BIO-DERIVED POROUS CARBON SILICON DIOXIDE COMPOSITIONS AND METHODS OF MAKING AND USING SAME - Patent application

Abstract

In various embodiments, the present disclosure provides bioporous carbon dioxide compositions and methods of making and using same. [Selected Figure] Figure 1

Description

[Technical field]

[0001] Claiming priority This application claims priority to U.S. Provisional Patent Application No. 62 / 685,126, filed June 14, 2018, the entire contents of which are incorporated herein by reference.

[0002] This disclosure generally relates to Origin The present invention relates to porous carbon silicon dioxide compositions and methods of making and using same. [Background technology]

[0003] raw Origin The use of porous carbon silicon dioxide compositions reduces the non-renewable energy required for silicon production. Drugs These have the potential to reduce the use and environmental impact of Origin The use of the porous carbon silicon dioxide compositions also has the potential to increase throughput, reduce energy usage, extend electrode life, produce higher purity silicon, allow the use of small sized silicon dioxide (quartz) in typical electric arc and submerged arc furnaces, and allow the recycling of silica fume, thereby improving the production of silicon. Such compositions, as well as methods of making and using, are disclosed herein. Summary of the Invention

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

[0005] Provided herein is a high carbon composition comprising silicon dioxide. The composition can comprise, on a dry basis, at least about 50% by weight total carbon, up to about 5% by weight hydrogen, up to about 1% by weight nitrogen, up to about 0.5% by weight phosphorus, up to about 0.2% by weight sulfur, up to about 0.02% by weight titanium, up to about 0.5% by weight calcium, up to about 0.1% by weight aluminum, and silicon dioxide.

[0006] The composition can include, on a dry basis, at least about 50% by weight total carbon, up to about 5% by weight hydrogen, up to about 1% by weight nitrogen, up to about 0.5% by weight phosphorus, up to about 0.2% by weight sulfur, up to about 0.02% by weight titanium, up to about 0.5% by weight calcium, up to about 0.1% by weight aluminum, and silicon dioxide, which can be included within river rock.

[0007] The composition can include, on a dry basis, at least about 50% by weight total carbon, up to about 5% by weight hydrogen, up to about 1% by weight nitrogen, up to about 0.5% by weight phosphorus, up to about 0.2% by weight sulfur, up to about 0.02% by weight titanium, up to about 0.5% by weight calcium, up to about 0.1% by weight aluminum, and silicon dioxide, which can be included within silica fume.

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

[0009] The composition can comprise at least about 1% by weight, at least about 5% by weight, at least about 10% by weight, at least about 15% by weight, at least about 20% by weight, or at least about 25% by weight silicon dioxide.

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

[0011] In some embodiments, the composition is extruded. In some embodiments, the composition is extruded to form pellets. In some embodiments, the composition is extruded to improve the density of the composition, mix carbon and silicon dioxide, improve the combined product density, thereby making the composition "sink" in an electric arc furnace, or to make the exterior of the composition water-resistant and dust-resistant to improve the usage and improve the efficiency of the furnace.

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

[0013] In some embodiments, the composition has dimensions of at least about 0.64 cm (0.25 inches) by about 2.5 cm (1.0 inches) and up to about 5.1 cm (2.0 inches) by about 15 cm (6.0 inches).

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

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

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

[0017] The composition comprises a high carbon, carbide, or carbide-based, composition comprising, on a dry basis, at least about 50% by weight total carbon, up to about 5% by weight hydrogen, up to about 1% by weight nitrogen, up to about 0.5% by weight phosphorus, up to about 0.2% by weight sulfur, up to about 0.02% by weight titanium, up to about 0.5% by weight calcium, up to about 0.1% by weight aluminum, and at least about 15% by weight silicon dioxide. DrugsThe composition may include, the silicon dioxide may be contained within river rock, the composition may be densified and formed into a pellet shape with dimensions of about 0.64 cm (0.25 in) by about 2.5 cm (1.0 in), and may have a mass of about 560 kg / m 3 (35 lbs / ft3) ~ approx. 720 kg / m 3 (45 pounds per cubic foot).

[0018] The composition comprises a high carbon, carbide, or carbide-based, composition comprising, on a dry basis, at least about 50% by weight total carbon, up to about 5% by weight hydrogen, up to about 1% by weight nitrogen, up to about 0.5% by weight phosphorus, up to about 0.2% by weight sulfur, up to about 0.02% by weight titanium, up to about 0.5% by weight calcium, up to about 0.1% by weight aluminum, and at least about 15% by weight silicon dioxide. Drugs The composition may include, where the silicon dioxide may be contained within a silica fume, the composition may be densified and formed into a pellet shape with dimensions of about 0.64 cm (0.25 in) by about 2.5 cm (1.0 in), and may have a mass fraction of about 560 kg / m 3 (35 lbs / ft3) ~ approx. 720 kg / m 3 (45 pounds per cubic foot).

[0019] Provided herein is a method for producing high carbon Drugs derived fromThe process includes providing a carbon-containing feedstock comprising dried biomass, preheating the feedstock in a preheating zone in the presence of a substantially inert gas for at least about 5 minutes and at a preheating temperature selected from about 80° C. to about 500° C., pyrolyzing the feedstock in a pyrolysis zone in the presence of a substantially inert gas for at least about 10 minutes and at a pyrolysis temperature selected from about 250° C. to about 700° C. to produce hot pyrolyzed solids, condensable vapors, and non-condensable gases, separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids, cooling the hot pyrolyzed solids in a cooling zone in the presence of a substantially inert gas for at least about 5 minutes and at a cooling temperature lower than the pyrolysis temperature to produce warm pyrolyzed solids, cooling the warm pyrolyzed solids in a cooler separate from the cooling zone to produce low temperature pyrolyzed solids, and producing a high carbon product comprising at least a portion of the low temperature pyrolyzed solids. Drugs derived from and recovering the silicon dioxide source, and the process further comprises introducing a silicon dioxide source into the process.

[0020] In some embodiments, the process further comprises drying the feedstock to remove at least a portion of the moisture contained within the feedstock.

[0021] In some embodiments, the process includes degassing the feedstock or dry feedstock to remove any residual gases, if any, contained within the feedstock. Inside the gap Further comprising removing at least a portion of the oxygen.

[0022] In some embodiments, the process further comprises further cooling the warm pyrolyzed solids in a cooler separate from the cooling zone to produce lower temperature pyrolyzed solids.

[0023] In some embodiments, the process further comprises introducing a silicon dioxide source into the low temperature pyrolyzed solids. In some embodiments, the process further comprises introducing a silicon dioxide source into the feedstock prior to pyrolysis.

[0024] In some embodiments, introducing the silicon dioxide source comprises introducing silica fume. In some embodiments, introducing the silicon dioxide comprises introducing river rock. In some embodiments, the particle size of the silicon dioxide source, whether river rock or silica fume, can be from about 0.01 mm to about 12 mm. In some embodiments, the particle size can be from about 0.01 mm to about 12 mm in increments of about 0.05 mm.

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

[0026] In some embodiments, high density The transformation , using an additive to improve densification, mixing the additive, carbon, and silicon dioxide, extruding the mixture through a die to thereby produce pellets, and optionally drying the pellets.

[0027] In some embodiments, densification can include optionally using an additive, such as bentonite, to improve densification in about 0.5% increments from about 0.5% to about 15%, optionally adding water, for example, from about 5% to about 50%, mixing the additive, carbon, and silicon dioxide, extruding the mixture through a die thereby producing pellets, optionally heating or cooling the extruder and / or die plate to improve densification, optionally venting the extruder, and optionally drying the pellets.

[0028] In some embodiments, the process includes a high carbon production Drugs derived from further comprising compressing, bonding, pelletizing, extruding, or agglomerating the mixture. [Brief description of the drawings]

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0045] This description enables a person skilled in the art to make and use the disclosure and describes several embodiments, adaptations, variations, alternatives, and uses of the disclosure. These and other embodiments, features, and advantages of the disclosure will become more apparent to those skilled in the art upon reference to the following detailed description of the disclosure in conjunction with the accompanying drawings.

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

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

[0048] As used herein, the term "biomass" refers to any living Origin Raw or raw Origin Raw materials and non-raw materials Origin The term "biomass" refers to a mixture of biomass and feedstock. Essentially, biomass contains at least carbon, hydrogen, and oxygen. The disclosed method and apparatus can accommodate a wide range of feedstocks of various types, sizes, and moisture contents.

[0049] As used herein, the term "activation" refers to any of a variety of processes by which the pore structure is strengthened.

[0050] As used herein, the phrase "porous carbon" describes, in various embodiments, materials that can be produced by the processes and systems of the present disclosure. Any limitations on carbon content or any other concentration are to be ascribed only by reference to specific embodiments and their equivalents, and not from the term itself. For example, starting materials with very low initial carbon content that are subjected to the disclosed processes may produce products that are highly enriched in carbon relative to the starting material (high yield of carbon), but that are nevertheless relatively low in carbon (low purity carbon), containing about 50% or less carbon by weight. Origin It will be appreciated that porous carbon may be produced.

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

[0052] As used herein, " Drugs " is intended to mean material in its broadest sense, Drugs can be, for example, a fuel, a chemical, a material, a compound, an additive, a blend component, a solvent. Drugs does not necessarily mean that a chemical reaction occurs or that it is involved in a chemical reaction. Drugs It doesn't have to be. Drugs may or may not be a chemical reactant and may or may not be consumed in the reaction. Drugs can be a chemical catalyst for certain reactions. Drugs teeth, Drugs can cause or participate in the modification of the mechanical, physical, or rheological properties of the material to which they can be added. For example, Drugs can be introduced into metals to give them specific strength properties. Drugs is of sufficient purity ( Context of the Specification In the case of , it can be a material of typically carbon purity.

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

[0054] As used herein, the term "reactor" refers to a discrete unit in which atmospheric and temperature conditions can be controlled and in which physical and / or chemical reactions can take place.

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

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

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

[0058] As used herein, when the indefinite article "a" or "an" is used in connection with a statement or description of the presence of a step in a process disclosed herein, such indefinite article does not limit the presence of the step in the process to one, unless the statement or description explicitly provides to the contrary. As used herein, when an amount, concentration, or other value or parameter is given as either a range, a preferred range, or a list of upper preferred values ​​and lower preferred values, this should be understood as specifically disclosing all ranges formed from any pair of any upper or preferred value and any lower or preferred value, regardless of whether the ranges are individually disclosed.

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

[0060] As used herein, the terms "comprising" and "including," or grammatical variations thereof, are deemed to specify the inclusion of the recited features, integers, actions, or components without excluding the addition of one or more additional features, integers, actions, components, or groups thereof. For example, a composition, mixture, process, method, article, or apparatus that includes a list of elements is not necessarily limited to only those elements, but may include other elements not expressly listed or inherent in such composition, mixture, process, method, article, or apparatus. "Comprising" is broader than and includes the terms "consisting of" and "consisting essentially of," as defined in the U.S. Patent and Trademark Office Manual of Patent Examining Procedures. Additionally, unless expressly stated to the contrary, "or" refers to an inclusive or and not an exclusive or.

[0061] Unless otherwise indicated, all numerical values ​​expressing reaction conditions, stoichiometries, concentrations of ingredients, and the like used in the specification and claims are to be understood as being 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, at least on particular analytical techniques.

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

[0063] The composition can comprise, on a dry basis, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 90%, or at least about 95% total carbon, up to about 5% hydrogen, up to about 1% nitrogen, up to about 0.5% phosphorus, up to about 0.2% sulfur, up to about 0.02% titanium, up to about 0.5% calcium, up to about 0.1% aluminum, and at least about 1%, at least about 5%, at least about 10%, at least about 15%, at least about 20%, or at least about 25% silicon dioxide.

[0064] The composition has, on a dry basis, at least about 50% by weight total carbon, at most about 5% by weight hydrogen, at most about 1% by weight nitrogen, at most about 0.5% by weight phosphorus, at most about 0.2% by weight sulfur, at most about 0.02% by weight titanium, at most about 0. 5% of calcium, up to about 0. 1% of aluminum, and at least about 15% by weight of silicon dioxide, the silicon dioxide being contained within river rock, the composition being densified and in the form of pellets having dimensions of at least about 0.64 cm (0.25 in) by about 2.5 cm (1.0 in), and having a mass fraction of about 560 kg / m 3 (35 lbs / ft3) ~ approx. 720 kg / m 3 (45 pounds per cubic foot).

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

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

[0067] The composition can comprise at least about 1% by weight, at least 5% by weight, at least about 10% by weight, at least about 15% by weight, at least about 20% by weight, or at least about 25% by weight silicon dioxide.

[0068] In some embodiments, Origin The starting materials for producing the carbon compositions have very low initial carbon content, but when subjected to the disclosed process, the resulting compositions are highly enriched in carbon relative to the starting materials (high yield of carbon), but are nevertheless relatively carbon-poor (low purity carbon), containing about 50% or less by weight carbon. Origin Carbon is bio Origin It has a relatively high carbon content compared to the initial feedstock used to produce the carbon. The typical carbon content of biomass is about 50% by weight or less. OriginCarbon usually contains more than half the weight of carbon. More typically, depending on the composition of the feedstock, Origin The carbon contains at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, or at least about 99% carbon by weight.

[0069] In some embodiments, Origin The carbon composition is activated. Activation refers to any process in which the pore size of the resulting carbon is enhanced. Conventional processes for producing porous carbon require large energy inputs and suffer from low yields.

[0070] Various embodiments of the present disclosure use carbon-containing feedstocks other than biomass, such as fossil fuels (e.g., coal or petroleum coke) or any mixture of biomass and fossil fuels (such as a biomass / coal blend). Origin The feedstock may be or include coal, oil shale, crude oil, asphalt, or solids from crude oil processing (such as petroleum coke). The feedstock may include scrap tires, recycled plastics, recycled paper, and other waste or recycled materials. Any of the methods, apparatus, or systems described herein may be used with any carbonaceous feedstock. The carbon-containing feedstock may be transported by any known means, such as trucks, trains, ships, barges, tractor trailers, or any other vehicle or conveyance.

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

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

[0073] In some embodiments, the composition is extruded. Extrusion can be used, for example, to increase density, mix carbon with silicon dioxide, modify the particle size of the carbon to increase the combined product density, produce a product that "sinks" in an electric arc furnace, and create a water- and dust-resistant exterior of the extrudate to improve usage and improve furnace efficiency.

[0074] In some embodiments, the composition is densified, the densification process being described in more detail below.

[0075] In some embodiments, the composition is in the form of a pellet. In some embodiments, the composition can have dimensions of at least about 0.25 inches by about 1.0 inches and up to about 2.0 inches by about 6.0 inches. For example, the composition can have a particle size as shown in Table 1 below. [Table 1]

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

[0077] Increasing porosity improves the reactivity of the carbon and facilitates the conversion of the composition to pure silicon. The composition may have an iodine number of at least about 300. The iodine number is a parameter used to characterize the performance of porous carbon. The iodine number measures the degree of activation of the carbon and is a measurement of the micropore (e.g., 0-20 Å) content. It is an important measurement for liquid phase applications. In some embodiments, the porous carbon products produced by embodiments of the present disclosure have an iodine number of about 300, about 400, about 500, about 600, about 750, about 900, about 1000, about 1100, about 1200, about 1300, about 1500, about 1600, about 1750, about 1900, about 2000, about 2100, and about 2200. Price In some embodiments, the porous carbon products produced according to embodiments of the present disclosure have an iodine content of at least about 300, at least about 400, at least about 500, at least about 600, at least about 750, at least about 900, at least about 1000, at least about 1100, at least about 1200, at least about 1300, at least about 1500, at least about 1600, at least about 1750, at least about 1900, at least about 2000, at least about 2100, and at least about 2200. Price In yet another embodiment, the porous carbon product produced according to embodiments of the present disclosure has an iodine content of about 300 to about 2200, about 500 to about 1500, about 750 to about 1750, about 900 to about 1300, about 1000 to about 1500, about 1500 to about 2200, or about 1200 to about 1900. Price has.

[0078] process Provided herein is a method for producing high carbon Drugs derived fromIn some embodiments, the process includes providing a carbon-containing feedstock comprising dried biomass; preheating the feedstock in a preheating zone in the presence of a substantially inert gas for at least about 5 minutes and at a preheating temperature selected from about 80° C. to about 500° C.; pyrolyzing the feedstock in a pyrolysis zone in the presence of a substantially inert gas for at least about 10 minutes and at a pyrolysis temperature selected from about 250° C. to about 700° C. to produce hot pyrolyzed solids, condensable vapors, and non-condensable gases; separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids; cooling the hot pyrolyzed solids in a cooling zone in the presence of a substantially inert gas for at least about 5 minutes and at a cooling temperature lower than the pyrolysis temperature to produce warm pyrolyzed solids; cooling the warm pyrolyzed solids in a cooler separate from the cooling zone to produce low temperature pyrolyzed solids; and producing a high carbon feedstock comprising at least a portion of the low temperature pyrolyzed solids. Drugs derived from and recovering the silicon dioxide, and the process further comprises introducing silicon dioxide into the process.

[0079] High carbon Drugs derived from Disclosed herein is a process for producing a carbon-containing feedstock comprising: providing a carbon-containing feedstock comprising biomass; optionally drying the feedstock to remove at least a portion of the moisture contained within the feedstock; and optionally degassing the feedstock or the dried feedstock to remove any residual carbon, if any, contained within the feedstock. Inside the gapremoving at least a portion of the oxygen; pyrolyzing the feedstock in a pyrolysis zone in the presence of a substantially inert gas for at least about 10 minutes and at a pyrolysis temperature selected from about 250° C. to about 700° C. to produce hot pyrolyzed solids, condensable vapors, and non-condensable gases; separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids; cooling the hot pyrolyzed solids in a cooling zone in the presence of a substantially inert gas for at least about 5 minutes and at a cooling zone temperature lower than the pyrolysis temperature to produce warm pyrolyzed solids; further cooling the warm pyrolyzed solids in an optional cooler separate from the cooling zone to produce low temperature pyrolyzed solids; and producing a high carbon product comprising at least a portion of the warm or low temperature pyrolyzed solids. Drugs derived from and recovering the

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

[0081] In some embodiments, the high carbon Drugs derived from The process for producing comprises a reactor. In some embodiments, the reactor is a separate unit where the temperature and atmospheric conditions can be controlled. In some embodiments, the reaction takes place in the reactor. In another embodiment, the reactor can comprise one or more zones. In some embodiments, the one or more zones are regions within the reactor where the temperature and atmospheric conditions can be controlled relative to other zones within the reactor.

[0082] In various embodiments, high carbon Drugs derived fromThe process for producing includes a biomass processing unit ("BPU"). In some embodiments, the BPU includes multiple output passages configured to transport the feedstock or feedstock at different stages of processing gases, condensate by-products, and heat from the various reactors and zones to any one or more of other reactors or zones, material feed systems, carbon recovery units, and any other contemplated components of the systems described herein. In one embodiment, after the feedstock passes through each of the zones of the BPU, the feedstock is carbonized.

[0083] In some embodiments, the high carbon Drugs derived from The process for producing the compound includes carbonization. In some embodiments, the carbonization comprises carbonizing the non-carbon-containing material from the biomass. Reduce "High carbon biomass" can be achieved by either increasing the amount of carbon dioxide produced, adding carbon atoms to biomass, or both. Drugs derived from This can be illustratively achieved by forming

[0084] As discussed below, various multi-zone BPU embodiments include a single reactor, and various multi-zone BPU embodiments may also include multiple separate reactors. It should be understood that other embodiments discussed below include multiple separate reactors, each reactor having at least one zone. For purposes of this disclosure, the features, principles, processes, alternatives, and embodiments discussed with respect to all single reactor multi-zone BPU embodiments apply equally to all multiple separate reactor embodiments, and vice versa.

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

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

[0087] In some embodiments, the pyrolysis temperature is selected from about 400° C. to about 600° C. In some embodiments, the pyrolysis of step (d) is carried out for at least about 20 minutes. The cooling zone temperature can be selected, for example, from about 150° C. to about 350° C.

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

[0089] In some embodiments, each of the zones is located within a single reactor or BPU. In other embodiments, each of the zones is located in a separate BPU or reactor. It should be understood that some embodiments include one or more BPUs, each of which includes at least one zone.

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

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

[0092] In some embodiments, the process includes monitoring and controlling the process with at least one reactive gas probe, such as two or more reactive gas probes. Monitoring and controlling the process can improve the energy efficiency of the process. Monitoring and controlling the process can improve the properties of high carbon production, such as, but not limited to, carbon content, energy content, structural integrity, or mechanical strength. Drugs derived from It is also possible to improve product attributes related to

[0093] The process may further include thermal oxidation (i.e., combustion) of at least a portion of the condensable and non-condensable vapors with an oxygen-containing gas. The thermal oxidation may be facilitated by the combustion of natural gas. The heat produced from the thermal oxidation may be utilized, at least in part, to dry the feedstock. Additionally, the heat produced from the thermal oxidation may be utilized, at least in part, to heat the substantially inert gas prior to entering one of the zones or reactors, such as the pyrolysis zone.

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

[0095] Therefore, the condensable steam can be used either for energy in processes (such as by thermal oxidation) or for carbon enrichment to produce high carbon products. Drugs derived from Certain non-condensable gases, such as CO or CH4, can be utilized either as energy in the process or as part of the substantially inert gas for the pyrolysis step.

[0096] In some embodiments, the process further comprises introducing at least one additive selected from an acid, a base, or a salt thereof, which may be selected from the group consisting of (but is not limited to) sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, potassium permanganate, and combinations thereof.

[0097] In some embodiments, the process further comprises introducing at least one additive selected from the group consisting of metals, metal oxides, metal hydroxides, metal halides, and combinations thereof. The additive may be selected from (but is not limited to) the group consisting of magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halides, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, fluorite, fluorspar, bentonite, calcium oxide, lime, and combinations thereof.

[0098] The additives, including silicon dioxide or silica fume, may be added any time before or after harvest, including to the feedstock itself, before, during, or after any one or more steps of the process. The additives may be introduced, for example, before or during step (b), before or during step (d), during step (f), during step (g), between steps (f) and (g), or after step (g). The additives may be introduced to the warm pyrolyzed solids. For example, the additives may be introduced in an aqueous solution, vapor, or aerosol to facilitate cooling of the warm pyrolyzed solids in step (g). In these or other embodiments, the additives are introduced to the cool pyrolyzed solids to enhance the cooling of the high carbon product containing the additive. Drugs derived from Form.

[0099] In some embodiments, the process further comprises introducing at least a portion of the low temperature pyrolyzed solids into a separate unit for additional pyrolysis in the presence of a substantially inert gas for at least about 30 minutes and at a pyrolysis temperature selected from about 200° C. to about 600° C. to produce a solid product having a higher carbon content than the low temperature pyrolyzed solids.

[0100] In some embodiments, the process further includes operating a cooler to cool the warm pyrolyzed solids with steam, thereby producing low temperature pyrolyzed solids and superheated steam, and drying is performed at least in part with the superheated steam obtained from the external cooler. Optionally, the cooler can be operated to cool the warm pyrolyzed solids first with steam to reach a first cooler temperature and then with air to reach a second cooler temperature, the second cooler temperature being lower than the first cooler temperature and associated with reduced combustion risk for the warm pyrolyzed solids in the presence of air.

[0101] In the process disclosed herein, the introduction of silicon dioxide can include the introduction of silica fume. Silica fume is an ultrafine (generally containing particles less than 1 μm in diameter) silica powder by-product from silicon production, for example, trapped in a baghouse in the production of silicon metal or ferrosilicon alloys. Silicon metal and alloys are produced in electric furnaces. Silica fume is mainly composed of amorphous (non-crystalline) silicon dioxide.

[0102] In the process disclosed herein, the introduction of silicon dioxide can include the introduction of raw silicon dioxide. For example, the introduction of silicon dioxide can include the introduction of river rock or quartz. Free silica occurs in many crystalline forms with compositions very close to that of silicon dioxide, for example, 46.75% silicon by weight and 53.25% oxygen. Quartz is by far the most commonly occurring form. Tridymite, cristobalite, and the hydrous silica mineral opal are rare, and vitreous (glassy) silica, coesite, and stishovite have been reported from only a few localities.

[0103] Silicon dioxide, whether introduced as silica fume or river rock, can be introduced into the process after pyrolysis by adding silicon dioxide to the low temperature pyrolyzed solids. Silicon dioxide, whether introduced as silica fume or river rock, can be introduced prior to pyrolysis, where the silicon dioxide can improve heat transfer and thereby improve the pyrolysis of the biomass.

[0104] The silicon dioxide introduced can be smaller than previously used in submerged arc or electric arc furnaces because it is contained within a raw material feedstock, such as silica fume or river rock. For example, the particle size of the silicon dioxide feedstock, whether river rock or silica fume, can be from about 0.01 mm to about 12 mm. For example, the particle size can be from about 0.01 mm to about 12 mm, in increments of about 0.05 mm.

[0105] The process may further include pressing, bonding, pelletizing, extruding, or agglomerating the composition.

[0106] The process can further include densification, thereby producing the composition in, for example, pellet shape. Other shapes can also be produced, for example, spheres. The proximity of carbon and silicon dioxide in the densified composition results in more efficient conversion of the composition to silicon.

[0107] The densification process can create the final composition of the material. Densification allows the material to be mixed and blended in a controlled manner with other particles, including the compositions described herein. The described compositions can be processed and extruded through densification equipment. Such equipment can include commercially available machines. The densification equipment extrudes the composition through a forming die, thereby producing, for example, pellets. The faceplate temperature of the extrusion equipment is typically about 72°C (165°F) to about 85°C (185°F). The pellets can exit at a temperature of about 43°C (110°F) and no greater than about 121°C (250°F). As the pellets exit the extruder, there can be a slight coating on the outer surface of the pellets. This coating can include lignin, a naturally occurring substance in cellulosic materials. The pellets can then be transferred to a finished product conveyor / cooler.

[0108] Following formation, the pellets can be cooled by cooling means including, but not limited to, air coolers, air conditioners, or liquid nitrogen. The cooling process allows the pellets to harden into the shape created by the extruder and allows the components of the pellets to maintain their integrity. In one embodiment, the pellets, once sufficiently cooled and hardened, are placed through a shaker screen. This separates fine particles from discrete particles. The fine particle output can be separated and recycled again or extruded by the extruder. This minimizes the potential for waste generated by any excess particles that make up the pellets.

[0109] The densification process can include using additives to improve densification, mixing the additives, carbon, and silicon dioxide, extruding the mixture through a die thereby producing pellets, and optionally drying the pellets.

[0110] The densification process can optionally include using an additive, such as bentonite, to improve densification in about 0.5% increments to about 0.5% to about 15%, optionally adding water, for example, about 5% to about 50%, mixing the additive, carbon, and silicon dioxide, extruding the mixture through a die thereby producing pellets, optionally heating or cooling the extruder and / or die plate to improve densification, optionally degassing the extruder, and optionally drying the pellets.

[0111] Extruders can also be used to shape and mix materials. Extrusion is a process used to create objects of fixed cross-sectional profile. The material is forced through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes are that very complex cross-sections can be created and brittle materials can be processed since the material only encounters compressive and shear stresses. It also forms products with excellent surface finishes. Extrusion can be continuous (producing theoretically infinitely long pieces of material) or semi-continuous (producing many pieces). The extrusion process can be done at high or low temperatures. Various binders, coatings, and extrusion recipes can be used to achieve a variety of product attributes ranging from greater than 99% of the "pellet durability index," to dust-free, to hydrophobic. Die thickness, die taper, screw speed, moisture content, pre-compression, product size, and many other variables can affect pellet quality. For example, if more water is used during extrusion and then the product is dried, it is easier to apply a wax-based coating than if less water is used in the extrusion.

[0112] Referring generally to Figures 1-13, block flow diagrams of several exemplary multiple reactor embodiments of the present disclosure are illustrated. Each figure is discussed in turn below. It should be understood that Figures 1-13 represent several exemplary embodiments, but not all contemplated embodiments of the present disclosure. As discussed below, various additional non-illustrated embodiments and combinations of several components and features discussed herein are also contemplated. As will be understood in the discussion below, any of the multiple reactors discussed herein may be separate reactors or may be within a single reactor, and the BPU may include multiple zones, or combinations thereof. It should be understood that while the figures each show different alternative embodiments, all other discussions in this disclosure are applicable to each of the illustrated and non-illustrated embodiments.

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

[0114] In the illustrated embodiment, a feedstock 109 such as biomass is optionally dried and sized outside the system and is introduced into the first reactor 100 in a low oxygen atmosphere by using a material feed system 108. As discussed in more detail below and illustrated in FIG. 3, the material feed system 108 reduces the oxygen level in the ambient air in the system to about 3% or less. After the oxygen level is reduced in the first reactor, the feedstock 109 enters the first reactor 112 via an enclosed material transport unit 304. In one embodiment, the feedstock transport unit includes an encapsulated jacket or sleeve through which steam and off-gas from the reactor are routed and used to directly preheat the biomass or are routed to a process gas heater and / or heat exchanger and then routed and used to preheat or pyrolyze the biomass.

[0115] In the illustrated embodiment, the raw material 109 first travels from the material feed system 108 on the material transport unit 304 to the first reactor of the BPU 112 .

[0116] As discussed in more detail below, in one embodiment, the first reactor 112 is configured to be connected to any other reactors in the system to recover waste heat 132 and conserve energy through a suitable waste heat recovery system. In one embodiment, the waste heat released in the first reactor 112 is used to operate a steam bin or another suitable heating mechanism configured to dry the raw material 109 inside or outside the system. In various embodiments, other by-products of the waste heat, such as substantially heated inert gas, can be used elsewhere in the system to further concentrate the material at any point along the process.

[0117] In the illustrated embodiment, biomass 109 enters the first reactor 112 and the temperature is increased from a range of about ambient temperature to about 150° C. to a temperature of about 100° C. to about 200° C. In one embodiment, the temperature does not exceed 200° C. in the first reactor 112. As discussed in more detail below, the first reactor 112 can include an output mechanism to capture and vent off-gas 120 from the biomass 123 while it is being heated. In one embodiment, the off-gas 120 is optionally extracted for later use. In various embodiments, the heat source used for the various zones in the BPU 102 is electric or gas. In one embodiment, the heat source used for the various reactors of the BPU 102 is waste gas from other reactors of the unit 102 or from an external source. In various embodiments, the heat is indirect.

[0118] Following preheating in the first reactor 112, the material transport unit 304 passes the preheated material 123 through the optional second reactor 114. In one embodiment, the reactor 114 is the same as the reactor 112. In one embodiment, where the reactor 114 is different from the reactor 112, the material transport unit 304 penetrates the second reactor 114 through a high temperature steam seal system (e.g., an airlock), which allows the material transport unit 304 to penetrate the second reactor while preventing gases from escaping. In one embodiment, the interior of the second reactor 114 is heated to a temperature of about 100°C to about 600°C or about 200°C to about 600°C. In another embodiment, the second reactor 114 includes an output port similar to the first reactor 102 for capturing and venting the gases 122 released from the preheated material 123 while it is being carbonized. In one embodiment, the gases 122 are optionally extracted for later use. In one illustrative embodiment, the off-gas 120 from the first reactor 112 and the off-gas 122 from the second reactor 114 are combined into one gas stream 124. Once carbonized, the carbonized biomass 125 exits the second reactor 114 and enters the third reactor 116 for cooling. Again, the third reactor may be the same reactor as 112 or 114 or may be different.

[0119] In one embodiment, Drugs derived from As the carbonized biomass 125 enters the third reactor 116, it can be cooled (actively or passively) to a particular temperature range to form the carbonized biomass 126, as discussed above. In one embodiment, the temperature of the carbonized biomass 125 is reduced in the third reactor under substantially inert atmospheric conditions. In another embodiment, the third reactor cools the carbonized biomass 125 with an additional water cooling mechanism. It should be appreciated that the carbonized biomass 126 can be cooled in the third reactor 116 to a point where it will not spontaneously ignite when exposed to oxygenated air. In one such embodiment, the third reactor 116 reduces the temperature of the carbonized biomass to below 200° C. In one embodiment, the third reactor includes a mixer (not shown) for agitating and uniformly cooling the carbonized biomass. It should be understood that cooling may occur either directly or indirectly with water or other liquid, cooling may occur either directly or indirectly with air or other cooling gas, or any combination of the above.

[0120] It should be understood that in some embodiments (not shown), one or more additional coolers or cooling mechanisms are used to further reduce the temperature of the carbonized biomass. In various such embodiments, the cooler is separate from the other reactors 112, 114, 116 along the material transport system. In some embodiments, the cooler follows the reactor. In some embodiments, the cooler can be the same as the reactors 112, 114, 116. In other embodiments, the cooler is, for example, a screw, an auger, a conveyor (specifically, a belt conveyor in one embodiment), a drum, a screen, a pan, a countercurrent bed, a vertical tower, a jacketed paddle, a cooling screw, or combinations thereof, which are cooled directly or indirectly with water or other liquids, or directly or indirectly with other gases, or combinations of the above. In various embodiments, the cooler can include water spray, a chilled inert gas stream, liquid nitrogen, or ambient air if below ignition temperature. It should be appreciated that heat can be recovered from this step by capturing the flash steam produced by the water spray or the superheated steam produced when saturated steam is introduced and heated by the carbonized biomass.

[0121] As illustrated in Figures 1 and 5, the gas phase separator unit 200 includes at least one input and multiple outputs. At least one input is connected to exhaust ports on the first reactor 112 and the second reactor 114 of the BPU 102. One of the outputs is connected to the carbon recovery unit 104, and another of the outputs is connected to collection equipment or further processing equipment such as the acid hydrogenation unit 106 or a distillation column. In various embodiments, the gas phase separator processes the off-gases 120, 122 from the first reactor 112 and the second reactor 114 to produce a condensate 128 and an enriched gas 204. In various embodiments, the condensate can be used for energy recovery (134) (e.g., in a dryer, reactor, or process gas heater) or other carbon enrichment. In various embodiments, the non-condensables (e.g., CO) can be used for energy recovery (134) (e.g., in a dryer, reactor, or process gas heater), as an inert gas in the process (e.g., in a degassing unit, reactor, BPU, or cooler, discussed in more detail below), or for carbon enrichment.

[0122] In various embodiments, the condensate 128 includes polar compounds such as acetic acid, methanol, and furfural. In another embodiment, the enriched gas 204 produced by the gas phase separator 200 includes at least non-polar gases, such as carbon monoxide, terpenes, methane, carbon dioxide, and the like. In one embodiment, the gas phase separator comprises a fractionation column. In one embodiment, the acetic acid is sent via line 128 to an optional acid hydrogenation unit. In another embodiment, the methanol and / or furfural are sent via optional additional line(s) 136 to a distillation / processing unit 138.

[0123] In various embodiments, as discussed in more detail below, the carbon recovery unit itself has provisions for concentrating the material. In various other embodiments, the material is concentrated in a material concentrating unit separate from the carbon recovery unit. It should be understood that in some such embodiments, the carbon recovery unit is a vessel for storing the carbonized material, and the separate material concentrating unit is a unit into which gas is introduced to concentrate the material.

[0124] In the illustrated embodiment, the carbon recovery unit 500 also concentrates the carbonized biomass 126. The carbonized biomass 126 exits the third reactor along the material transport unit 304 and enters the carbon recovery unit 500. In various embodiments, the carbon recovery unit 500 also includes an input 524 connected to the gas phase separator 200, as shown in more detail in FIG. 5 and discussed above. In one embodiment, the concentrated gas 204 is directed to the carbon recovery unit to concentrate the carbonized biomass 126. Drugs derived from Combined with 126, it produces high-carbon Drugs derived from In another embodiment, carbon enriched gas from an external source is also directed to a carbon recovery unit and combined with the carbonized biomass 126 to produce the final high carbon biomass produced. Drugs derived from Additional carbon can be added to the biomass 126. In various embodiments, the carbonized biomass 126 is a carbonized biomass that has been reduced in temperature. Illustratively, the system 100 can be co-located near a wood processing facility and carbon enriched gas from the wood processing facility can be used as the gas from the external source.

[0125] Referring now generally to FIG. 2, a block flow diagram of a single reactor, multi-zone embodiment of the present disclosure is illustrated. In the illustrated embodiment, a feedstock 209, such as biomass, is introduced to the reactor 200 in a low-oxygen atmosphere, optionally by using the material feed system 108 previously described. As discussed in more detail below, the material feed system 108 reduces the oxygen level in the ambient air in the system to about 3% or less. After the oxygen level is reduced, the feedstock 209 enters the BPU 202 in an enclosed material transport unit 304. In one embodiment, the material transport unit includes an encapsulated jacket or sleeve through which steam and off-gas from the reactor 200 are routed and used to preheat the biomass.

[0126] In the illustrated embodiment, the raw material first travels from the material feed system 108 on the material transport unit 304 through the optional drying zone 210 of the BPU 202. In one embodiment, the optional drying zone 210 heats the raw material to remove water and other moisture before passing to the preheat zone 212. In one embodiment, the interior of the optional drying zone 210 is heated to a temperature between about ambient temperature and about 150° C. Water 238 or other moisture removed from the raw material 209 can be exhausted from the optional drying zone 210, for example. In another embodiment, the optional drying zone is adapted to allow for the extraction of steam and vapor. In another embodiment, the steam and steam from the optional drying zone are extracted for optional later use. As discussed below, the steam or steam extracted from the optional drying zone can be used in a suitable waste heat recovery system with the material feed system. In one embodiment, the steam and steam used in the material feed system preheats the raw material while oxygen levels are purged in the material feed system. In another embodiment, the biomass is dried outside the reactor and the reactor does not include a drying zone.

[0127] As discussed in more detail below, in one embodiment, optional drying zone 210 is configured to be connected to cooling zone 216 to recover waste heat 232 and conserve energy through a suitable waste heat recovery system. In one embodiment, the waste heat released in cooling zone 216 is used to operate a heating mechanism configured to dry feedstock 209 in optional drying zone 210. After being dried for a desired period of time, dried biomass 221 exits optional drying zone 210 and enters pre-heating zone 212.

[0128] In the illustrated embodiment, the dried biomass 221 enters the first (preheating) zone 212 where the temperature is increased from a range of about ambient temperature to about 150° C. to a temperature range of about 100° C. to about 200° C. In one embodiment, the temperature does not exceed 200° C. in the first / preheating zone 212. It should be understood that if the preheating zone 212 is too hot or not hot enough, the dried biomass 221 may be mistreated before entering the second zone 214. As discussed in more detail below, the preheating zone 212 may include an output mechanism to capture and vent gases 220 from the dried biomass 221 while it is being preheated. In another embodiment, the off-gases 220 are optionally extracted for later use. In various embodiments, the heat source used for the various zones in the BPU 202 is electric or gas. In one embodiment, the heat source used for the various zones of the BPU 202 is waste gas from other zones of the unit 202 or from an external source. In various embodiments, the heat is indirect.

[0129] Following the preheat zone 212, the material transport unit 304 passes the preheated material 223 through the second (pyrolysis) zone 214. In one embodiment, the material transport unit 304 penetrates the second / pyrolysis zone through a high temperature steam seal system (such as an airlock, not shown), which allows the material transport unit 304 to penetrate the high temperature pyrolysis zone while preventing (or minimizing) gas escape. In one embodiment, the interior of the pyrolysis zone 214 is heated to a temperature of about 100°C to about 600°C or about 200°C to about 500°C. In another embodiment, the pyrolysis zone 214 includes an output port similar to the preheat zone 212 to capture and vent the gases 222 released from the preheated biomass 223 while it is being carbonized. In one embodiment, the gases 222 are optionally extracted for later use. In one illustrative embodiment, off-gas 220 from pre-heating zone 212 and off-gas 222 from pyrolysis zone 214 are combined into one gas stream 224. Once carbonized, the carbonized biomass 225 exits the second / pyrolysis zone 214 and enters the third / temperature reduction or cooling zone 216.

[0130] In one embodiment, when the carbonized biomass 225 enters the cooling zone 216, the carbonized biomass 225 is cooled to a specified temperature range of about 20° C. to 25° C. (about room temperature) as discussed above to become the reduced temperature carbonized biomass 226. In various embodiments, the BPU 202 includes multiple cooling zones. In one embodiment, the cooling zone 216 cools the carbonized biomass to less than 200° C. In one embodiment, the cooling zone includes a mixer to agitate and uniformly cool the material. In various embodiments, one or more of the multiple cooling zones are external to the BPU 202.

[0131] As illustrated in FIG. 2 and FIG. 5, the gas phase separator unit 200 includes at least one input and multiple outputs. In this illustrative embodiment, the at least one input is connected to exhaust ports on the first / preheat zone 212 and the second / pyrolysis zone 214 of the BPU 202. One of the outputs is connected to a carbon recovery unit 500 (configured to concentrate the material), and another one of the outputs is connected to collection equipment or further processing equipment such as an acid hydrogenation unit 206 or a distillation column. In various embodiments, the gas phase separator processes the off-gases 220, 222 from the first / preheat zone 212 and the second / pyrolysis zone 214 to produce a condensate 228 and a concentrated gas 204. In one embodiment, the condensate 228 includes polar compounds such as acetic acid, methanol, and furfural. In one embodiment, the concentrated gas 204 produced by the gas phase separator 200 includes at least non-polar gases. In one embodiment, the gas phase separator comprises a fractionation column. In one embodiment, the acetic acid is sent via line 228 to the optional acid hydrogenation unit 206. In another embodiment, the methanol and / or furfural are sent via optional additional line(s) 236 to the distillation / treatment unit 238.

[0132] In the illustrated embodiment, the carbonized biomass exits the cooling reactor / zone along the material transfer unit 304 and enters the carbon recovery unit 500. In various embodiments, the carbon recovery unit 500 also includes an input 524 connected to the gas phase separator 200, as illustrated in more detail in FIG. 5 and discussed above. In one embodiment, the enriched gas 204 is directed to the carbon recovery unit 500 to be mixed with the biomass. Drugs derived from Combined with 226, it produces high-carbon Drugs derived from In another embodiment, carbon enriched gas from an external source is also produced. Drugs derived from Combined with 226 Drugs derived fromThe gas may be directed to a carbon recovery unit 500 to add additional carbon to the BPU 202. In various embodiments, the gas withdrawn from the carbon recovery unit 500 at reference 234 is optionally used in an energy recovery system and / or a system for further carbon enrichment. Similarly, in various embodiments, the gas withdrawn from one or more zones of the BPU 202 is optionally used in an energy recovery system and / or a system for further carbon enrichment. Illustratively, the system 200 may be co-located near a wood processing facility, and carbon enriched gas from the wood processing facility may be used as gas from an external source.

[0133] Now referring generally to FIG. 3, one material feed system embodiment of the present disclosure is illustrated. As discussed above, high oxygen levels in the ambient air surrounding the raw material being processed can cause undesirable combustion or oxidation of the raw material, which can reduce the quantity and quality of the final product. In one embodiment, the material feed system is a closed system and includes one or more manifolds configured to purge oxygen from the air surrounding the raw material. In one embodiment, oxygen levels of about 0.5% to about 1.0% are used for preheating, pyrolysis / carbonization, and cooling. It should be appreciated that the primary goal of a closed material feed system is to reduce oxygen levels to about 3% or less, about 2% or less, about 1% or less, or about 0.5% or less. After the oxygen levels are reduced, the biomass is transported along the material feed system to the BPU. It should be appreciated that in various embodiments, preheating the inert gas with recovered process energy and then introducing the preheated inert gas into the BPU, reactor, or trimming reactor makes the system more efficient.

[0134] In some embodiments, a trimming reactor is included in the system. In one embodiment of the trimming reactor, the pyrolyzed material from the BPU is fed to a separate additional reactor for further pyrolysis, where heated inert gas is introduced to create a product with higher fixed carbon levels. In various embodiments, the secondary process may be carried out in a container such as a drum, tank, barrel, bin, tote, pipe, bag, press, or roll-off container. In various embodiments, the final container may also be used for transport of the carbonized biomass. In some embodiments, the inert gas is extracted from the BPU and heated through a heat exchanger that draws heat from the gas combusted in the process gas heater.

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

[0136] In one embodiment, the raw material feed hopper 300 is any suitable open-air or closed-air container configured to receive the raw material or sizing / dried biomass 109 / 209. The raw material feed hopper 300 is operatively connected to a material transport unit 304, which in one embodiment is a screw or auger system operatively rotated by a drive source. In one embodiment, the raw material 109 / 209 is fed to the material transport unit 304 by a gravity feed system. It should be understood that the material transport unit 304 in FIG. 3 is constructed such that the screw or auger 305 is enclosed in a suitable enclosure 307. In one embodiment, the enclosure 307 is substantially cylindrical. In various embodiments, the material feed system includes an air conveying device including a screw, an auger, a drum, a screen, a chute, a drop chamber, a rotary airlock, or a double or triple flap airlock.

[0137] As the raw material 109 / 209 is fed from the raw material feed hopper 300 to the material transport unit 304, the auger or screw 305 rotates, moving the raw material 109 / 209 towards the oxygen purge manifold 302. It should be appreciated that when the raw material 109 / 209 reaches the oxygen purge manifold 302, the ambient air between the raw material 109 / 209 in the material transport unit 304 contains approximately 20.9% oxygen. In various embodiments, the oxygen purge manifold 302 is arranged adjacent to or around the material transport unit 304. In one embodiment of the oxygen folded manifold, the enclosure 307 of the material transport unit 304 includes multiple gas inlet ports 310a, 310b, 310c and multiple gas outlet ports 308a, 308b, 308c.

[0138] The oxygen purge manifold 302 has at least one gas inlet line 312 and at least one gas outlet line 314. In various embodiments, the at least one gas inlet line 312 of the oxygen purge manifold 302 is in operative communication with each of the plurality of gas inlet ports 310a, 310b, 310c. Similarly, in various embodiments, the at least one gas outlet line 314 of the oxygen purge manifold 302 is in operative communication with each of the plurality of gas outlet ports 308a, 308b, 308c. It should be appreciated that in one embodiment, the gas inlet line 312 is configured to pump an inert gas to the gas inlet ports 310a, 310b, 310c. In one such embodiment, the inert gas is substantially oxygen-free nitrogen. In one embodiment, the inert gas flows countercurrently to the biomass.

[0139] As will be appreciated, the introduction of the inert gas 312 into the sealed material transport unit 304 pushes ambient air out of the sealed system. During operation, as the inert gas 312 is introduced into the first gas inlet port 310a of one embodiment, a volume of oxygen-rich ambient air is pushed out of the outlet port 308a. At this point, it should be appreciated that the desired levels of about 2% oxygen or less, about 1% oxygen or less, about 0.5% oxygen or less, or about 0.2% oxygen or less may not be achieved. Therefore, in various embodiments, an additional injection of inert gas 312 must be performed to purge the required amount of oxygen from the air surrounding the raw material 109 in the sealed system. In one embodiment, the second gas inlet port 310b pumps the inert gas 312 into the sealed system following the injection at the first gas inlet port 310a, thereby purging more of the remaining oxygen from the sealed system. It should be understood that the desired level of less oxygen may be achieved after one or two injections of inert gas 312 to purge the oxygen 314. In one embodiment, if the desired oxygen level is not achieved after two inert gas injections, a third injection of inert gas 312 at gas inlet 310c purges the remaining undesirable amount of oxygen 314 from the sealed system at gas outlet 308c. Additional inlets / outlets may also be incorporated as needed. In various embodiments, oxygen levels are monitored throughout the material supply system to allow for calibration of the amount and location of inert gas injection.

[0140] In an alternative embodiment, heat, steam, and gases recovered from the reactor are directed to a feed system that is sealed in a jacket and isolated from direct contact with the feed, but indirectly heats the feed before it is introduced into the reactor.

[0141] In an alternative embodiment, heat, steam, and gases recovered from the drying zone of the reactor are directed into a feed system that is enclosed in a jacket and isolated from direct contact with the feed material, but indirectly heats the feed material before it is introduced into the reactor.

[0142] It should be appreciated that the gas inlet ports 310a, 310b, 310c and corresponding gas outlet ports 308a, 308b, 308c of an embodiment are slightly offset from one another relative to a perpendicular bisecting plane through the material transport unit 304. For example, in one embodiment, the inlet port 310a and corresponding outlet port 308a are offset in the material transport unit 304 by an amount that approximately corresponds to the pitch of the auger 305 in the material transport unit 304. In various embodiments, after the atmosphere surrounding the raw material 109 / 209 is sufficiently deoxygenated, it is supplied to the BPU 102 from the material supply system 108. In various embodiments, oxygen levels are monitored throughout the material supply system to allow for calibration of the amount and location of inert gas injection.

[0143] It should be understood that in one embodiment, the raw material 109 / 209, followed by the dried biomass 221, the preheated biomass 123 / 223, the carbonized biomass 125 / 225, and the carbonized biomass 126 / 226, travels through the reactor 102 (or multiple reactors) along the continuous material transport unit 304. In another embodiment, the material transport units carrying the material are different at different stages in the process. In one embodiment, the process of moving material through the reactor, zone, or reactor is continuous. In such an embodiment, the speed of the material transport unit 304 is appropriately calibrated and calculated by the associated controller and processor so that the operation of the material transport unit 304 does not require interruption as the material moves through one or more reactors.

[0144] In another embodiment, the controller associated with the reactor 102 or multiple reactors (112 / 114 / 116) is configured to adjust the speed of the material transport unit 304 based on one or more feedback sensors, detected gases (e.g., from an optional FTIR), measured parameters, temperature gauges, or other suitable variables in the reactor process. It should be understood that in various embodiments, any suitable moisture, temperature, or gas sensors in operative communication with the controller and processor can be integrated into or between each zone / reactor or at any suitable location along the material transport unit 304. In one embodiment, the controller and processor use information from the sensors or gauges to optimize the speed and efficiency of the BPU 100 / 200. In one embodiment, the controller associated with the reactor 102 or multiple reactors (112 / 114 / 116) is configured to operate the material transport unit 304. In one embodiment, a controller associated with the reactor 102 or multiple reactors (112 / 114 / 116) is configured to monitor gas concentration, temperature, and moisture inside the material transport unit 304 or inside any reactor. In one embodiment, the controller is configured to adjust the speed of the material transport unit 304, the gas input to the material transport unit, and the heat added to the material in the material transport unit based on one or more readings obtained by various sensors.

[0145] 2 and 4, an embodiment of the BPU 102 is illustrated. It should be understood that the graphical representation of the BPU 202 in FIG. 4 corresponds substantially to the BPU 202 in FIG. 2. It should also be understood that in various embodiments, the BPU 202 is enclosed in a kiln shell to control and manipulate the bulk of the heat required for the reactor process. As can be seen in FIG. 4, in one embodiment, the kiln shell of the BPU 202 includes several insulating chambers (416, 418) that surround the four zones 210, 212, 214, and 216. In one embodiment, the kiln includes four separated zones. In various embodiments, each of the four zones 210, 212, 214, and 216 of the BPU 202 includes at least one inlet flight and at least one outlet flight. As discussed in more detail below, within each zone of one such embodiment, the inlet and outlet flights are configured to be adjustable to control the flow of feedstock, gas, and heat into and out of the zone. A supply of inert air can be introduced into the inlet flights and purged air can be extracted from the corresponding outlet flights. In various embodiments, one or more of the outlet flights of the zones in the BPU 202 are connected to one or more of the other inlet or outlet flights in the BPU.

[0146] In one embodiment, the feedstock 209 is deoxygenated in the material feed system 108 before being introduced into the BPU 202, specifically into the first of four zones, the optional drying zone 210. As seen in FIG. 4, the drying zone includes an inlet flight 422b and an outlet flight 420a. In one embodiment, the drying zone is heated to a temperature of about 80° C. to about 150° C. to remove water or other moisture from the feedstock 209. The biomass is then moved to the second or preheat zone 212, where the biomass is preheated as described above.

[0147] In another embodiment, the dried and preheated material is optionally moved to a third or carbonization zone. In one embodiment, carbonization is performed at a temperature between about 200°C and about 700°C, for example, about 200°C, about 210°C, about 220°C, about 230°C, about 240°C, about 250°C, about 260°C, about 270°C, about 280°C, about 290°C, about 300°C, about 310°C, about 320°C, about 330°C, about 340°C, about 350°C, about 360°C, about 370°C, about 380°C, about 390°C, about 400°C, 410°C, about 420°C, about 430°C, The carbonization occurs at a temperature of about 440° C., about 450° C., about 460° C., about 470° C., about 480° C., about 490° C., about 500° C., about 510° C., about 520° C., about 530° C., about 540° C., about 550° C., about 560° C., about 570° C., about 580° C., about 590° C., about 600° C., about 610° C., about 620° C., about 630° C., about 640° C., about 650° C., about 660° C., about 670° C., about 680° C., about 690° C., or about 700° C. In another embodiment, the carbonization zone of the reactor 421 is adapted to allow extraction of the gas produced during carbonization. In another embodiment, the gas produced during carbonization is optionally extracted for later use. In one embodiment, the carbonization temperature is selected to minimize or eliminate the production of methane (CH4) and maximize the carbon content of the carbonized biomass.

[0148] In another embodiment, the carbonized biomass is moved to a temperature reduction or cooling zone (third zone) and passively or actively cooled. In one embodiment, the carbonized biomass solids are cooled to a temperature of room temperature ±10, 20, 30, or 40°C.

[0149] In various embodiments, the BPU includes multiple gas introduction probes and gas extraction probes. In the embodiment of the BPU illustrated in FIG. 4, the BPU further includes multiple gas introduction probes: 408, 410, 412, and 414, and multiple gas extraction probes: 400, 402, 404, and 406. It should be understood that in various embodiments, one of each gas introduction probe and one of each gas extraction probe corresponds to a different one of the multiple zones 210, 212, 214, and 216. It should also be understood that in various alternative embodiments, the BPU 202 includes any suitable number of gas introduction probes and gas extraction probes, including two or more gas introduction probes and two or more gas extraction probes for each of the multiple zones.

[0150] In the illustrated embodiment, the drying zone 210 is associated with a gas introduction probe 412 and a gas extraction probe 402. In one embodiment, the gas introduction probe 412 introduces nitrogen into the drying zone 210 and the gas extraction probe 402 extracts gas from the drying zone 210. It should be appreciated that in various embodiments, the gas introduction probe 412 is configured to introduce a mixture of gases into the drying zone 210. In one embodiment, the gas extracted is oxygen. It should be appreciated that in various embodiments, the gas extraction probe 402 extracts gas from the drying zone 210 to be reused in a heat or energy recovery system, as described in more detail above.

[0151] In the illustrated embodiment, the preheat zone 212 is associated with a gas introduction probe 414 and a gas extraction probe 400. In one embodiment, the gas introduction probe 414 introduces nitrogen into the preheat zone 212 and the gas extraction probe 400 extracts gas from the preheat zone 212. It should be appreciated that in various embodiments, the gas introduction probe 414 is configured to introduce a mixture of gases into the preheat zone 212. In various embodiments, the gas extracted with the gas extraction probe 400 includes carbon enriched off-gas. It should be appreciated that in one embodiment, as discussed above, the gas extracted from the preheat zone 212 and the pyrolysis zone 214 is reintroduced into the material at a later stage in the process, for example, in a carbon recovery unit. In various embodiments, the gas extracted from any of the reactor zones is used for either energy recovery in a dryer or process gas heater, further pyrolysis in a trimming reactor, or a carbon enrichment unit.

[0152] In the illustrated embodiment, the pyrolysis zone 214 is associated with a gas introduction probe 410 and a gas extraction probe 404. In one embodiment, the gas introduction probe 410 introduces nitrogen into the pyrolysis zone 214 and the gas extraction probe 404 extracts gas from the pyrolysis zone 214. It should be appreciated that in various embodiments, the gas introduction probe 410 is configured to introduce a mixture of gases into the pyrolysis zone 214. In various embodiments, the gas extracted with the gas extraction probe 404 includes carbon-enriched off-gas. It should be appreciated that in one embodiment, the carbon-enriched gas extracted from the pyrolysis zone 214 is used and reintroduced to the material at a later stage in the process, as discussed above. In various embodiments, the extracted gas 400 from the preheat zone 212 and the extracted gas 404 from the pyrolysis zone 214 are combined before being reintroduced to the material, as described in more detail below.

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

[0154] It should be appreciated that the gas introduction and extraction probes of the various embodiments described above are configured to operate in conjunction with the controller and sensors described above to regulate the levels and concentrations of gas introduced to and extracted from each zone.

[0155] In various embodiments, the gas inlet and gas extraction probes are made of suitable pipes configured to withstand high temperature fluctuations. In one embodiment, the gas inlet and gas extraction probes include multiple openings through which gas is introduced or extracted. In various embodiments, the multiple openings are located below the inlet and gas extraction probes. In various embodiments, each of the multiple openings extends a significant length within the respective zone.

[0156] In one embodiment, a gas introduction probe extends from one side of the BPU 202 through each zone. In one such embodiment, each of the four gas introduction probes extends from one side of the BPU to each of the zones. In various embodiments, a gaseous catalyst is added that enriches the fixed carbon level. It should be understood that in such an embodiment, the multiple openings for each of the four gas introduction probes are located only in the respective zone associated with that particular gas introduction probe.

[0157] For example, looking at FIG. 4, if each of the gas introduction probes extends from the left side of the drying zone into each zone, all four gas introduction probes will travel through the drying zone and the gas introduction probe of the drying zone will terminate in the drying zone. The remaining three gas introduction probes will all travel through the preheat zone and the gas introduction probe of the preheat zone will terminate in the preheat zone. The remaining two gas introduction probes will pass through the pyrolysis zone and the gas introduction probe of the pyrolysis zone will terminate in the pyrolysis zone. The gas introduction probe of the cooling zone is the only gas introduction probe that travels to and terminates in the cooling zone. It should be understood that in various embodiments, the gas extraction probes are configured similarly to the gas introduction probes described in this example. It should also be understood that the gas introduction probes and the gas extraction probes can each start on either side of the BPU.

[0158] In various embodiments, the gas introduction probes are arranged concentrically with one another to conserve space used by the multi-port configuration described in the example above. In one such embodiment, each of the four inlet probes / ports has a smaller diameter than the previous inlet probe / port. For example, in one embodiment, the gas introduction probe in the drying zone has the largest inner diameter, the gas introduction probe in the preheating zone is within the inner diameter of the inlet probe / port in the drying zone, then the gas introduction probe in the pyrolysis zone is within the inner diameter of the gas introduction probe in the preheating zone, and the gas introduction probe in the cooling zone is within the gas introduction probe in the pyrolysis zone. In one exemplary embodiment, a suitable connector is attached to each of the four gas introduction probes on the outside of the BPU 102 to control the air injected into each of the four gas introduction probes individually.

[0159] In such an embodiment, as in the example above, the gas introduction probe for the drying zone terminates in the drying zone, while the other three gas introduction probes continue to the preheat zone. However, in a concentric or substantially concentric arrangement, only the outermost gas introduction probe is exposed in each zone before terminating. Thus, in such an embodiment, the gas introduction of the individual zones is effectively controlled independently of each other while only requiring one continuous gas introduction probe line. It should be understood that in an embodiment, a similar concentric or substantially concentric configuration is suitably used for the gas extraction probes.

[0160] In one embodiment, each zone or reactor is adapted to extract and collect off-gas from one or more of the individual zones or reactors. In another embodiment, the off-gas from each zone / reactor remains separate for disposal, analysis, and / or later use. In various embodiments, each reactor / zone contains a gas detection system, such as an FTIR, that can monitor gas formation within the zone / reactor. In another embodiment, the off-gas from multiple zones / reactors is combined for disposal, analysis, and / or later use, and in various embodiments, the off-gas from one or more zones / reactors is fed to a process gas heater. In another embodiment, the off-gas from one or more zones / reactors is fed to a carbon recovery unit. In another embodiment, the off-gas from one or more zones / reactors is fed to a gas phase separator before being introduced to the carbon recovery unit. In one embodiment, the gas phase separator comprises a fractionation tower. Any fractionation tower known to one of skill in the art may be used. In one embodiment, the off-gas is separated into non-polar and polar compounds using a standard fractionation tower or a packed tower heated to a suitable temperature. In another embodiment, non-polar compounds or concentrated gases from the gas phase separator are extracted for optional later use, and in various embodiments, off-gases from one or more zones / reactors are fed to a process gas heater. In one embodiment, gases extracted from the preheat zone / reactor, pyrolysis zone / reactor, and optionally the cooling zone / reactor are extracted into a combined stream and fed to the gas phase separator. In various embodiments, one or more of the zones / reactors are configured to control whether and how much gas is introduced into the combined stream.

[0161] As discussed above and generally illustrated in FIG. 5, the off-gas 124 / 224 from the BPU 102 / 202 is directed to a gas phase separator 200. In various embodiments, the off-gas 124 / 224 includes the extract gas 120 from the first / preheat zone / reactor 112 / 212 combined with the extract gas 122 / 222 from the second / pyrolysis zone / reactor 114 / 214, or only either gas stream. Once the off-gas 124 / 224 enters the gas phase separator 200, the off-gas 124 / 224 is separated into polar compounds 128 / 228 / 136 / 236 and non-polar compounds 204, such as non-polar gases. In various embodiments, the gas phase separator 200 is a known fractionation tower.

[0162] In various embodiments, the enriched gas 204 extracted from the combined off-gas 124 / 224 is directed from the gas phase separator 200 to the carbon recovery unit 500 via the input 524 to enrich the material. As discussed above and illustrated in FIGS. 8 and 11, it should be understood that in various embodiments, the extracted gas is first introduced to the material enrichment unit and then to a separate carbon recovery unit. In the embodiment illustrated in FIG. 5, enrichment of the material occurs in the carbon recovery unit 500. In one embodiment (FIG. 5), the gas phase separator 200 includes multiple outputs. In various embodiments, one output from the gas phase separator 200 is connected to the carbon recovery unit 500 to introduce the enriched gas stream to the carbon recovery unit 500. In one embodiment, a portion of the enriched gas stream is directed to the carbon recovery unit 500 and another portion is directed to a scrubber or another suitable purification device for cleaning and disposing of the unwanted gas. In various embodiments, off-gas that is not sent to the carbon recovery unit may be used for energy recovery (e.g., in a process gas heater) or as an inert gas (e.g., in a degassing unit, reactor, BPU, or cooler). Similarly, in various embodiments, off-gas from the carbon recovery unit may be used for energy recovery (e.g., in a process gas heater), as an inert gas (e.g., in a degassing unit, reactor, BPU, or cooler), or in a secondary recovery unit.

[0163] In one embodiment, another output from the gas phase separator extracts polar compounds and optionally condenses them into liquid components including multiple different liquid portions. In various embodiments, the liquids include water, acetic acid, methanol, and furfural. In various embodiments, the output liquids are stored, disposed of, further processed, or reused. For example, it should be understood that in one embodiment, the output water can be reused to heat or cool another portion of the system. In another embodiment, the water is drained. It should also be understood that in one embodiment, the output acetic acid, methanol, and furfural can be sent to a storage tank for reuse, resale, distillation, or purification.

[0164] As seen in Figure 5, the carbon recovery unit 500 of one embodiment comprises a housing having an upper portion and a lower portion. It should be understood that in various embodiments in which the material enrichment unit is separate from the carbon recovery unit, the material enrichment unit includes similar features as discussed with respect to the carbon recovery unit 500 of Figure 5. In one embodiment, the carbon recovery unit includes a housing 502 having an upper portion 502a and a lower portion 502b, an inlet 524 at the bottom of the lower portion of the housing configured to convey the reactor off-gas, an outlet 534 at the top of the upper portion of the housing configured to convey the enriched gas stream, a pathway 504 defined between the upper and lower portions of the housing, and Drugs and a path-following transport system 528 configured to transport the Drugs is configured to adsorb at least a portion of the reactor off-gas. In various embodiments, the upper portion includes a plurality of outlets and the lower portion includes a plurality of inlets.

[0165] In one embodiment, the housing 502 is substantially free of corners having angles of 110 degrees or less, 90 degrees or less, 80 degrees or less, or 70 degrees or less. In one embodiment, the housing 502 is substantially free of convex corners. In another embodiment, the housing 502 is substantially free of convex corners that can create vortices or trap air. In another embodiment, the housing 502 is substantially shaped like a cube, a prism, an ellipsoid, a solid ellipsoid, a spheroid, two cones glued together at their bases, a regular tetrahedron glued together at their bases, two pyramids glued together at their bases, or two isosceles prisms glued together at their bases.

[0166] In one embodiment, the upper portion 502a and the lower portion 502b of the housing 502 are each shaped substantially like a half ellipsoid, a half prism, a half-ellipsoid, a half spheroid, a cone, a regular tetrahedron, a pyramid, an isosceles prism, or a rounded corner duct transition.

[0167] In another embodiment, the inlet 524 at the bottom of the lower portion of the housing 502b and the outlet 534 at the top of the upper portion of the housing 502a are configured to connect with a pipe. In another embodiment, the top of the lower portion of the housing 502b and the bottom of the upper portion of the housing 502a are substantially rectangular, circular, or oval. In another embodiment, the width between the top of the lower portion of the housing 502b and the bottom of the upper portion of the housing 502a is greater than the width of the transport system 528. In one embodiment, the width of the transport system 528 is its height.

[0168] In one embodiment, the carbon capture unit 500 includes a pathway 504 defined between an upper portion and a lower portion, an inlet opening 506, and an outlet opening 508. In one embodiment, the inlet opening and the outlet opening are configured to receive a transport system. In one embodiment, the transport system 528 is at least semi-permeable or permeable to the enriched gas.

[0169] In one embodiment, the inlet opening 506 includes an inlet opening sealing mechanism to reduce leakage of gas and the outlet opening 508 includes an outlet opening sealing mechanism to reduce leakage of gas. In one embodiment, the inlet and outlet opening sealing mechanisms comprise airlocks.

[0170] In various embodiments, the lower portion 502b of the housing of the carbon recovery unit has a narrow round-bottom connecting opening, which is connected to the gas phase separator 200 for the transport of the gas stream 204. In various embodiments, the top of the lower portion 502b of the housing of the carbon recovery unit 500 is substantially rectangular in shape and is substantially wider than the narrow round-bottom connecting opening. It should be understood that in one embodiment, the lower portion transitions from the round-bottom opening to the rectangular top opening. In one embodiment, the rectangular top opening of the lower portion is about 6 feet wide (along the direction of the conveyor system). In various embodiments, the top of the carbon recovery unit 500 is substantially similar in shape to the lower portion. In one embodiment, the bottom opening of the top is wider than the top opening of the lower portion. In one embodiment, the rectangular bottom opening of the top is about 6.5 feet wide (along the direction of the conveyor system). In one embodiment, the top is configured to capture all gas passing through the carbon recovery unit 500 that is not adsorbed by the porous material.

[0171] In various embodiments, the shape of the lower portion of the carbon capture unit is Drugs derived from It should be appreciated that the flares help to slow down and disperse the gas 204 over the larger surface area of ​​the conveyor carrying the 126 / 226. In various embodiments, the exact shape of the lower 502b and upper 502a portions of the carbon capture unit 500 depends on the angle of gas dispersion coming from the gas phase separator pipes. In various embodiments, it should be appreciated that gases naturally tend to expand when pumped at a flare range of 5 degrees to 30 degrees from vertical. In one embodiment, the flare angle is approximately 15 degrees. It should be appreciated that the lower portion of the carbon capture unit is constructed with as few folds and corners as possible to prevent air entrapment or the formation of vortices.

[0172] In one embodiment, the carbon recovery unit 500 is configured to connect to the gas phase separator 200 and the BPU 102 / 202 as discussed above. In various embodiments, the carbon recovery unit 500 is connected to the output of the cooling reactor / zone 216 / 116 or the last cooling zone of the BPU 102 / 202 or outside the BPU. In one embodiment, the output of the cooling reactor / zone 116 / 216 is connected to the raw material processed in the BPU 102 / 202. Drugs derived from In one embodiment, Drugs derived from 126 / 226 enters the carbon recovery unit 500 along a suitable transport system. In various embodiments, the top and bottom of the carbon recovery unit are connected to each other and define a path through which the transport system passes. In one embodiment, the transport system is constructed of a porous or mesh material configured to allow gas to pass therethrough. It should be understood that the transport system is configured to pass through an opening in the carbon recovery unit 500 and then through an exit opening in the carbon recovery. In some embodiments, the inlets and outlets to and from the carbon recovery unit are suitably sealed with an airlock or another suitable sealing mechanism to prevent gas from escaping through the conveyor openings. In various embodiments, the off-gas that is not sent to the carbon recovery unit may be used for energy recovery (e.g., in a process gas heater) or as an inert gas (e.g., in a degassing unit, reactor, BPU, or cooler). Similarly, in various embodiments, the off-gas from the carbon recovery unit may be used for energy recovery (e.g., in a process gas heater), as an inert gas (e.g., in a degassing unit, reactor, BPU, or cooler), or in a secondary recovery unit.

[0173] In various embodiments, the process begins by first extracting the generated refrigerant from the cooling reactor / zone 116 / 216 into a transport system using a suitable discharge mechanism from the cooling reactor / zone 116 / 216. Drugs derived from In one embodiment, the 126 / 226 output is Drugs derived from 126 / 2 26 are spread across the width of the transport system to minimize stacking or bundling of material and maximize surface area for gas absorption. Drugs derived from 126 / 2 2 Once 6 is deposited and suitably spread on the delivery system, in various embodiments, the delivery system is Drugs derived from 126 / 2 2 6 is transported through an opening in the carbon recovery unit 104 defined between the lower and upper portions discussed above. Drugs derived from 126 / 2 2 6 adsorbs the gas piped from the gas phase separator 200 to the bottom of the carbon recovery unit 104. Drugs derived from is condensed with a non-polar gas and then Drugs derived from High carbon Drugs derived from It should be understood that in various embodiments, Drugs derived from is the end product of the processes disclosed herein and is transported from the carbon recovery unit 104 to suitable storage or post-treatment equipment.

[0174] In one embodiment, the concentrated gas 204 is conveyed through a conveyor and Drugs derived from 126 / 2 2 After passing through 6, the resulting gas is extracted at the top of the carbon recovery unit 104. In various embodiments, the exhaust gas 134 is conveyed away to a suitable scrubber, stack, or capture system. In some embodiments, the exhaust gas is utilized for any reusable quality in the system, including for use in a secondary carbon recovery unit or for energy. In various embodiments, the off-gas that is not sent to the carbon recovery unit can be used for energy recovery (e.g., in a process gas heater) or as an inert gas (e.g., in a degassing unit, reactor, BPU, or cooler). Similarly, in various embodiments, the off-gas from the carbon recovery unit can be used for energy recovery (e.g., in a process gas heater), as an inert gas (e.g., in a degassing unit, reactor, BPU, or cooler), or in a secondary recovery unit.

[0175] raw Drugs derived from 126 / 2 2 It should be appreciated that 6 contains a large amount of carbon, which has a high preference for adsorbing non-polar gases. It should also be appreciated that the enriched gas stream 204 contains primarily non-polar gases, such as terpenes, carbon monoxide, carbon dioxide, and methane. In various embodiments, as the enriched gas is directed from the gas phase separator to the carbon recovery unit, the gas flow rate and conveyor speed are monitored and controlled to ensure that the enriched gas is not depleted. Drugs derived from 126 / 2 2 6. In another embodiment, the energetic organic compounds are eluted during carbonization of the biomass and comprise at least a portion of the enriched gas 204 output from the gas phase separator 200 to the carbon recovery unit 104. In various embodiments, the enriched gas 204 is further enriched with additional additives before being introduced into the carbon recovery unit or the material enrichment unit.

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

[0177]

[0023] Referring more generally to Figures 6-13, various embodiments of the present disclosure are illustrated and discussed. It should be understood that the various embodiments and alternatives discussed below with respect to Figures 6-13 apply to the embodiments of Figures 1-5 discussed above, and vice versa.

[0178] Now, specifically, with reference to FIG. 6, this embodiment can utilize a BPU that includes a single reactor with two or more different zones. In the illustrative embodiment, two zones are shown, but any different number of zones can be used. In one embodiment, each zone is connected to at least one other zone via a material transport unit (not shown). In one embodiment, the material transport unit controls the atmospheric and temperature conditions.

[0179] Specifically, in one embodiment illustrated in Figure 6, system 600 includes a material feed system 602, a BPU 606 including a pyrolysis zone 608 and a cooling zone 610, a cooler 614, and a carbon recovery unit 616. It should be understood that the cooler 614 in Figure 6 is external to the BPU 606 and is in addition to the cooling zone 610 that is present within the BPU 606.

[0180] In various embodiments, the system 600 includes an optional dryer between the material supply system 602 and the BPU 606. In various embodiments, the BPU 606 includes multiple zones. In FIG. 6, the BPU 606 includes a pyrolysis zone 608 and a cooling zone 610. The BPU 606 also includes at least multiple inlets and outlets for adding and removing various substances from the multiple zones 608, 610, including at least condensable vapors and non-condensable gases 612. It should be understood that in various embodiments discussed below, one or more of the multiple zones 608 or 610 are enclosed by the BPU 606.

[0181] Referring now to FIG. 7, an embodiment of a system 700 is illustrated and discussed. The system 700 includes a single reactor system including a material feed system 702, a preheater 706, a pyrolysis reactor 708, a cooler 714, and a carbon recovery unit 716. In various embodiments, the system 700 includes an optional dryer 704 between the material feed system 702 and the preheater 706. As seen in FIG. 7, the pyrolysis reactor 708 of an embodiment includes at least one gas inlet 710 and at least one outlet 712 for outputting material from the pyrolysis reactor 708. In various embodiments, the material output through the outlet 712 includes condensable vapors and / or non-condensable gases. It should be understood that the pyrolysis reactor 708 can include one or more zones not discussed in detail herein. In various embodiments, the system 700 includes one or more reactors in addition to the pyrolysis reactor 708.

[0182] Now referring to FIG. 8, one embodiment of a single reactor, multi-zone BPU system 800 is illustrated and discussed. The system 800 includes a material feed system 802, a BPU 808 having a pyrolysis zone 810 and a cooling zone 812, a material enrichment unit 818, and a carbon recovery unit 820. As with the embodiments discussed above, FIG. 8 also includes an optional dryer 804 located between the material feed system 802 and the BPU 808. It should be understood that moisture 806 from the dryer 804 is removed during the drying process. FIG. 8 also includes an optional cooler 816 outside the BPU 808 and prior to the material enrichment unit 818. As will be discussed in more detail below, the material enrichment unit 818 is in communication with a gas outlet 814 of the BPU 808, which carries condensable vapors and non-condensable gases from the BPU. It should be understood that the various embodiments illustrated in FIG. 8 include a carbon recovery unit 820 separate from the material enrichment unit 818. As discussed above, in various embodiments, the carbon recovery unit 820 of FIG. 8 is a suitable container in which the concentrated material is stored following the material concentration unit 818, and the carbon recovery unit 820 does not further concentrate the material.

[0183] It should be appreciated that in various embodiments, an optional process gas heater 824 is disposed in the system and attached to the BPU 808. In various embodiments, steam or other off-gas from the BPU 808 is input to the optional process gas heater 824 along with one or more external sources of air, natural gas, and nitrogen. As discussed below, in various embodiments, the air discharge from the process gas heater 824 is input to the dryer 804 as a heat or energy recovery system.

[0184] 9, a BPU 908 of a system 900 of one embodiment is illustrated and discussed. The BPU 908 includes multiple zones: a preheat zone 904, a pyrolysis zone 910, and a cooling zone 914. The BPU 908 of one embodiment also includes a material feed system 902 in communication with one of the zones at least one gas inlet 906 in communication with one or more of the zones 904, 910, 914. In various embodiments, one of the zones also includes at least one outlet 912 for outputting, in one embodiment, materials, condensable vapors, and / or non-condensable gases, as discussed below. In various embodiments, one of the zones also includes an outlet for outputting advanced carbon from the system 900.

[0185] 9 shows the gas inlet 906 connected to the preheat zone 904, it should be understood that various embodiments include inlets to any combination of the three zones. Similarly, the gaseous outlet 912 comes from the pyrolysis zone 910, but it should be understood that various embodiments include outlets from one or more of any combination of the three zones. As discussed below, various contemplated embodiments include inputs and outputs within the BPU: for example, the outlet of the pyrolysis zone 910 is then input to the preheat zone 904. It should be understood that in the illustrated embodiment, each of the reactors in the BPU are connected to each other via a material supply system, as discussed above.

[0186] In various embodiments, the preheat zone 904 of the BPU 908 is configured to feed the biomass 902 (or another carbon-containing feedstock) in a manner that does not "shock" the biomass, which breaks down cell walls and initiates rapid decomposition of the solid phase into steam and gas. In one embodiment, the preheat zone 904 can be considered a gentle pyrolysis.

[0187] In various embodiments, the pyrolysis zone 910 of the BPU 908 is configured as a primary reaction zone, where preheated material undergoes pyrolysis chemistry to release gases and condensable vapors, resulting in a solid material that is a high-carbon reaction intermediate. Biomass components (mainly cellulose, hemicellulose, and lignin) decompose to create vapors that escape by penetrating pores or creating new nanopores. The latter effect contributes to the creation of porosity and surface area.

[0188] In various embodiments, the cooling zone 914 of the BPU 908 is configured to receive the high carbon reaction intermediates and cool the solids, i.e., the cooling zone 914 is at a lower temperature than the pyrolysis zone 910. In the cooling zone 914, the chemistry and mass transport can be complex. In various embodiments, secondary reactions occur in the cooling zone 914. Carbon--containing components that are in the gas phase can form additional fixed carbon and / or adsorb to carbon. Thus, the advanced carbon 916 is not simply the solid degassed residue of the processing step, but includes additional carbon deposited from the gas phase, such as by decomposition of organic vapors (e.g., tars) that can form carbon.

[0189] Now, with reference to Figures 10-13, various multiple reactor embodiments of the system are illustrated and discussed. As with each of the embodiments, the system includes an optional degasser and an optional dryer, as discussed in more detail below. With reference to Figure 10, the system 1000 includes a material feed system 1002, a pyrolysis reactor 1012, a cooling reactor 1018, a cooler 1020, and a carbon recovery unit 1022. As discussed further below, a gas source 1016 is configured to input gas to one or both of the pyrolysis reactor 1012 and the cooling reactor 1018. In various embodiments, the pyrolysis reactor includes an outlet for outputting at least condensable vapors and / or non-condensable gases. In various embodiments, the carbon recovery unit 1022 includes an outlet 1024 for outputting porous carbon from the system 1000.

[0190] It should be understood that in at least various embodiments illustrated in Figures 10-13, the illustrated system includes an optional degasser and an optional dryer. For example, as can be seen in Figure 10, represented by dashed lines, optional degasser 1004 is connected to system 1000 between material supply system 1002 and pyrolysis reactor 1002. Similarly, dryer 1006 is connected to system 1000 between material supply system 1002 and pyrolysis reactor 1012. In various embodiments, dryer 1006 and degasser 1004 are also connected to each other such that material from the material supply system can follow any number of different paths through the material supply system, degasser, dryer, and pyrolysis reactor. It should be understood that in some embodiments, material passes through only one of optional degasser 1004 and dryer 1006.

[0191] In some embodiments, referring to FIG. Drugs derived from The process for producing a carbonaceous material comprises the steps of: providing a carbonaceous feedstock comprising biomass; optionally drying the feedstock to remove at least a portion of the moisture contained within the feedstock; and optionally degassing the feedstock to remove any residual moisture, if any, contained within the feedstock. Inside the gapremoving at least a portion of the oxygen; pyrolyzing the feedstock in the presence of a substantially inert gas phase for at least about 10 minutes and at least one temperature selected from about 250° C. to about 700° C. to produce a high temperature pyrolyzed solid, a condensable vapor, and a non-condensable gas; separating at least a portion of the condensable vapor and at least a portion of the non-condensable gas from the high temperature pyrolyzed solid; cooling the high temperature pyrolyzed solid to produce a low temperature pyrolyzed solid; and separating the high carbon product comprising at least a portion of the low temperature pyrolyzed solid. Drugs derived from and recovering the

[0192] 11, an embodiment of a multiple reactor system 1100 is illustrated. Similar to the embodiment discussed above and illustrated in FIG. 10, this embodiment includes a material feed system 1102, a pyrolysis reactor 1112, a cooling reactor 1118, and a carbon recovery unit 1124. In the illustrated embodiment of FIG. 11, the cooler 1120 is optional, and a material enrichment unit 1122 is disposed between the optional cooler 1120 and the carbon recovery unit 1124. It should be understood that in various embodiments, the material enrichment unit 1122 enriches the material before continuing to a separate carbon recovery unit 1124, which may or may not further enrich the material. In various embodiments, an optional degasser 1104 and an optional dryer 1106 are disposed between the material feed system 1102 and the pyrolysis reactor 1112. In the illustrated embodiment, the pyrolysis reactor 1112 also includes an outlet 1114 configured to remove substances such as condensable vapors and non-condensable gases and send the removed substances to a material enrichment unit 1122.

[0193] Various embodiments extend the concept of additional carbon formation by including a separate material enrichment unit 818, 1122 in which the cooled carbon is subjected to an environment containing carbon-containing species to enrich the carbon content of the final product. If the temperature of this unit is lower than the pyrolysis temperature, the additional carbon is expected to be in the form of adsorbed carbonaceous species rather than additional fixed carbon.

[0194] Referring now to FIG. 14, one embodiment of a single reactor biomass processing unit 1400 is illustrated. The unit 1400 includes a hopper 1404 into which a feedstock 1402 is fed. The hopper 1404 is optionally configured to allow for the addition and / or mixing of reactor off-gas (e.g., steam stream 1414) and / or additives and / or gases from an external source 1462 to the feedstock 1402 prior to conveying the feedstock 1402 to the reactor 1412. Activated carbon 1426 is mechanically conveyed through the reactor 1412 before exiting at the opposite end. Steam, nitrogen, carbon dioxide, or a combination thereof 1452 is introduced into the reactor 1412 in a countercurrent manner compared to the biomass path. The steam stream 1414 is at least partially removed from the reactor 1412 and optionally fed to the hopper 1404 and then to the thermal oxidizer 1424. Heat exchanger 1454 allows heat from the thermal oxidizer discharge to heat gas stream 1458, which may include nitrogen and / or carbon dioxide. Gas stream 1458, or a portion thereof, is recycled via path 1460 to reactor 1412 and / or, optionally, to feedstock 1402 prior to entering reactor 1412 (not shown). Off-gas 1456 can be disposed of according to standard methods, for example, through a stack.

[0195] Referring now to Figure 15, one embodiment of a two reactor biomass processing unit 1500 is illustrated. The unit 1500 includes a first multi-zone reactor unit 1512A that is configured substantially similarly to the processing unit 1400 described above with respect to Figure 14. However, in this embodiment, the biomass produced by the reactor 1512A is mixed with the first multi-zone reactor unit 1512A. OriginAt least a portion of the activated carbon 1526A is fed to a hopper 1504 and then fed to the second reactor 1512B via path 1502. At least a portion of the optionally thermally oxidized and optionally conditioned vapor stream 1560 produced by the first reactor 1512A, the thermal oxidizer 1524, and the heat exchanger 1554 is fed in countercurrent to the second reactor 1512B. Optionally, at least a portion of the off-gas from the second reactor 1512B is recycled via path 1572 to indirectly heat the second reactor 1512B. Alternatively, or in addition, the portion of the off-gas that is not recycled as heat can be disposed of, for example, by a stack, via path 1556B. Origin The activated carbon product exits the second reactor 1512B via path 1526B.

[0196] As described in detail below, numerous options exist with regard to intermediate input and output (purge or probe) streams of one or more phases present in any particular reactor, various mass and energy recycle schemes, various additives that may be introduced anywhere in the process, tunability of process conditions, including both reaction and separation conditions to tailor product distribution, etc. Zone or reactor specific input and output streams allow for superior process monitoring and control, such as through FTIR sampling and dynamic process adjustments.

[0197] The present disclosure differs from fast pyrolysis and also differs from conventional slow pyrolysis. High quality carbon materials in the present disclosure, including compositions with a high percentage of fixed carbon, can be obtained from the disclosed processes and systems.

[0198] Exemplary Uses Silicon products can be produced using porous carbon and some form of silicon dioxide in a furnace. Generally, the silicon dioxide introduced into a silicon production furnace needs to be relatively large (e.g., tennis ball size). Both silica fume and raw silicon (river rock) can be used in a silicon production furnace only if they are combined into larger carbon rods that allow the product to "sink" toward the electrode in the furnace. The raw material is essentially river rock. The supply of river rock that is both of sufficient purity and useful size is limited. A composition that overcomes this problem is disclosed herein.

[0199] Surprisingly, the inventors have found that (1) the compositions described herein allow for the use of higher purity and / or smaller (cheaper) silicon dioxide sources than previously available for use in silicon production furnaces, e.g., electric arc furnaces and submerged arc furnaces, (2) the proximity of carbon and silicon dioxide in the densified compositions results in more efficient conversion to silicon (thus the closer proximity achieved by densification is an important structural aspect), and (3) the compositions, due to their higher purity (higher purity is an important structural aspect), improve the overall quality of any final silicon product produced using the compositions.

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

[0201] All publications, patents, and patent applications cited in this specification are herein incorporated by reference in their entirety as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated herein.

[0202] Where the methods and steps described above indicate certain events occurring in a particular order, one of ordinary skill in the art will recognize that the order of certain steps may be varied and that such variations are consistent with the variations of the present disclosure. Additionally, certain steps may be performed simultaneously in a parallel process where possible, or may be performed sequentially.

[0203] Some variations of the present disclosure, at least in part, allow multiple reactors or multiple zones within a single reactor to be designed and operated to optimize carbon yield and product quality from pyrolysis while maintaining flexibility and adjustability to feedstock variations and product requirements.

[0204] The above explanation is Origin It should not be construed as limiting in any way with respect to the potential applications of the porous carbon. Origin Injection of porous carbon into gas streams can be useful in controlling pollutant emissions in gas or liquid streams derived from coal-fired power plants, biomass-fired power plants, metal processing plants, crude oil refineries, chemical plants, polymer plants, pulp and paper plants, cement plants, waste incinerators, food processing plants, gasification plants, and syngas plants. EXAMPLES

[0205] Example 1. Silicon dioxide Origin Preparation of Porous Carbon Compositions—General Methods. Woody biomass (red pine sawdust) is placed in a hopper and optionally conveyed to a dryer where the moisture in the wood is reduced to less than 15%, and then the biomass is conveyed to a reactor system described herein where the biomass is heated to about 650 degrees Celsius for about 30 minutes and activated with a gas stream containing primarily CO2 and H2O. The porous carbon is then discharged from the reactor, cooled with N2 and H2O, and conveyed to a mixer where 25% by weight of silicon dioxide is introduced and mixed with the porous carbon for about 5 minutes. The mixed silicon dioxide raw material is then cooled with N2 and H2O. OriginThe porous carbon composition was conveyed to an extruder where it was extruded into approximately 0.25 inch by 1 inch pellets which were then sent to a dryer and dried to less than about 8 percent moisture.

[0206] It will also be appreciated that, although specific embodiments have been described herein for purposes of illustration, various modifications may be made without departing from the scope of the invention. Accordingly, the invention is not limited except as by the appended claims.

[0207] paragraph A. A slag product comprising, on a dry basis, at least about 50% by weight total carbon, at most about 5% by weight hydrogen, at most about 1% by weight nitrogen, at most about 0.5% by weight phosphorus, at most about 0.2% by weight sulfur, at most about 0.02% by weight titanium, at most about 0.5% by weight calcium, at most about 0.1% by weight aluminum, and silicon dioxide, wherein the total carbon is Origin Carbon-containing, high-carbon Drugs derived from composition.

[0208] paragraph B. A river rock comprising, on a dry basis, at least about 50% by weight total carbon, at most about 5% by weight hydrogen, at most about 1% by weight nitrogen, at most about 0.5% by weight phosphorus, at most about 0.2% by weight sulfur, at most about 0.02% by weight titanium, at most about 0.5% by weight calcium, at most about 0.1% by weight aluminum, and silicon dioxide, wherein the silicon dioxide is contained within the river rock and the total carbon is at least about 50% by weight hydrogen, at most about 5% by weight nitrogen, at most about 1% by weight phosphorus, at most about 0.2% by weight sulfur, at most about 0.02% by weight titanium, at most about 0.5% by weight calcium, at most about 0.1% by weight aluminum, and silicon dioxide; Origin Carbon-containing, high-carbon Drugs derived from composition.

[0209] paragraph C. A silica fume sintered product comprising, on a dry basis, at least about 50% by weight total carbon, at most about 5% by weight hydrogen, at most about 1% by weight nitrogen, at most about 0.5% by weight phosphorus, at most about 0.2% by weight sulfur, at most about 0.02% by weight titanium, at most about 0.5% by weight calcium, at most about 0.1% by weight aluminum, and silicon dioxide, wherein the silicon dioxide is contained within the silica fume and the total carbon is at least about 50% by weight of the silica fume sintered product. Origin Carbon-containing, high-carbon Drugs derived from composition.

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

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

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

[0213] paragraph G. A high-carbon biomaterial comprising at least about 70% by weight of total carbon, comprising any one of Paragraphs A to F. Drugs derived from composition.

[0214] paragraph H. A high-carbon biomass of any one of Paragraphs A to G, containing at least about 95% by weight of total carbon. Drugs derived from composition.

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

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

[0217] paragraph K. Any one of Paragraphs A to J, comprising at least about 1% by weight of silicon dioxide. Drugs derived from composition.

[0218] paragraph L. High carbon raw material Drugs derived from The composition is a high carbon composite material selected from any one of Para A to K, which is extruded. Drugs derived from composition.

[0219] paragraph M. High carbon raw material Drugs derived from The composition is a high-carbon composite material selected from any one of Para A to Para L, which is densified. Drugs derived from composition.

[0220] paragraph N. High carbon raw material Drugs derived from The composition is a high-carbon composite material according to any one of Para A to Para M, which is in the form of pellets. Drugs derived from composition.

[0221] paragraph O. High carbon raw material Drugs derived from The composition is a high carbon fiber composite material comprising any one of Para A to N having dimensions of at least about 0.64 cm (0.25 inches) by about 2.5 cm (1.0 inches) and up to about 5.1 cm (2.0 inches) by about 15 cm (6.0 inches). Drugs derived from composition.

[0222] paragraph P. high carbon raw material Drugs derived from The composition has a viscosity of about 560 to about 720 kg / m 3 A high-carbon raw material having a bulk density of 35 to 45 pounds per cubic foot (35 to 45 pounds per cubic foot) Drugs derived from composition.

[0223] paragraph Q.High carbon raw material Drugs derived from The composition comprises any one of Para A to Para P having an iodine value of at least about 300. Drugs derived from composition.

[0224] paragraph R. A river rock comprising, on a dry basis, at least about 50% by weight total carbon, at most about 5% by weight hydrogen, at most about 1% by weight nitrogen, at most about 0.5% by weight phosphorus, at most about 0.2% by weight sulfur, at most about 0.02% by weight titanium, at most about 0.5% by weight calcium, at most about 0.1% by weight aluminum, and at least about 15% by weight silicon dioxide, wherein the silicon dioxide is contained within the river rock and the total carbon is Origin Contains carbon and is high in carbon Drugs derived fromThe composition is densified and in the form of pellets having dimensions of at least about 0.25 inches by about 1.0 inches, and has a compressibility of about 560 to about 720 kg / m 3 High carbon raw material with a bulk density of 35-45 pounds per cubic foot Drugs derived from composition.

[0225] paragraph S. A silica fume sintered product, comprising, on a dry basis, at least about 50% by weight total carbon, at most about 5% by weight hydrogen, at most about 1% by weight nitrogen, at most about 0.5% by weight phosphorus, at most about 0.2% by weight sulfur, at most about 0.02% by weight titanium, at most about 0.5% by weight calcium, at most about 0.1% by weight aluminum, and at least about 15% by weight silicon dioxide, wherein the silicon dioxide is contained within the silica fume and the total carbon is at least about 10% by weight of the silica fume sintered product. Origin Contains carbon and is high in carbon Drugs derived from The composition is densified and in the form of pellets having dimensions of at least about 0.25 inches by about 1.0 inches, and has a compressibility of about 560 to about 720 kg / m 3 High carbon raw material with a bulk density of 35-45 pounds per cubic foot Drugs derived from composition.

[0226] paragraph T. high carbon biogenic Drugs derived from16. A process for producing a carbon-containing feedstock comprising: providing a carbon-containing feedstock comprising dried biomass; preheating the feedstock in a preheating zone in the presence of a substantially inert gas for at least about 5 minutes and at a preheating temperature selected from about 80° C. to about 500° C.; pyrolyzing the feedstock in a pyrolysis zone in the presence of a substantially inert gas for at least about 10 minutes and at a pyrolysis temperature selected from about 250° C. to about 700° C. to produce a high-carbon product comprising at least a portion of the condensable vapors and at least a portion of the non-condensable gases; cooling the high-carbon product in a cooling zone in the presence of the substantially inert gas for at least about 5 minutes and at a cooling temperature lower than the pyrolysis temperature to produce a warm pyrolyzed solid; cooling the warm pyrolyzed solid in a cooler separate from the cooling zone to produce a low-carbon product; Drugs derived from and recovering said silicon dioxide, and further comprising introducing silicon dioxide into said process.

[0227] paragraph U. The process of para T, further comprising drying said feedstock to remove at least a portion of moisture contained within said feedstock, if present, prior to preheating said feedstock.

[0228] paragraph V. The process of Para T or U, further comprising degassing said feedstock prior to preheating said feedstock to remove at least a portion of the molecular oxygen, if present, contained within said feedstock.

[0229] paragraph W. The process of any one of Paras T through V, wherein introducing the silicon dioxide includes introducing silica fume.

[0230] paragraphX. The process of any one of Paras T through W, wherein introducing the silicon dioxide includes introducing river rock.

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

[0232] paragraph Z. High carbon raw material Drugs derived from The process of any one of paras. T-Y, further comprising pressing, combining, pelletizing, extruding, or agglomerating the The present application provides the following aspects of the invention. (Aspect 1) High carbon Drugs derived from A composition comprising, on a dry basis: at least about 50% by weight total carbon; up to about 5% by weight hydrogen, up to about 1% by weight of nitrogen, up to about 0.5% by weight phosphorus; up to about 0.2% by weight sulfur; A maximum of about 0.02% by weight of titanium, Up to about 0.5% calcium, A maximum of about 0.1% aluminum, and Contains silicon dioxide, The total carbon is Origin Carbon-containing, high-carbon Drugs derived from composition. (Aspect 2) High carbon Drugs derived from A composition comprising, on a dry basis: at least about 50% by weight total carbon; up to about 5% by weight hydrogen, up to about 1% by weight of nitrogen, up to about 0.5% by weight phosphorus; up to about 0.2% by weight sulfur; A maximum of about 0.02% by weight of titanium, Up to about 0.5% calcium, A maximum of about 0.1% aluminum, and Contains silicon dioxide, the silicon dioxide is contained within river rocks; The total carbon is Origin Carbon-containing, high-carbon Drugs derived from composition. (Aspect 3) High carbon Drugs derived from A composition comprising, on a dry basis: at least about 50% by weight total carbon; up to 5% by weight hydrogen, maximum 1% by weight of nitrogen, up to about 0.5% by weight phosphorus; up to about 0.2% by weight sulfur; A maximum of about 0.02% by weight of titanium, Up to about 0.5% calcium, A maximum of about 0.1% aluminum, and Contains silicon dioxide, The silicon dioxide is contained within a silica fume; The total carbon is Origin Carbon-containing, high-carbon Drugs derived from composition. (Aspect 4) 2. The high carbon production method according to claim 1, wherein the silicon dioxide is contained within river rocks. Drugs derived from composition. (Aspect 5) 2. The high carbon production method according to claim 1, wherein the silicon dioxide is contained within silica fume. Drugs derived from composition. (Aspect 6) 6. The high carbon feedstock of any one of claims 1 to 5, comprising at least about 65% by weight of total carbon. Drugs derived from composition. (Aspect 7) 7. The high carbon feedstock of any one of claims 1 to 6, comprising at least about 70% by weight of total carbon. Drugs derived from composition. (Aspect 8) 8. The high carbon feedstock of any one of claims 1 to 7, comprising at least about 95% by weight of total carbon. Drugs derived from composition. (Aspect 9) The high carbon composite material according to any one of the first to seventh embodiments, comprising at least about 15% by weight of silicon dioxide. Drugs derived from composition. (Aspect 10) The high carbon fiber material according to any one of the first to sixth aspects, comprising at least about 25% by weight of silicon dioxide. Drugs derived from composition. (Aspect 11) The high carbon composite material according to any one of the first to eighth embodiments, comprising at least about 1 wt. % silicon dioxide. Drugs derived from composition. (Aspect 12) The high carbon Drugs derived from 12. The high carbon fiber composition according to any one of the preceding claims, wherein the composition is extruded. Drugs derived from composition. (Aspect 13) The high carbon Drugs derived from 13. The high carbon composition according to any one of aspects 1 to 12, wherein the composition is densified. Drugs derived from composition. (Aspect 14) The high carbon Drugs derived from 14. The high carbon production method according to any one of aspects 1 to 13, wherein the composition is in the form of pellets. Drugs derived from composition. (Aspect 15) The high carbon Drugs derived from 15. The high carbon fiber composition of any one of embodiments 1 to 14, wherein the composition has dimensions of at least about 0.25 inches by about 1.0 inches and up to about 2.0 inches by about 6.0 inches. Drugs derived from composition. (Aspect 16) The composition has a viscosity of about 560 to about 720 kg / m 3 The high carbon raw material according to any one of embodiments 1 to 15, having a bulk density of about 35 to about 45 pounds per cubic foot. Drugs derived from composition. (Aspect 17) The high carbon Drugs derived from The high carbon composition according to any one of the first to third aspects, wherein the composition has an iodine value of at least about 300. Drugs derived from composition. (Aspect 18) High carbon Drugs derived from A composition comprising, on a dry basis: at least about 50% by weight total carbon; up to about 5% by weight hydrogen, up to about 1% by weight of nitrogen, up to about 0.5% by weight phosphorus; up to about 0.2% by weight sulfur; A maximum of about 0.02% by weight of titanium, Up to about 0.5% calcium, A maximum of about 0.1% aluminum, and Contains at least about 15% by weight of silicon dioxide; the silicon dioxide is contained within river rocks; The total carbon is Origin Contains carbon, The high carbon Drugs derived from The composition is densified and in the form of pellets having dimensions of at least about 0.25 inches by about 1.0 inches, and has a compressibility of about 560 to about 720 kg / m 3 High carbon raw material with a bulk density of 35-45 pounds per cubic foot Drugs derived from composition. (Aspect 19) High carbon Drugs derived from A composition comprising, on a dry basis: at least about 50% by weight total carbon; up to about 5% by weight hydrogen, up to about 1% by weight of nitrogen, up to about 0.5% by weight phosphorus; up to about 0.2% by weight sulfur; A maximum of about 0.02% by weight of titanium, Up to about 0.5% calcium, A maximum of about 0.1% aluminum, and Contains at least about 15% by weight of silicon dioxide; the silicon dioxide is contained within silica fume; The total carbon is Origin Contains carbon, The high carbon Drugs derived from The composition is densified and in the form of pellets having dimensions of at least about 0.25 inches by about 1.0 inches, and has a compressibility of about 560 to about 720 kg / m 3High carbon raw material with a bulk density of 35-45 pounds per cubic foot Drugs derived from composition. (Aspect 20) High carbon Drugs derived from 1. A process for producing a compound comprising: Providing a carbon-containing feedstock comprising dry biomass; preheating the feedstock in a preheat zone in the presence of a substantially inert gas for at least about 5 minutes and at a preheat temperature selected from about 80° C. to about 500° C.; pyrolyzing the feedstock in a pyrolysis zone in the presence of a substantially inert gas for at least about 10 minutes and at a pyrolysis temperature selected from about 250° C. to about 700° C. to produce hot pyrolyzed solids, condensable vapors, and non-condensable gases; separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids; cooling the hot pyrolyzed solids in a cooling zone in the presence of the substantially inert gas for at least about 5 minutes and at a cooling temperature below the pyrolysis temperature to produce warm pyrolyzed solids; cooling the warm pyrolyzed solids in a cooler separate from the cooling zone to produce low temperature pyrolyzed solids; A high carbon product comprising at least a portion of the low temperature pyrolyzed solids. Drugs derived from and recovering the The process further comprising introducing silicon dioxide into the process. (Aspect 21) 21. The process of embodiment 20, further comprising drying the feedstock prior to preheating the feedstock to remove at least a portion of moisture contained within the feedstock, if present. (Aspect 22) 22. The process of claim 20 or 21, further comprising degassing the feedstock prior to preheating the feedstock to remove at least a portion of molecular oxygen, if present, contained within the feedstock. (Aspect 23) 23. The process of any one of embodiments 20-22, wherein introducing the silicon dioxide comprises introducing silica fume. (Aspect 24) 24. The process of any one of embodiments 20-23, wherein introducing the silicon dioxide comprises introducing river rock. (Aspect 25) The process of any one of embodiments 20-24, further comprising densification. (Aspect 26) The high carbon Drugs derived from 26. The process of any one of embodiments 20-25, further comprising pressing, combining, pelletizing, extruding, or agglomerating the mixture.

Claims

1. A method for producing a biologically derived agent comprising silicon dioxide for use in silicon production, the method comprising: Providing a carbon-containing feedstock comprising dry biomass; preheating the feedstock in a preheat zone in the presence of an inert gas for at least 5 minutes and at a preheat temperature selected from 80° C. to 500° C.; pyrolyzing the feedstock in a pyrolysis zone in the presence of an inert gas for at least 10 minutes and at a pyrolysis temperature selected from 250° C. to 700° C. to produce hot pyrolyzed solids, condensable vapors, and non-condensable gases; separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids; cooling the hot pyrolyzed solids in a cooling zone in the presence of the inert gas for at least 5 minutes and at a cooling temperature below the pyrolysis temperature to produce warm pyrolyzed solids; cooling the warm pyrolyzed solids in a cooler separate from the cooling zone to produce low temperature pyrolyzed solids; recovering a biological agent comprising at least a portion of the low temperature pyrolyzed solids; introducing silicon dioxide contained within river rock or within silica fume into the process to form said silicon dioxide-containing biological agent; The silicon dioxide-containing biological agent comprises, on a dry basis: at least 50% by weight total carbon; At least trace amounts up to 5% by weight of hydrogen, At least trace amounts up to 1% by weight of nitrogen; At least trace amounts up to 0.5% by weight of phosphorus; At least trace amounts up to 0.2 wt. % sulfur; at least 0% and at most 0.02% by weight titanium; at least 0% by weight and up to 0.5% calcium, at least 0% by weight and up to 0.1% aluminum, and at least 1 wt.%, at least 15 wt.%, or at least 25 wt.% silicon dioxide; and The method, wherein the total carbon comprises biological carbon.

2. The method of claim 1, wherein when said river rock is used, the grain size is between 0.01 mm and 12 mm.

3. 3. The method of claim 1 or 2, further comprising drying the feedstock prior to preheating the feedstock to remove at least a portion of the moisture, if present, contained within the feedstock.

4. 4. The method of claim 1, further comprising degassing the feedstock prior to preheating the feedstock to remove at least a portion of the molecular oxygen, if present, contained within the feedstock.

5. The method of any one of claims 1 to 4, further comprising densification.

6. 6. The method of any one of claims 1 to 5, further comprising compressing, binding, pelletizing, extruding, or agglomerating the silicon dioxide-containing biological agent.

7. A biologically derived pharmaceutical composition comprising silicon dioxide for use in the production of silicon, comprising, on a dry basis: at least 50% by weight total carbon; At least trace amounts up to 5% by weight of hydrogen, At least trace amounts up to 1% by weight of nitrogen; At least trace amounts up to 0.5% by weight of phosphorus; At least trace amounts up to 0.2 wt. % sulfur; at least 0% and at most 0.02% by weight titanium; at least 0% by weight and up to 0.5% calcium, at least 0% by weight and up to 0.1% aluminum, and at least 1 wt.%, at least 15 wt.%, or at least 25 wt.% silicon dioxide; the total carbon includes biogenic carbon; the silicon dioxide is derived from river rocks, or A biopharmaceutical composition comprising silicon dioxide for use in the production of silicon, wherein the silicon dioxide is derived from silica fume.

8. 8. The composition for use in silicon production of claim 7 comprising at least 65%, at least 70%, or at least 95% by weight total carbon.

9. 9. A composition for use in silicon production according to claim 7 or 8, which is extruded, densified or in pellet form.

10. 10. A composition for use in the production of silicon according to any one of claims 7 to 9 having dimensions of at least 0.64 cm (0.25 in) by 2.5 cm (1.0 in) and up to 5.1 cm (2.0 in) by 15 cm (6.0 in).

11. 560-720kg / m ３ 11. The composition for use in silicon production according to any one of claims 7 to 10, having a bulk density of (35 to 45 pounds per cubic foot).

12. A composition for use in the production of silicon according to any one of claims 7 to 11 having an iodine value of at least 300.

13. 13. The composition for use in producing silicon, Contains at least 15% by weight of silicon dioxide; the silicon dioxide is derived from river rock; the total carbon includes biogenic carbon; and The composition is densified and in the form of pellets having dimensions of at least 0.64 cm (0.25 in) by 2.5 cm (1.0 in), and has a compressibility of 560 to 720 kg / m ３ (35-45 pounds per cubic foot); A composition for use in the production of silicon according to any one of claims 7 to 12.

14. 13. The composition for use in producing silicon, Contains at least 15% by weight of silicon dioxide; the silicon dioxide is derived from silica fume; the total carbon includes biogenic carbon; and The composition is densified and in the form of pellets having dimensions of at least 0.64 cm (0.25 in) by 2.5 cm (1.0 in), and has a compressibility of 560 to 720 kg / m ３ 13. The composition for use in silicon production according to any one of claims 7 to 12, having a bulk density of (35 to 45 pounds per cubic foot).

15. A method for producing a biologically derived agent comprising silicon dioxide for use in silicon production, the method comprising: Providing a carbon-containing feedstock comprising dry biomass; preheating the feedstock in a preheat zone in the presence of an inert gas for at least 5 minutes and at a preheat temperature selected from 80° C. to 500° C.; pyrolyzing the feedstock in a pyrolysis zone in the presence of an inert gas for at least 10 minutes and at a pyrolysis temperature selected from 250° C. to 700° C. to produce hot pyrolyzed solids, condensable vapors, and non-condensable gases; separating at least a portion of the condensable vapors and at least a portion of the non-condensable gases from the hot pyrolyzed solids; cooling the hot pyrolyzed solids in a cooling zone in the presence of the inert gas for at least 5 minutes and at a cooling temperature below the pyrolysis temperature to produce warm pyrolyzed solids; cooling the warm pyrolyzed solids in a cooler separate from the cooling zone to produce low temperature pyrolyzed solids; recovering a biological agent comprising at least a portion of the low temperature pyrolyzed solids; introducing silicon dioxide contained within river rock or silica fume into the process to form the silicon dioxide-containing biological agent; The method uses at least 1 wt.%, at least 15 wt.%, or at least 25 wt.% silicon dioxide; The silicon dioxide-containing biological agent comprises, on a dry basis: at least 50% by weight total carbon; At least trace amounts up to 5% by weight of hydrogen, At least trace amounts up to 1% by weight of nitrogen; At least trace amounts up to 0.5% by weight of phosphorus; At least trace amounts up to 0.2 wt. % sulfur; at least 0% and at most 0.02% by weight titanium; at least 0% by weight and up to 0.5% calcium, at least 0% by weight and up to 0.1% aluminum, and at least 1 wt.%, at least 15 wt.%, or at least 25 wt.% silicon dioxide; and The method, wherein the total carbon comprises biological carbon.

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