Carbon-negative metallurgical products

Patent metadata

Field	Value
Publication number	US-2022267869-A1
Application number	US-202217673998-A
Country	US
Kind code	A1
Filing date	Feb 17, 2022
Priority date	Feb 18, 2021
Publication date	Aug 25, 2022
Grant date	—

Abstract

Some variations provide a carbon-negative carbon product that is characterized by a carbon intensity less than 0 kg CO2e per metric ton of the carbon-negative carbon product, wherein the carbon-negative carbon product contains at least about 50 wt % carbon. In some embodiments, the carbon intensity is less than −500 kg CO2e per metric ton of the carbon-negative carbon product. Other variations provide a carbon-negative metal product (e.g., a steel product) that is characterized by a carbon intensity less than 0 kg CO2e per metric ton of the carbon-negative metal product, wherein the metal product contains from 50 wt % to 100 wt % of one or more metals and optionally one or more alloying elements. In some embodiments, the carbon-negative metal product is characterized by a carbon intensity less than −200 kg CO2e per metric ton of the carbon-negative metal product. The carbon-negative metal product can contain a wide variety of metals.

First claim

What is claimed is:

1 . A carbon-negative carbon product that is characterized by a carbon intensity less than 0 kg CO 2 e per metric ton of the carbon-negative carbon product, wherein the carbon-negative carbon product contains at least about 50 wt % fixed carbon.

2 . The carbon-negative carbon product of claim 1 , wherein the carbon intensity is less than about −500 kg CO 2 e per metric ton of the carbon-negative carbon product.

3 . The carbon-negative carbon product of claim 1 , wherein the carbon intensity is less than about −1000 kg CO 2 e per metric ton of the carbon-negative carbon product.

4 . The carbon-negative carbon product of claim 1 , wherein the carbon intensity is less than about −2000 kg CO 2 e per metric ton of the carbon-negative carbon product.

5 . The carbon-negative carbon product of claim 1 , wherein the carbon intensity is less than about −3000 kg CO 2 e per metric ton of the carbon-negative carbon product.

6 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product contains at least about 60 wt % fixed carbon.

7 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product contains at least about 80 wt % fixed carbon.

8 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product comprises from about 1 wt % to about 30 wt % moisture.

9 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product comprises from about 0.1 wt % to about 1 wt % moisture.

10 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product further contains an additive.

11 . The carbon-negative carbon product of claim 10 , wherein the carbon-negative carbon product comprises from about 0.2 wt % to about 25 wt % of the additive.

12 . The carbon-negative carbon product of claim 10 , wherein the additive is capable of being partially oxidized and/or combusted.

13 . The carbon-negative carbon product of claim 10 , wherein the additive is a renewable material.

14 . The carbon-negative carbon product of claim 10 , wherein the additive is a carbon-neutral or carbon-negative additive.

15 . The carbon-negative carbon product of claim 10 , wherein the additive is a binder.

16 . The carbon-negative carbon product of claim 15 , wherein the binder is selected from starch, thermoplastic starch, crosslinked starch, starch polymers, cellulose, cellulose ethers, carboxymethyl cellulose, cellulose esters, hemicellulose, methylcellulose, chitosan, lignin, lactose, sucrose, dextrose, maltodextrin, banana flour, wheat flour, wheat starch, soy flour, corn flour, wood flour, coal tars, coal fines, met coke, asphalt, coal-tar pitch, petroleum pitch, bitumen, pyrolysis tars, gilsonite, bentonite clay, borax, limestone, lime, waxes, vegetable waxes, baking soda, baking powder, sodium hydroxide, potassium hydroxide, iron ore concentrate, silica fume, gypsum, Portland cement, guar gum, polyvidones, polyacrylamides, polylactides, formaldehyde, peat, sphagnum peat, phenol-formaldehyde resins, vegetable resins, recycled shingles, recycled tires, derivatives thereof, or any combinations of the foregoing.

17 . The carbon-negative carbon product of claim 15 , wherein the binder is selected from starch, thermoplastic starch, crosslinked starch, starch polymers, derivatives thereof, or any combinations of the foregoing.

18 . The carbon-negative carbon product of claim 15 , wherein the binder is a thermoplastic starch that is optionally crosslinked.

19 . The carbon-negative carbon product of claim 18 , wherein the thermoplastic starch is a reaction product of starch and a polyol, wherein the polyol is optionally selected from ethylene glycol, propylene glycol, glycerol, butanediols, butanetriols, erythritol, xylitol, sorbitol, or combinations thereof, and wherein the reaction product is optionally formed from a reaction that is catalyzed by an acid or by a base.

20 . The carbon-negative carbon product of claim 10 , wherein the additive reduces the reactivity of the carbon-negative carbon product compared to an otherwise-equivalent carbon product without the additive.

21 . The carbon-negative carbon product of claim 10 , wherein the additive is pore-filling within the carbon-negative carbon product.

22 . The carbon-negative carbon product of claim 10 , wherein the additive is disposed on the surface of the carbon-negative carbon product.

23 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product is in powder form, in granular form, in agglomerated form, or a combination thereof.

24 . The carbon-negative carbon product of claim 23 , wherein the agglomerated form is a carbon-negative carbon pellet.

25 . The carbon-negative carbon product of claim 24 , wherein the carbon-negative carbon pellet is characterized by a Hardgrove Grindability Index of at least 30.

26 . The carbon-negative carbon product of claim 24 , wherein the carbon-negative carbon pellet is characterized by a Pellet Durability Index of at least 80%.

27 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product is a carbon-negative metallurgical carbon product.

28 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product is a carbon-negative non-metallurgical carbon product.

29 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product contains at least 90% renewable carbon content as determined from a measurement of the 14 C/ 12 C isotopic ratio of the carbon.

30 . The carbon-negative carbon product of claim 1 , wherein the carbon-negative carbon product contains 100% renewable carbon content as determined from a measurement of the 14 C/ 12 C isotopic ratio of the carbon.

Assignees

• Carbon Tech Holdings Llc

Inventors

• Mennell James A
• Daugaard Daren
• Slack Dustin

Classifications

• C22B1/244

  organic · CPC title

• C21C5/00

  Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel {or stainless steel} · CPC title

• C21B5/007 Primary

  Conditions of the cokes or characterised by the cokes used · CPC title

• C22C38/00 Primary

  Ferrous alloys, e.g. steel alloys (cast-iron alloys C22C37/00) · CPC title

• C22B1/2406

  pelletizing · CPC title