System and method of manufacturing biocarbon and activated carbon extruded pellets

Abstract

A pyrolysis plant processes organic waste to manufacture biocarbon pellets, and more specifically to manufacture activated biocarbon pellets by slow pyrolysis. The process to produce the pellets involves using biocarbon powder, bio-oil, and pyroligneous acid produced from the pyrolysis plant to provide an improved activated biocarbon pellet. The activated biocarbon pellet comprises a biocarbon powder blended with a bio-oil at a ratio of 5% to 35% with a moisture content of 8% or less and a ball-pan hardness of greater than 90.

Description

SYSTEM AND METHOD OF MANUFACTURINGBIOCARBON AND ACTIVATED CARBON EXTRUDED PEEEETSFIEED

[0001] This field herein is directed to manufacturing biocarbon pellets, and more specifically to manufacturing activated biocarbon pellets by slow pyrolysis.BACKGROUND

[0002] U.S. Pat. No. 11,654,418 to Titan Clean Energy Projects Corporation, assignee of the present application, discloses a process for pelletizing a spent bleaching earth (SBE) into a clay- biocarbon composite including classifying the SBE based on at least one parameter of the SBE, selecting at least one filler compound and mixing the at least one filler compound with the SBE to make a mixture, forming a plurality of pellets out of the mixture, and pyrolyzing the pellets to produce the clay-biocarbon composite. Pyrolyzing a pelleted spent bleaching earth (SBE) may include advancing the pelleted SBE with a distributer to a first thermal chamber for providing even thermal processing, releasing the pelleted SBE to an auger to cool to room temperature, and condensing at least one volatile compound emitted from the pelleted SBE during thermal processing to produce a condensate for reuse.SUMMARY

[0003] The aspects described herein in any and / or all combinations.receiving an organic waste product; an infeed auger advancing the organic waste product to a rotary valve; a rotary valve receiving the organic waste product from the infeed auger and transferring the organic waste product to a distribution auger via an infeed airlock; a plurality of retorts each receiving a portion of the organic waste product from the distribution auger, the plurality of retorts each having a rotating retort auger therein moving the organic waste product along the retort, the plurality of retorts have an oxygen-free atmosphere therein; a pyrolysis unit with the plurality of retorts passing therethrough, the pyrolysis unit heating the plurality of retorts to pyrolyze the organic waste product to produce a biocarbon; a pipe located at or near a top of the retorts receive volatile compounds emitted from the organic waste product; a condenser coupled to the pipe condensing at least a portion of the volatile compounds into a condensate; a separator receiving the condensate and separating the condensate into a pyroligneous acid, a bio-oil, and a syngas; a vinegar pump pumping the pyroligneous acid to a pyroligneous acid tank; a tar pump pumping the bio-oil to a tar tank; a syngas vacuum pump compressing the syngas to provide to the pyrolysis unit for combustion; a spray pump collecting remaining moisture and applying the moisture to a heat exchanger to cool the condenser; a retort collection auger receiving the biocarbon from the plurality of retorts; and a discharge auger advancing the biocarbon to a discharge airlock to discharge the biocarbon. In some aspects, the infeed airlock comprises a six- chamber rotary valve. A rate of rotation of the rotary valve may be controlled by a variable frequency drive synchronized with the infeed auger and the distribution auger. The plurality of retorts may be between three retorts and six retorts. Each of the plurality of retorts may be tubular shaped. A vacuum pump may maintain the plurality of retorts at a negative pressure. At least one thermocouple may measure a temperature within the plurality of retorts. The pyrolysis unit mayThe condenser may comprise a continuous closed-loop water cooling system.

[0005] According to another aspect, there is provided a process for producing an activated biocarbon pellet. The process may blend a mixture of a biocarbon powder with a bio-oil and a pyroligneous acid in a solvent solution; heat the mixture to between 60°C and 95°C to produce a dry biocarbon powder; pelletizing the dry biocarbon powder with water or wood vinegar to produce a plurality of pellets; drying the pellets to less than about 8% moisture; and calcining the dry pellets in a steam or carbon dioxide atmosphere to produce a plurality of calcined pellets. The mixture may have a ratio of about 5% to about 35% of the biocarbon powder to the bio-oil. The mixture may be blended for between about 6-hours to about 24-hours. The plurality of pellets may be calcined at between 500°C to 1000°C. The process may further comprise milling the biocarbon powder to a target particle size of between about 1 -micron to about 100-microns before blending. The process may further comprise pyrolyzing an organic waste product in an oxygen-free atmosphere to produce the biocarbon powder, the bio-oil, and the pyroligneous acid. The process may further comprise adding at least one of: a strong acid, a strong base, a nutrient, mineral, and a cellulosic material to the mixture. The process may further comprising impregnating the calcined pellets with at least one nutrient to produce a plurality of impregnated pellets; and further drying the impregnated pellets to produce a slow-release fertilizer. The process may further comprise soaking the calcined pellets in at least one of: the pyroligneous acid, a metal salt, a strong acid, and a strong base to produce a plurality of soaked pellets; further drying the soaked pellets to produce a plurality of further dried pellets; and recalcining the further dried pellets.

[0006] According to another aspect, there is provided an activated biocarbon pellet comprising: a biocarbon powder blended with a bio-oil at a ratio of about 5% to about 35%; a moisture contentsize of between about 1 -micron to about 100-microns. A pellet size may be selected from 2-mm, 3-mm, 4-mm, 5-mm, and 6-mm.DESCRIPTION OF THE DRAWINGS

[0007] While the claims are in the concluding portions hereof, example embodiments are provided in the accompanying detailed description which may be understood in conjunction with the accompanying diagrams where like parts in the several diagrams are labeled with like numbers, and where:

[0008] Figure 1 is a process flow diagram for a pyrolysis plant;

[0009] Figure 2 is another process diagram of the pyrolysis plant;

[0010] Figure 3 is a flowchart of a process for the pyrolysis plant;

[0011] Figure 4 is a side cross-section view of a secondary gas process chamber of the pyrolysis plant;

[0012] Figure 5 is a vacuum system for the pyrolysis plant;

[0013] Figure 6 is a photograph of a biocarbon in powdered form; and

[0014] Figure 7 is a photograph of a plurality of activated biocarbon pellets.DETAILED DESCRIPTION

[0015] Illustrative embodiments described below. The following explanation provides specific details for a thorough understanding of and enabling description for these embodiments. Oneother instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments.

[0016] Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise," "comprising," and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of "including, but not limited to." Words using the singular or plural number also include the plural or singular number respectively. Additionally, the words "herein," "above," "below" and words of similar import, when used in this application, refer to this application as a whole and not to any particular portions of this application. When the claims use the word "or" in reference to a list of two or more items, that word covers all the following interpretations of the word: any of the items in the list, all of the items in the list and any combination of the items in the list. When the word "each" is used to refer to an element that was previously introduced as being at least one in number, the word "each" does not imply a plurality of the elements but can also mean a singular element.

[0017] Biocarbon (e.g. biochar) is a material that sequesters approximately 3-tonnes of carbon dioxide per tonne of biochar produced. This is accomplished by thermally stabilizing the carbon entrained in the plant material that uses carbon dioxide from the atmosphere for its growth from photosynthesis. The biocarbon is 100% renewable and can be produced in a sustainable manner from an organic waste products (e.g. agricultural biomass and / or waste wood) so that a significant net amount of carbon dioxide is sequestered from the atmosphere during manufacturing. As described herein, the organic waste product is waste wood that is converted to a high-carbon content biocarbon (e.g. >85% carbon, <15% ash). The biocarbon may have properties including,may also be sterile with zero moisture.

[0018] When the biocarbon are bulky, dusty granules or fine dusty powders 600 (such as shown in FIG. 6), the biocarbon is difficult to handle, poses an inhalation hazard, and / or a fire hazard. As described herein, an activated biocarbon pellet 700 (such as shown in FIG. 7) may be produced that mitigates one or more of these attributed of powdered biocarbon. The activated biocarbon pellets may be a durable, extruded pellet and may have a chemical adsorption effect, a moisture absorption effect and / or a disinfection effect.

[0019] The activated biocarbon pellets may have applications in agriculture, odour adsorption, and / or chemical adsorption, such as for example odour control of pet, household, and / or appliance (such as kitchen dehydrators or composters) odors. For example, the activated biocarbon pellets can be used in a kitchen composter, mixed in with kitty litter, placed in a compost bucket, and / or placed in a perforated container in a refrigerator or automobile. The pellets can be used in industrial air filter cartridges for odour and chemical removal.

[0020] According to an aspect, the activated biocarbon pellets may be bound with a combination of molecular and / or mechanical forces, as described herein, that provide integrity to the pellet while allowing for odour adsorption and / or moisture absorption.

[0021] Turning to FIGS. 1 and 2, a pyrolysis plant 100 comprises an infeed hopper 102 receiving generally loose organic waste products. An infeed auger 104 advances the loose organic waste products to a rotary valve 106. The rotary valve 106 may be coupled to an infeed airlock 152, which generally provides an airtight seal with a distributer 108. The infeed airlock 152 prevents air entry into the retorts 112 which are under negative pressure during operation. The infeed airlockinfeed auger 104 and transfer the loose biomass to the distribution auger 108. The rate of rotation of the valve may be controlled by a variable frequency drive to synchronize with the infeed auger 104 and the distribution auger 108.

[0022] The distributer 108 may distribute the loose organic waste products to one or more retorts 112 that pass through a pyrolysis unit 110 (e.g. a temperature-controlled oven). In this aspect, there may be between three retorts 112 and six retorts 112. The retorts 112 may have a generally tubular shape of between about 16-inches (40.6-cm) in diameter and 18-ft (548.6-cm) long. The retorts 112 may be constructed of heavy-gage steel pipe each containing a rotating retort auger 109 to move wood material axially through the pyrolysis unit 110. The retorts 112 may have a combined internal volume of about 2.135-cubic meters to about 4.27-cubic meters. The rotating augers 109 may be heavy gage material transport augers driven by a chain arrangement connected to a motor driven gearbox. A variable frequency drive controls a rate of the drive system motor. These retorts 112, in conjunction with air locks and variable speed feed augers, convey the wood material through the heating chamber at a prescribed rate to ensure complete carbonization. During processing the externally heated retorts 112 may be maintained at negative pressure by a vacuum pump 136.

[0023] Within the retorts 112 of the pyrolysis unit 110, an environment may be a substantially oxygen-free atmosphere, such as a nitrogen environment. The pyrolysis unit 110 may be heated to a set temperature using a burner array 114 that, in this aspect, combusts a syngas provided by a fuel store 116 and / or a recycled syngas from the pyrolysis unit 110. In this aspect, the burner array 114 may be four Maxon Kinemax multi-fuel burners which provide up to 4 million British Thermal Unit per Hour (BTUH) on fuel oil, bio-oil 900, or syngas. A temperature within the pyrolysis unitthermocouples are 16 K type thermocouples in contact with the retorts 112. A positioning of the thermocouples defines four evenly spaced monitored heat zones along the retorts 112. The temperature measurements may be communicated to a computer where the measurements may be displayed and / or logged to a file and retained.

[0024] The burner array 114 may be fueled by fuel oil or bio-oil 900 until a process target temperature is attained, after which recycled syngas may be used to fuel the burner array 114. A burner controller 160 may receive the temperature measurements and may control the burner array 114 to maintain the set temperature within the pyrolysis unit 110 in order to pyrolyze the loose organic waste products into biocarbon. In this aspect, the temperature may be maintained between 500°C and 900°C and may be for a time period of a minimum of 30-minutes. In this aspect, the temperature is maintained above 650°C. The temperature and the time period may be dependent on the particular volatile compounds, in this aspect a syngas, emitted from the loose organic waste product within the retorts 112 within the pyrolysis unit 110 into a generally vertical pipe 118 located at or near the top of the retorts 112.

[0025] The vertical pipe 118 may be coupled to a condenser 132 that condenses at least a portion of the volatile compounds and water vapor into a condensate. The condenser 132 may be provided with a continuous closed-loop water cooling system to ensure proper temperature is maintained in the condensers 132. The cooling water may be sent through a forced air heat exchanger and returned to the cooling loop by a water circulation pump. A thermal capacity of the cooling system may be approximately 150 kW to a water AT of 10°C above ambient air temperature. The air flow to the condenser may be provided by a direct drive fan coupled to a 5-kW motor.condenser 132B. The primary condenser 132A may comprise a single counter flow unit that cools the syngas received from an exit manifold of the retorts 112 and removes heavy oil fractions to the condensate tanks 144, 148. Water vapor not trapped by the primary condenser 132A or condensate tanks 144, 148 is further processed by the second condenser 132B to prevent trace water from condensing in the vacuum pump 136. The second condenser 132B may comprise a bank of three series-connected counter-flow condensers with condensate traps placed between each and routed to the condensate tanks 144, 148.

[0027] The condensate and the remaining volatile gases may be passed into a separator 134. The separator 134 splits this mixture into at least one of: a wood vinegar 800, a tar, a syngas, and / or moisture. The wood vinegar 800 flows to a wood vinegar pump 142 for storage in a pyroligneous acid tank 144 (e.g. wood vinegar tank). The wood vinegar 800 (e.g. pyroligneous acid), as shown in FIG. 8, may provide natural antimicrobial properties. Similarly, the wood tar 900 flows to a tar pump 146 for storage in a tar tank 148. The wood tar 900 may be a thick bio-crude material (e.g. bio-oil) 900, as shown in FIG. 9. The syngas flows to a syngas vacuum pump 136 that compresses the syngas. The compressed syngas may be provided to the burner array 114. Any remaining moisture may flow to a spray pump 140 for application to a heat exchanger 138 that provides cooling to the condenser 132.

[0028] In some aspects as shown particularly in FIG. 4, the syngas may be stored in syngas tanks 156 excess syngas may be routed to a secondary heating chamber 400. The secondary heating chamber 400 may be located within the pyrolysis unit 110. The secondary heating chamber 400 may have three tubular stainless-steel vessels 402, 404, 406 placed alongside each other. Each of the vessels 402, 404, 406 may be connected to each other in series from inlet 414 to outlet 416.with a total volume of 0.221-cubic meters. An inlet 414 may provide syngas into the first vessel 402 and an outlet 416 may allow syngas to exit the vessel 406. The secondary chamber 400 may comprise three thermocouples 408, 410, 412 at equal distances along an internal flow path to monitor a gas temperature as the gas progresses through the secondary heating chamber 400 during processing. The secondary heating chamber 400 may be sized to ensure a minimum retention time of 2-seconds at a minimum of 850°C before flaring by a flaring system 158.

[0029] The secondary heating chamber 400 may be equipped with an auxiliary port 418 at or near the inlet 414 to periodically inject steam (e.g. at shutdown) to facilitate cleaning carbon buildup within an interior of the secondary heating chamber 400. The auxiliary port 418 may be used to inject air into the syngas stream (which is over 850°C) to augment heating of the syngas by a partial combustion of the syngas in the secondary chamber 400. The secondary heating chamber 400 may be a tubular chamber. Due to physical constraints of the secondary heating chamber 400, the syngas follows a defined path through the secondary heating chamber 400 facilitating an accurate residence time calculation based on a gas temperature density and a mass flow of the syngas.

[0030] The outlet 416 of the secondary chamber 400 may be monitored by a pitot tube flow meter and a temperature sensor to determine a velocity and temperature of the syngas for mass flow calculations. The mass flow may be converted to volume at the temperature of the secondary chamber 400 to determine a residence time of the syngas in the secondary chamber 400.

[0031] The following parameters are used for secondary chamber residence time calculations.

[0032] Rs = Residence time in seconds

[0034] P = Gage pressure Pa

[0035] A = Gage area normal to flow (m2)

[0036] ts = Standard temp (K) = 300

[0037] tp = Gage flow temperature Kelvin

[0038] Th = Secondary chamber gas temperature

[0039] p = Standard syngas density = 1.22 kg-m-3

[0040] Pitot tube diameter (m) = 1.5

[0041] Conversion factor (in wc) to (Pa) = 249.1

[0042] The wood tar (e.g. slow pyrolysis bio-oil) 900 and / or wood vinegar 800 are used in the pelleting process, described in further detail herein, as ingredients for pelletizing both biocarbon and / or activated charcoal powders. The wood tar 900 and / or wood vinegar 800 may be combined with other binding agents such as carboxymethyl cellulose (CMC) or bentonite clay. The resultant pellets may be impregnated with a variety of chemicals, such as wood vinegar 800 and other acids or bases, metals, and / or cationic or anionic polymers to enhance the adsorption and / or disinfection effects of the pellets.

[0043] Returning to the retorts 112, the heat from the burner array 114 transforms the loose organic waste products into a biocarbon as the organic waste products travel along the retorts 112. The biocarbon may then exit the retorts 112 via an airtight seal (not shown) into a retort collection auger 120. In this aspect, the retort collection auger 120 is in a vertical orientation. At a bottom of the retort collection auger 120, a discharge auger 122 may be coupled to the retort collection auger 120 via another airtight seal (not shown). The discharge auger 122 advances the biocarbon towards a discharge airlock 124. The discharge airlock 124 may be provided by compression of the biocarbon and ash in the discharge auger 122 against a movable preloaded plate (not shown). Water may be added to the biocarbon and ash at this point to decrease gas permeability through augers 120, 122 and to drop the biocarbon and ash exiting the air lock 124 to below an auto ignition temperature. A speed of the discharge auger 122 may be controlled by a variable frequency drive.through the air lock 124, the biocarbon may be placed into a surge bin 126. The biocarbon may then be dispensed via a dispensing auger 128 for packaging into bags and / or bulk storage 130.

[0044] Turning to FIG. 3, a flowchart 200 of a process for the pyrolysis plant 100 begins at initialization 202. In this aspect, the initialization 202 involves starting a generator, powering power control systems, and starting a computer. When initialization 202 is complete, a preheat step 204 is performed, which may involve initiating a Burner Management System (BMS) on fuel oil or bio-oil 900, preheating the pyrolysis unit 110 to a setpoint temperature about 650°C, and / or setting a feed system mode to manual. A check step 206 may be performed that measures the thermocouples within the pyrolysis unit 110 and determines when a measured temperature is over 650°C. When the setpoint temperature is reached, an automatic feed control step 208 may be initiated setting the feed system mode to automatic. An availability of recycled syngas step 210 may be periodically performed and when available, the burner controller 160 may switch to the recycled syngas 212. When no further organic waste product is available for processing, a run termination step 214 may be performed.

[0045] In the event of a low temperature alarm or error condition, the pyrolysis plant 100 may revert to a safe mode (e.g. stop mode). The infeed auger 104 stops taking the organic waste material from the infeed hopper 102 to the infeed airlock 152. The retort augers 109 stop transferring the organic waste material through the pyrolysis unit 110. The retort collection auger 120 stops collecting the biocarbon and ash output from the retort augers 109. The discharge auger 122 stops conveying the biocarbon to the air lock 124. The secondary chamber combustion chamber 400 combusts the remaining syngas if active and reverts to an off position. The stoppage of the infeed auger 104 prevents organic waste material from entering the pyrolysis unit 110 andunit 110 until such time as the temperature in the retorts 112 and / or the secondary chamber 400 return to above 650°C. Once the temperature returns, the pyrolysis plant 100 may be automatically or manually taken out of the safe mode to resume processing.

[0046] When the run is terminated at the termination step 214, a shutdown process 215 may be performed. The burner controller 160 may switch the fuel over to fuel oil or bio-oil 900 at step 216. The infeed is terminated 218. The syngas production systems may be stopped 220. Finally, shutdown procedures 222 may be initiated that may turn off the power control systems, the generator, and / or the computer.

[0047] Turning to FIG. 5, details of a vacuum system 500 for the pyrolysis plant 100 is shown. Main power 502 may be provided to a variable frequency drive (VFD) 516 via a manual switch 504. A differential pressure transducer 512 may measure a differential pressure between the infeed airlock pressure tap 508 and an ambient pressure 510. In some aspects, the measurement period may be determined by a programmable time delay filter 514. When the differential pressure is greater than 260 Pa, a control signal controls the VFD 516. In this aspect, the control signal is a 4-20 mA signal. The VFD 516 activates the vacuum pump 136 to provide a vacuum to a retort syngas manifold 506 and provides the syngas to the syngas tank 156.

[0048] When the biocarbon from the pyrolysis plant 100 is not a fine enough powder, the biocarbon may be milled or extruded into an ultrafine powder with a target particle size of between about 1 -micron to about 100-microns. The fine or ultrafine biocarbon powder 600 may then be blended with the bio-oil (biotar) 900 from the tar tank 148 and / or wood vinegar 800 from the wood vinegar tank 144 and / or water. In some aspect, water may also be added to the blend. The blendedthe pellet size may be selected from 2-mm, 3-mm, 4-mm, 5-mm, and 6-mm. The pellets may then be dried to produce dried pellets. In some aspect, the pellets may be further activated with steam, carbon dioxide, acids, and / or bases to produce activated pellets.

[0049] According to one example pellet, the ultrafine biochar is blended with bio-oil 900 generated from the slow pyrolysis of wood or agricultural fibre at a ratio of 5 to 35% w / w bio-oil 900 and enough water or wood vinegar 800 to the material to pelletize in a pellet mill. The pellets are dried to a moisture content of 8% or less and calcined at 500°C to 1000°C in a steam or carbon dioxide atmosphere to provide a hard and durable biochar pellet (e.g. calcined pellets). The pellets have a minimum ball-pan hardness of 90 and in some aspects, greater than about 98. The pellets may be further activated to enhance surface area or adsorption efficiency with steam, carbon dioxide, acids, or bases, and washed and dried for use without any loss in hardness.

[0050] According to another example for an activated biocarbon pellet, pelletizing the activated biocarbon may be more difficult and complex than pelletizing inactivated biocarbon. Unlike nonactivated biochar, using only bio-oil 900 as a binder for activated biochar or other activated carbon powders does not produce a sufficiently hard pellet. The fine micropores and high absorption capacity of the activated material may inhibit sufficiently hard pellets as a ball-pan hardness (ATSM Designation D3802 - 23) of greater than 90% and in some aspects, greater than about 98 provides suitable hardness. A solvent infuses the activated biocarbon with bio-oil 900 so that strong binding properties can be achieved. The ultrafine activated biochar is blended with bio-oil 900 at a ratio of 5 to 35% in a solvent solution with acetone, methyl acetate, or another suitable solvent and maintained in solution for between about 6-hours to about 24-hours. The solution is then heated to between 60°C and 95 °C to recover the solvent from the solution and results in a dryinfuse the pores, providing a similar effect to inactivated biocarbon. The dried powder may then be blended with water and / or wood vinegar 800 to pelletize and dry. The dry pellets are then calcined at 500°C to 1000°C in a steam or carbon dioxide atmosphere to provide durable pellets with a minimum ball-pan hardness of 90.

[0051] In other example pellets, the addition of bentonite, starch or CMC, and / or the use of wood vinegar 800 and / or acids / bases and other additives may be varied to adjust the adsorption effect.

[0052] The process may further include adding at least one of: a strong acid, a strong base, a nutrient, mineral, and a cellulosic material to the mixture. The process may further include impregnating the calcined pellets with at least one nutrient to produce a plurality of impregnated pellets; and further drying the impregnated pellets to produce a slow-release fertilizer. The process may further include soaking the calcined pellets in at least one of: the pyroligneous acid, a metal salt, a strong acid, and a strong base to produce a plurality of soaked pellets; further drying the soaked pellets to produce a plurality of further dried pellets; and recalcining the further dried pellets.

[0053] The above detailed description of the embodiments is not intended to be exhaustive or to limit the scope of the claims to the precise form disclosed above or to the particular field of usage mentioned in this disclosure. While specific embodiments and examples are described above for illustrative purposes, various equivalent modifications are possible within the scope of the claims, as those skilled in the relevant art recognizes. Also, the teachings of the description provided herein can be applied to other systems. The elements and acts of the various embodiments described above can be combined to provide further embodiments.in accompanying filing papers, are incorporated herein by reference. Aspects can be modified to employ the systems, functions, and concepts of the various references described above to provide yet further embodiments.

[0055] Changes can be made considering the above "Detailed Description." While the above description details embodiments and describes the mode contemplated, no matter how detailed the above appears in text, the description can be practiced in many ways. Therefore, implementation details may vary considerably while still being encompassed by the claims herein. As noted above, terminology used when describing features or aspects are not to be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects with which that terminology is associated.

[0056] While aspects are presented below in claim forms, the various aspects are contemplated within the scope of the claims. Accordingly, additional claims may be added after filing the application to pursue such additional claim forms for other aspects.

[0057] The foregoing is considered illustrative of the principles of the description. Further, since numerous changes and modifications will readily occur to those skilled in the art, any such suitable changes or modifications in structure or operation which may be resorted to are intended to fall within the scope of the claims.

Claims

1. A pyrolysis plant comprising: an infeed hopper receiving an organic waste product; an infeed auger advancing the organic waste product to a rotary valve; a rotary valve receiving the organic waste product from the infeed auger and transferring the organic waste product to a distribution auger via an infeed airlock; a plurality of retorts each receiving a portion of the organic waste product from the distribution auger, the plurality of retorts each having a rotating retort auger therein moving the organic waste product along the retort, the plurality of retorts have an oxygen-free atmosphere therein; a pyrolysis unit with the plurality of retorts passing therethrough, the pyrolysis unit heating the plurality of retorts to pyrolyze the organic waste product to produce a biocarbon; a pipe located at or near a top of the retorts receive volatile compounds emitted from the organic waste product; a condenser coupled to the pipe condensing at least a portion of the volatile compounds into a condensate; a separator receiving the condensate and separating the condensate into a pyroligneous acid, a bio-oil, and a syngas; a vinegar pump pumping the pyroligneous acid to a pyroligneous acid tank; a tar pump pumping the bio-oil to a tar tank; a syngas vacuum pump compressing the syngas to provide to the pyrolysis unit for combustion; a spray pump collecting remaining moisture and applying the moisture to a heat exchanger to cool the condenser; a retort collection auger receiving the biocarbon from the plurality of retorts; andbiocarbon.

2. The pyrolysis plant according to claim 1, wherein the infeed airlock comprises a six- chamber rotary valve.

3. The pyrolysis plant according to claim 1, wherein a rate of rotation of the rotary valve is controlled by a variable frequency drive synchronized with the infeed auger and the distribution auger.

4. The pyrolysis plant according to claim 1, wherein the plurality of retorts is between three retorts and six retorts.

5. The pyrolysis plant according to claim 1, wherein each of the plurality of retorts is tubular shaped.

6. The pyrolysis plant according to claim 1, further comprising a vacuum pump maintaining the plurality of retorts at a negative pressure.

7. The pyrolysis plant according to claim 1, further comprising at least one thermocouple measuring a temperature within the plurality of retorts.

8. The pyrolysis plant according to claim 1, wherein the pyrolysis unit heats the retorts to a temperature between about 500°C and 900°C for a period at least 30-minutes.

9. The pyrolysis plant according to claim 1, wherein the condenser comprises a continuous closed-loop water cooling system.

10. A process for producing an activated biocarbon pellet comprising: blending a mixture of a biocarbon powder with a bio-oil and a pyroligneous acid in a solvent solution; heating the mixture to between 60°C and 95 °C to produce a dry biocarbon powder;pellets; drying the pellets to less than about 8% moisture; and calcining the dry pellets in a steam or carbon dioxide atmosphere to produce a plurality of calcined pellets.

11. The process according to claim 10, wherein the mixture has a ratio of about 5% to about 35% of the biocarbon powder to the bio-oil.

12. The process according to claim 10, wherein the mixture is blended for between about 6- hours to about 24-hours.

13. The process according to claim 10, wherein the plurality of pellets is calcined at between 500°C to 1000°C.

14. The process according to claim 10, further comprising milling the biocarbon powder to a target particle size of between about 1 -micron to about 100-microns before the blending.

15. The process according to claim 10, further comprising pyrolyzing an organic waste product in an oxygen-free atmosphere to produce the biocarbon powder, the bio-oil, and the pyroligneous acid.

16. The process according to claim 10, further comprising adding at least one of: a strong acid, a strong base, a nutrient, mineral, and a cellulosic material to the mixture.

17. The process according to claim 10, further comprising impregnating the calcined pellets with at least one nutrient to produce a plurality of impregnated pellets; and further drying the impregnated pellets to produce a slow-release fertilizer.

18. The process according to claim 10, further comprising soaking the calcined pellets in at least one of: the pyroligneous acid, a metal salt, a strong acid, and a strong base to produce a plurality of soaked pellets; further drying the soaked pellets to produce a plurality of further dried pellets; and recalcining the further dried pellets.

19. An activated biocarbon pellet comprising: a biocarbon powder blended with a bio-oil at a ratio of about 5% to about 35%; a moisture content of 8% or less; and a ball-pan hardness of greater than 90.

20. The activated biocarbon pellet according to claim 19, wherein the biocarbon powder has a particle size of between about 1 -micron to about 100-microns.

21. The activated biocarbon pellet according to claim 19, wherein a pellet size is selected from 2-mm, 3-mm, 4-mm, 5-mm, and 6-mm.

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