target packing density, and / or disposing the raw material within a reactor. The combustion reaction can optionally be initiated by sealing the reactor, igniting the raw material, and / or applying a predetermined reaction pressure to the raw material. An exemplary predetermined reaction pressure can include 350 kilopascals.

[0013] In some embodiments of the disclosed method of the first aspect, the method can further include moving the reaction zone of the combustion reaction towards a second portion of the feedstock such that the reactive gas reacts with the second portion of the feedstock at a predetermined reaction temperature to enable the production of a second portion of the dry durable carbon product. Enabling the reactive gas to react with the second portion of the feedstock can include, for example, liberating volatile chemicals from the second portion of the feedstock before moving the reaction zone of the combustion reaction towards the second portion of the feedstock.

[0014] In addition and / or alternatively, enabling the reactive gas to react with the second portion of the feedstock can include liberating volatile chemicals from the second portion of the feedstock before moving the reaction zone of the combustion reaction towards the second portion of the feedstock. Liberating the volatile chemicals can optionally include liberating a majority of the volatile chemicals from the second portion of the feedstock, whereas enabling the reaction gas to react with the second portion of the feedstock can optionally include subjecting the entire feedstock to the combustion reaction.

[0015] In selected embodiments, the method can further include terminating the combustion reaction. Terminating the combustion reaction can include, for example, detecting a reduction in the production of the reacted gas, detecting that the temperature of the combustion reaction is decreasing, and / or lowering the temperature of the feedstock.

[0016] In some embodiments of the disclosed method of the first aspect, the method can further include forming a reacted gas that excludes bio-oil and tar. Forming the reacted gas can include partially oxidizing the bio-oil and tar produced by the combustion reaction into gaseous components, decomposing the bio-oil and tar produced by the combustion reaction into lighter hydrocarbons, and / or creating precursor char materials from the bio-oil and tar produced by the combustion reaction. The precursor char materials can form, for example, solid char particles.

[0017] In some embodiments of the disclosed method of the first aspect, the method can further include controlling the reaction between the reactive gas and the feedstock. Controlling the reaction can include, for example, controlling the reaction to increase the percentage of carbon in the feedstock that is converted to a dry durable carbon product and / or to decrease the amount of liquid produced in the form of bio-oil and tar.

[0018] In some embodiments of the disclosed method of the first aspect, the reactive gas can include oxygen.

[0019] In some embodiments of the disclosed method of the first aspect, the method can further include recovering the dry durable carbon product. Recovering the dry durable carbon product can include removing the dry durable carbon product from the reaction zone, storing the recovered dry durable carbon product, and / or packaging the recovered dry durable carbon product.

[0020] In some embodiments of the disclosed method of the first aspect, the feedstock can include a biomass feedstock.

[0021] In some embodiments of the disclosed method of the first aspect, the dry durable carbon product can have a ratio of oxygen to carbon of less than 5 percent.

[0022] In some embodiments of the disclosed method of the first aspect, the dry durable carbon product can have a ratio of hydrogen to carbon of less than 5 percent.

[0023] In some embodiments of the disclosed method of the first aspect, increasing the temperature of the combustion reaction can include increasing the temperature of the combustion reaction to between 500 °C and 700 °C.

[0024] According to a second aspect disclosed herein, a system for generating dry durable carbon is shown, and the system can comprise means for implementing each embodiment of the method of the first aspect. The system can comprise, for example, a double containment reaction volume for containing the raw materials prior to the start of the combustion reaction. In a selected embodiment, the system can comprise a first storage means having a first housing for defining a first internal chamber for receiving the raw materials, and a second storage means having a second housing for defining a second internal chamber for receiving the first storage means.

[0025] According to a third aspect disclosed herein, a computer program for generating dry durable carbon is shown, and a computer program product comprises instructions for executing each embodiment of the method of the first aspect. The computer program product of the third aspect is optionally encoded on one or more non-transitory machine-readable storage media.

Brief Description of the Drawings

[0026] To more fully understand the nature and objects of the present disclosure, reference should be made to the following detailed description in conjunction with the accompanying drawings. These accompanying drawings form a part of this specification and illustrate various embodiments.

Figure 1

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Figure 9A

Figure 9B

DETAILED DESCRIPTION OF THE INVENTION

[0027] Conventional pyrolysis systems are unable to produce high-value carbon, are expensive, and are compatible with only limited types of feedstock materials. Thus, a system for producing high-value carbon at low cost using a wide variety of feedstock materials is desirable, and such a system can provide the basis for a wide range of applications such as the production of dry durable carbon. This result can be achieved, according to one embodiment disclosed herein, by a batch reactor 1000 as shown in FIG. 1.

[0028] In selected embodiments, the term “dry durable carbon” as used herein can be interpreted to mean a compound having a carbon content of at least 90 percent on a dry basis, produced with a non-aqueous liquid fraction of less than 10 weight percent of the carbon produced, and having less than 5 weight percent oxygen and / or less than 2 weight percent hydrogen.

[0029] The term “non-friable dry durable carbon” as used herein can optionally be interpreted to mean a dry durable carbon that withstands cracking into small pieces during normal handling.

[0030] In addition and / or alternatively, the term "combustion" as used herein can be interpreted to include "biomass combustion" and / or can include an exothermic reaction between oxygen and an organic compound that produces a sustained peak temperature of at least 600 °C at the hottest point of the reaction within the feedstock.

[0031] In selected embodiments, the term "inert" as used herein can be interpreted to mean that such a compound, composition, or substance does not react with biomass or by-products of its pyrolysis at the temperatures and pressures achieved within the reaction vessel in the practice of the present disclosure.

[0032] Referring now to the drawings, FIG. 1 shows an exemplary embodiment of a batch reactor 1000 for producing dry durable carbon.

[0033] Reactor 1000 of FIG. 1 is shown as including a first storage container 1010 and a second storage container 1030. In selected embodiments, the first storage container 1010 can include a first storage container system (or means), whereas the second storage container 1030 can include a second storage container system (or means). The first storage container 1010 can include, for example, a first housing 1011 for defining a first internal chamber 1012 that can dispose and / or hold a feedstock 1020. In addition and / or alternatively, the second storage container 1030 can include a second housing 1031 for defining a second internal chamber 1032. As shown in FIG. 1, the first storage container 1010 can be disposed, in whole or in part, within the second internal chamber 1032 defined by the second storage container 1030. In other words, the first storage container 1010 can be at least partially surrounded by the second housing 1031 of the second storage container 1030.

[0034] In a selected embodiment, the first internal chamber 1012 can be configured to communicate with the outer or otherwise external reactor operating environment 1190 of the reactor 1000. The first housing opening 1181 can be defined, for example, by the first housing 1011 and can communicate or otherwise cooperate with a second housing opening 1182 defined by the second housing 1031. Thereby, the first internal chamber 1012 can communicate with the reactor operating environment 1190 via the cooperating first and second housing openings 1181, 1182.

[0035] Although described as including only a single first housing opening 1181 and a single second housing opening 1182 for illustrative purposes only, the reactor 1000 can include any predetermined first number of first housing openings 1181 and any predetermined second number of second housing openings 1182, each first housing opening 1181 can communicate or otherwise cooperate with one or more of the second housing openings 1182, and / or each second housing opening 1182 can communicate or otherwise cooperate with one or more of the first housing openings 1181.

[0036] The first storage container 1010 can be configured to hold a raw material 1020 containing any unreacted raw material and / or any reacted raw material before the reaction process. The reactor 1000 can, in other words, include a double containment reaction volume for containing the amount of unreacted raw material before the start of the reaction. In a selected embodiment, the first storage container 1010 can define one or more holes, perforations, ports, or other openings (not shown) to allow gas to escape into the second storage container 1030, and the first storage container 1010 can optionally be configured to maintain a predetermined pressure level. The openings can be defined at predetermined locations of the first storage container 1010 to allow the supplied reactive gas to flow in at least one desired pattern. The first storage container 1010 can be manufactured, for example, from a thin metal and can have a light weight compared to the second storage container 1030. In a selected embodiment, the first housing 1011 of the first storage container 1010 can be formed from a mesh or other porous material.

[0037] The reactor 1000 can advantageously be configured to control the heat flow within the reactor 1000. As shown in FIG. 1, for example, a heat flow control zone 1015 can be defined between the first storage container 1010 and the second storage container 1030. In a selected embodiment, the heat flow control zone 1015 can be at least partially filled with gas. Additionally and / or alternatively, the heat flow control zone 1015 can be completely or partially filled with a preselected insulating material.

[0038] In the heat flow control zone 1015, optionally, one or more baffles (not shown) can be arranged. The baffles can advantageously be configured to reduce radiative heat transfer from the reaction towards the second storage container 1030. In a selected embodiment, piping (not shown) for a liquid or gas flow can be disposed within the heat flow control zone 1015. A high-temperature or low-temperature fluid can flow through the piping and can serve to adjust the heat flow between the first storage container 1010 and the second storage container 1030. Above, for illustrative purposes only, it has been shown as including the heat flow control zone 1015, baffles, and / or piping, but one or more other suitable devices such as heat oil, baffles, and / or other items can be utilized for the control of the heat flow within the reactor 1000. Suitable devices for controlling the heat flow within the reactor 1000 can, for example, actively or passively control the temperature as desired.

[0039] In a selected embodiment, the reactor 1000 can include one or more external ports (not shown). As shown in FIG. 1, exemplary external ports can include, but are not limited to, a gas inlet port 1040 defined in the upper region of the reactor 1000, a gas outlet port 1050 defined in the lower region of the reactor 1000, and / or one or more utility ports 1060 defined at a predetermined location of the reactor 1000. The number and / or location of the utility ports 1060 can depend on the preselected use of the reactor 1000.

[0040] The ignition device (or means) 1065 can be disposed at a target ignition location within the reactor 1000. In a selected embodiment, the ignition device 1065 can be an electrically actuated device. One or more wirings for operating the ignition device 1065 can be routed through the respective utility ports 1060.

[0041] The first containment top (or means) 1013 can be disposed in the upper region of the first containment vessel 1010 and, in the selected embodiment, can enable access to the raw material 1020, or a product such as the dry durable carbon product 3100 (shown in FIG. 9B), after the reaction. The first containment lid 1030 can be hingedly connected, for example, between an open position to enable access to the raw material 1020 or the product after the reaction and a closed position to prevent access to the raw material 1020 or the product after the reaction. In some embodiments, since the raw material 1020 is the only available path for the input gas, the first containment lid 1013 can be removed when the gas input into the upper region of the reactor 1000 is forced to flow through the raw material 1020.

[0042] The second containment top (or means) 1021 can be disposed in the upper region of the second containment vessel 1030. The second containment lid 1021 can enable access to the first containment vessel 1020 and the raw material 1020 or the product after the reaction. In the selected embodiment, the second containment lid 1021 can be hingedly connected between an open position to enable access to the raw material 1020 or the product after the reaction and a closed position to prevent access to the raw material 1020 or the product after the reaction.

[0043] As shown in FIG. 1, the upper plenum 1100 can be created in the space 1183 above the raw material 1020 where the gas 1184 can collect before flowing into the raw material 1020. The reactive gas preferably flows evenly into the raw material 1020. In the selected embodiment, the upper plenum 1100 can include a baffle or other mechanism (not shown) to maximize the uniform distribution of the reactive gas flow into the raw material 1020. For example, each 10 square centimeter area of the raw material 1020 can receive a proportion of the total area flow rate within 30 percent, or more preferably within 10 percent.

[0044] Additionally and / or alternatively, the lower plenum 1150 can optionally be created within a space 1185 below the feedstock 1020 where the gas 1186 can collect before exiting the reactor 1000 through the gas outlet port 1050. In selected embodiments, the lower plenum 1150 can include a baffle or other mechanism (not shown) to maximize the uniform distribution of the reactive gas flow into the feedstock 1020. The baffle or other mechanism can optionally generate a backpressure to assist the distributed gas flow.

[0045] Referring to FIG. 2, the reactor 100 is shown as being associated with a system 1002 for producing dry durable carbon. The system 1002 can, in other words, include the reactor 1000 and additional equipment to support the process for producing dry durable carbon. For example, the additional equipment can provide pressurized (or compressed) air or other reactive gas to the reactor 1000. The system 1002 of FIG. 2 is shown as including a compressor (or air compression means) 1070 for providing air at an elevated pressure. The system 1002 can provide the pressurized air from the compressor 1070 to the reactor 1000 in any suitable manner. As shown in FIG. 2, the compressor 1070 can be coupled to the gas inlet port 1040 of the reactor 1000 via a pipe 1072.

[0046] The system 1002 can include, for example, a flow controller (or flow controller means) 1073 for providing the pressurized air from the compressor 1070 to the first internal chamber 1012 of the reactor 1000. The flow controller 1073 can advantageously be configured to control the flow rate of the pressurized air. In other words, the flow controller 1073 can control the flow rate (or mass flow rate) of the pressurized air to a predetermined flow rate level and / or maintain the flow rate within a predetermined range of flow rate levels.

[0047] The flow rate through reactor 1000 can depend on the cross-sectional area of reactor 1000. In the selected embodiment, flow controller 1073 can control the flow rate of pressurized air to be within a range of from 1 kilogram (or cubic meter) of pressurized air per minute per square meter of feedstock 1020 in reactor 1000 to 25 kilograms of pressurized air per minute per square meter of feedstock 1020. Preferably, the flow rate of pressurized air can be within a range of from 3 kilograms of pressurized air per minute per square meter of feedstock 1020 in reactor 1000 to 15 kilograms of pressurized air per minute per square meter of feedstock 1020, and more preferably within a range of from 3 to 10 kilograms of pressurized air per minute per square meter of feedstock 1020.

[0048] In the selected embodiment, flow controller 1073 can include, but is not limited to, a mass flow control device. Exemplary mass flow control devices can include, for example, mass flow controllers available from Aalborg Instruments & Controls, Inc., headquartered in Orangeburg, N.Y., MKS Instruments, Inc., headquartered in Andover, Mass., Alicat Scientific Inc., headquartered in Tucson, Ariz., and Brooks Instrument, LLC, headquartered in Hatfield, Pa. Flow controller 1073 can optionally be based on thermal control technology and / or ultrasonic control technology.

[0049] Flow controller 1073 can be separate from air compressor 1070 or can be at least partially integrated. In other words, flow controller 1073 can be included as part of air compressor 1070 and / or pressurized air can be routed to flow controller 1073. In the selected embodiment, pressurized air can be routed from air compressor 1070 to flow controller 1073 via piping 1072.

[0050] In a selected embodiment, the system 1002 can be configured to control the air pressure level of the pressurized air to a predetermined air pressure level and / or maintain the air pressure level within a predetermined range of air pressure levels. The system 1002 can be controlled, for example, to maintain the air pressure level of the pressurized air within a pressure range of 0 to 1750 kilopascals (gauge pressure). Preferably, the air pressure level can be maintained within a pressure range of 100 kilopascals to 1000 kilopascals, more preferably within a pressure range of 100 kilopascals to 400 kilopascals.

[0051] The system 1002 can optionally include a pressure regulating device (or means) (not shown) for maintaining or otherwise controlling the air pressure level of the pressurized air. The pressure regulating device can be separate from the air compressor 1070 or at least partially integrated therewith. In other words, the pressure regulating device can be included as part of the air compressor 1070, and / or the pressurized air can be routed to the pressure regulating device, for example, via the pipe 1072.

[0052] In addition and / or alternatively, the air compressor 1070 can provide pressurized air to the first internal chamber 1012 of the reactor 1000 via a moisture control device (or means) 1074. The moisture control device 1074 can increase and / or decrease the amount of moisture in the pressurized air. In a selected embodiment, the moisture control device 1074 can be configured to reduce the proportion of moisture in the pressurized air to a predetermined level. The moisture control device 1074 can, for example, reduce the proportion of moisture in the pressurized air to a dew point below 20°C. Preferably, the proportion of moisture in the pressurized air can be reduced to a dew point below 0°C, more preferably below -40°C. As shown in FIG. 2, the moisture control device 1074 can be coupled to the air compressor 1070 and / or the flow controller 1073 via the pipe 1072.

[0053] System 1002 can optionally be configured to adjust or otherwise control the chemical composition of the pressurized air. In selected embodiments, system 1002 includes an oxygen concentration (or enrichment) device (or means) to enable adjustment of the oxygen concentration in the pressurized air and / or a nitrogen concentration device (not shown) to enable adjustment of the nitrogen concentration in the pressurized air. The oxygen concentration device can, for example, increase and / or decrease the oxygen concentration in the pressurized air. The oxygen concentration device can be configured to control the oxygen concentration in the pressurized air to a predetermined oxygen concentration level and / or maintain the oxygen concentration in the pressurized air within a predetermined range of oxygen concentration levels.

[0054] In selected embodiments, the oxygen concentration device can maintain the oxygen concentration in the pressurized air within an enrichment range of 5 percent to 40 percent. Preferably, the oxygen concentration can be maintained within a concentration range of 10 percent to 30 percent, more preferably within a concentration range of 15 percent to 25 percent. The percentage can be determined, for example, as the volume fraction of oxygen in the reaction gas stream. The oxygen concentration device can be separate from the air compressor 1070 or at least partially integrated. In other words, the oxygen concentration device can be included as part of the air compressor 1070 and / or the pressurized air can be routed into and / or out of the oxygen concentration device via the pipe 1072.

[0055] In addition and / or alternatively, the nitrogen concentration device can increase and / or decrease the nitrogen concentration in the pressurized air. The nitrogen concentration device can be configured to control the nitrogen concentration in the pressurized air to a predetermined nitrogen concentration level and / or maintain the nitrogen concentration in the pressurized air within a predetermined range of nitrogen concentration levels.

[0056] In the selected embodiment, the nitrogen enrichment device can maintain the nitrogen concentration in the pressurized air within a concentration range of from 0 percent to 90 percent. Preferably, the nitrogen concentration can be maintained within a concentration range of from 50 percent to 90 percent, more preferably within a concentration range of from 70 percent to 90 percent. The percentage can be determined, for example, as the volume fraction of nitrogen in the reactive gas stream. The nitrogen enrichment device can be separate from the air compressor 1070 or at least partially integrated. In other words, the nitrogen enrichment device may be included as part of the air compressor 1070, and / or the pressurized air can be routed into and / or out of the nitrogen enrichment device via the pipe 1072.

[0057] As shown in FIG. 2, the system 1002 can optionally include a storage for the reactive chemical 1076. The system 1002 can provide the reactive chemical 1076 from the storage to the reactor 1000 in any suitable manner. The storage for the reactive chemical 1076 can be coupled to the gas inlet port 1040 of the reactor 1000 via the pipe 1072, for example, in the manner shown in FIG. 2.

[0058] The reactive chemical 1076 can include at least one of oxygen, nitrogen, and other reactive or inert gases. In the selected embodiment, the reactive chemical 1076 can include one or more liquids. The reactive chemical 1076 can combine with the pressurized air from the air compressor 1070 to form a reactive gas. The reactive gas can be provided to the reactor 1000 via the gas inlet port 1040.

[0059] System 1002 can similarly process gases such as the reacted process gas 1350 (shown in FIG. 4) that can be output from the reactor 1000. As shown in FIG. 2, the pressure control valve (or means) 1080 can be coupled to the gas outlet port 1050 of the reactor 1000 to receive the reacted process gas 1350. The pressure control valve 1080 can be coupled to the gas outlet port 1050 via the pipe 1078. The pipe 1078 can advantageously lower the temperature of the reacted process gas 1350 before the reacted process gas 1350 reaches the pressure control valve 1080. The pipe 1078 can lower the temperature of the reacted process gas 1350 in any suitable manner, such as, but not limited to, via air, water, or other fluids. In the selected embodiment, the heat removed from the reacted process gas 1350 can be used to generate electricity through a steam generation process.

[0060] The reacted process gas 1350 can be provided to the thermal oxidizer (or means) 1086 of the system 1002. For example, the reacted process gas 1350 can be provided directly from the reactor 1000 to the thermal oxidizer 1086 and / or indirectly provided to the thermal oxidizer 1086 via the pressure control valve 1080 as shown in FIG. 2. The pressure control valve 1080 and the thermal oxidizer 1086 can communicate in any suitable manner, such as via the pipe 1082. The thermal oxidizer 1086 can include an inlet pipe 1084 for receiving the reacted process gas 1350 from the reactor 1000.

[0061] The thermal oxidizer 1086 can combine the reacted process gas 1350 with oxygen from air or supplied oxygen, such as supplied oxygen, for the oxidation of the chemicals contained in the reacted process gas 1350. The oxygen can be provided to the thermal oxidizer 1086 in any suitable manner. In the selected embodiment, the thermal oxidizer 1086 can include a blower (not shown) for providing air. Additionally and / or alternatively, the air can be supplied via an air compressor 1070 and / or another gas supply system (not shown). After reaching the interior of the thermal oxidizer 1086, the system exhaust gas 1088 can be directed to flow into the atmosphere through the exhaust stack 1090.

[0062] The thermal oxidizer 1086 can enable the reacted process gas 1350 and oxygen to react. The reaction between the reacted process gas 1350 and the oxygen generated inside the thermal oxidizer 1086 can release heat, which can advantageously be captured and used to improve the energy efficiency of the system 1002. In the selected embodiment, the heat can be captured via a heat exchange system 1092 by supplying water at the exchange system inlet 1094 and capturing steam at the exchange system outlet 1096. The thermal oxidizer 1086 can utilize any suitable working fluid, such as oil.

[0063] Uses for the heated working fluid include, but are not limited to, biomass drying, power generation, reactor heating, building heating, and / or external supply of process heat. The externally supplied process heat is advantageously used, for example, for a process operating adjacent to the system 1002. In the selected embodiment, the steam can be routed to a steam generation system (not shown) for power generation. Additionally and / or alternatively, the steam can be used directly with a heat exchanger (not shown) to create a heated air stream. The heated air stream can provide heat for local buildings or other domestic uses. The heated air stream can also be used to flow over biomass to reduce its moisture content before use.

[0064] Reactor 1000 and / or system 1002 can produce a dry durable carbon product 3100 (shown in FIG. 9B) in any suitable manner. An exemplary method 2000 for producing a dry durable carbon product is shown in FIG. 3A. In the selected embodiment, method 2000 can be carried out via reactor 1000 (shown in FIGS. 1 and 2) and / or system 1002 (shown in FIG. 2) to produce a dry durable carbon product 3100 (shown in FIG. 9B).

[0065] Referring to FIG. 3A, method 2000 is shown as including, at 2010, preparing a raw material 1020 for the reaction. At 2020, a reaction for the prepared raw material 1020 can be initiated to produce a dry durable carbon product 3100 (shown in FIG. 9B). The reaction can end at 2030, and at 2040, the produced dry durable carbon product 3100 can be recovered.

[0066] At 2010, the raw material 1020 can be prepared for the reaction in any suitable manner. An exemplary manner for preparing the raw material 1020 for the reaction at 2010 is shown in FIG. 3B. Referring to FIG. 3B, at 2012, the raw material 1020 can be prepared for the reaction by selecting the raw material 1020 and / or drying the raw material 1020 to a desired moisture level. The moisture content can depend on the raw material substance, but in the selected embodiment, it is generally less than 30 percent moisture by mass. Method 2000 can advantageously utilize a wide variety of raw materials 1020 including, but not limited to, agricultural residues such as walnut shells, peaches and olive seeds, thinned wood such as pine pellets and wood chips, and aquatic plants such as cattails.

[0067] In 2014, the raw material 1020 can be rearranged to achieve a predetermined target packing density. The raw material 1020 can be rearranged, for example, by physical size and characteristics. In the selected embodiment, the raw material 1020 can be rearranged to provide a predetermined bulk density to be loaded.

[0068] The raw material substance can optionally be chemically treated. For example, the raw material 1020 can be sprayed with an iron salt and / or immersed in a liquid bath containing a certain concentration of an iron salt. The treated raw material 1020 can be dried and / or the iron salt can be dispersed throughout. During subsequent reactions, the iron salt can react with a reactive gas to form metallic iron particles. The iron particles can be useful in environmental remediation applications.

[0069] In 2016, the raw material 1020 can be loaded into the reactor 1000. In other words, in 2016, the raw material 1020 can be disposed in the first storage container 1010 (shown in FIG. 1) of the reactor 1000. The raw material 1020 can be loaded into the reactor 1000 in any suitable manner. For example, the loading of the raw material 1020 can include an opening at the top of the reactor 1000 and / or a preselected loading port (not shown). The raw material 1020 can be loaded into the reactor 1000 via an auger, an air lift conveyor, or other suitable lift system (not shown). In the selected embodiment, the first storage container 1010 can be removed from the second storage container 1030 (shown in FIG. 1) via an overhead crane and loaded from the outside of the second storage container 1030. After loading, the first storage container 1010 can be placed back in the second storage container 1030.

[0070] In a preferred embodiment, a load cell (not shown) can be installed on a reactor support leg (not shown) or in a lower region of the reactor 1000 so as to measure or otherwise determine the mass of the reactor 1000. The load cell can preferably be arranged so as to be able to determine the mass at any time. The amount of the charged raw material 1020 can be determined, for example, by the height occupied by the raw material 1020 in the first storage container 1010, and the mass of the raw material 1020 disposed in the first storage container 1010 can be determined using the load cell.

[0071] In 2020, if the raw material 1020 has a bulk density that falls within an acceptable range, the reaction can be started. If the bulk density of the raw material 1020 is less than the lower bulk density limit value, the first storage container 1010 and / or the reactor 1000 can be vibrated while attempting to increase the packing density of the raw material 1020. Alternatively, if the bulk density of the raw material 1020 exceeds the upper bulk density limit value, the raw material 1020 can be removed from the reactor 1000 and reloaded into the reactor 1000.

[0072] In 2020, the reaction of the prepared raw material 1020 can be started in any suitable manner. An exemplary manner for starting the reaction of the prepared raw material 1020 in 2020 is shown in FIG. 3C. Referring to FIG. 3C, in 2022, the reaction of the prepared raw material 1020 can be started by sealing the reactor 1000. In a selected embodiment, in 2022, the reactor 1000 can be sealed by sealing the first storage container 1010 and / or sealing the second storage container 1030. By sealing the reactor 1000, gas leakage from the reactor 1000 can be advantageously prevented.

[0073] In a selected embodiment, the reactor 1000 can be sealed such that when the reactor 1000 is pressurized up to 50 pounds per square gauge (or PSIG), the leakage from the reactor 1000 is less than 1000 milliliters per minute. Preferably, when pressurized up to 50 PSIG, the leakage from the reactor 1000 is less than 500 milliliters per minute, and more preferably, when pressurized up to 50 PSIG, the leakage from the reactor 1000 is less than 200 milliliters per minute. When pressurized up to 50 PSIG, the leakage from the reactor 1000 is less than 500 milliliters.

[0074] Once the reactor 1000 is sealed, in 2024, the flow of a reactive gas (or reactive gas mixture) 1300 (shown in FIG. 4) can be initiated within the reactor 1000. A gas path can be formed within the reactor 1000 to enable the reactive gas 1300 to contact the raw material 1020 and react with the raw material 1020. When the reactive gas 1300 is introduced into the reactor 1000 via the gas inlet port 1040 (shown in FIG. 1), for example, an exemplary gas path can allow the introduced reactive gas 1300 to flow through the interior of the first storage container 1010 and into the upper region of the first storage container 1010, and exit into the gas outlet port 1050 (shown in FIG. 1) through the lower region of the first storage container 1010. Thereby, all of the introduced reactive gas 1300 can be forced to contact the raw material 1020. The resulting gas path preferably avoids any unintended bypass routes. In some embodiments, the reactive gas 1300 can be sampled through one or more of the utility ports 1060.

[0075] In 2026, the reactor 1000 can be pressurized once it is sealed. When the reactive gas 1300 is introduced into the reactor 1000 via the gas inlet port 1040, for example, the pressure within the reactor 1000 can be increased to a target operating (or reaction) pressure. In other words, the target reaction pressure can be applied to the reactor 1000.

[0076] In selected embodiments, the pressure control valve 1080 (shown in FIG. 1) can be constrained to increase the pressure within the reactor 1000 to a desired operating pressure, while the flow rate of the reactive gas 1300 can be fixed at a target rate by the flow controller 1073 (shown in FIG. 1). The mass flow rate of the reactive gas 1300 can be adjusted and / or maintained at a fixed value, for example, over the duration of the manufacturing process. As the reaction proceeds and the reactor 1000, the loaded feedstock 1020, and / or the reacted product are heated, the pressure control valve 1080 can automatically operate to maintain the reactor 1000 at the target pressure. In some embodiments, the target pressure within the reactor 1000 may change during the reaction. This change in the target pressure can be achieved based on pre-programming the pressure control valve 1080 to target a pre-selected pressure at a given time point, based on the position of the reaction front within the feedstock bed, and / or based on another predetermined trigger condition.

[0077] Once the flow rate of the reactive gas 1300 and the pressure within the reactor 1000 have stabilized to their respective desired flow rate and operating pressure, the reaction can be initiated. The reaction can be initiated by igniting the feedstock 1020 in 2027. The feedstock 1020 can be ignited, for example, via a heated element (not shown).

[0078] In selected embodiments, the heated element can include an electric ignition coil. The combustion reaction can be initiated by applying a voltage to the electric ignition coil (not shown) to drive a current through the ignition coil. The ignition coil can have, for example, an energy density of at least one-quarter kilowatt per 100 square centimeter of feedstock area. Preferably, at least half of the feedstock area at the ignition location can be exposed to the heated element to assist in ensuring uniform ignition.

[0079] In the selected embodiment, the feedstock 1020 can be ignited in the end region of the feedstock on the side opposite to the ingress of the reactive gas mixture into the reactor 1000. In a vertically oriented reactor 1000 where the reactive gas mixture is introduced in the upper region of the reactor 1000, for example, the feedstock can be ignited in the bottom region of the reactor 1000.

[0080] Once the reaction is initiated, the reacted process gas 145 can be discharged from the reactor 1000 via the gas outlet port 1050. In certain embodiments, the reacted process gas 1350 · 0 to 60% nitrogen, · 10 to 50% CO2, · 0 to 50% H2, · 10 to 50% CO, · 0 to 20% CH4, · 0 to 5% ethane, · 0 to 5% ethylene, and / or · 0 to 5% heavy hydrocarbons (C3+) can include at least one of.

[0081] In certain embodiments, the reacted process gas 1350 can contain less than 5 percent oxygen. Nitrogen can be included in the reacted process gas 1350 when air or enriched air is used as the reactive gas 1300. The composition of the reacted process gas 1350 depends on one or more specific properties of the feedstock 1020, but generally can have a high chemical potential energy. In the selected embodiment, the reacted process gas 1350 can advantageously be captured in the reactor 1000 and / or remotely from the system 1002 and used later.

[0082] In certain embodiments, method 2000 can optionally include, at 2028, starting thermal oxidizer 1086 (shown in FIG. 2). Thermal oxidizer 1086 can receive a gas such as reacted process gas 1350 exiting reactor 1000 via gas outlet port 1050 and can provide an environment for oxidation of the reacted process gas 1350. In 2020, the reaction that is initiated can include, for example, the combustion of a conventional hydrocarbon where the reacted process gas 1350 combines with oxygen in the air to produce primarily carbon dioxide, water, and heat. In certain embodiments, a catalyst bed can be utilized to combine the reacted process gas 1350 and oxygen to produce primarily carbon dioxide, water, and heat. Thermal oxidizer 1086 can advantageously convert potentially undesirable hydrocarbons into emissions-safe chemicals such as carbon dioxide and water.

[0083] In addition and / or alternatively, at 2029, optionally, energy recovery for the reaction can be initiated. Energy recovery can advantageously include the recovery of energy in the form of electricity. When a hot fluid such as water is exposed to the heat generated within thermal oxidizer 1086, the heated hot fluid can be utilized to generate an energy working fluid such as steam. The steam can be used to drive a steam turbine (not shown) configured to generate electricity.

[0084] In 2030, the reaction of the prepared raw material 1020 can be terminated in any suitable manner. An exemplary manner for terminating the reaction of the prepared raw material 1020 in 2030 is shown in FIG. 3D. After the reaction has proceeded throughout the bed of the raw material 1020, in 2032, the reacted process gas 1350 can decrease with the cessation of the reaction and / or the temperature of the gas being discharged begins to drop. After all the reactions have ceased, the gas takes the form of the reactive gas 1300. In the selected embodiment, the end of the reaction can be determined by monitoring the discharge temperature of the gas and / or the composition of the reacted process gas 1350. At the end of the reaction, the delivery of oxygen can be stopped in an attempt to retain the solid dry durable carbon product 3100.

[0085] In 2034, cooling of the raw material 1020 can be initiated. Cooling the raw material 1020 can advantageously serve to retain as much of the solid dry durable carbon product 3100 as possible. Any solid dry durable carbon product 3100 that is heated above a certain temperature and exposed to air or oxygen can react with the oxygen and reduce the amount of the solid dry durable carbon product 3100. In certain situations, a runaway reaction may also occur, which can endanger nearby personnel.

[0086] In selected embodiments, water can be added to the dry durable carbon product 3100 to eliminate or minimize water in the dry durable carbon product 3100. Water delivered in liquid form can vaporize when it contacts the solid dry durable carbon product 3100 at high temperatures. For shipping purposes, it is desirable to minimize the amount of water trapped in the solid dry durable carbon product 3100. Preferably, after removal from the reactor 1000, the additional water present per kilogram of the dry durable carbon product 3100 is less than 200 grams. More preferably, after removal from the reactor 1000, the additional water present per kilogram of the dry durable carbon product 3100 is less than 100 grams. Most preferably, after removal from the reactor 1000, the additional water present per kilogram of the dry durable carbon product 3100 is less than 50 grams.

[0087] Preferably, water without minerals can be used to eliminate or minimize mineral deposits formed on the solid dry durable carbon product 3100 during vaporization. The additional water can be defined as the amount of water present in the dry durable carbon product 3100 compared to the dry durable carbon product 3100 that is removed without water being added.

[0088] Water can be introduced as an aerosol with nitrogen or other inert gas. In selected embodiments, air may be used, but the use of air poses a risk of reacting with the high-temperature product, which may react with the solid and reduce this amount. When the water loading is high, air is more likely to function without significant loss of the solid amount. Additionally and / or alternatively, assuming the temperature of the reactor 1000 is high enough to allow the vapor to remain vaporous, steam can be used as a carrier gas. Water droplets can be created using an aerosol nozzle, nebulizer, or other aerosolizing device (not shown). The aerosolizing device can be used alone or in combination with a device (not shown) for directly applying a water stream to the solid dry durable carbon product 3100.

[0089] In a selected embodiment, a liquid water delivery device (not shown) can be utilized to directly deliver water to the solid dry durable carbon product 3100. A pipe in the form of a ring (not shown) can be disposed within the reactor 1000 inside the first storage container 1010 and / or the second storage container 1030 having holes along the ring, so that a water stream can be sprayed onto the solid dry durable carbon product 3100 and can be used in combination with aerosol water delivery.

[0090] Thermal radiation can provide an exemplary heat transfer mode at a temperature where the solid carbon is at risk of significant oxidation. If the temperature of the dry durable carbon product 3100 can be lowered below the critical oxidation temperature, the dry durable carbon product 3100 can be removed into the atmosphere. In a selected embodiment, recirculated water is used to cool the wall of the first storage container 1010 to below 100°C, so that when heat is transferred from the inside of the wall of the reactor 1000 mainly through radiative heat transfer, the temperature of the dry durable carbon product 3100 can be lowered. An optional fixed flow rate of water flowing on the outer wall of the first storage container 1010 can be used, and the temperature of the water collected immediately after flowing to the outer wall can be monitored. The increase in the water temperature can be used to estimate the temperature of the dry durable carbon product 3100, the heat transfer rate from the dry durable carbon product 3100, and thereby the time when the dry durable carbon product 3100 can be safely removed from the reactor 1000.

[0091] In 2040, the produced dry durable carbon product 3100 can be recovered in any suitable manner. An exemplary manner for recovering the produced dry durable carbon product 3100 in 2040 is shown in FIG. 3E. Referring to FIG. 3E, in 2042, the dry durable carbon product 3100 can be removed from or otherwise removed from the reactor 1000. In the selected embodiment, removing the dry durable carbon product 3100 can be done by opening the upper regions of the second storage container 1030 and the first storage container 1010 and removing the dry durable carbon product 3100 by means of an auger (not shown) and / or an air lift conveyor (not shown).

[0092] In addition and / or alternatively, the dry durable carbon product 3100 can be removed by opening a separate loading port (not shown) of the reactor 1000 and removing the dry durable carbon product 3100 by means of an auger and / or an air lift conveyor. In other embodiments, the lower region of the second storage container 1030 can be opened (or removed) to allow the dry durable carbon product 3100 to fall out of the reactor 1000 when the lower region of the first storage container 1010 is opened. Thereby, the reactor 1000 can provide direct access to and removal of the dry durable carbon product 3100. In 2044, the dry durable carbon product 3100 removed from the reactor 1000 can be stored and / or packaged for shipment.

[0093] Referring now to FIG. 4, an exemplary schematic view of a section of the feedstock 1020 inside the reactor 1000 near the reaction surface is shown. In other words, FIG. 4 shows an exemplary area around the reaction zone 1500 (shown in FIG. 5) within the reactor 1000. If the reactor 1000 includes a vertical reactor with ignition in the lower region and a reactive gas 1300 supplied from the upper region, the section of the feedstock 1020 can include one or more distinct solid materials including unreacted feedstock 1020, reacting (or reacted) feedstock 1200, and / or a first reacted product 1250, as shown in FIG. 4. In a selected embodiment, the reacted product 1250 can include a dry durable carbon product 3100 (shown in FIG. 9B).

[0094] In addition and / or alternatively, if the reactor 1000 includes a batch reactor, the reaction zone 1500 can be at any suitable position along the feedstock 1020 as the reaction moves from the ignition surface through the unreacted feedstock 1020 to the end of the feedstock charge. In a continuous reactor, the reaction zone 1500 can generally be fixed in position with the reacting feedstock 1200 removed on one side and unreacted feedstock 1020 replacing the volume lost in the reaction zone 1500, maintaining the reaction zone 1500 in a fixed location.

[0095] The reactive gas 1300 is shown in FIG. 4 flowing through the reactor 1000 from the upper region of the reactor 1000 above the feedstock 1020, reacting around the reaction zone 1500, and exiting the lower region of the reactor 1000 as the reacted process gas 1350. Thereby, the reaction can include a multi-step process by which a dry durable carbon product 3100 can be obtained by first exposing the unreacted feedstock 1020 to a high temperature and a high heat transfer rate that leads to the liberation of volatile chemical species. In other words, the feedstock 1020 can be exposed to heat, which preferably warms the feedstock 1020 and liberates chemical species prior to the initiation of a high temperature combustion reaction. As the reaction proceeds at a suitable rate, the temperature rises and further volatile chemical species can be liberated.

[0096] As volatile chemicals are generated from the heated feedstock 1020, they can be conveyed into the stream of reactive gas 1300. When encountering the high-temperature zone and oxygen, the volatile chemicals react, release heat, and the reaction can continue. This mode of operation partially reacts and / or decomposes heavy hydrocarbon species, minimizing (or in selected embodiments, eliminating) the formation of undesirable liquid fractions such as oil and tar. The chemistry of the reaction can depend, for example, on one or more operating characteristics and / or the amount of oxygen available in the reactive gas 1300.

[0097] In a selected embodiment, the reaction can include a limited combustion reaction. The limited combustion reaction can be configured to move from a reaction initiation zone in the lower portion of the feedstock 1020, through the central body of the feedstock 1020, and to the upper portion of the feedstock 1020 over a period of time. Advantageously, the limited combustion reaction is carried out using a limited amount of oxygen, so it may not consume the entire amount of the feedstock of the feedstock 1020. By limiting the amount of oxygen supplied to the reaction zone, the volatile chemicals can be consumed by the limited combustion reaction while maintaining the required carbon fraction.

[0098] Figure 5 is an exemplary schematic view of individual fragments of the reacting and unreacted feedstock within the reactor 1000. As shown in Figure 5, the feedstock material can include unreacted feedstock 1020, reacting feedstock 1200, and / or primary reacted product 1250. Individual fragments of the section of the feedstock 1020 inside the reactor 1000 are shown as adjacent to the reaction zone 1500.

[0099] In the selected embodiment, the reaction zone 1500 can be defined as the location where most of the chemical reactions occur and / or can be associated with the highest temperature within the reactor 1000. If the reactor 1000 alternatively includes a cylindrical batch reactor, for example, the reaction zone 1500 can be formed around a plane bounded by an upper reaction surface 1510 and a lower reaction surface 1520. The thickness of the reaction zone 1500 can be associated with the distance between the upper reaction surface 1510 and the lower reaction surface 1520 and can range from less than 1 centimeter to more than 10 centimeters depending on the reaction rate of the feedstock 1020, the flow of the reactive gas 1300, and / or the composition of the reactive gas 1300 in the selected embodiment.

[0100] As shown in FIG. 5, the reactive gas 1300 can enter the reaction zone 1500 from above the feedstock material 1120, flow within the reaction zone 1500 and / or above the main reacted product 1250, and exit from below the feedstock material 1120 as the reacted process gas 1350. The heat flow 1450 can be associated with the flow of the reactive gas 1300. Since the oxygen present in the reactive gas 1300 is consumed during the chemical reaction, the reacted process gas 1350 may have mostly lost oxygen. Typically, the reacted process gas 1350 can contain energy-rich hydrocarbons and / or carbon monoxide depending on the specific chemical characteristics of the reaction.

[0101] In the selected embodiment, the reaction can produce specific hydrocarbons during the early stages of heating of the feedstock 1020. As it progresses through the reaction zone 1500, the hydrocarbons can form carbon-rich soot particles 1260. As shown in FIG. 6, the soot particles 1260 can deposit on larger fragments of the main reacted product 1250. In some embodiments, it may be desirable to separate the soot particles 1260 from the main reacted product 1250 since the chemical compositions of the soot particles 1260 and the main reacted product 1250 can be significantly different.

[0102] In the selected embodiment, optionally, one or more separation techniques can be used to separate the soot particles 1260 from the main reacted product 1250. Exemplary separation techniques can include, but are not limited to, mechanical separation techniques such as screening techniques, vibrating (or rocking) screening techniques, liquid screening techniques, and / or aerosol screening techniques. The screening technique can involve selecting a screen (not shown) that defines an opening having a size, shape, or other dimension that allows the passage of the soot particles 1260 while preventing the passage of the main reacted product 1250. In other words, the dimensions of the opening can be made large enough to allow the soot particles 1260 to pass through the opening, but small enough to prevent the main reacted product 1250 from passing through the opening.

[0103] Separation techniques that include rocking or other vibrations can help increase the rate at which the soot particles 1260 are separated from the main reacted product 1250. Exemplary liquid separation techniques can include, but are not limited to, flotation separation techniques and / or foam separation techniques. Exemplary aerosol screening techniques can include, but are not limited to, aerosol separation techniques based on particle size through a device (not shown) such as an air classifier. The aerosol screening technique can utilize a carrier gas to pass and / or convey the soot particles 1260 and the main reacted product 1250. The soot particles 1260 can be separated from the main reacted product 1250 via a separation device (not shown) such as a cyclone, based on the relative size and / or relative weight of the soot particles 1260 and the main reacted product 1250.

[0104] Another exemplary method 2500 for producing a dry durable carbon product is shown in FIG. 7. In the selected embodiment, method 2500 can be carried out via reactor 1000 (shown in FIGS. 1 and 2) and / or system 1002 (shown in FIG. 2) to produce a dry durable carbon product 3100 (shown in FIG. 9B). Referring to FIGS. 5-7, method 2500 for producing a dry durable carbon product in the selected embodiment can include a multi-step process. Method 2500 can include, at 2510, transferring heat from reaction zone 1500 using reactor 1000. At 2510, heat transfer can include, for example, transferring heat from the high-temperature reaction zone 1500 by radiative heat transfer.

[0105] At 2520, one or more raw material volatile components 1400 can be placed into the high-temperature reaction zone 1500. In other words, the volatile fraction is discharged from the unreacted raw material 1020 in the form of the raw material volatile component 1400 and conveyed into the reaction zone 1500. The raw material volatile component 1400 can include any predetermined portion of the volatile fraction. In the selected embodiment, most of the volatile fraction will be discharged from the unreacted raw material 1020 in the form of the raw material volatile component 1400 and conveyed into the reaction zone 1500.

[0106] While in the reaction zone 1500, at 2530, the raw material volatile component 1400 can react with the reactive gas 1300. The reaction between the raw material volatile component 1400 and the reactive gas 1300 can, in the selected embodiment, desirably produce a mixture of components that eliminates bio-oil and tar. The mixture of components can eliminate bio-oil and tar in any suitable manner. For example, the mixture of components can eliminate bio-oil and tar by partially oxidizing bio-oil and tar to gaseous components, by decomposing bio-oil and tar into lighter hydrocarbons, and / or by forming or otherwise producing precursor char materials from bio-oil and tar, and the precursor char materials form solid char particles 1260.

[0107] Historically, bio-oil and bio-tar have added significant expenses to the operating costs of biomass processing facilities. Method 2500 can advantageously control the reaction between the raw material volatile components 1400 and the reactive gas 1300. By controlling the reaction between the raw material 1020 and the reactive gas 1300 such as oxygen, the proportion of carbon converted from the biomass raw material 1020 to durable carbon can be increased while minimizing the amount of liquid produced in the form of bio-oil and bio-tar. Thereby, method 2500 can provide dry durable carbon.

[0108] As the reaction continues in the moving reaction zone 1500, the reacting and / or newly reacted fragments of the raw material 1020 can transfer heat, for example, by radiative and / or conductive mechanisms. As the temperature within the reaction zone 1500 rises, the proportion of heat transfer caused by the radiative process can continue to increase. The temperature of the unreacted fragments also rises, allowing volatile chemicals to be released. Thereby, method 2500 can provide a self-sustaining reaction between the raw material volatile components 1400 and the reactive gas 1300, which reaction can generate high temperatures and / or move through the raw material 1020 from the ignition surface until the raw material 1020 is completely consumed.

[0109] Method 2500 can advantageously provide several process characteristics. Exemplary process characteristics of method 2500 can include the amount and concentration of oxygen supplied. In other words, if too much oxygen is supplied, a large proportion of the dry durable carbon product 3100 can be consumed. Another process characteristic of method 2500 can similarly include control of the flow rate of the reactive gas 1300. If the flow rate of the reactive gas 1300 is overly high, heat transfer to the unreacted mass of the raw material 1020 can be reduced by convective heat transfer.

[0110] In addition and / or alternatively, control of the moisture content of feedstock 1020 is another process characteristic of method 2500. Excess moisture in feedstock 1020 can, for example, reduce the reaction rate and / or lower the temperature within reaction zone 1500. Method 2500 can similarly provide control over the energy content of feedstock 1020. In other words, the energy content of feedstock 1020 is preferably high enough to provide energy for the reaction, whereas significantly decayed biomass can prevent the success of the reaction. In the selected embodiment, method 2500 can provide an appropriate packing density of feedstock 1020 to enable an appropriate gas flow rate and / or energy density. [Examples]

[0111] Batch, dry olive seeds, countercurrent configuration An exemplary system 1002 (shown in FIG. 1) can include a batch reactor 1000 (shown in FIG. 1) having a first storage container 1010 (shown in FIG. 1) with a 30-inch diameter, and can produce dry durable carbon using a second storage container 1030 (shown in FIG. 1) with a 36-inch diameter. The first storage container 1010 is removed from the second storage container 1030 and loaded with a total of 690 kilograms of olive seeds with a moisture content of 8.5 percent. After loading, the first storage container 1010 can be placed inside the second storage container 1030 by an overhead crane, and the lids of the first and second storage containers 1010, 1030 can be resealed. The insulating gap between the first and second storage containers 1010, 1030 can include a gas pocket, rather than being filled with an optional insulating material for the purposes of this example.

[0112] Compressed air can be introduced into reactor 1000 at 1.13 standard cubic meters per minute. The downstream pressure control valve 1080 (shown in FIG. 1) can be constrained to reach and maintain a gauge pressure of 415 kPa inside the second storage container 1030, while the flow rate of the compressed air was kept constant within ±0.05 standard cubic meters per minute. Reactor 1000 can be configured to operate in a countercurrent mode where air is supplied from the upper region of reactor 1000 and flows over the raw material 1020 (shown in FIG. 1) including a bed of olive seeds (not shown) and then exits through the lower region of reactor 1000. System 1002 can be configured and tested such that at least 95 percent of the gas flow is through the first storage container 1010.

[0113] The electric heating coil near the raw material in the lower region of the first storage container 1010 can be excited for 5 minutes to ignite the combustion reaction between the raw material 1020 and the flowing air. Ignition can be confirmed by a rapid increase in the reactor pressure, which is relaxed by opening the pressure control valve to maintain the pressure at 415 ± 15 kPa.

[0114] The reaction can be characterized by an exothermic heat wave propagating from the lower region of reactor 1000 to the lower region of reactor 1000 over a period of 289 minutes. The gas exiting reactor 1000 through the pressure control valve 1080 can be directed to a combustion flare to convert the gas into a safe exhaust gas, for example, containing carbon dioxide, water, and nitrogen. The combustion flare can combine the gas exiting reactor 1000 with air from a blower (not shown) that operates electrically at a variable speed. No tar or bio-oil was observed at any point in the outlet stream.

[0115] After the reaction was completed, the dry durable carbon remained inside the storage containers 1010 and 1030 for a period of 24 hours to allow the dry durable carbon to cool to below 100°C. After cooling, the first storage container 1010 can be removed from the second storage container 1030, and the dry durable carbon can be placed in a storage bin (not shown).

[0116] Another exemplary method 2600 for producing a dry durable carbon product is shown in FIG. 8. In the selected embodiment, the method 2600 can be carried out via the reactor 1000 (shown in FIGS. 1 and 2) and / or the system 1002 (shown in FIG. 2) to produce a dry durable carbon product 3100 (shown in FIG. 9B).

[0117] The method 2600 can advantageously control the rate of heat loss from the reacting raw materials. In the selected embodiment, the rate of heat loss from the reacting raw materials can be adjusted via the equipment configuration of the system 1002. The rate of heat loss can be defined, for example, at least in part, in the manner discussed herein with reference to the method 2000 of FIGS. 3A - 3E, by providing an appropriate raw material form and packing density within the appropriate limits within the reaction volume.

[0118] Referring to FIG. 8, the method 2600 can produce a dry durable carbon product 3100 (shown in FIG. 9B) by initiating a combustion reaction of the biomass raw material 1020 at 2610. The combustion reaction can be caused, for example, by heating the biomass raw material 1020 to cause a combustion reaction in the presence of oxygen. In the selected embodiment, the combustion reaction can be initiated by an external device (or means) such as a high-temperature ignition coil, a spark generator, or other combustion ignition device.

[0119] Once the combustion reaction is initiated, the combustion reaction can advantageously automatically continue and / or maintain a high-temperature zone while a certain proportion of biomass feedstock 1020 and oxygen are combined in an exothermic combustion reaction. As a part of the biomass feedstock 1020 is consumed and becomes the reacted feedstock, for example, the combustion front of the combustion reaction can move to the remaining (or unreacted) portion of the biomass feedstock 1020 at 2620, enabling the combustion process to continue. In other words, the feedstock 1020 can include unreacted feedstock and reacted feedstock, and the combustion front can move from the reacted feedstock towards the unreacted feedstock as the combustion process continues.

[0120] Combustion can continue until the entire amount of the biomass feedstock 1020 undergoes the combustion reaction at 2630. The combustion reaction can end at 2640. In the selected embodiment, the combustion reaction can end at 2640 after the entire amount of the biomass feedstock 1020 has undergone the combustion reaction. Thereby, the amount remaining inside the reactor 1000 can include dry durable carbon that can be allowed to cool.

[0121] In the selected embodiment, one or more process conditions are preferably supplied to achieve the production of dry durable carbon. The first process condition can include, for example, utilizing an amount of feedstock (or biomass) containing sufficient net chemical energy to sustain a combustion reaction of at least 600 °C. The net chemical energy of the amount of feedstock can be affected by the water (or moisture) content of the feedstock. In the selected embodiment, the water content of the feedstock is preferably kept relatively low.

[0122] The water content of the feedstock can be maintained, for example, within a moisture range of less than 50 percent. Preferably, the water content of the feedstock can be within a moisture range of less than 25 percent, more preferably within a moisture range of 5 percent to 15 percent.

[0123] Exemplary second process conditions can include configuring reactor 1000 to limit the amount of heat lost from the high-temperature reaction zone to the environment. In a selected embodiment, heat loss can be limited using a double-stored reaction volume such as reactor 1000 of FIG. 1 having first and second storage vessels 1010, 1030. Heat loss can advantageously be reduced by providing a space between the feed volume and the environment. The space can include voids and / or can be filled with one or more insulating materials.

[0124] In addition and / or alternatively, the use of a reactor 1000 having an expanded diameter can help minimize heat loss because the amount of feed contacting the outer periphery of reactor 1000 can be reduced as the diameter of reactor 1000 increases as a function of the geometry. The first storage vessel 1010 and the second storage vessel 1030 can have any suitable size, shape, diameter or other dimension. Exemplary dimensions of the first storage vessel 1010 can include, but are not limited to, dimensions within a range of 2 feet to 10 feet, such as a dimension of 3 feet. The dimensions of the second storage vessel 1030 can be larger than the dimensions of the first storage vessel 1010 and can include, but are not limited to, dimensions within a range of 4 feet to 15 feet, such as a dimension of 10 feet.

[0125] As a third process condition, the combustion reaction can preferably be configured to liberate most of the volatile fraction from the unreacted biomass before entering the high-temperature combustion zone. Most of the volatile fraction can be liberated, for example, as the combustion reaction transfers heat to the unreacted feedstock mainly through radiative heat transfer. Once liberated, the volatile chemicals of the volatile fraction can be transported into the combustion zone by the flowing air. The volatile chemicals can react due to the high temperature within the combustion zone from both pyrolysis and reaction with oxygen. In a selected embodiment, the reaction of the volatile chemicals can occur in a countercurrent reactor where oxygen is supplied from the upper region of the countercurrent reactor, and the gases generated during the reaction can exit the countercurrent reactor in the lower region of the countercurrent reactor. For example, ignition of the feedstock 1020 can occur in the lower region of the countercurrent reactor and can move upward within the countercurrent reactor until all of the feedstock 1020 has reacted.

[0126] In addition and / or alternatively, the fourth process condition can include supplying oxygen at a mass flow rate sufficient to sustain the combustion reaction with the feedstock while at a flow rate low enough to avoid overly cooling the combustion reaction and providing sufficient time across the reaction zone. In a preferred embodiment, such a combustion reaction can be achieved, for example, by increasing the operating pressure of the combustion reaction and / or by increasing the concentration of oxygen.

[0127] Application Forms of Dry Durable Carbon There are many application forms for dry durable carbon. In some embodiments, as a result of customers or others having an interest in carbon sequestration, it may be desirable to identify application forms that ensure carbon remains in solid form over the long term to minimize or eliminate the release of carbon gases such as carbon dioxide.

[0128] In a selected embodiment, the form including the microstructure of the raw material 3000 of dry durable carbon can potentially affect the performance of the dry durable carbon product 3100. The form can be at least partially controlled, for example, by selecting a raw material including a microstructure similar to the desired form of the dry durable carbon product 3100.

[0129] Referring to FIG. 9A, various forms (or raw materials), such as plants, that are naturally generated and can be utilized as the raw material 1020 (shown in FIG. 1) by the reactor 1000 (shown in FIG. 1) are shown. The selected raw material 3000 can include, but is not limited to, one or more oak leaves 3010, one or more pine needles 3020, and / or one or more peach seeds 3030. In addition to the diversity seen in the leaves 3010, needles 3020 (such as pine needles), peach seeds 3030, and visible seeds (not shown), the microstructures including many of the naturally generated raw materials 3000 can also have just as much diversity.

[0130] In the manner discussed in more detail herein, the reactor 1000 can process the raw material 1020 to produce a dry durable carbon product 3100. In a selected embodiment, the reactor can process a raw material 1020 including a naturally created raw material 3000 to produce a dry durable carbon product 3100. An exemplary dry durable carbon product 3100 produced from a raw material 1020 including a naturally generated raw material 3000 is shown in FIG. 9B. Referring to FIG. 9B, the exemplary dry durable carbon product 3100 can include a first dry durable carbon product 3110 produced from walnut shells, a second dry durable carbon product 3120 produced from beet fibers, a third dry durable carbon product 3130 produced from peach seeds 3030 (shown in FIG. 9A), and / or a fourth dry durable carbon product 3140 produced from, but not limited to, pine needles or other pine pressings.

[0131] Depending on the end use, a particular form may be more advantageous. The second dry durable carbon product 3120 produced from the beat fiber raw material can be refined to produce a high aspect ratio material with high conductivity.

[0132] In selected embodiments, the raw material 1020 (shown in FIG. 1) and / or the raw material 3000 for use as the dry durable carbon product 3100 can be refined via a milling process.

[0133] In selected embodiments, jet milling can be used alone or in combination with ball milling to refine the dry durable carbon product 3100. A jet mill enables brittle or crystalline materials to be ground to 1 to 10 microns and optionally enables subsequent classification into a very narrow particle size range simultaneously. This is because brittle or crystalline materials can be processed and conveyed in a gas stream.

[0134] The embodiments disclosed herein are not limited to the examples described above and can be used in any combination with each other. Some of the embodiments can be combined together to form further embodiments. The methods or systems disclosed herein can include at least one of the embodiments described above herein. It will be understood that the benefits and advantages described above may relate to selected embodiments or to several embodiments. Embodiments are not limited to those that solve any or all of the problems described above or have any or all of the benefits and advantages described above. It should be further understood that references to "an" item refer to one or more of that item. The term "comprising" is used herein to mean including the subsequent features or acts without excluding the presence of one or more additional features or acts.

[0135] In a selected embodiment, one or more of the features disclosed herein can be provided as a computer program product. The computer program product can be encoded, for example, but not limited to, on one or more non-transitory machine-readable storage media such as any kind of magnetic, optical, and / or electronic storage media. As used herein, a phrase in the form of at least one of A, B, C, and D in this specification shall be construed to mean one or more of A, one or more of B, one or more of C, and / or one or more of D. Similarly, a phrase in the form of A, B, C, or D shall be construed to mean A or B or C or D as used in this specification. For example, a phrase in the form of A, B, C, or combinations thereof shall be construed to mean A or B or C, or any combination of A, B, and / or C.

[0136] The disclosed embodiments are subject to various modifications and alternative forms, and specific examples thereof are shown by way of illustration in the drawings and described in detail herein. However, the disclosed embodiments are not limited to the specific forms or methods disclosed, but rather, it should be understood that the disclosed embodiments encompass all modifications, equivalents, and alternative forms.

Claims

1. A method for producing dry durable carbon, A step of initiating a combustion reaction for a raw material having a first portion disposed within a reaction zone of the combustion reaction and a second portion disposed outside the reaction zone, The steps include raising the temperature of the combustion reaction to a predetermined reaction temperature, The steps include forming a gas path through the reaction zone to enable a reactive gas to react with a first portion of the raw material at a predetermined reaction temperature to produce a first portion of a dry durable carbon product, The step of enabling the volatile components of the raw material discharged from the second portion of the raw material to enter the reaction zone and react with the reactive gas to form a reacted gas that excludes bio-oil and tar, The method, including the method described above.

2. The method according to claim 1, further comprising the step of preparing raw materials for the combustion reaction.

3. The method according to claim 2, wherein the step of preparing the raw materials includes a step of drying the raw materials to a predetermined moisture level, and / or the step of preparing the raw materials includes a step of rearranging the raw materials to achieve a predetermined target packing density.

4. The method according to claim 2, wherein the step of preparing the raw materials includes the step of arranging the raw materials in a reactor.

5. The method according to claim 1, wherein the step of initiating the combustion reaction includes the step of sealing the reactor and igniting the raw materials.

6. The method according to claim 5, wherein the step of initiating the combustion reaction includes the step of applying a predetermined reaction pressure to the raw materials.

7. The method according to claim 1, further comprising the step of moving the reaction zone of the combustion reaction toward the second portion of the raw material, thereby enabling the reactive gas to react with the second portion of the raw material at a predetermined reaction temperature to produce the second portion of the dry durable carbon product.

8. The method according to claim 7, wherein the step of enabling the reactive gas to react with the second portion of the raw material includes the step of releasing volatile chemicals from the second portion of the raw material before moving the reaction zone of the combustion reaction toward the second portion of the raw material.

9. The method according to claim 8, wherein the step of releasing the volatile chemical substance includes the step of releasing most of the volatile chemical substance from the second portion of the raw material.

10. The method according to any one of claims 7, 8, or 9, wherein the step of enabling the reactive gas to react with the second portion of the raw material includes the step of subjecting the entire raw material to the combustion reaction.

11. The method according to claim 1, further comprising the step of forming a reacted gas that excludes the bio-oil and the tar.

12. The method according to claim 11, wherein the step of forming the reacted gas includes a step of partially oxidizing the bio-oil and tar produced by the combustion reaction to convert them into gaseous components, and / or the step of forming the reacted gas includes a step of decomposing the bio-oil and tar produced by the combustion reaction to convert them into lighter hydrocarbons.

13. The method according to claim 11, wherein the step of forming the reacted gas includes the step of producing a precursor soot substance from the bio-oil and tar produced by the combustion reaction.

14. The method according to claim 13, wherein the precursor soot material forms solid soot particles.

15. The method according to claim 1, further comprising the step of controlling the reaction between the reactive gas and the raw material.

16. The method according to claim 15, wherein the step of controlling the reaction increases the percentage of carbon in the raw materials and converts them into the dry durable carbon product, and / or the step of controlling the reaction reduces the amount of liquid produced in the form of bio-oil and tar.

17. The method according to claim 1, wherein the reactive gas contains oxygen and / or the step of raising the temperature of the combustion reaction includes the step of raising the temperature of the combustion reaction to 500°C to 700°C.

18. The method according to claim 1, wherein the raw material includes a biomass raw material.

19. The method according to claim 18, wherein the dry-durable carbon product has an oxygen-to-carbon ratio of less than 5 percent, and / or the dry-durable carbon product has a hydrogen-to-carbon ratio of less than 5 percent.

20. A system for producing dry durable carbon, wherein the system comprises means for carrying out the method according to any one of claims 1, 2, 5, 7, 11, 15, 17, or 18.

21. The system according to claim 20, further comprising a double containment reaction volume for containing the raw materials before the commencement of the combustion reaction.

22. A computer program product for generating dry-durable carbon, the computer program product comprising instructions for performing the method according to any one of claims 1, 2, 5, 7, 11, 15, 17, or 18.

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