High-carbon biogenic reagents and uses thereof

Patent metadata

Field	Value
Publication number	US-2021355396-A1
Application number	US-202117390330-A
Country	US
Kind code	A1
Filing date	Jul 30, 2021
Priority date	Apr 15, 2011
Publication date	Nov 18, 2021
Grant date	—

Abstract

This invention provides processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

First claim

I/We claim:

1 . A biogenic carbon breeze composition comprising, on a dry basis:
at least about 55 wt % total carbon; at most about 5 wt % hydrogen; at most about 1 wt % nitrogen; at most about 0.5 wt % phosphorus; at most about 0.2 wt % sulfur; and an additive selected from a metal, a metal oxide, a metal hydroxide, a metal halide, a combination thereof, or a derivative thereof.

2 . The biogenic carbon breeze composition of claim 1 , wherein the additive is selected from magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, magnesium oxide, dolomite, dolomitic lime, fluorite, fluorospar, bentonite, calcium oxide, lime, a combination thereof, or a derivative thereof.

3 . The biogenic carbon breeze composition of claim 1 , comprising at least about 70 wt % total carbon on a dry basis.

4 . The biogenic carbon breeze composition of claim 1 , comprising a particle size of at most about 6 mm, at most about 3 mm, at most about 2 mm, or at most about 1 mm.

5 . The biogenic carbon breeze composition of claim 1 , comprising: a particle size of at most about 6 mm; at least about 80 wt % carbon; at least about 0.6 wt % to at most about 0.8 wt % sulfur; at least about 1 wt % to at most about 20 wt % volatile matter; at most about 13 wt % ash; and at most about 13 wt % moisture.

6 . The biogenic carbon breeze composition of claim 1 , comprising: at least about 80 wt % carbon; at most about 0.8 wt % sulfur; at most about 20 wt % volatile matter; at most about 13 wt % ash; at most about 13 wt % moisture; and a maximum dimension of about 6 mm.

7 . The biogenic carbon breeze composition of claim 1 , comprising: at least about 55 wt % carbon; at most about 0.4 wt % sulfur; at most about 0.035 wt % phosphorous; and a heat value of at least about 11,000 Btu per pound.

8 . The biogenic carbon breeze composition of claim 1 , wherein the biogenic carbon breeze composition is substantially free of fossil fuel, and wherein the carbon consists essentially of biogenic carbon.

9 . A process for producing iron from iron ore comprising:
sintering the iron ore, wherein the sintering is achieved using a biogenic carbon breeze composition, and wherein the biogenic carbon breeze composition comprises, on a dry basis: at least about 55 wt % total carbon; at most about 5 wt % hydrogen; at most about 1 wt % nitrogen; at most about 0.5 wt % phosphorus; at most about 0.2 wt % sulfur; and an additive selected from a metal, a metal oxide, a metal hydroxide, a metal halide, a combination thereof, or a derivative thereof.

10 . A process for producing a taconite pellet comprising:
firing a pellet comprising a taconite iron ore, wherein the firing is achieved using a biogenic carbon breeze composition, and wherein the biogenic carbon breeze composition comprises, on a dry basis: at least about 55 wt % total carbon; at most about 5 wt % hydrogen; at most about 1 wt % nitrogen; at most about 0.5 wt % phosphorus; at most about 0.2 wt % sulfur; and an additive selected from a metal, a metal oxide, a metal hydroxide, a metal halide, a combination thereof, or a derivative thereof; thereby producing a taconite pellet.

11 . A biogenic carbon breeze composition comprising, on a dry basis:
at least about 55 wt % total carbon; at most about 5 wt % hydrogen; at most about 1 wt % nitrogen; at most about 0.5 wt % phosphorus; at most about 0.2 wt % sulfur; and an additive selected from an acid or a salt thereof, or a base or a salt thereof.

12 . The biogenic carbon breeze composition of claim 11 , wherein the additive is selected from sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, potassium permanganate, or a combination thereof.

13 . The biogenic carbon breeze composition of claim 11 , comprising at least about 70 wt % total carbon on a dry basis.

14 . The biogenic carbon breeze composition of claim 11 , comprising a particle size of at most about 6 mm, at most about 3 mm, at most about 2 mm, or at most about 1 mm.

15 . The biogenic carbon breeze composition of claim 11 , comprising: a particle size of at most about 6 mm; at least about 80 wt % carbon; at least about 0.6 wt % to at most about 0.8 wt % sulfur; at least about 1 wt % to at most about 20 wt % volatile matter; at most about 13 wt % ash; and at most about 13 wt % moisture.

16 . The biogenic carbon breeze composition of claim 11 , comprising: at least about 80 wt % carbon; at most about 0.8 wt % sulfur; at most about 20 wt % volatile matter; at most about 13 wt % ash; at most about 13 wt % moisture; and a maximum dimension of about 6 mm.

17 . The biogenic carbon breeze composition of claim 11 , comprising: at least about 55 wt % carbon; at most about 0.4 wt % sulfur; at most about 0.035 wt % phosphorous; and a heat value of at least about 11,000 Btu per pound.

18 . The biogenic carbon breeze composition of claim 11 , wherein the biogenic carbon breeze composition is substantially free of fossil fuel, and wherein the carbon consists essentially of biogenic carbon.

19 . A process for producing iron from iron ore comprising:
sintering the iron ore, wherein the sintering is achieved using a biogenic carbon breeze composition, and wherein the biogenic carbon breeze composition comprises, on a dry basis: at least about 55 wt % total carbon; at most about 5 wt % hydrogen; at most about 1 wt % nitrogen; at most about 0.5 wt % phosphorus; at most about 0.2 wt % sulfur; and an additive selected from an acid or a salt thereof, or a base or a salt thereof.s

20 . A process for producing a taconite pellet comprising:
firing a pellet comprising a taconite iron ore, wherein the firing is achieved using a biogenic carbon breeze composition, and wherein the biogenic carbon breeze composition comprises, on a dry basis: at least about 55 wt % total carbon; at most about 5 wt % hydrogen; at most about 1 wt % nitrogen; at most about 0.5 wt % phosphorus; at most about 0.2 wt % sulfur; and an additive selected from an acid or a salt thereof, or a base or a salt thereof; thereby producing a taconite pellet.

21 . A biogenic carbon breeze composition comprising, on a dry basis:
at least about 55 wt % total carbon; at most about 0 .4 wt % sulfur; at most about 0.035 wt % phosphorous; a heat value of at least about 11,000 BTU/lb; is substantially free of fossil fuel; and wherein the carbon consists essentially of biogenic carbon.

22 . A process for producing iron from iron ore comprising:
sintering the iron ore, wherein the sintering is achieved using a biogenic carbon breeze composition, and wherein the biogenic carbon breeze composition comprises, on a dry basis: at least about 55 wt % total carbon; at most about 0.4 wt % sulfur; at most about 0.035 wt % phosphorous; a heat value of at least about 11,000 BTU/lb; is substantially free of fossil fuel; and wherein the carbon consists essentially of biogenic carbon.

23 . A process for producing a taconite pellet comprising:
firing a pellet comprising a taconite iron ore, wherein the firing is achieved using a biogenic carbon breeze composition, and wherein the biogenic carbon breeze composition comprises, on a dry basis: at least about 55 wt % total carbon; at most about 0.4 wt % sulfur; at most about 0.035 wt % phosphorous; a heat

Assignees

• Carbon Tech Holdings Llc

Inventors

• Despen Daniel J
• Mennell James A
• Filips Steve

Classifications

• C10B57/06

  containing additives · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• Y02E50/30

  Fuel from waste, e.g. synthetic alcohol or diesel · CPC title

• C10L5/04

  Raw material {of mineral origin} to be used; Pretreatment thereof {(pretreatment of fuels of non-mineral origin C10L5/40)} · CPC title

• C10B41/00

  Safety devices, e.g. signalling or controlling devices for use in the discharge of coke · CPC title