Biomass Pyrolysis Liquid Recapture for High-Fixed-Carbon Biocarbon
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Solution Overview
Problem
Existing pyrolysis processes for producing biocarbon compositions are inefficient and polluting, with a need for improved carbon yield and biocarbon properties.
Innovation Solution
A process involving pyrolyzing biomass in a first reactor, condensing the vapor to generate a liquid and vapor, contacting the biogenic reagent with the condenser liquid, thermally treating the intermediate material, and recovering biocarbon, with optional pelletizing and mechanical treatment steps to enhance carbon recovery and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional charcoal-making technologies are used, then the process is simple, but the process is energy-inefficient and highly polluting
Solution Approach 1:
The pyrolysis process is divided into multiple stages with different temperature zones and residence times. The process segments the conversion of biomass into distinct phases: initial heating, active pyrolysis, and cooling, allowing optimization of energy utilization at each stage while maintaining process manageability
Solution Approach 2:
The patent employs controlled changes in temperature parameters and vapor residence time to optimize energy efficiency. By adjusting these parameters, the process achieves high carbon yield in the biocarbon composition while recovering energy through condensation of pyrolysis vapors, thus resolving the energy efficiency problem without sacrificing process simplicity
2Ease of manufacture
If traditional charcoal-making technologies are used, then the process is simple, but the process is highly polluting
Solution Approach 1:
The patent converts the harmful pyrolysis vapors that would normally be pollutants into a useful resource. By condensing these vapors and contacting them with biogenic reagent, the process recovers carbon that would otherwise be lost, transforming pollution into valuable biocarbon composition while maintaining operational simplicity
Solution Approach 2:
The pyrolysis process operates in an oxygen-free or limited oxygen environment, preventing combustion and the formation of harmful oxides and pollutants. This inert atmosphere control allows the process to remain simple while eliminating the polluting effects associated with traditional open burning or poorly controlled pyrolysis
3Quantity of substance
If moderate temperatures and short vapor residence times are used, then liquids are produced, but carbon yield is reduced
Solution Approach 1:
The patent performs preliminary condensation of pyrolysis vapors before final product formation. By condensing the vapors and contacting them with biogenic reagent in advance, the process recovers carbon that would otherwise be lost, allowing moderate pyrolysis conditions to produce liquids while maintaining high overall carbon yield through the subsequent condensation and recovery steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves high carbon yield, producing biocarbon with high fixed carbon content, low ash content, and improved physical properties such as bulk density and compressive strength, while being environmentally friendly.
Implementation Method 1
pyrolyzing a feedstock in a first pyrolysis reactor, wherein the feedstock comprises biomass, thereby generating a first biogenic reagent and a first pyrolysis vapor
Implementation Method 2
introducing the first pyrolysis vapor to a condensing system, thereby generating a condenser liquid and a condenser vapor
Implementation Method 3
thermally treating the intermediate material in a thermal-treatment unit, thereby generating a second biogenic reagent and an off-gas
Data Source
AI summary
This disclosure provides a method of making a high-fixed-carbon material comprising pyrolyzing biomass to generate intermediate solids and a pyrolysis vapor; condensing the pyrolysis vapor to generate pyrolysis liquid; blending the pyrolysis liquid with the intermediate solids, to generate a mixture; and further pyrolyzing the mixture to generate a high-fixed-carbon material. A process can comprise: pyrolyzing a biomass-comprising feedstock in a first pyrolysis reactor to generate a first biogenic reagent and a first pyrolysis vapor; introducing the first pyrolysis vapor to a condensing system to generate a condenser liquid; contacting the first biogenic reagent with the condenser liquid, thereby generating an intermediate material; further pyrolyzing the intermediate material in a second pyrolysis reactor to generate a second biogenic reagent and a second pyrolysis vapor; and recovering the second biogenic reagent as a high-yield biocarbon composition. The process can further comprise pelletizing the intermediate material. Many process and system configurations are disclosed.