Charcoal and carbon-containing products, and related systems, devices, and methods

Abstract

Disclosed herein are a carbonized product and a coal- or coke-containing mixed product, as well as related systems, devices, and methods. The carbonized product component of the mixed product can be made by receiving an input material in an oven and heating the oven containing the input material to a predetermined temperature of at least 900°F for a predetermined time period of 48 hours or less to produce the carbonized product. Advantageously, embodiments of the present technology can enable a more efficient mixed product manufacturing process. The resulting mixed product can also have higher quality in terms of desired coke strength after reaction (CSR), coke reactivity index (CRI), volatile content, ash content, sulfur content, particle size, etc.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to charcoal and carbon-containing products, as well as related systems, devices, and methods. [Background technology]

[0002] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Patent Application No. 63 / 384,017, filed November 16, 2022, and entitled "CHARRED PRODUCTS AND ASSOCIATED SYSTEMS, DEVICES AND METHODS," the disclosures of which are incorporated herein by reference in their entireties. This application is also related to U.S. Patent Application No. 18 / 501,795, filed November 3, 2023, and entitled "COAL BLENDS, FOUNDRY COKE PRODUCTS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS," and U.S. Patent Application No. 18 / 052,760, filed November 4, 2022, and entitled "FOUNDRY COKE PRODUCTS, AND ASSOCIATED SYSTEMS, DEVICES, AND METHODS," the disclosures of which are incorporated herein by reference in their entireties.

[0003] Existing technologies for carbonized product production include open combustion, traditional kiln processes, and modern pyrolysis reactors. Open combustion is simple but often leads to incomplete combustion and releases harmful pollutants. Traditional kiln processes are labor-intensive and energy-inefficient. To address some of these issues, other thermochemical processes, such as roasting, have been developed, but require significant energy input and their design can be complex and costly. Furthermore, operating temperatures for roasting are typically limited (e.g., below 900°F) and lead to relatively long processing times. Therefore, there is a need for improved, efficient carbonized product production methods and systems that provide consistent product quality, reduce energy consumption, minimize environmental impact, and enable large-scale production for a variety of applications.

[0004] The features, aspects, and advantages of the techniques of the present disclosure may be better understood with regard to the following drawings. [Brief explanation of the drawings]

[0005] [Figure 1A] FIG. 1 is a partial schematic isometric view of a portion of a coke plant, in accordance with an embodiment of the present technique; [Figure 1B] FIG. 1B is a side cross-sectional view of the coke plant of FIG. 1A. [Figure 2] FIG. 1 is a schematic diagram of an oven that receives a carbonaceous input and produces a carbonized product output in accordance with an embodiment of the present technology; [Figure 3] FIG. 1 is a block flow diagram illustrating a method for producing a carbonized product, in accordance with an embodiment of the present technology. [Figure 4] 10 is a data table corresponding to properties of a carbonized product, in accordance with an embodiment of the present technology; [Figure 5] 10 is a data table corresponding to properties of a carbonized product, in accordance with an embodiment of the present technology; [Figure 6] 10 is a data table corresponding to properties of a carbonized product, in accordance with an embodiment of the present technology; [Figure 7] 10 is a data table corresponding to properties of a carbonized product, in accordance with an embodiment of the present technology; [Figure 8A] 1 illustrates input materials being heated in an oven in accordance with an embodiment of the present technology; [Figure 8B] 8B is a carbonized product produced via the input material of FIG. 8A. [Figure 8C] 8B is a carbonized product produced via the input material of FIG. 8A. [Figure 9A] 1 illustrates a carbonized product formed through an oven in accordance with an embodiment of the present technology. [Figure 9B] 1 illustrates a carbonized product formed through an oven in accordance with an embodiment of the present technology. [Figure 9C] 1 illustrates a carbonized product formed through an oven in accordance with an embodiment of the present technology. [Figure 9D] 1 illustrates a carbonized product formed through an oven in accordance with an embodiment of the present technology. DETAILED DESCRIPTION OF THE INVENTION

[0006] Those skilled in the art will appreciate that the features shown in the drawings are for illustrative purposes and that variations are possible, including different and / or additional features and arrangements thereof.

[0007] I. Introduction Embodiments of the present technology relate to charcoal and carbon-containing products, as well as related systems, devices, and methods. Such products, i.e., coal-char blended products and coke-char blended products, can have properties that make them desirable for certain industrial applications, such as steel production. For example, the carbonized (or bicarbonated) product component of the blend can include a relatively high calcium content, which can reduce the ash fusion temperature of the coke product component of the blend and advantageously allows for more carbon transfer from the coke to the molten iron in a cupola.

[0008] However, conventional methods for making carbonized products are limited in various aspects. For example, charcoal products are traditionally produced using heat-integrated kilns that heat input materials to approximately 900°F (or less). Some production techniques include a drying stage in which the moisture content of the input raw materials is reduced, a distillation stage in which hot stove gas is injected through the dried input material, a carbonization stage in which the input material is roasted and converted into charcoal, and a cooling stage in which the charcoal is cooled using a cooled inert gas. These and related production processes have limitations, such as a maximum temperature of approximately 900°F and / or a cycle time greater than 48 hours. As a result, the size (e.g., diameter or minimum cross-sectional dimension) of the input material and / or the moisture content of the input material are often limited (e.g., below 3 inches).

[0009]

[0006] Embodiments of the present technology address at least some of the above problems for producing a carbonized product. For example, embodiments of the present disclosure include receiving an input material in an oven and heating the oven containing the input material to a predetermined temperature of at least 900°F for a predetermined time period of 48 hours or less to produce a carbonized product. The predetermined temperature may be at least 950°F, 1000°F, 1050°F, 1100°F, 1150°F, 1200°F, 1250°F, 1300°F, 1400°F, 1500°F, 1750°F, 2000°F, 2250°F, 2500°F, 2800°F, or in the range of 950-2800°F, and the predetermined time may be 46 hours, 44 hours, 42 hours, 40 hours, 38 hours, 36 hours, 34 hours, 32 hours, 30 hours, 28 hours, 26 hours, 24 hours, 22 hours, 20 hours, 18 hours, 16 hours, 14 hours or less, or in the range of 14-46 hours. The input material can include carbonaceous, non-metallic, or metal-containing materials, such as wood products (e.g., logs or split timber of hickory, oak, red oak, spruce, etc.) and / or iron fines. In some embodiments, the input material can include one or more additives to be processed in the oven, such as calcium (e.g., calcium oxide or lime, calcium sulfate, etc.), sodium (e.g., sodium hydroxide), and / or clay. The oven can be a devolatilization oven configured to heat coal to produce coke (e.g., foundry coke, blast furnace coke, coke breeze, etc.), and can include a heat recovery oven (as described elsewhere herein) or a non-heat recovery oven (e.g., a by-product oven). As such, the oven can be designed to withstand temperatures up to 2800°F.

[0010] The carbonized product can include charcoal and / or biochar and / or can include desired volatiles, ash, sulfur, calcium oxide, size, and product:fines ratio. For example, the carbonized product can have (i) at least 0.1%, 0.3%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, or a desired volatile content in the range of 0.1-25%; (ii) at least 0.1-9% of the desired volatile content; %, 3-8%, 4-6%, 5-6%, or 8%, 7%, 6%, or 5% or less ash; (iii) 1%, 0.9%, 0.8%, 0.7%, 0.5%, 0.25%, 0.1%, 0.05%, or less sulfur content in the range of 0.05-1%; (iv) at least 60%, 65%, 70%, 75%, 78%, or 60-78% calcium oxide. (v) a size where at least 12%, 14%, 16%, 18%, 20%, or in the range of 12-20% of the carbonized product have a size of at least ¾ inch, or at least 6%, 8%, 10%, or in the range of 6-10% of the carbonized product have a size of ¾ inch, or a size where 80%, 85%, 90%, 95%, 99%, or in the range of 80-99% have a size of ⅛ inch or less, and / or (vi) a carbonized product:fines ratio of at least 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 8.0, 9.0, 10.0, or in the range of 2.0-10.0.

[0011] Advantageously, embodiments of the present technology can enable a more efficient carbonized product manufacturing process and / or process a wider range of input materials. For example, due in part to the oven's ability to heat the product at higher temperatures than conventional charcoal manufacturing processes, embodiments of the present technology can process input materials having a diameter or minimum cross-sectional dimension that is at least 2 inches (e.g., at least 4 inches, 6 inches, 8 inches, 12 inches, 18 inches, 24 inches, within the range of 2 to 6 inches, or within the range of 4 to 24 inches). Furthermore, this can be done with a shorter cycle time than conventional charcoal manufacturing processes. As a result, embodiments of the present technology can produce carbonized products in an economical manner.

[0012] Embodiments of the present technology also include coal-charcoal mixed products and coke-charcoal mixed products. Coal-charcoal mixed products include mixtures of one or more coal blends and carbonized products. The carbonized products can be made from one or more of a variety of different input materials and can be ground to a desired size for mixing with the coal blend. Coke-carbonized mixed products include mixtures of coked products and double carbonized products. In some embodiments, the double carbonized products can exhibit certain properties that are superior or more desirable than those of the carbonized products. In some embodiments, for example, the coke-charcoal mixed product can be made by pyrolyzing or otherwise heating the coal-charcoal mixed product so that the input material for the carbonized product is effectively heat-treated twice.

[0013] Advantageously, embodiments of the present technology can enable a more efficient product manufacturing process. Products manufactured according to embodiments of the present technology can also exhibit superior properties compared to other blended products. For example, blending a carbonized product with a coal blend may result in a superior blended product than blending biomass or other input materials that have not been treated with the coal blend. The disclosed blended products can also have higher quality in terms of desired post-reaction coke strength (CSR), coke reactivity index (CRI), volatile content, ash content, sulfur content, size, etc., as disclosed herein.

[0014] In the figures, like reference numbers generally identify similar and / or identical elements. Many of the details, dimensions, and other features shown in the figures are merely illustrative of particular embodiments of the disclosed technology. Thus, other embodiments may have other details, dimensions, and features without departing from the spirit or scope of the present disclosure. Additionally, those skilled in the art will appreciate that further embodiments of the disclosed technology may be practiced without some of the details described below.

[0015] II. Carbonized Products, Mixtures Including Carbonized Products, and Related Systems, Devices, and Methods FIG. 1A is a partial schematic isometric view of a portion of a coke plant or system 10 (“system 10”) in accordance with an embodiment of the present technology, and FIG. 1B is a side cross-sectional view of the coke plant of FIG. 1A. Referring together to FIGS. 1A and 1B, system 10 includes an oven 100. The oven 100 shown is a horizontal heat recovery oven, although other ovens (e.g., non-heat recovery, by-product, etc.) can also be used. As shown in FIG. 1A, oven 100 includes an open cavity defined by an oven floor 102, a pusher-side oven door 104, an output-side oven door 106 opposite the pusher-side oven door 104, an opposing sidewall 108 extending upward from floor 102 and between the pusher-side oven door 104 and the output-side oven door 106, and a crown 110 forming the top surface of the open cavity of an oven chamber 112. Controlling airflow and pressure within oven chamber 112 can play an important role in the efficient operation of the heat treatment cycle. Embodiments of the present technology include one or more crown air inlets 114 that admit primary combustion air into the oven chamber 112. In some embodiments, multiple crown air inlets 114 penetrate the crown 110 in a manner that selectively places the oven chamber 112 in open fluid communication with the ambient environment outside the oven 100. The oven 100 may include an intake elbow air inlet with an air damper 116 that can be positioned in any of several positions between fully open and fully closed to vary the amount of air flow through the air inlet. Other oven air inlets, including the door air inlet and crown air inlet 114, include air dampers 116 that operate in a similar manner. The intake elbow air inlet may be positioned to allow air to enter the common tunnel 128, while the door air inlet and crown air inlet 114 vary the amount of air flow into the oven chamber 112. Although embodiments of the present technology may exclusively use crown air inlets 114 to provide primary combustion air to the oven chamber 112, other types of air inlets, such as door air inlets, may be used in certain embodiments without departing from aspects of the present technology.

[0016] Various air inlets can be used with or without one or more air distributors to direct, circulate, and / or distribute air within the oven chamber. As used herein, the term "air" can include ambient air, oxygen, oxidizer, nitrogen, nitrous oxide, diluent, combustion gas, air mixture, oxidizer mixture, exhaust gas, recycled vent gas, steam, gas with additives, inert agent, endothermic agent, liquid-phase material such as water droplets, multi-phase material such as droplets atomized via a gaseous carrier, aspirated liquid fuel, atomized liquid heptane in a gaseous carrier stream, fuel such as natural gas or hydrogen, cooled gas, other gases, liquids, or solids, or combinations of these materials. In various embodiments, the air inlets and / or distributors can function (i.e., open, close, change air distribution patterns, etc.) in response to manual control or an automated advanced control system. The air inlets and / or air distributors may be operated by dedicated advanced control systems and may be controlled by a more extensive draft control system that regulates the air inlets and / or distributors, as well as intake dampers, single flue dampers, and / or other air distribution paths within the coke oven system.

[0017] During operation, volatile gases released from the input material positioned within the oven chamber 112 may collect at the crown and be drawn downstream into downcomer channels 118 formed in one or both sidewalls 108. The downcomer channels 118 may fluidly connect the oven chamber 112 to a separate flue 120 positioned below the oven floor 102. The separate flue 120 may form a bypass path below the oven floor 102. The volatile gases released from the input material may be combusted within the separate flue 120, thereby generating heat to support processing of the input material to produce processed materials (e.g., reduction of coal to coke). The downcomer channels 118 are fluidly connected to intake channels 122 formed in one or both sidewalls 108. A secondary air inlet 124 may be provided between the separate flue 120 and the atmosphere, and the secondary air inlet 124 may include a secondary air damper 126 that may be positioned in any of a number of positions between fully open and fully closed to vary the amount of secondary air flow into the separate flue 120. The intake channels 122 are fluidly connected to a common tunnel 128 by one or more intake ducts 130. A tertiary air inlet 132 may be provided between the intake ducts 130 and the atmosphere. The tertiary air inlet 132 may include a tertiary air damper 134, which may be positioned in any of a number of positions between fully open and fully closed to vary the amount of tertiary air flow into the intake ducts 130.

[0018] Each intake duct 130 includes an intake damper 136 that can be used to control the flow of gas through the intake duct 130 and within the oven 100. The intake damper 136 can be positioned in any number of positions between fully open and fully closed to vary the amount of oven draft within the oven 100. The intake damper 136 can comprise any automatically or manually controlled flow control device or orifice blocking device (e.g., any plate, seal, block, etc.). For example, the intake damper 136 can be set to a flow position between 0 and 2, representing "closed," and 14, representing "fully open." It is contemplated that even in the "closed" position, the intake damper 136 may still allow a small amount of air to pass through the intake duct 130. Similarly, it is contemplated that a small portion of the intake damper 136 may be at least partially positioned in the airflow through the intake duct 130 when the intake damper 136 is in the "fully open" position. It will be appreciated that the intake damper can have a nearly infinite number of positions between 0 and 14. Some exemplary settings for the intake damper 136 that provide increasing amounts of flow restriction include 12, 10, 8, and 6. In some embodiments, the flow position numbers simply reflect the use of 14 inches of intake duct, with each number representing the amount of intake duct 130 that is open in inches. It will be appreciated that the flow position number scale from 0 to 14 can otherwise be understood simply as incremental settings between open and closed.

[0019] As used herein, "draft" refers to a negative pressure relative to the atmosphere. For example, a 0.1 inch draft of water indicates a water pressure 0.1 inch below atmospheric pressure. The inch of water is a non-SI unit of pressure and is conventionally used to describe draft at various locations within a coke plant. In some embodiments, the draft ranges from about 0.12 to about 0.16 inches of water. As the draft increases or otherwise becomes greater, the pressure becomes further below atmospheric pressure. As the draft decreases, drops, or otherwise becomes smaller or lower, the pressure approaches atmospheric pressure. Controlling the oven draft with intake damper 136 can control the air entering oven 100 through crown air inlet 114 and air leakage into oven 100. Typically, as shown in FIG. 1B, an individual oven 100 includes two intake ducts 130 and two intake dampers 136, however, the use of two intake ducts and two intake dampers is not required and the system can be designed to use one or more intake ducts and two intake dampers.

[0020] During operation, processed materials (e.g., carbonized products, coke, etc.) are produced in the oven 100 by first loading an input material (e.g., wood, biomass, iron powder, additives, etc.) into the oven chamber 112, heating the input material in an oxygen-limited (e.g., oxygen-depleted) environment, devolatilizing the input material, and then oxidizing the volatile matter (VM) in the oven 100, capturing and using the released heat. In some embodiments, the oven 100 is configured to apply partial densification to the input material. In some embodiments, during operation, processed material mixtures (e.g., a mixture of dual carbonized products and coke) are produced in the oven 100 by first loading an input mixture (e.g., a mixture of carbonized products and a coal blend), heating the input material in an oxygen-limited (e.g., oxygen-depleted) environment, devolatilizing the input mixture, and then oxidizing the volatile matter (VM) in the oven 100, capturing and using the released heat.

[0021] In some embodiments, the input material can include a carbonaceous feedstock, a non-metallic feedstock, or a metal-bearing feedstock. In some embodiments, the carbonaceous feedstock can include at least one of wood, biomass, petroleum residue, or waste feedstock. Additionally or alternatively, the carbonaceous feedstock can include a bundle of wood logs approximately 10 feet long, 4 feet high, and 4 feet wide. The individual wood logs can have a diameter or minimum cross-sectional dimension of at least 4 inches, 6 inches, 8 inches, 10 inches, 12 inches, 14 inches, 16 inches, 18 inches, 20 inches, 22 inches, 24 inches, or in the range of 2 to 24 inches. In some embodiments, the metal-bearing feedstock can include mineral raw materials or recycled metal-bearing materials.

[0022] When the input material includes a carbonaceous feedstock, the VM of the carbonaceous feedstock is oxidized in the oven 100 over a coking cycle, releasing heat to regeneratively drive the carbonization of the feedstock and produce coke or a carbonized product. The coking cycle begins when the pusher-side oven door 104 is opened and the input material is loaded onto the oven floor 102 in a manner that defines the input material bed. Heat from the oven (e.g., from a previous coking cycle) initiates the carbonization cycle. In many embodiments, no additional fuel is used other than the fuel produced by the coking process. Approximately half of the total heat transfer to the input material bed is radiated to the top surface of the coal bed from the input material bed and the luminous flame in the radiant oven crown 110. The other half of the heat is transferred to the coal bed by conduction from the oven floor 102, which is convectively heated from the volatilization of gases in the single flue 120. In this way, the "waves" of the carbonization process of plastic flow of coal particles and the formation of high strength cohesive coke proceed from both the upper and lower boundaries of the coal seam.

[0023] In some embodiments, each oven 100 operates at negative pressure, so that the pressure difference between the oven 100 and the atmosphere draws air into the oven during the reduction process. Primary combustion air is added to the oven chamber 112 to at least partially oxidize volatiles from the input material. In some embodiments, the amount of this primary air is controlled so that only a portion of the volatiles released from the coal are combusted within the oven chamber 112, thereby releasing only a small fraction of their combustion enthalpy within the oven chamber 112. In various embodiments, primary air is introduced into the oven chamber 112 above the coal seam through a crown air inlet 114, with the amount of primary air controlled by a crown air damper 116. Other embodiments may use different types of air inlets without departing from aspects of the present technology. For example, primary air may be introduced into the oven through an air inlet, a damper port, and / or an opening in the oven sidewall or door. Regardless of the type of air inlet used, the air inlet can be used to maintain a desired operating temperature within the oven chamber 112. Increasing or decreasing the flow of primary air into the oven chamber 112 through the use of an air inlet damper can increase or decrease the combustion of VM within the oven chamber 112, and therefore increase or decrease the temperature.

[0024] The oven 100 may include crown air inlets 114 configured to introduce combustion air into the oven chamber 112 through the crown 110 in accordance with embodiments of the present technology. In one embodiment, three crown air inlets 114 are positioned along the oven length between the pusher-side oven door 104 and the midpoint of the oven 100. Similarly, three crown air inlets 114 are positioned between the coke-side oven door 106 and the midpoint of the oven 100. However, it is contemplated that one or more crown air inlets 114 may be disposed at various locations along the length of the oven through the oven crown 110. The selected number and positioning of the crown air inlets will depend, at least in part, on the configuration and use of the oven 100. Each crown air inlet 114 may include an air damper 116 that can be positioned in any of a number of positions between fully open and fully closed to vary the amount of air flow into the oven chamber 112. In some embodiments, the air damper 116, in the “fully closed” position, may still allow a small amount of ambient air to pass through the crown air inlets 114 and into the oven chamber. Thus, various embodiments of the crown air inlet 114, intake elbow air inlet, or door air inlet may include a cap that may be removably secured to the open top portion of the particular air inlet. The cap may substantially prevent weather (such as rain and snow), additional ambient air, and other foreign objects from passing through the air inlet. It is contemplated that the oven 100 may further include one or more distributors configured to direct / distribute the air flow into the oven chamber 112.

[0025] In various embodiments, the crown air inlet 114 is operated to introduce ambient air into the oven chamber 112 during the heat treatment cycle in a manner similar to how other air inlets, such as those typically located in the oven door, are operated. However, the use of the crown air inlet 114 provides a more uniform air distribution throughout the oven crown, which has been shown to provide better combustion, higher temperatures within the single flue 120, and a slower crossover time during which the reaction within the oven 100 changes from an exothermic to an endothermic process. The uniform distribution of air within the crown 110 of the oven 110 reduces the likelihood of air contacting the surface of the feedstock bed and creating hot spots that could cause burn damage to the surface. Instead, the crown air inlet 114 substantially reduces the occurrence of such hot spots and creates a uniform feedstock bed surface as the heat treatment progresses. In certain embodiments of use, the air dampers 116 of each of the crown air inlets 114 are set in similar positions relative to each other. Thus, if one air damper 116 is fully open, all of the air dampers 116 can be placed in the fully open position, and if one air damper 116 is set to the half-open position, all of the air dampers 116 can be set to the half-open position. However, in certain embodiments, the air dampers 116 can be altered independently of one another. In various embodiments, the air dampers 116 of the crown air inlets 114 can be quickly opened after loading the oven 100 or immediately before loading the oven 100. The first adjustment of the air dampers 116 to the ¾-open position is made at a time when the first door hole burnout would typically occur. The second adjustment of the air dampers 116 to the ½-open position is made at a time when the second door hole burnout would typically occur. Additional adjustments are made based on operating conditions detected throughout the coke oven 100.

[0026] The partially burned gases pass from the oven chamber 112 through a downcomer channel 118 into a separate flue 120, where secondary air is added to the partially burned gases. The secondary air is introduced through a secondary air inlet 124. The amount of secondary air introduced is controlled by a secondary air damper 126. The introduction of secondary air allows the partially burned gases to be more completely combusted in the separate flue 120, thereby extracting the remaining combustion enthalpy that is transported through the oven floor 102 to add heat to the oven chamber 112. The fully or nearly fully burned exhaust gases exit the separate flue 120 through an intake duct 122 and flow into an intake duct 130. Tertiary air is added to the exhaust gases through a tertiary air inlet 132, the amount of which is controlled by a tertiary air damper 134, whereby any remaining unburned gases in the exhaust gases are oxidized downstream of the tertiary air inlet 132. At the end of the heat treatment cycle, the input material has been processed to produce a treated material. The processed material may be removed from the oven 100 through the output oven door 106 using a mechanical extraction system, such as a pusher ram. Finally, the processed material may be quenched (e.g., wet or dry quenching). In some embodiments, the oven 100 may be configured to allow the processed material to cool before it is removed from the oven 100. At least a portion of the heat from cooling the processed material within or outside the oven 100 may be recycled. For example, the heat from cooling the processed material within the oven 100 may be used to maintain the temperature within the oven 100 or to dry fresh input material. As another example, the heat from cooling the processed material within the oven 100 may be used to preheat fresh input material before it is fed into the oven 100, or to heat water to generate steam suitable for use in the system 10 or elsewhere.

[0027] In some embodiments, a treatment time may be set before the heat treatment begins. In some embodiments, the treatment duration may be adjusted substantially in real time as the heat treatment progresses. In some embodiments, the treatment duration may be determined or controlled based on operating parameters related to the heat treatment within oven 100. Exemplary operating parameters include at least one of the temperature at an opening of oven 100 or at a location within oven 100, the composition of the oven 100 exhaust (also referred to as exhaust gas), the gas flow rate of the exhaust, or the temperature at an exterior surface of oven 100.

[0028] In some embodiments, system 10 can include multiple ovens 100, and in such embodiments, at least two of the multiple ovens 100 are thermally coupled such that one constitutes a heat source for the other. For example, a second oven 100 can be configured to heat a material undergoing an exothermic process, and at least a portion of the heat generated in the exothermic process of the second oven 100 is transferred to a first oven 100 undergoing an endothermic reaction. As another example, system 10 can include three ovens 100 arranged side by side such that two side ovens 100 are located on opposite sides of an intermediate oven 100, and at least one of the two side ovens 100 can be thermally coupled to the intermediate oven 100 such that at least one side oven 100 can constitute a heat source for the intermediate oven 100. In such embodiments, the intermediate oven can be configured to produce a carbonized product, which is an endothermic process, and an adjacent oven can be configured to produce a coke product, which is an exothermic process, and provide heat to the intermediate oven.

[0029] FIG. 2 is a schematic diagram of a system 200 including a grinder or mill 220 (“mill 220”), an oven 240, and a mixing assembly 270. The mill 220 can be configured to receive and grind an input material 210 to reduce the size of the input material 210. The oven 240 can be configured to receive the ground input material 230 and produce a carbonized product 250 in accordance with embodiments of the present technology. The mixing assembly 270 can be configured to receive the carbonized product 250 from the oven 240 and mix it with one or more coal blends 260 (e.g., coal blends for making foundry coke or blast coke) to produce a coal-charcoal mixed product 280. The oven 240 (or a different oven) can be configured to receive the coal-charcoal mixed product 280 and produce a coke-charcoal mixed product 290. Thus, the coke-charcoal mixed product 290 can include a coking product (e.g., foundry coke) and a dual carbonization product. In some embodiments, the material may be passed through the mill 220, oven 240, and / or mixing assembly 270 fewer times, more times, or in a different order.

[0030] 1A and 1B and can include any one or more of the features described herein. For example, input material 210 can correspond to the input material(s) described with reference to FIGS. 1A and 1B, oven 240 can correspond to oven(s) 100 described with reference to FIGS. 1A and 1B, and carbonized product 250 can correspond to the carbonized product(s) described with reference to FIGS. 1A and 1B.

[0031] FIG. 3 is a block flow diagram illustrating a method 300 for producing a coal-charcoal blend product according to an embodiment of the present technology. The method 300 includes receiving an input material in an oven (process portion 310), which may include any oven configured to process coal to produce a coke product, including the ovens described herein with respect to FIGS. 1A-2 and / or thermal recovery or non-thermal recovery ovens. The input material may include any of the input materials described with reference to FIGS. 1A-2. For example, the input material may include a carbonaceous feedstock, a non-metallic feedstock, or a metal-bearing feedstock. The carbonaceous feedstock may include wood, biomass, petroleum residue, or a waste feedstock. Wood may include hickory, oak, red oak, or spruce. Additionally or alternatively, the carbonaceous feedstock may include logs, split logs, stumps, and / or bundles of logs as described above. The individual wood logs can have a diameter or minimum cross-sectional dimension of at least 4 inches, 6 inches, 8 inches, 10 inches, 12 inches, 14 inches, 16 inches, 18 inches, 20 inches, 22 inches, 24 inches, or in the range of 2-24 inches. Additionally or alternatively, the input material can have an input moisture content of at least 10%, 12%, 14%, 16%, 18%, 20%, 22%, 24%, 26%, 28%, 30%, 40%, 50%, or in the range of 10-50%. In some embodiments, the input material includes, for example, one of a plurality of additives in addition to the carbonaceous feedstock. The additives can include calcium (e.g., calcium oxide or lime, calcium sulfate, etc.), sodium (e.g., sodium hydroxide), and / or clay. In some embodiments, the metalliferous feedstock may include mineral raw materials or recycled metalliferous materials.

[0032] Method 300 may further include heating the oven containing the input material to a predetermined temperature of at least 900°F for a predetermined time period of 48 hours or less to produce a carbonized product (e.g., carbonized product 250) (process portion 320). Method 300 may further include mixing the carbonized product from the oven with a coal blend to form a coal-char mixed product (e.g., coal-char mixed product 280) (process portion 320). In some embodiments, the carbonized product and the coal blend are mixed in an autonomously or manually operated mixing assembly (e.g., mixing assembly 270). In some embodiments, two or more coal blends are mixed with the carbonized product. In some embodiments, the coal-char mixed product may have a mass ratio of the carbonized product that is at least 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, or 30%, or in a range of 1-30%, 1-15%, or 15-30%. In some embodiments, the coal-char blend product can have any one or more of the properties discussed above with respect to the carbonized product (e.g., ash content, sulfur content, calcium oxide content, size, carbonized product:fines ratio, volatile content).

[0033] Method 300 can include additional process steps. For example, method 300 can further include grinding the input material to a desired particle size, such as 10 mesh, or at least 2 mm, 3 mm, or 4 mm, or within a range of 2-4 mm. In another example, method 300 can further include cooling the carbonized product and / or coal-charcoal mixture product for at least 24 hours after production, for example, until the product reaches a temperature of 120° F. or less. Cooling can include, for example, fluidly isolating the carbonized product and / or coal-charcoal mixture product from oxygen (or limiting the carbonized product's exposure to oxygen) by placing or placing the carbonized product and / or coal-charcoal mixture product in an at least partially sealed container, and cooling the carbonized product and / or coal-charcoal mixture product to 120° F. or less in an oven while the carbonized product is fluidly isolated from the at least partially sealed container.

[0034] Method 300 may further include receiving the coal-charcoal mixed product in an oven and heating the oven containing the coal-charcoal mixed product to a second predetermined temperature of at least 900°F for a second predetermined time period of 48 hours or less based on customer or product needs to produce a coke-charcoal mixed product (e.g., coke-charcoal mixed product 290). As an example, the coke-charcoal mixed product may include a dual-carbonized product containing a relatively high calcium content and a low sulfur content, and a foundry coke product for use in a foundry cupola. Without being bound by theory, the calcium content may lower the ash fusion temperature of the foundry coke product, advantageously allowing for more carbon transfer from the coke to the molten iron in the cupola. Method 300 may further include cooling the coke-charcoal mixed product.

[0035] The predetermined temperature (when heating the input material) and / or the second predetermined temperature (when heating the coal-charcoal blend product) can be at least 950°F, 1000°F, 1050°F, 1100°F, 1150°F, 1200°F, 1250°F, 1300°F, 1400°F, 1500°F, 1750°F, 2000°F, 2250°F, 2500°F, 2800°F, or in the range of 950-2800°F. The predetermined time (when heating the input material) and / or the second predetermined time (when heating the coal-char mixture product) can be 46 hours, 44 hours, 42 hours, 40 hours, 38 hours, 36 hours, 34 hours, 32 hours, 30 hours, 28 hours, 26 hours, 24 hours, 22 hours, 20 hours, 18 hours, 16 hours, 14 hours or less, or in the range of 14 to 46 hours. Advantageously, such temperatures are higher than temperatures used in conventional carbonized product manufacturing processes, and associated, such times are lower than times used in conventional carbonized product manufacturing processes.

[0036] The carbonized product, the coal-charcoal blended product, and / or the coke-charcoal blended product can include any of the carbonized products or properties described with reference to Figures 1A-2. For example, the carbonized product can include charcoal and / or biochar. The carbonized product, the coal-charcoal blended product, and / or the coke-charcoal blended product can have a desired ash, sulfur, calcium oxide, size, and product:fines ratio. For example, the char, the coal-charcoal blended product, and / or the coke-charcoal blended product can have: (i) 0.1%, 0.3%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, or within the range of 0.1-25%. (ii) an ash content of 0.1-9%, 3-8%, 4-6%, 5-6%, or 8%, 7%, 6%, or 5% or less; (iii) a sulfur content of 1%, 0.9%, 0.8%, 0.7%, 0.5%, 0.25%, 0.1%, 0.05%, or less, or in the range of 0.05-1%; (iv) a sulfur content of at least 60%, 65%, 70%, 75%, 78%, or 60-78%. (v) a size where at least 12%, 14%, 16%, 18%, 20%, or in the range of 12-20% of the carbonized product have a size of at least ¾ inch, or at least 6%, 8%, 10%, or in the range of 6-10% of the carbonized product have a size of ¾ inch, or a size where 80%, 85%, 90%, 95%, 99%, or in the range of 80-99% have a size of ⅛ inch or less, and / or (vi) a carbonized product:fines ratio of at least 2.0, 2.5, 3.0, 3.5, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 8.0, 9.0, 10.0, or in the range of 2.0-10.0.

[0037] In some embodiments, the carbonized product, coal-charcoal blended product, and / or coke-charcoal blended product are produced with a volatile content of at least 0.1%, 0.5%, 1%, 3%, 5%, or within a range of 0.1-5%. Additionally or alternatively, the volatile content may vary between individual carbonized products. For example, the carbonized and / or blended product may have an average volatile content of 4-6%, with a first amount of individual particles of the carbonized product containing 2% or less of volatile content, and a second amount of individual particles of the carbonized product containing at least 8% of volatile content. In another example, the carbonized and / or blended product may have an average volatile content of 1-5%, with a first amount of individual particles of the blended product containing 1% or less of volatile content, and a second amount of individual particles of the blended product containing at least 5% of volatile content.

[0038] In some embodiments, the carbonized product, the coal-charcoal blended product, and / or the coke-charcoal blended product comprises particles having an average cross-sectional dimension of about 10 mesh or at least 2 mm, 3 mm, 4 mm, or in the range of 2-4 mm (e.g., as achieved by mill 220). In some embodiments, the carbonized product, the coal-charcoal blended product, and / or the coke-charcoal blended product comprises a coked product having (i) a post-reaction coke strength (CSR) of 2%, 1%, 0.5%, 0.1% or less, or in the range of 0.1-2%, and / or (ii) a coke reactivity index (CRI) of at least 30%, 40%, 50%, 60%, or in the range of 30-60%.

[0039] Overall, the coked product of the mixed products disclosed herein can have low CSR values, high CRI values, low volatile content, low ash content, low sulfur content, and high inert content. The manufacturing process is also more efficient, producing less or minimal carbon dioxide.

[0040] III. Experimental Results 4-7 illustrate data tables corresponding to properties of a carbonized product, according to embodiments of the present technology. Referring initially to FIG. 4, the table shows values ​​of various properties of a carbonized product produced via the systems and methods described herein. As shown in FIG. 4, these properties include volatile matter (VM), total ash, total sulfur, ash initial deformation temperature, ash softening temperature, ash hemisphere temperature, and ash fluid temperature. In addition, FIG. 4 also shows the chemical composition content of the carbonized product, including aluminum oxide (Al2O3), titanium dioxide (TiO2), silicon dioxide (SiO2), magnesium oxide (MgO), calcium oxide (CaO), potassium oxide (KO), iron oxide (Fe2O3), sodium oxide (Na2O), and sulfur trioxide (SO3). FIG. 4 also shows the base number and acid number of the carbonized product, as well as the fouling index (R f ) is shown.

[0041] FIG. 5 illustrates a table containing the properties of the carbonized product or charcoal and the input materials used to produce the charcoal. For example, as shown in FIG. 5, the table includes the type of wood used (e.g., red oak, hickory, or oak), wood shape, coking time, wood moisture, charge weight, dry wood-based charcoal yield, wet wood-based charcoal yield, charcoal moisture, wet charcoal yield, dry charcoal yield, charcoal fines dry yield, charcoal fines percentage, charcoal sulfur, charcoal ash content, and charcoal VM. For each test, the wood was placed in a container and burned in an oven (e.g., oven 100, FIGS. 1A and 1B) to produce charcoal. Note that certain properties shown in the table in FIG. 5 (e.g., coking time, charge weight, unloaded material weight, and uncoked wood weight) apply only to the test and not to actual production. For example, the coking time for a fully loaded oven may be approximately 24 hours instead of the 4-7 hours shown in the table, or the load weight may be higher. FIG. 6 illustrates a table containing the characteristics of at least ½ inch char products, and FIG. 7 illustrates a table containing the size distributions (e.g., ½ inch, ¾ inch, 1 inch, 2 inches, 3 inches+) for each box text shown in FIGS. 5 and 6.

[0042] Figure 8A illustrates split logs packed in a container heated in a combustion oven, and Figures 8B and 8C are carbonized products produced through the feedstock of Figure 8A. The container is approximately 3 feet x 3 feet x 2 and has a cover that restricts air intrusion when processed in the oven. During operation, the split logs were loaded into a container containing multiple thermocouples for monitoring the temperature during devolatilization within the oven. Once devolatilization was complete and no more smoke was coming out of the container, the container was removed from the oven and cooled. Once removed, a cover (as shown in Figures 9B - 9D) was placed over the container to prevent air intrusion and the container was cooled for at least 24 hours.

[0043] Figures 9A - 9D illustrate carbonized products formed through a devolatilization oven according to an embodiment of the present technology. Figure 9A is an image of a container 905 loaded with a carbonaceous feedstock. The container 905 is shown within the devolatilization oven and positioned relative to the oven door. The container 905 was heated within the oven until the carbonaceous feedstock was devolatilized and converted to charcoal. Figure 9B is an image of the container 905 removed from the oven after devolatilization before the charcoal in the container 905 has been cooled for at least 24 hours. Figure 9C is an image of a cover 915 placed over the container 905 to prevent air intrusion into the container 905, and Figure 9D is an image of the cover 915 disposed over the container 905.

[0044] IV. Conclusion It will be apparent to those skilled in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the present disclosure. In some instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of embodiments of the present technology. Although method steps may be presented herein in a particular order, in alternative embodiments, the steps may be performed in a different order. Similarly, certain aspects of the present technology disclosed in the context of certain embodiments may be combined or eliminated in other embodiments. Furthermore, while advantages associated with certain embodiments of the presently disclosed technology may be disclosed in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments necessarily need to exhibit such advantages or other advantages disclosed herein to fall within the scope of the present technology. Thus, the present disclosure and related technology may encompass other embodiments not expressly shown or described herein, and the present invention is not limited except as by the appended claims.

[0045] Throughout this disclosure, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Additionally, the terms "comprising," "including," and "having" should be interpreted as meaning the inclusion of at least the recited feature(s), so as not to exclude any more of the same features and / or additional types of features.

[0046] References herein to "one embodiment," "an embodiment," "some embodiments," or similar formulations mean that a particular feature, structure, operation, or characteristic described in connection with an embodiment may be included in at least one embodiment of the technology. Thus, appearances of such phrases or formulations herein are not necessarily all referring to the same embodiment. Furthermore, various particular features, structures, operations, or characteristics may be combined in any suitable manner in one or more embodiments.

[0047] Unless otherwise indicated, all numerical values ​​expressing temperature, composition, and other values ​​used in the specification and claims should be understood to be modified in all instances by the term "about." Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and appended claims are approximations that may vary depending on the desired properties sought to be obtained by the technology. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter should be construed in light of the number of reported significant digits by applying ordinary rounding techniques. Additionally, all ranges disclosed herein should be understood to encompass any and all subranges subsumed therein. For example, a range "1 to 10" includes any and all subranges between (and including) a minimum value of 1 and a maximum value of 10, i.e., any and all subranges with a minimum value of 1 or more and a maximum value of 10 or less, e.g., 5.5 to 10.

[0048] The foregoing disclosure is not to be interpreted as reflecting an intention that any claim requires more features than are expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. As such, the claims following this Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment. The present disclosure includes all permutations of independent claims with their dependent claims.

[0049] The present technology is described according to various aspects, which are described below as numbered clauses (1, 2, 3, etc.) for convenience. These are provided as examples and are not intended to limit the present technology. Note that any of the dependent clauses may be combined in any combination and each may be placed into an independent clause. Other clauses may be presented similarly. 1. A method for producing a carbonized product, comprising: receiving a charge material in an oven; and heating the oven containing the input material to a predetermined temperature of at least 900°F for a predetermined time period of not more than 48 hours to produce a carbonized product. 2. The method of any one of the clauses herein, wherein the input material comprises at least one of a carbonaceous feedstock, a non-metallic feedstock, or a metal-containing feedstock. 3. The method of any one of the clauses herein, wherein the input material comprises mineral raw materials or metalliferous raw materials, including recycled metalliferous materials. 4. The method of any one of the clauses herein, wherein the input material comprises iron fines. 5. The method of any one of the clauses herein, wherein the input material comprises an additive comprising calcium (e.g., calcium oxide or lime, calcium sulfate, etc.), sodium (e.g., sodium hydroxide), and / or clay. 6. The method of any one of the clauses herein, wherein at least a portion of the input material has a minimum cross-sectional dimension of at least 2 inches, 3 inches, 4 inches, 5 inches, or 6 inches. 7. The method of any one of the clauses herein, wherein the input material has an input moisture content of at least 10%, 12%, 14%, 16%, 18%, 20%, 22%, 24%, 26%, 28%, 30%, 40%, 50%, or in the range of 10-50%. 8. The method of any one of the clauses herein, wherein the wood comprises logs having an average cross-sectional diameter or dimension of at least 2 inches, 4 inches, 6 inches, 8 inches, 10 inches, 12 inches, 14 inches, 16 inches, 18 inches, 20 inches, 22 inches, 24 inches, or within the range of 2 to 24 inches. 9. The method of any one of the clauses herein, wherein the predetermined time is 46 hours, 44 hours, 42 hours, 40 hours, 38 hours, 36 hours, 34 hours, 32 hours, 30 hours, 28 hours, 26 hours, 24 hours, 22 hours, 20 hours, 18 hours, 16 hours, 14 hours or less, or in the range of 14 to 46 hours. 10. The method of any one of the clauses herein, wherein the predetermined temperature is at least 950°F, 1000°F, 1050°F, 1100°F, 1150°F, 1200°F, 1250°F, 1300°F, 1400°F, 1500°F, 1750°F, 2000°F, 2250°F, 2500°F, 2800°F, or within the range of 950-2800°F. 11. The method of any one of the clauses herein, wherein the predetermined temperature is within the range of 1150-1300 degrees Fahrenheit, 1200-1300 degrees Fahrenheit, or 1200-1250 degrees Fahrenheit. 12. The method of any one of the clauses herein, wherein the carbonized product comprises charcoal and the input material comprises wood. 13. The method of any one of the clauses herein, wherein the carbonized product comprises charcoal and the input material comprises at least one of oak, red oak, hickory, or spruce. 14. The method of any one of the clauses herein, wherein the carbonized product comprises charcoal and the input material comprises at least one of logs and / or split wood. 15. The method of any one of the clauses herein, wherein the carbonized product comprises biochar and the input material comprises biomass. 16. The method of any one of the clauses herein, wherein the input material comprises wood, the carbonized product comprises charcoal, and the ratio of charcoal to wood is at least 20%, 22%, 24%, 26%, 28%, 30%, or in the range of 20-30%. 17. The method of any one of the clauses herein, wherein the carbonized product comprises a volatile content of at least 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, or in the range of 1-25%. 18. The method of any one of the clauses herein, wherein the carbonized product comprises an average volatile content of 4-6%, a first amount of individual particles of the carbonized product comprises 2% or less volatile content, and a second amount of individual particles of the carbonized product comprises at least 8% volatile content. 19. The method of any one of the clauses herein, wherein the carbonized product comprises a volatile content of 5%, 4%, 3%, 2% or less, or in the range of 2-5%. 20. The method of any one of the clauses herein, wherein the carbonized product comprises 3-8%, 4-6%, or 5-6% ash. 21. The method of any one of the clauses herein, wherein the carbonized product contains no more than 8%, 7%, 6%, or 5% ash. 22. The method of any one of the clauses herein, wherein the ash of the carbonized product contains no more than 0.5%, 0.25%, 0.1%, or 0.05% sulfur. 23. The method of any one of the clauses herein, wherein the ash of the carbonized product comprises at least 60%, 65%, 70%, 75%, or 78% calcium oxide. 24. The method of any one of the clauses herein, wherein at least 12%, 14%, 16%, 18%, 20%, or in the range of 12-20% of the carbonized product has a size of at least 3 / 4 inch. 25. The method of any one of the clauses herein, wherein at least 6%, 8%, 10%, or in the range of 6-10% of the carbonized product comprises fines less than 3 / 4 inch in size. 26. The method of any one of the clauses herein, wherein the carbonized product comprises a charcoal to fines ratio of at least 2.0, 2.5, 3.0, 3.5, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 8.0, 9.0, 10.0, or in the range of 2.0 to 10.0. 27. The method of any one of the clauses herein, wherein receiving the input material comprises receiving an at least partially sealed container containing the input material therein. 28. The method of clause 25, further comprising cooling the partially sealed container and / or carbonized product in the oven to below 120°F. 29. The method of any one of the clauses herein, further comprising: (i) fluidly separating the carbonized product from oxygen; and (ii) cooling the partially sealed container and / or the carbonized product to 120 degrees Fahrenheit or less while the carbonized product is fluidly separated. 30. A system for producing carbon, comprising: The system includes an oven configured to receive a carbonaceous input material and to be heated to a predetermined temperature of at least 900 degrees Fahrenheit for a predetermined time period of 48 hours or less to produce a carbonized product. 31. The system of any one of the clauses herein, wherein the input material comprises at least one of a carbonaceous feedstock, a non-metallic feedstock, or a metal-containing feedstock. 32. A system according to any one of the clauses herein, wherein the input material comprises mineral raw materials or metalliferous raw materials, including recycled metalliferous materials. 33. A system as described in any one of the clauses herein, wherein the input material comprises iron fines. 34. The system of any one of the clauses herein, wherein the input material includes an additive comprising calcium (e.g., calcium oxide or lime, calcium sulfate, etc.), sodium (e.g., sodium hydroxide), and / or clay. 35. A system described in any one of the clauses herein, wherein at least a portion of the input material has a minimum cross-sectional dimension of at least 2 inches, 3 inches, 4 inches, 5 inches, or 6 inches. 36. The system of any one of the clauses herein, wherein the input material has an input moisture content of at least 10%, 12%, 14%, 16%, 18%, 20%, 22%, 24%, 26%, 28%, 30%, 40%, 50%, or within the range of 10-50%. 37. The system of any one of the clauses herein, wherein the timber comprises logs having an average cross-sectional diameter or dimension of at least 2 inches, 4 inches, 6 inches, 8 inches, 10 inches, 12 inches, 14 inches, 16 inches, 18 inches, 20 inches, 22 inches, 24 inches, or within the range of 2 to 24 inches. 38. A system described in any one of the clauses herein, wherein the predetermined time is 46 hours, 44 hours, 42 hours, 40 hours, 38 hours, 36 hours, 34 hours, 32 hours, 30 hours, 28 hours, 26 hours, 24 hours, 22 hours, 20 hours, 18 hours, 16 hours, 14 hours or less, or in the range of 14 to 46 hours. 39. A system as described in any one of the clauses herein, wherein the predetermined temperature is at least 950°F, 1000°F, 1050°F, 1100°F, 1150°F, 1200°F, 1250°F, 1300°F, 1400°F, 1500°F, 1750°F, 2000°F, 2250°F, 2500°F, 2800°F, or within the range of 950-2800°F. 40. A system as described in any one of the clauses herein, wherein the predetermined temperature is within the range of 1150-1300 degrees Fahrenheit, 1200-1300 degrees Fahrenheit, or 1200-1250 degrees Fahrenheit. 41. A system described in any one of the clauses herein, wherein the carbonized product comprises charcoal and the input material comprises wood. 42. The system of any one of the clauses herein, wherein the carbonized product comprises charcoal and the input material comprises at least one of oak, red oak, hickory, and spruce. 43. A system described in any one of the clauses herein, wherein the carbonized product comprises charcoal and the input material comprises at least one of logs and / or split wood. 44. The system of any one of the clauses herein, wherein the carbonized product comprises biochar and the input material comprises biomass. 45. A system described in any one of the clauses herein, wherein the input material comprises wood, the carbonized product comprises charcoal, and the ratio of charcoal to wood is at least 20%, 22%, 24%, 26%, 28%, 30%, or within the range of 20-30%. 46. ​​The system of any one of the clauses herein, wherein the carbonized product comprises a volatile content of at least 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, or in the range of 1-25%. 47. The system of any one of the clauses herein, wherein the carbonized product comprises an average volatile content of 4-6%, a first amount of individual particles of the carbonized product comprises 2% or less volatile content, and a second amount of individual particles of the carbonized product comprises at least 8% volatile content. 48. A system described in any one of the clauses herein, wherein the carbonized product comprises a volatile content of 5%, 4%, 3%, 2% or less, or in the range of 2-5%. 49. The system of any one of the clauses herein, wherein the carbonized product comprises 3-8%, 4-6%, or 5-6% ash. 50. A system described in any one of the clauses herein, wherein the carbonized product comprises no more than 8%, 7%, 6%, or 5% ash. 51. A system described in any one of the clauses herein, wherein the ash of the carbonization product contains no more than 0.5%, 0.25%, 0.1%, or 0.05% sulfur. 52. A system described in any one of the clauses herein, wherein the ash of the carbonization product comprises at least 60%, 65%, 70%, 75%, or 78% calcium oxide. 53. A system described in any one of the clauses herein, wherein at least 12%, 14%, 16%, 18%, 20%, or in the range of 12-20% of the carbonized product has a size of at least 3 / 4 inch. 54. A system described in any one of the clauses herein, wherein at least 6%, 8%, 10%, or in the range of 6-10% of the carbonized product comprises fines less than 3 / 4 inch in size. 55. The system of any one of the clauses herein, wherein the carbonized product comprises a charcoal to fines ratio of at least 2.0, 2.5, 3.0, 3.5, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 8.0, 9.0, 10.0, or in the range of 2.0 to 10.0. 56. Carbonized products, charcoal and / or biochar; a volatile content in the range of 2-15%; 3-8% ash content and and a sulfur content of 0.25% or less. 57. A carbonized product according to any one of the clauses herein, wherein the carbonized product comprises charcoal or biochar. 58. A carbonized product according to any one of the clauses herein, wherein the carbonized product comprises a volatile content of at least 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, or in the range of 1-25%. 59. A carbonized product described in any one of the clauses herein, wherein the carbonized product has an average volatile content of 4-6%, a first amount of individual particles of the carbonized product has a volatile content of 2% or less, and a second amount of individual particles of the carbonized product has a volatile content of at least 8%. 60. A carbonized product according to any one of the clauses herein, wherein the carbonized product comprises a volatile content of 5%, 4%, 3%, 2% or less, or in the range of 2-5%. 61. A carbonized product according to any one of the clauses herein, wherein the carbonized product comprises 3-8%, 4-6%, or 5-6% ash. 62. A carbonized product according to any one of the clauses herein, wherein the carbonized product contains no more than 8%, 7%, 6%, or 5% ash. 63. A carbonized product according to any one of the clauses herein, wherein the ash of the carbonized product contains no more than 0.5%, 0.25%, 0.1%, or 0.05% sulfur. 64. A carbonized product described in any one of the clauses herein, wherein the ash of the carbonized product comprises at least 60%, 65%, 70%, 75%, or 78% calcium oxide. 65. A carbonized product described in any one of the clauses herein, wherein at least 12%, 14%, 16%, 18%, 20%, or in the range of 12-20% of the carbonized product has a size of at least 3 / 4 inch. 66. A carbonized product described in any one of the clauses herein, wherein at least 6%, 8%, 10%, or in the range of 6-10% of the carbonized product contains fines less than 3 / 4 inch in size. 67. A carbonized product according to any one of the clauses herein, wherein the carbonized product comprises a charcoal to fines ratio of at least 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 8.0, 9.0, 10.0, or in the range of 2.0 to 10.0. 68. Coal-charcoal blended products, Coal blending, a carbonized product made from input material heated to a predetermined temperature of at least 900 degrees Fahrenheit for a predetermined time of 48 hours or less. 69. A mixed product described in any one of the clauses herein, wherein the mass ratio of the carbonized product is at least 1%, 2%, 3%, 4%, 5%, 10%, 15%, or in the range of 1 to 15%. 70. A mixed product described in any one of the clauses herein, wherein the mass ratio of the carbonized product is at least 15%, 20%, 25%, 30%, or in the range of 15-30%. 71. A mixture product described in any one of the clauses herein, wherein the mixture product comprises a volatile content of at least 0.1%, 0.5%, 1%, 3%, 5%, or in the range of 0.1 to 5%. 72. A blended product according to any one of the clauses herein, wherein the blended product contains an ash content of 9%, 8%, 7%, 6%, 5%, 1%, 0.5%, 0.3%, 0.2%, 0.1% or less, or in the range of 0.1 to 9%. 73. A blended product according to any one of the clauses herein, wherein the blended product has a sulfur content of 1%, 0.9%, 0.8%, 0.7%, 0.5%, 0.25%, 0.1%, 0.05% or less, or in the range of 0.05 to 1%. 74. A mixed product described in any one of the clauses herein, wherein the ash of the carbonized product contains calcium oxide at least 60%, 65%, 70%, 75%, 78%, or in the range of 60-78%. 75. A mixed product described in any one of the clauses herein, wherein the carbonized product comprises particles having an average cross-sectional dimension of at least 2 mm, 3 mm, 4 mm, or in the range of 2 to 4 mm. 76. A mixed product according to any one of the clauses herein, wherein the input materials are heated in a heat recovery oven. 77. The blended product of any one of the clauses herein, further comprising a second coal blend, wherein the coal blend and the second coal blend have different volatile mass fractions. 78. A coke-charcoal mixed product, said mixed product comprising: a coking product made from the coal blend heated in an oven; and a double carbonized product made from a carbonized product heated in the oven with the coal blend, wherein the carbonized product is made from input materials heated to a predetermined temperature of at least 900 degrees Fahrenheit for a predetermined time period of 48 hours or less. 79. A blended product according to any one of the clauses herein, wherein the coked product has a post-reaction coke strength (CSR) of 2%, 1%, 0.5%, 0.1% or less, or in the range of 0.1 to 2%. 80. A blended product according to any one of the clauses herein, wherein the coked product has a coke reactivity index (CRI) of at least 30%, 40%, 50%, 60%, or in the range of 30-60%. 81. A mixed product according to any one of the clauses herein, wherein the coking product comprises foundry coke. 82. A mixed product described in any one of the clauses herein, wherein the carbonized product comprises charcoal or biochar. 83. A blended product according to any one of the clauses herein, wherein the coked product has an average volatile content of 0.1 to 1%, a first amount of individual particles of the blended product has a volatile content of 0.1% or less, and a second amount of individual particles of the blended product has a volatile content of at least 0.5%. 84. A mixed product described in any one of the clauses herein, wherein at least 12%, 14%, 16%, 18%, 20%, or in the range of 12 to 20% of the carbonized product has a size of at least 1 / 8 inch. 85. A mixed product described in any one of the clauses herein, wherein at least 80%, 85%, 90%, 95%, 99%, or in the range of 80-99%, of the carbonized product has a size of 1 / 8 inch or less. 86. A system for producing a coal-charcoal blend product, comprising: an oven configured to receive a carbonaceous input material and to be heated to a predetermined temperature of at least 900°F for a predetermined time period of not more than 48 hours to produce a carbonized product; a mixing assembly configured to receive and mix the carbonized product and a coal blend from the oven to form the coal-charcoal blend product. 87. The system of any one of the clauses herein, wherein the input material comprises at least one of a carbonaceous feedstock, a non-metallic feedstock, or a metal-containing feedstock. 88. A system as described in any one of the clauses herein, wherein the input material comprises logs having an average cross-sectional diameter or dimension of at least 2 inches, 4 inches, 6 inches, 8 inches, 10 inches, 12 inches, 14 inches, 16 inches, 18 inches, 20 inches, 22 inches, 24 inches, or within the range of 2 to 24 inches. 89. A system described in any one of the clauses herein, wherein at least a portion of the input material has a minimum cross-sectional dimension of at least 2 inches, 3 inches, 4 inches, 5 inches, 6 inches, or within the range of 2 to 6 inches. 90. A system described in any one of the clauses herein, wherein the input material has an input moisture content of at least 10%, 12%, 14%, 16%, 18%, 20%, 22%, 24%, 26%, 28%, 30%, 40%, 50%, or within the range of 10-50%. 91. A system described in any one of the clauses herein, wherein the carbonized product comprises charcoal and the input material comprises wood. 92. The system of any one of the clauses herein, wherein the carbonized product comprises biochar and the input material comprises biomass. 93. The system of any one of the clauses herein, wherein the oven is further configured to receive the coal-charcoal mixed product and heat it to a second predetermined temperature of at least 900 degrees Fahrenheit for a second predetermined time period of not more than 48 hours to produce a coke-charcoal mixed product. 94. The system of any one of the clauses herein, further comprising a grinder or mill configured to reduce the size of the input material before the oven receives the input material. 95. A method for producing a coal-charcoal blend product, comprising: receiving a charge material in an oven; heating the oven containing the input material to a predetermined temperature of at least 900°F for a predetermined time period of not more than 48 hours to produce a carbonized product; and mixing the carbonized product from the oven and a coal blend to form the coal-char mixed product. 96. The method of any one of the clauses herein, wherein the predetermined temperature is within the range of 1150-1300 degrees Fahrenheit, 1200-1300 degrees Fahrenheit, or 1200-1250 degrees Fahrenheit. 97. The method of any one of the clauses herein, wherein the input material comprises an additive comprising calcium, sodium, and / or clay. 98. The method of any one of the clauses herein, wherein the predetermined time is 46 hours, 44 hours, 42 hours, 40 hours, 38 hours, 36 hours, 34 hours, 32 hours, 30 hours, 28 hours, 26 hours, 24 hours, 22 hours, 20 hours, 18 hours, 16 hours, 14 hours or less, or in the range of 14 to 46 hours. 99. The method of any one of the clauses herein, wherein receiving the input material in the oven includes receiving an at least partially sealed container containing the input material therein. 100. The method of any one of the clauses herein, further comprising cooling the at least partially sealed container and / or the carbonized product in the oven to 120°F or less. 101. fluidly separating the carbonized product from oxygen; The method of any one of the clauses herein, further comprising cooling the at least partially sealed container and / or the carbonized product in an oven to 120 degrees Fahrenheit or less while the carbonized product is fluidly separated. 102. receiving the coal-charcoal mixture product in the oven; The method of any one of the clauses herein, further comprising heating the oven containing the coal-charcoal mixed product to a second predetermined temperature of at least 900°F for a second predetermined time period of not more than 48 hours to produce a coke-charcoal mixed composition.

Claims

1. 1. A coal-charcoal blend product configured to be processed in an oven, comprising: Coal blending, a carbonized product, wherein the size of individual particles of the carbonized product is equal to or smaller than the size of individual coals of the coal blend; A coal-charcoal mixed product comprising:

2. 2. The mixed product of claim 1, wherein the mass ratio of the carbonized product is at least 10%.

3. 10. The blended product of claim 1, wherein the carbonized product comprises at least 1% volatiles.

4. 10. The blended product of claim 1, wherein the blended product comprises an ash content in the range of 0.1 to 9%.

5. 10. The blended product of claim 1, wherein the blended product has a sulfur content in the range of 0.05 to 1%.

6. 10. The mixed product of claim 1, wherein the ash of the carbonized product comprises at least 60% calcium oxide.

7. 10. The blended product of claim 1, wherein the carbonized product comprises individual particles having an average cross-sectional dimension of 3 mm or less.

8. 10. The mixed product of claim 1, wherein the carbonized product is made from input materials that are heated to a predetermined temperature of at least 900 degrees Fahrenheit for a predetermined time period of 48 hours or less.

9. 9. The mixed product of claim 8, wherein the input materials are heated in a heat recovery oven.

10. 10. The mixed product of claim 1, wherein the coal blend is a first coal blend and the mixed product further comprises a second coal blend, the first coal blend having a first volatile mass fraction and the second coal blend having a second volatile mass fraction different from the first volatile mass fraction.

11. A coke-charcoal mixed product, said mixed product comprising: a coking product made from the coal blend heated in an oven; a double carbonized product made from a carbonized product heated in the oven with the coal blend, the double carbonized product being made from input materials heated to a predetermined temperature of at least 900°F for a predetermined time period of 48 hours or less; 1. A coke-charcoal mixed product comprising:

12. 12. The mixed product of claim 11, wherein the coked product comprises at least 0.1% volatiles.

13. 12. The mixed product of claim 11, wherein the coked product has a post-reacted coke strength (CSR) of 12% or less.

14. 12. The mixed product of claim 11, wherein the coked product has a coke reactivity index (CRI) of at least 30%.

15. 12. The mixed product of claim 11, wherein the coking product comprises foundry coke.

16. 12. The mixed product of claim 11, wherein the carbonized product comprises charcoal or biochar.

17. 12. The blended product of claim 11, wherein the blended product comprises an average volatile content of 0.1 to 1%, a first amount of individual particles of the blended product comprises 0.1% or less of a volatile content, and a second amount of individual particles of the blended product comprises at least 0.5% of a volatile content.

18. 12. The blended product of claim 11, wherein at least 10% of the carbonized product has a size of at least 1 / 8 inch.

19. 12. The mixed product of claim 11, wherein at least 90% of the carbonized product has a size of 1 / 8 inch or less.

20. 1. A system for producing a coal-charcoal blend product, comprising: an oven configured to receive a carbonaceous input material and to be heated to a predetermined temperature of at least 900°F for a predetermined time period of 48 hours or less to produce a carbonized product; a mixing assembly configured to receive and mix the carbonized product and the coal blend from the oven to form the coal-charcoal mixed product; A system comprising:

21. 21. The system of claim 20, wherein the input material comprises logs having an average cross-sectional diameter or dimension of at least 2 inches.

22. 21. The system of claim 20, wherein at least a portion of the input material has a minimum cross-sectional dimension of at least 2 inches.

23. 21. The system of claim 20, wherein the input material has an input moisture content in the range of 10 to 50%.

24. 1. A method for producing a coal-charcoal blend product, comprising: receiving a charge material in an oven; heating the oven containing the input material to a predetermined temperature of at least 900°F for a predetermined time period of not more than 48 hours to produce a carbonized product; mixing the carbonized product from the oven and a coal blend to form the coal-char mixed product; A method comprising:

25. 25. The method of claim 24, wherein the predetermined temperature is in the range of 1150 to 1300 degrees Fahrenheit.

26. 25. The method of claim 24, wherein the input material includes an additive comprising calcium, sodium, and / or clay.

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