U.S. patent application number 17/588194 was filed with the patent office on 2022-08-25 for methods and systems for producing an enhanced surface area biochar product.
This patent application is currently assigned to ARIES CLEAN TECHNOLOGIES LLC. The applicant listed for this patent is ARIES CLEAN TECHNOLOGIES LLC. Invention is credited to Brandon Davis, Matt Newman, Joseph Regnery, Joel Thornton.
Application Number | 20220267158 17/588194 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-25 |
United States Patent
Application |
20220267158 |
Kind Code |
A1 |
Regnery; Joseph ; et
al. |
August 25, 2022 |
METHODS AND SYSTEMS FOR PRODUCING AN ENHANCED SURFACE AREA BIOCHAR
PRODUCT
Abstract
Herein disclosed are apparatus and associated methods related to
producing an enhanced surface area biochar product with a desired
activation level based on receiving biochar into a processing
vessel configured with multiple independently
temperature-controlled chambers and counter-flow steam injection,
controlling activation levels of the biochar by moving the biochar
through the processing vessel and adjusting the temperature of the
biochar by injecting steam into at least one temperature-controlled
chamber of the processing vessel, recovering volatiles driven off
through dehydration using a thermal oxidizer, cooling the biochar
to a desired discharge temperature using steam and retention time,
and discharging the activated biochar product. The processing
vessel may be a calciner, a rotary calciner, or a kiln. Biochar may
be heated or cooled to a desired thermochemical processing
temperature depending on the temperature of the received biochar.
Counter-flow saturated steam may sweep volatile gases to a thermal
oxidizer using a vacuum system.
Inventors: |
Regnery; Joseph; (Castle
Pines, CO) ; Thornton; Joel; (Nashville, TN) ;
Newman; Matt; (Spring Hill, TN) ; Davis; Brandon;
(Murfreesboro, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ARIES CLEAN TECHNOLOGIES LLC |
Franklin |
TN |
US |
|
|
Assignee: |
ARIES CLEAN TECHNOLOGIES
LLC
Franklin
TN
|
Appl. No.: |
17/588194 |
Filed: |
January 28, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17359689 |
Jun 28, 2021 |
11268039 |
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17588194 |
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17359698 |
Jun 28, 2021 |
11268030 |
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17359689 |
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17359708 |
Jun 28, 2021 |
11268029 |
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17359698 |
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17359743 |
Jun 28, 2021 |
11268031 |
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17359708 |
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63240543 |
Sep 3, 2021 |
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63153643 |
Feb 25, 2021 |
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63153021 |
Feb 24, 2021 |
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International
Class: |
C01B 32/324 20060101
C01B032/324; C01B 32/336 20060101 C01B032/336; C10J 3/84 20060101
C10J003/84; C10B 47/30 20060101 C10B047/30; C10B 19/00 20060101
C10B019/00; C10B 39/06 20060101 C10B039/06; C10B 47/18 20060101
C10B047/18; C10B 57/00 20060101 C10B057/00 |
Claims
1. A method comprising: receiving biochar (809) into a processing
vessel (803) configured with multiple independently
temperature-controlled chambers and counter-flow steam injection;
controlling activation levels of the biochar (809) by moving the
biochar (809) through the processing vessel (803) and adjusting the
temperature of the biochar (809) by steam (831) injection into at
least one temperature-controlled chamber of the processing vessel
(803); recovering volatiles driven off through dehydration using a
thermal oxidizer (505); cooling the biochar (809) to a desired
discharge temperature using steam (831) and retention time; and
discharging an activated biochar product (833).
2. The method of claim 1, wherein receiving biochar (809) further
comprises receiving biochar (809) from a downdraft gasifier
(600).
3. The method of claim 1, wherein the processing vessel (803)
further comprises a calciner, a rotary calciner, or a kiln.
4. The method of claim 1, wherein the method further comprises
sweeping volatile gases to a thermal oxidizer (505) using a vacuum
system and counter-flow saturated steam (831).
5. The method of claim 1, wherein the multiple independently
temperature-controlled chambers configured in the processing vessel
(803) further comprise a processing vessel heating section (824)
and a processing vessel cooling section (827).
6. The method of claim 5, wherein the processing vessel (803)
further comprises a processing vessel inlet (806) disposed at a
processing vessel head (1100) wherein the processing vessel inlet
(806) is configured to be fluidly coupled with the processing
vessel heating section (824), and a processing vessel outlet (830)
disposed at a processing vessel tail (1120) wherein the processing
vessel outlet (830) is configured to be fluidly coupled with the
processing vessel cooling section (827).
7. The method of claim 5, wherein receiving biochar (809) further
comprises receiving biochar (809) into the processing vessel
heating section (824).
8. The method of claim 5, wherein discharging the activated biochar
product (833) further comprises discharging the activated biochar
product (833) from the processing vessel cooling section (827).
9. The method of claim 5, wherein the processing vessel (803)
further comprises a control system (925) configured to adjust the
temperature of biochar (809) using the processing vessel heating
section (824).
10. The method of claim 9, wherein the control system (925) further
comprises configuration to govern retention time of biochar (809)
in the processing vessel (803) based on controlling fluid coupling
of the processing vessel heating section (824) with the processing
vessel cooling section (827).
11. The method of claim 9, wherein the control system (925) further
comprises configuration to determine the temperature in the at
least one temperature-controlled chamber of the processing vessel
(803).
12. The method of claim 11, wherein adjusting the temperature of
the biochar (809) retained by at least one temperature-controlled
chamber of the processing vessel (803) further comprises using the
control system (925) to release biochar (809) from the processing
vessel heating section (824) into the processing vessel cooling
section (827) in response to the control system (925) determining
the temperature in the processing vessel heating section (824) is
at least a predetermined minimum temperature.
13. The method of claim 11, wherein adjusting the temperature of
the at least one temperature-controlled chamber of the processing
vessel (803) further comprises using the control system (925) to
retain biochar (809) in the at least one temperature-controlled
chamber of the processing vessel (803) until the control system
(925) determines the temperature of the at least one
temperature-controlled chamber of the processing vessel (803)
satisfied at least a predetermined minimum temperature for at least
a predetermined minimum period of time.
14. The method of claim 11, wherein adjusting the temperature of
the at least one temperature-controlled chamber of the processing
vessel (803) further comprises cooling the biochar (809) based on
increasing biochar (809) retention time in the at least one
temperature-controlled chamber of the processing vessel (803) using
the control system (925).
15. The method of claim 11, wherein the control system (925)
further comprises configuration to adjust the temperature of
biochar (809) using the processing vessel (803) heating section
(824) to heat the biochar (809) to a predetermined target
temperature in response to the control system (925) determining the
biochar (809) temperature is less than a predetermined minimum.
16. The method of claim 9, wherein the control system (925) further
comprises configuration to adjust the temperature of biochar (809)
using the processing vessel (803) cooling section (827) to cool the
biochar (809).
17. The method of claim 1, wherein adjusting the temperature of the
biochar (809) retained by at least one temperature-controlled
chamber of the processing vessel (803) further comprises heating
the at least one temperature-controlled chamber of the processing
vessel (803) using processing vessel heating means (905).
18. The method of claim 17, wherein the processing vessel heating
means (905) further comprises an electric heating element.
19. The method of claim 17, wherein the processing vessel heating
means (905) further comprises recovered process heat.
20. The method of claim 1, wherein receiving biochar (809) further
comprises receiving biochar (809) from a cyclone (812).
21. The method of claim 1, wherein the method further comprises
heating biochar (809) using a processing vessel heating means (905)
to heat a processing vessel heating section (827).
22. The method of claim 1, wherein the method further comprises
cooling biochar (809) by injecting steam (831) into a processing
vessel cooling section (827).
23. The method of claim 14, wherein the processing vessel (803) is
configured with three distinct temperature-controlled sections
comprising a heating section (824), a steam injection/activation
chamber, and a cooling chamber (827).
24. The method of claim 1, wherein the method further comprises
enhancing and controlling activation levels of carbon in the
biochar (809) using steam (831) injected into the processing vessel
(803).
25. The method of claim 1, wherein the method further comprises
sweeping volatile gases from the biochar (809) using the injected
steam (831).
26. The method of claim 25, wherein the method further comprises
decomposing the volatile gases swept from the biochar (809) using a
thermal oxidizer (505).
27. The method of claim 1, wherein the method further comprises
injecting steam (831) further comprising saturated steam.
28. The method of claim 1, wherein the method further comprises
forming additional macro and micro pores in the activated biochar
product (833) using the injected steam (831).
29. The method of claim 1, wherein the method further comprises the
processing vessel (803) is configured to cause received biochar
(809) to flow in a direction from a processing vessel inlet (806)
to a processing vessel outlet (830).
30. The method of claim 29, wherein the method further comprises
the processing vessel (803) is configured to cause injected steam
(831) to flow in a direction counter to the biochar (809) flow.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-in-part of U.S.
application Ser. Nos. 17/359,689; 17/359,698; 17/359,708; and Ser.
No. 17/359,743; all four of which were filed on Jun. 28, 2021. In
addition, this application claims priority to Provisional
Application No. 63/240,543 filed Sep. 3, 2021; Provisional
Application No. 63/153,643 filed Feb. 25, 2021; and Provisional
Application No. 63/153,021 filed Feb. 24, 2021. The contents of
which are incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates generally to activating and cooling
biochar, and more particularly, to the production of a controlled
activation level enhanced surface area biochar product based on
adjusting biochar temperature, cooling biochar with injected steam,
and recovering volatiles driven off through dehydration.
BACKGROUND
[0003] Decarbonization of the energy sector is a topic of
importance to avoid irreversible global warming. Hydrogen has been
considered as an option to replace fossil fuels in industrial,
residential, and transport applications. However, hydrogen
production has been almost limited to the reforming of
hydrocarbons. Reforming hydrocarbons may release large amounts of
CO.sub.2, thus requiring several downstream purification
processes.
[0004] Gasification is a thermal decomposition process in which
solid organic or carbonaceous materials (feedstock) may break down
into a combustible gas mixture. The combustible gas components
formed are primarily carbon monoxide (CO), hydrogen (H.sub.2), and
methane (CH.sub.4). Other non-combustible gases such as nitrogen
(N.sub.2), steam (H.sub.2O), and carbon dioxide (CO.sub.2) may also
be present in various quantities. The process of gasification may
involve pyrolysis followed by partial oxidation, which may be
controlled by injecting air or other oxygen containing gases into
the partially pyrolyzed feedstock. More specifically, biomass
gasification may be a sequence of reactions including water
evaporation, lignin decomposition, cellulosic deflagration and
carbon reduction. An external heat source may begin the reaction,
but partial oxidation may provide heat to maintain the thermal
decomposition of the feedstock. If concentrated oxygen is used, the
resulting gas mixture may be called syngas. If air (which includes
nitrogen) is used as the oxidant, the resulting gas mixture may be
called producer gas. For simplicity, the term "Producer Gas" as
used herein shall include both syngas and producer gas. Both gas
mixtures are considered a "fuel gas" and can be used as a
replacement for natural gas in some processes. They can also be
used as a precursor to generate various industrial chemicals and
motor fuels. When biomass is used as the feedstock, gasification
and combustion of the Producer Gas is considered to be a source of
renewable energy.
[0005] As a general matter, gasification offers a more efficient,
cost effective and environmentally friendly alternative for
extracting potential energy from solid feedstock as compared to
combustion. As a result of gasification, the feedstock's potential
energy can be converted to Producer Gas, which is cleaner burning,
compressible and more portable. Producer Gas may be burned directly
in some engines and burners, purified to produce methanol and
hydrogen, or converted via the Fischer-Tropsch and other methods
and processes into synthetic liquid fuel.
[0006] In general, biomass gasification is the thermochemical
conversion of organic (waste) feedstock in a high-temperature
environment, through which biomass may be converted not only to
syngas for energy generation but also to chemicals, for instance,
methane, ethylene, adhesives, fatty acids, surfactants, detergents,
and plasticizers. A byproduct of biomass gasification is hot
biochar.
[0007] In various aspects the present disclosure relates to direct
cooling of biochar resulting from gasification by downdraft and
fluidized bed gasifiers. Brief downdraft and fluidized bed
gasification descriptions and simple examples of downdraft and
fluidized bed gasifiers are provided. Exemplary downdraft
gasification may be implemented using downdraft gasification
techniques disclosed with reference to FIGS. 1-21 of U.S. Pat. No.
10,662,386 by Kelfkens, et al., filed on Dec. 6, 2019 as U.S.
patent application Ser. No. 16/705,837, and entitled "Method for
gasifying feedstock with high yield production of biochar," the
entire contents of which are herein incorporated by reference.
Exemplary fluidized bed gasification may be implemented using
fluidized bed gasification techniques disclosed with reference to
FIGS. 1-8 of U.S. Pat. No. 10,696,913 by Kelfkens, et al., filed on
Dec. 20, 2019 as U.S. patent application Ser. No. 16/723,538, and
entitled "Gasification reactor with pipe distributor," the entire
contents of which are herein incorporated by reference.
[0008] Downdraft Gasification
[0009] In downdraft gasification, all feedstock, air and gases flow
in the same direction--from top to bottom. Although updraft
gasification is typically favored for processing of biomass
feedstock and fluid bed gasification is typically used in
gasification of coal, downdraft gasification process has a number
of advantages. One advantage of downdraft gasification is low
levels of tar in the resulting Producer Gas because the tars
generated during pyrolysis must pass through the Oxidation Zone and
the char bed in the Reduction Zone before exiting the gasifier. The
high temperature of the Oxidation Zone and the top of the char bed
breaks down the tars (i.e., thermal cracking). The result is a
Producer Gas that may be cooled and more easily cleaned for use in
reciprocating engines, gas-fired turbines and catalytic reforming
processes.
[0010] In an exemplary downdraft gasifier implementation, there may
be three zones: a Pyrolysis Zone, an Oxidation Zone and a Reduction
Zone. In such a gasifier, (1) the residence time of feedstock could
be controlled in the Oxidation Zone (relative to the flow of
feedstock through the rest of the gasifier) to allow the maximum
amount of feedstock to undergo gasification before passing out of
the Oxidation Zone into the Reduction Zone and (2) the Reduction
Zone would be designed to cause the hot gas produced in the
Oxidation Zone to mix with the char in the Reduction Zone as
quickly and as thoroughly as possible to promote thorough
gasification.
[0011] Fluidized-Bed Gasification
[0012] In an exemplary fluidized-bed gasifier implementation,
oxidant may be blown through a bed of solid particles at a
sufficient velocity to keep the solid particles in a state of
suspension. The feedstock is introduced to the gasifier, very
quickly mixed with the bed material and almost instantaneously
heated to the bed temperature either externally or using a heat
transfer medium. Most of these fluidized-bed gasifiers are equipped
with an internal cyclone in order to minimize char (carried over
into the Producer Gas stream) and remove fluidizing media from the
Producer Gas. The major advantages include feedstock flexibility
and the ability to easily control the reaction temperature, which
allows for gasification of fine grained materials (sawdust, etc.)
without the need of pre-processing. Fluidized-bed gasifiers also
scale very well to large sizes.
[0013] In various exemplary gasification scenarios, hot
carbonaceous residue may come off or through the grate of a
downdraft gasifier, off the bottom of a cyclone, or off the bottom
of a cyclone in association with a fluidized bed gasifier. Both
downdraft and fluidized bed gasifier systems may employ an
expensive indirect cooling approach to create a cool biochar that
may not be resizable (Grinder) based on product demand by a
gasifier system using indirect cooling.
[0014] Some prior art biochar cooling implementations may
indirectly utilize heated steam to run over biochar to improve the
biochar's compositional characteristics. These prior art biochar
cooling processes may heat steam to extremely high temperatures to
react with ambient temperature biochar. Some prior art biochar
cooling implementations may indirectly utilize heated hydrocarbon
gas run over biochar to improve compositional characteristics and
decompose methane. These prior art biochar cooling processes may
heat hydrocarbon gas streams to extremely high temperatures to
react with the ambient temperature biochar.
[0015] In an illustrative example, the composition of biochar
product from a gasifier employing indirect cooling may not be
useful in high value applications, such as, for example, as an
alternative to activated carbon. In addition, the biochar product
from a gasifier employing indirect cooling may not be useful in
production of high purity carbon for manufacturing purposes, such
as, for example, graphene.
SUMMARY
[0016] Herein disclosed are apparatus and associated methods
related to producing an enhanced surface area biochar product with
a desired activation level based on receiving biochar into a
processing vessel configured with multiple independently
temperature-controlled chambers and counter-flow steam injection,
controlling activation levels of the biochar by moving the biochar
through the processing vessel and adjusting the temperature of the
biochar by injecting steam into at least one temperature-controlled
chamber of the processing vessel, recovering volatiles driven off
through dehydration using a thermal oxidizer, cooling the biochar
to a desired discharge temperature using steam and retention time,
and discharging the activated biochar product. The processing
vessel may be a calciner, a rotary calciner, or a kiln. Biochar may
be heated or cooled to a desired thermochemical processing
temperature depending on the temperature of the received biochar.
Counter-flow saturated steam may sweep volatile gases to a thermal
oxidizer using a vacuum system.
[0017] An exemplary biochar activation and cooling implementation
for producing a controlled activation level enhanced surface area
biochar product may comprise adjusting biochar temperature, cooling
biochar with injected steam, and recovering volatiles driven off
through dehydration. An exemplary biochar activation and cooling
implementation may comprise a processing vessel configured with
multiple independently temperature-controlled chambers or sections
that are used for control of temperature during production of the
activated and cooled biochar product. An exemplary biochar
activation and cooling implementation may comprise calcination of
the product. The processing vessel may be, for example, a calciner,
a rotary calciner, or a kiln. Some implementations may be
configured to use steam to enhance and control activation levels of
the carbon in the biochar, by injecting steam into the processing
vessel. The biochar may be received from a downdraft gasifier. In
an illustrative example, an exemplary implementation may be
generally referred to as integrated calcination and cooling of
biochar produced in a down draft gasifier.
[0018] An exemplary biochar activation and cooling implementation
for producing a controlled activation level enhanced surface area
biochar product may comprise capability to control (increase or
decrease) the temperature of carbonaceous material (biochar) as the
biochar moves through a processing vessel such as, for example, a
rotary calciner. Some implementations may be configured with a
control system configured to measure and control (increase or
decrease) the temperature of the carbonaceous material (biochar) as
the biochar moves through the processing vessel. An exemplary
biochar activation and cooling processing vessel implementation may
be configured with multiple distinct independently
temperature-controllable processing zones. In one implementation,
the biochar activation and cooling processing vessel is configured
with three distinct operating zones (heating, steam
injection/activation, final cooling), of which each section may be
separated by concentric cylinders or other separating means
depending on the appropriate processing vessel design.
[0019] An exemplary biochar activation and cooling implementation
for producing a controlled activation level enhanced surface area
biochar product may comprise using multiple independently
temperature-controllable processing vessel sections or chambers to
process the biochar in sequence from section to section as the
biochar is moved through the processing vessel. In an illustrative
example, the biochar or other carbonaceous material may be moved
through the processing vessel by a rotating inner cylinder passing
through the multiple independently temperature-controllable
processing vessel sections or chambers. In an exemplary
implementation, the first section of the processing vessel is the
heating section. The carbonaceous material may be received into the
processing vessel heating section from one or more gasifier. When
the carbonaceous material enters the processing vessel colder than
a predetermined activation temperature, an exemplary biochar
activation and cooling implementation may heat the biochar
indirectly in the heating section using electrical heating or other
heating means to insure proper reactivity of the carbonaceous
material. In an illustrative example, a biochar activation and
cooling implementation in accordance with the teaching of the
present disclosure may heat the biochar in the heating section
using hot exhaust from a gas heater or recovered process heat. In
some biochar activation and cooling implementations, hot air from
waste heat may be recovered using a waste gas power generator.
[0020] In an exemplary implementation, after passing through the
heating section, the carbonaceous material is received into the
next section of the processing vessel. In some implementations, the
heating section is followed by, in sequence, a steam
injection/activation chamber and a cooling section. In another
implementation, the heating section is followed by the cooling
section. In an illustrative example, when the carbonaceous material
enters the next section after the heating section, steam is
injected directly onto the carbonaceous material. The steam may be
injected using a steam lance or injection port. In an illustrative
example, the injected steam will react and cool the carbonaceous
material as the steam injection moves in a counter flow direction
to an off-gas outlet nearer the front of the processing vessel,
where the gas may be extracted as an off-gas. The extracted off-gas
may be sent to a thermal oxidizer using a vacuum pump/fan.
[0021] In an exemplary biochar activation and cooling
implementation the cooling section is the final section. In some
implementations, the cooling section may be the third section,
after a steam injection/activation section following the heating
section. In some implementations, the cooling section may be the
second and final section. In an illustrative example, water or cool
air may be used to indirectly cool carbonaceous material in the
cooling section. An implementation in accordance with the teaching
of the present disclosure may be configured to cause cooling
air/water flow to move in a co-current of counter flow direction to
the biochar outlet of the processing vessel. In an illustrative
example, the activated carbonaceous material may be moved by
flights in one rendition through a rotating inner cylinder that
passes the carbonaceous material through the section(s) exiting the
processing vessel. The processing vessel may be calciner. The
calciner may be a rotary calciner. The processing vessel may be a
kiln. The processing vessel may be a rotary kiln. An implementation
in accordance with the teaching of the present disclosure may be
designed with a screw auger configured in the inner cylinder of a
processing vessel (such as, for example, a calciner) to move the
carbonaceous material through the processing vessel. In an
exemplary biochar activation and cooling implementation for
producing a controlled activation level enhanced surface area
biochar product, reactions occurring within the processing vessel
may comprise evaporation, dehydration, and organic compound
decomposition.
[0022] Exemplary apparatus and method aspects may relate to cooling
hot biochar based on applying cool gas directly to the hot biochar.
The gas may be steam comprising water vapor. Biochar may be cooled
in a cooling chamber by cool steam injected into a steam loop
configured to cool the steam. The biochar cooled with steam may be
dried in a drying chamber by dry gas injected from a gas loop. The
gas may be hydrocarbon gas. Biochar may be heated in a processing
chamber. Heated biochar may be cooled in a cooling chamber by cool
hydrocarbon gas injected to the cooling chamber. Biochar in the
processing chamber may be heated with heat recovered from cooling.
Filtered byproducts and tail gas may be recovered from the cooling
chamber. Tail gas may be recycled. Various direct biochar cooling
implementations may produce biochar having enhanced carbon content,
increased surface area, and a hydrogen stream byproduct.
[0023] In an aspect, an apparatus may comprise: a cooling chamber;
a steam loop configured to be fluidly coupled with the cooling
chamber; a drying chamber configured to be fluidly coupled with the
cooling chamber; a gas loop configured to be fluidly coupled with
the drying chamber; and a control system configured to cause the
apparatus to perform operations comprising: inject cool steam from
the steam loop into the cooling chamber; apply the cool steam
directly to hot biochar retained within the cooling chamber; and in
response to a determination the biochar retained within the cooling
chamber cooled to a predetermined temperature: discharge the cooled
biochar into the drying chamber; inject dry gas from the gas loop
into the drying chamber; and in response to a determination the
biochar retained within the drying chamber dried to a predetermined
moisture level, discharge the cooled dried biochar from the drying
chamber.
[0024] The apparatus may further comprise the cooling chamber
configured to receive hot biochar via at least one discharge valve
configured to be fluidly coupled with the cooling chamber.
[0025] The operations performed by the apparatus may further
comprise receive hot biochar into the cooling chamber via at least
one discharge valve fluidly coupled with the cooling chamber.
[0026] Receive hot biochar may further comprise receive hot biochar
from a gasifier fluidly coupled with the apparatus.
[0027] The gasifier may further comprise a downdraft gasifier.
[0028] The gasifier may further comprise a fluidized bed
gasifier.
[0029] The steam loop may further comprise a heat exchanger.
[0030] The gas loop may further comprise a particulate filter.
[0031] The apparatus may further comprise at least one discharge
valve configured to fluidly couple the cooling chamber to the
drying chamber.
[0032] In an implementation, an apparatus may comprise: a cooling
chamber; at least one discharge valve configured to be fluidly
coupled with the cooling chamber, wherein the at least one
discharge valve is configured to be fluidly coupled with a gasifier
to direct hot biochar from the gasifier into the cooling chamber; a
steam loop configured to be fluidly coupled with the cooling
chamber, wherein the steam loop is configured with a steam
particulate filter and a heat exchanger; a drying chamber
configured to be fluidly coupled with the cooling chamber by at
least one discharge valve configured to direct biochar from the
cooling chamber into the drying chamber; a gas loop configured to
be fluidly coupled with the drying chamber, wherein the gas loop is
configured with a gas particulate filter and a heat exchanger; at
least one discharge valve configured to be fluidly coupled with the
drying chamber, wherein the at least one discharge valve is
configured to release biochar from the drying chamber; and a
control system configured to cause the apparatus to perform
operations comprising: receive hot biochar from the gasifier into
the cooling chamber; inject cool steam from the steam loop into the
cooling chamber; apply the cool steam directly to the hot biochar
retained within the cooling chamber; and in response to a
determination the biochar retained within the cooling chamber
cooled to a predetermined temperature: discharge the cooled biochar
into the drying chamber; inject dry gas from the gas loop into the
drying chamber; and in response to a determination the biochar
retained within the drying chamber dried to a predetermined
moisture level, release the cooled dried biochar from the drying
chamber.
[0033] The gasifier may further comprise a downdraft gasifier.
[0034] The gasifier may further comprise a fluidized bed
gasifier.
[0035] The cooling chamber may be fluidly coupled with the
gasifier.
[0036] The steam particulate filter may further comprise a ceramic
filter.
[0037] The gas particulate filter may further comprise a sintered
metal filter.
[0038] The apparatus may further comprise stainless steel.
[0039] In an implementation, an apparatus may comprise: a cooling
chamber configured with a gas inlet, a biochar inlet, a biochar
outlet, and a gas outlet; at least one discharge valve configured
to be fluidly coupled with the cooling chamber biochar inlet,
wherein the at least one discharge valve is configured to be
fluidly coupled with a gasifier to direct hot biochar from the
gasifier into the cooling chamber; a steam loop configured to be
fluidly coupled with the cooling chamber gas inlet and the cooling
chamber gas outlet, wherein the steam loop comprises a steam makeup
port fluidly coupled with the steam loop; a steam particulate
filter configured with an inlet and a filtered outlet, wherein the
steam particulate filter inlet is fluidly coupled with the cooling
chamber gas outlet, and wherein the steam particulate filter outlet
is fluidly coupled with the steam loop; a heat exchanger configured
in the steam loop, wherein the heat exchanger comprises a steam to
liquid heat exchanger; a drying chamber configured with a gas
inlet, a biochar inlet, a biochar outlet, and a gas outlet, wherein
the drying chamber biochar inlet is configured to be fluidly
coupled with the cooling chamber biochar outlet by at least one
discharge valve configured to direct biochar from the cooling
chamber into the drying chamber; a gas loop configured to be
fluidly coupled with the drying chamber gas inlet and the drying
chamber gas outlet, wherein the gas loop comprises a gas makeup
port fluidly coupled with the gas loop; a gas particulate filter
configured with an inlet and a filtered outlet, wherein the gas
particulate filter inlet is fluidly coupled with the drying chamber
gas outlet, and wherein the gas particulate filter outlet is
fluidly coupled with the gas loop; a heat exchanger configured in
the gas loop, wherein the heat exchanger comprises a gas to liquid
or gas to gas heat exchanger; and a control system configured to
cause the apparatus to perform operations comprising: receive hot
biochar from the gasifier into the cooling chamber; inject cool
steam from the steam loop into the cooling chamber gas inlet; apply
the cool steam directly to hot biochar retained within the cooling
chamber; and in response to a determination the biochar retained
within the cooling chamber cooled to a predetermined temperature:
discharge the cooled biochar into the drying chamber; inject dry
gas from the gas loop into the drying chamber; and in response to a
determination the biochar retained within the drying chamber dried
to a predetermined moisture level, release the cooled dried biochar
from the drying chamber.
[0040] The apparatus may further comprise a biochar recovery system
fluidly coupled with the drying chamber biochar outlet, and wherein
release the cooled dried biochar from the drying chamber further
comprises release the cooled dried biochar into the biochar
recovery system.
[0041] The operations performed by the apparatus may further
comprise inject cool steam into the steam loop steam makeup
port.
[0042] The operations performed by the apparatus may further
comprise inject dry gas into the gas loop gas makeup port.
[0043] In another aspect, an apparatus may comprise: a processing
chamber; a heat source thermally coupled with the processing
chamber; a cooling chamber configured to be fluidly coupled with
the processing chamber; and a control system configured to cause
the apparatus to perform operations comprising: heat biochar
retained within the processing chamber; and in response to a
determination the biochar retained within the processing chamber
heated to a predetermined temperature: discharge the hot biochar
into the cooling chamber; inject cool gas into the cooling chamber;
apply the cool gas directly to the hot biochar retained within the
cooling chamber; and in response to a determination the biochar
retained within the cooling chamber cooled to a predetermined
temperature, discharge the cooled biochar from the cooling
chamber.
[0044] The processing chamber may be configured to receive biochar
via at least one discharge valve configured to be fluidly coupled
with the processing chamber.
[0045] The operations performed by the apparatus may further
comprise receive biochar into the processing chamber via at least
one discharge valve fluidly coupled with the processing
chamber.
[0046] Receive biochar may further comprise receive biochar from a
gasifier fluidly coupled with the apparatus.
[0047] The gasifier may further comprise a downdraft gasifier.
[0048] The gasifier may further comprise a fluidized bed
gasifier.
[0049] The heat source may further comprise a heating element.
[0050] The heat source may further comprise process heat.
[0051] The apparatus may further comprise at least one discharge
valve configured to fluidly couple the processing chamber to the
cooling chamber.
[0052] In an implementation, an apparatus may comprise: a
processing chamber; at least one discharge valve configured to be
fluidly coupled with the processing chamber, wherein the at least
one discharge valve is configured to be fluidly coupled with a
gasifier to direct biochar from the gasifier into the processing
chamber; a heat source thermally coupled with the processing
chamber, wherein the heat source comprises a heating element; a
cooling chamber configured to be fluidly coupled with the
processing chamber by at least one discharge valve configured to
direct biochar from the processing chamber into the cooling
chamber, wherein the cooling chamber includes a gas inlet port, and
wherein the cooling chamber includes a gas outlet configured to be
fluidly coupled with a particulate filter by a discharge valve; a
CO.sub.2 removal filter having an inlet, a CO.sub.2 outlet, and a
mixed gas outlet, wherein the CO.sub.2 removal filter inlet is
fluidly coupled with the particulate filter; an H.sub.2 removal
filter having an inlet, an H.sub.2 outlet, and a mixed gas outlet,
wherein the H.sub.2 removal filter inlet is fluidly coupled with
the CO.sub.2 removal filter mixed gas outlet; at least one
discharge valve configured to be fluidly coupled with the cooling
chamber, wherein the at least one discharge valve is configured to
release biochar from the cooling chamber; and a control system
configured to cause the apparatus to perform operations comprising:
heat biochar retained within the processing chamber, using the heat
source; and in response to a determination the biochar retained
within the processing chamber heated to a predetermined
temperature: discharge the hot biochar into the cooling chamber;
inject cool gas comprising hydrocarbon into the cooling chamber
through the cooling chamber gas inlet port; apply the cool
hydrocarbon gas directly to the hot biochar retained within the
cooling chamber; and in response to a determination the biochar
retained within the cooling chamber cooled to a predetermined
temperature: release the cooled biochar from the cooling chamber;
and release the hydrocarbon gas into the particulate filter through
the cooling chamber gas outlet.
[0053] The gasifier may further comprise a downdraft gasifier.
[0054] The gasifier may further comprise a fluidized bed
gasifier.
[0055] The processing chamber may be fluidly coupled with the
gasifier.
[0056] The apparatus may further comprise a thermal oxidizer
thermally coupled with the processing chamber, and a tail gas
recycle loop fluidly coupled with the H.sub.2 removal filter mixed
gas output and the thermal oxidizer.
[0057] The tail gas recycle loop may be fluidly coupled with the
cooling chamber gas inlet port.
[0058] The apparatus may further comprise a biochar recovery system
and the operations performed by the apparatus further comprise
release the cooled biochar into the biochar recovery system.
[0059] In an implementation, an apparatus may comprise: a
processing chamber; at least one discharge valve configured to be
fluidly coupled with the processing chamber, wherein the at least
one discharge valve is fluidly coupled with a gasifier to direct
biochar from the gasifier into the processing chamber; a cooling
chamber configured to be fluidly coupled with the processing
chamber by at least one discharge valve configured to direct
biochar from the processing chamber into the cooling chamber,
wherein the cooling chamber includes a gas inlet port, and wherein
the cooling chamber includes a gas outlet configured to be fluidly
coupled with a particulate filter by a discharge valve; a CO.sub.2
removal filter having an inlet, a CO.sub.2 outlet, and a mixed gas
outlet, wherein the CO.sub.2 removal filter inlet is fluidly
coupled with the particulate filter; an H.sub.2 removal filter
having an inlet, an H.sub.2 outlet, and a mixed gas outlet, wherein
the H.sub.2 removal filter inlet is fluidly coupled with the
CO.sub.2 removal filter mixed gas outlet; a thermal oxidizer
thermally coupled with the processing chamber, and a tail gas
recycle loop fluidly coupled with the H.sub.2 removal filter mixed
gas output and the thermal oxidizer, wherein the tail gas recycle
loop is fluidly coupled with the cooling chamber gas inlet port; a
heat source thermally coupled with the processing chamber, wherein
the heat source comprises heat from the thermal oxidizer; at least
one discharge valve configured to be fluidly coupled with the
cooling chamber, wherein the at least one discharge valve is
configured to release biochar from the cooling chamber; and a
control system configured to cause the apparatus to perform
operations comprising: heat biochar retained within the processing
chamber, using the heat source; and in response to a determination
the biochar retained within the processing chamber heated to a
predetermined temperature: discharge the hot biochar into the
cooling chamber; inject cool gas comprising hydrocarbon into the
cooling chamber through the cooling chamber gas inlet port; apply
the cool hydrocarbon gas directly to the hot biochar retained
within the cooling chamber; in response to a determination the
biochar retained within the cooling chamber cooled to a
predetermined temperature: release the cooled biochar from the
cooling chamber; and release the hydrocarbon gas through the
cooling chamber gas outlet into the particulate filter.
[0060] The apparatus may further comprise a biochar recovery system
and the operations performed by the apparatus further comprise
release the cooled biochar into the biochar recovery system.
[0061] The apparatus may further comprise a tail gas recovery
system fluidly coupled with the H.sub.2 removal filter mixed gas
outlet.
[0062] The apparatus may further comprise an H.sub.2 gas recovery
system fluidly coupled with the H.sub.2 removal filter H.sub.2
outlet.
[0063] In an aspect, a method may comprise: injecting cool steam
into a cooling chamber; applying the cool steam directly to hot
biochar retained within the cooling chamber; and in response to a
determining the biochar retained within the cooling chamber cooled
to a predetermined temperature: discharging the cooled biochar into
a drying chamber; injecting dry gas into the drying chamber; and in
response to determining the biochar retained within the drying
chamber dried to a predetermined moisture level, discharging the
cooled dried biochar from the drying chamber.
[0064] Injecting cool steam may further comprise injecting steam
from a steam loop configured to cool steam.
[0065] The steam loop may further comprise a heat exchanger.
[0066] The method may further comprise receiving hot biochar into
the cooling chamber.
[0067] Receiving hot biochar may further comprise receiving hot
biochar from a gasifier.
[0068] The gasifier may further comprise a downdraft gasifier.
[0069] The gasifier may further comprise a fluidized bed
gasifier.
[0070] Injecting dry gas may further comprise injecting gas from a
gas loop configured to dry gas.
[0071] The gas loop may further comprise a particulate filter and a
heat exchanger.
[0072] In an implementation, a method may comprise: receiving hot
biochar from a gasifier into a cooling chamber; injecting cool
steam from a steam loop into the cooling chamber, wherein the steam
loop is configured with a steam particulate filter and a heat
exchanger comprising a heat sink; applying the cool steam directly
to the hot biochar retained within the cooling chamber; and in
response to determining the biochar retained within the cooling
chamber cooled to a predetermined temperature: discharging the
cooled biochar into a drying chamber; injecting dry gas from a gas
loop into the drying chamber, wherein the gas loop is configured
with a gas particulate filter and a heat exchanger comprising a
heat sink; and in response to determining the biochar retained
within the drying chamber dried to a predetermined moisture level,
releasing the cooled dried biochar from the drying chamber.
[0073] The gasifier may further comprise a downdraft gasifier.
[0074] The gasifier may further comprise a fluidized bed
gasifier.
[0075] The steam particulate filter may further comprise a ceramic
filter.
[0076] The steam particulate filter may further comprise a sintered
metal filter.
[0077] The gas particulate filter may further comprise a ceramic
filter.
[0078] The gas particulate filter may further comprise a sintered
metal filter.
[0079] In an implementation, a method may comprise: receiving hot
biochar from a gasifier into a cooling chamber through a discharge
valve; injecting cool steam from a steam loop into the cooling
chamber; applying the cool steam directly to hot biochar retained
within the cooling chamber; and in response to determining, by a
control system, the biochar retained within the cooling chamber
cooled to a predetermined temperature: discharging, by the control
system, the cooled biochar through a discharge valve into a drying
chamber; injecting dry gas from a gas loop into the drying chamber;
and in response to determining, by the control system, the biochar
retained within the drying chamber dried to a predetermined
moisture level, releasing, by the control system, the cooled dried
biochar from the drying chamber through a discharge valve.
[0080] Releasing the cooled dried biochar from the drying chamber
may further comprise releasing the cooled dried biochar into a
biochar recovery system.
[0081] The method may further comprise injecting cool steam into a
steam makeup port fluidly coupled with the steam loop.
[0082] The method may further comprise injecting dry gas into a gas
makeup port fluidly coupled with the gas loop.
[0083] In another aspect, a method may comprise: heating biochar
retained within a processing chamber, using a heat source thermally
coupled with the processing chamber; and in response to determining
the biochar retained within the processing chamber heated to at
least a predetermined temperature: discharging the heated biochar
into a cooling chamber; injecting cool gas into the cooling
chamber; applying the cool gas directly to the biochar retained
within the cooling chamber; and in response to determining the
biochar retained within the cooling chamber cooled to a
predetermined temperature, discharging the cooled biochar from the
cooling chamber.
[0084] The method may further comprise receiving biochar into the
processing chamber.
[0085] The method may further comprise receiving biochar from a
gasifier into the processing chamber, and retaining the biochar
within the processing chamber.
[0086] The gasifier may further comprise a downdraft gasifier.
[0087] The gasifier may further comprise a fluidized bed
gasifier.
[0088] The heat source may further comprise a heating element.
[0089] The heat source may further comprise process heat, and the
method may further comprise: in response to determining the process
heat is at least a predetermined minimum temperature, deactivating
the heating element.
[0090] Discharging the heated biochar into the cooling chamber may
further comprise fluidly coupling the processing chamber to the
cooling chamber.
[0091] The method may further comprise retaining the biochar within
the processing chamber for at least a predetermined time
period.
[0092] In an implementation, a method may comprise: receiving
biochar into a processing chamber configured to be fluidly coupled
with a gasifier; heating the biochar retained within the processing
chamber, using a heat source thermally coupled with the processing
chamber, wherein the heat source comprises a heating element and
process heat; and in response to determining the biochar retained
within the processing chamber heated to a predetermined
temperature: discharging the heated biochar into a cooling chamber;
injecting cool gas comprising hydrocarbon into the cooling chamber;
applying the cool gas comprising hydrocarbon directly to the
biochar retained within the cooling chamber; and in response to
determining the biochar retained within the cooling chamber cooled
to a predetermined temperature: releasing the cooled biochar from
the cooling chamber; and releasing gas from the cooling chamber
into a particulate filter fluidly coupled with the cooling
chamber.
[0093] The gasifier may further comprise a downdraft gasifier.
[0094] The gasifier may further comprise a fluidized bed
gasifier.
[0095] The gasifier may be fluidly coupled with the processing
chamber.
[0096] The method may further comprise recovering carbon dioxide
from a CO.sub.2 removal filter fluidly coupled with the particulate
filter.
[0097] The method may further comprise recovering hydrogen from an
H.sub.2 removal filter fluidly coupled with the particulate
filter.
[0098] The method may further comprise recycling tail gas as
cooling gas supplied to the cooling chamber through a tail gas
recycle loop fluidly coupled with the H.sub.2 removal filter and
the cooling chamber.
[0099] The method may further comprise heating the biochar retained
within the processing chamber using process heat comprising heat
generated by a thermal oxidizer from tail gas, wherein the thermal
oxidizer is thermally coupled with the processing chamber.
[0100] The method may further comprise supplying the tail gas to
the thermal oxidizer from an H.sub.2 removal filter fluidly coupled
with the particulate filter.
[0101] In an aspect, a method may comprise: receiving biochar from
a gasifier into a processing chamber; heating biochar retained
within the processing chamber, using a heat source thermally
coupled with the processing chamber, wherein the heat source
comprises a heating element and recovered process heat from a
thermal oxidizer supplied with tail gas; in response to a
determination, by a control system, the process heat is at least a
predetermined minimum temperature, deactivating, by the control
system, the heating element; and in response to determining, by a
control system, the biochar retained within the processing chamber
heated to at least a predetermined minimum temperature: discharging
the biochar into a cooling chamber; injecting cool gas into the
cooling chamber; applying the cool gas directly to the biochar
retained within the cooling chamber; and in response to a
determining, by the control system, the biochar retained within the
cooling chamber cooled to at least a predetermined maximum
temperature: releasing the biochar from the cooling chamber;
releasing gas from the cooling chamber into a particulate filter;
recovering carbon dioxide from a CO.sub.2 removal filter fluidly
coupled with the particulate filter; recovering hydrogen from an
H.sub.2 removal filter fluidly coupled with the CO.sub.2 removal
filter; supplying tail gas recovered from the H.sub.2 removal
filter to the thermal oxidizer; heating the processing chamber
using process heat comprising heat generated by the thermal
oxidizer from the tail gas; and recycling a portion of the tail gas
as cooling gas supplied to the cooling chamber.
[0102] The method may further comprise repeating the method with
the heating element deactivated.
[0103] The method may further comprise releasing the biochar from
the cooling chamber into a biochar recovery system.
[0104] Receiving biochar from the gasifier may further comprise
receiving biochar from a plurality of gasifiers.
[0105] More than one gasifier of the plurality of gasifiers may be
fluidly coupled with the processing chamber.
[0106] A direct biochar cooling implementation in accordance with
the present disclosure may provide an alternative to an indirect
biochar cooling design.
[0107] Various implementations in accordance with the present
disclosure relate to a cost-effective means to cool hot biochar
using direct application of cool gases comprising H.sub.2O or
CH.sub.4. An exemplary direct cooling implementation in accordance
with the present disclosure may decompose cooling gas comprising
methane.
[0108] A co-effect of an exemplary direct cooling approach in
accordance with the present disclosure may be that the cool gases
comprising compounds which include CH.sub.4 decompose into carbon,
which may aggregate as additional solid carbon. Another co-effect
may be that the physical and chemical composition of the biochar
may be modified as a result of the application of the cooling gas,
which may increase the surface area of the carbon and/or modify the
carbon structures.
[0109] In one aspect of the present disclosure, direct cooling of
hot biochar with steam as the hot biochar exits a gasifier or
cyclone may create an economical way to cool biochar while
enhancing the surface area of the biochar, resulting in a byproduct
that is comparable to activated carbon.
[0110] In another aspect of the present disclosure, direct cooling
of hot biochar with hydrocarbon gas as the hot biochar exits the
gasifier or cyclone may create an economical way to cool biochar
while enhancing the high-quality carbon content of the biochar with
nano tube type carbon formation on the biochar [chemical vapor
deposition], while producing a gas stream that may be filtered for
high value chemical (such as, for example, hydrogen) recovery.
[0111] In an illustrative example, various implementations in
accordance with the present disclosure may not use a formulated
metal catalyst. To the extent metals are present in biochar
produced by such implementations that do not use a formulated metal
catalyst, the metals present in the biochar may derive from the
natural presence of the metals in the biomass, or the metals'
non-deliberate presence in the biosolids.
[0112] In various aspects the present disclosure teaches direct
biochar cooling.
[0113] Direct biochar cooling may be implemented as an apparatus.
Direct biochar cooling may be implemented as a method.
[0114] The apparatus may comprise steam direct biochar cooling. The
apparatus may comprise hydrocarbon gas direct biochar cooling. The
apparatus may comprise hydrocarbon gas direct biochar cooling with
tail gas recycling.
[0115] The steam direct biochar cooling apparatus comprises a
cooling chamber. The steam direct biochar cooling apparatus
comprises a drying chamber configured to be fluidly coupled with
the cooling chamber. The cooling chamber comprises at least one
inlet. The cooling chamber comprises at least one outlet. The
drying chamber comprises at least one inlet. The drying chamber
comprises at least one outlet. The apparatus may comprise a
discharge valve configured to fluidly couple the cooling chamber
with the drying chamber. The apparatus may comprise a flange
configured to be fluidly coupled with the cooling chamber. The
cooling chamber may be fluidly coupled with the flange by a
discharge valve. The flange fluidly coupled with the cooling
chamber may be configured to be fluidly coupled with a gasifier.
The flange configured to be fluidly coupled with the gasifier may
be fluidly coupled with the cooling chamber by a discharge valve.
The apparatus may comprise at least one feed mechanism configured
to be fluidly coupled with at least one discharge valve. The at
least one feed mechanism may be configured to be fluidly coupled
with the cooling chamber. The at least one feed mechanism may be
configured to be fluidly coupled with the drying chamber. The
apparatus comprises a steam loop fluidly coupled with the cooling
chamber. The steam loop may be fluidly coupled with at least one
cooling chamber outlet. The steam loop may be fluidly coupled with
at least one cooling chamber inlet. The steam loop may comprise a
particulate filter serially coupled with at least one cooling
chamber outlet and at least one cooling chamber inlet. The steam
loop may comprise a heat exchanger serially coupled with at least
one cooling chamber outlet and at least one cooling chamber inlet.
The heat exchanger may comprise a heat sink. The steam loop may
comprise a steam inlet port. The apparatus comprises a gas loop
fluidly coupled with the drying chamber. The gas loop may be
fluidly coupled with at least one drying chamber outlet. The gas
loop may be fluidly coupled with at least one drying chamber inlet.
The gas loop may comprise a heat exchanger serially coupled with at
least one drying chamber outlet and at least one drying chamber
inlet. The heat exchanger may comprise a heat sink. The gas loop
may comprise a gas inlet port. The gas loop may comprise a
particulate filter serially coupled with at least one drying
chamber outlet and at least one drying chamber inlet. The apparatus
may comprise a flange configured to be fluidly coupled with the
drying chamber. The drying chamber may be fluidly coupled with the
flange by a discharge valve. The flange fluidly coupled with the
drying chamber may be configured to be fluidly coupled with a
biochar processing system. The apparatus may further comprise a
control system configured to cool hot biochar. Cooling hot biochar
may comprise operably couple one or more discharge valve and one or
more feed mechanism to receive hot biochar in the cooling chamber,
inject cool steam from the steam loop into the cooling chamber to
cool the hot biochar, retain the cool steam and biochar in the
cooling chamber until the biochar is cooled to a predetermined
temperature, direct the cooled biochar into the drying chamber,
inject dry gas from the gas loop into the drying chamber to dry the
moist biochar, retain the dry gas and biochar in the drying chamber
until the biochar is dried to a predetermined moisture level, and
discharge the dried cooled biochar from the drying chamber.
[0116] The hydrocarbon gas direct biochar cooling apparatus
comprises a processing chamber. The hydrocarbon gas direct biochar
cooling apparatus comprises a cooling chamber configured to be
fluidly coupled with the processing chamber. The processing chamber
comprises at least one inlet. The processing chamber comprises at
least one outlet. The cooling chamber comprises at least one inlet.
The cooling chamber comprises at least one outlet. The apparatus
may comprise a discharge valve configured to fluidly couple the
processing chamber with the cooling chamber. The apparatus may
comprise a flange configured to be fluidly coupled with the
processing chamber. The processing chamber may be fluidly coupled
with the flange by a discharge valve. The flange fluidly coupled
with the processing chamber may be configured to be fluidly coupled
with a gasifier. The flange configured to be fluidly coupled with
the gasifier may be fluidly coupled with the processing chamber by
a discharge valve. The apparatus may comprise at least one feed
mechanism configured to be fluidly coupled with at least one
discharge valve. The at least one feed mechanism may be configured
to be fluidly coupled with the processing chamber. The at least one
feed mechanism may be configured to be fluidly coupled with the
cooling chamber. The apparatus may comprise a heating element
thermally coupled with the processing chamber. The apparatus may
comprise the processing chamber thermally coupled with process heat
to receive heat from a gasification process or from biochar
cooling. The processing chamber may be thermally coupled with a
heat exchanger. The heat exchanger may comprise a heat sink. The
heat exchanger may be configured to extract heat from exhaust gas.
The heat exchanger may be configured to extract heat from the
cooling chamber. The cooling chamber may comprise at least one gas
inlet port. The apparatus may comprise at least one cooling chamber
outlet coupled with a particulate filter. The apparatus may
comprise at least one cooling chamber outlet coupled with a gas
chromatograph. The apparatus may comprise at least one cooling
chamber outlet coupled with a CO.sub.2 removal filter. The
apparatus may comprise at least one cooling chamber outlet coupled
with an H.sub.2 removal filter. The particulate filter may be
serially coupled with the CO.sub.2 removal filter. The particulate
filter may be serially coupled with the H.sub.2 removal filter. The
CO.sub.2 removal filter may be serially coupled with the H.sub.2
removal filter. The CO.sub.2 removal filter may have a mixed gas
outlet. The CO.sub.2 removal filter may have a CO.sub.2 outlet. The
H.sub.2 removal filter may have a mixed gas outlet. The CO.sub.2
removal filter may have an H.sub.2 outlet. The apparatus may
comprise a flange configured to be fluidly coupled with the cooling
chamber. The cooling chamber may be fluidly coupled with the flange
by a discharge valve. The flange fluidly coupled with the cooling
chamber may be configured to be fluidly coupled with a biochar
processing system. The apparatus may comprise a tail gas recycle
loop. The tail gas recycle loop may fluidly couple at least one
cooling chamber gas inlet port with at least one removal filter
mixed gas outlet. The at least one removal filter mixed gas outlet
coupled with the at least one cooling chamber gas inlet port may be
an H.sub.2 removal filter mixed gas outlet. The removal filter
mixed gas outlet coupled with the at least one cooling chamber gas
inlet port may be a CO.sub.2 removal filter mixed gas outlet. The
tail gas recycle loop may fluidly couple at least one cooling
chamber gas inlet port with at least one removal filter mixed gas
outlet and a thermal oxidizer. The thermal oxidizer may be
thermally coupled with a heat exchanger that is configured to be
thermally coupled with the processing chamber. The apparatus may
further comprise a control system configured to cool hot biochar.
Cooling hot biochar may comprise operably couple one or more
discharge valve and one or more feed mechanism to receive hot
biochar in the processing chamber, process the biochar based on
heating the biochar in the processing chamber, retain the biochar
in the processing chamber for a predetermined time or until the
biochar reaches a predetermined temperature, direct the biochar in
the processing chamber into the cooling chamber, inject cool gas
from the gas inlet port into the cooling chamber to cool the
biochar, retain the gas and biochar in the cooling chamber until
the biochar is cooled to a predetermined temperature, and discharge
the cooled biochar from the cooling chamber.
[0117] The method may comprise steam direct biochar cooling. The
method may comprise hydrocarbon gas direct biochar cooling. The
method may comprise hydrocarbon gas direct biochar cooling with
tail gas recycling.
[0118] The steam direct biochar cooling method may comprise
receiving hot biochar in a cooling chamber, injecting cool steam
into the cooling chamber, retaining the cool steam and biochar in
the cooling chamber until the biochar is cooled to a predetermined
temperature, directing the cooled biochar into the drying chamber,
injecting dry gas into the drying chamber, retaining the dry gas
and biochar in the drying chamber until the biochar is dried to a
predetermined moisture level, and discharging the dried cooled
biochar from the drying chamber. Receiving hot biochar in the
cooling chamber may comprise operably coupling one or more
discharge valve and one or more feed mechanism to receive the hot
biochar. Injecting cool steam into the cooling chamber may comprise
injecting cool steam from the steam loop into the cooling chamber
to cool the hot biochar. Injecting dry gas into the drying chamber
may comprise injecting dry gas from the gas loop into the drying
chamber to dry the moist biochar. Discharging the dried cooled
biochar from the drying chamber may comprise operably coupling one
or more discharge valve to discharge the dried cooled biochar.
[0119] The hydrocarbon gas direct biochar cooling method may
comprise receiving hot biochar in a processing chamber, processing
the biochar based on heating the biochar in the processing chamber,
retaining the biochar in the processing chamber until the biochar
reaches a predetermined temperature, directing the biochar in the
processing chamber into the cooling chamber, injecting cool gas
into the cooling chamber to cool the biochar, retaining the gas and
biochar in the cooling chamber until the biochar is cooled to a
predetermined temperature, and discharging the cooled biochar from
the cooling chamber. The method may comprise removing CO.sub.2 from
gas directed from the cooling chamber to a CO.sub.2 removal filter.
The method may comprise removing H.sub.2 from gas directed from the
CO.sub.2 removal filter to an H.sub.2 removal filter. The method
may comprise recovering tail gas from the H.sub.2 removal filter
mixed gas outlet. The method may comprise recycling the tail gas
through a tail gas recycle loop. Recycling the tail gas may
comprise fluidly coupling at least one cooling chamber gas inlet
port with the H.sub.2 removal filter mixed gas outlet through the
tail gas recycle loop. Recycling the tail gas may comprise fluidly
coupling at least one cooling chamber gas inlet port with the
H.sub.2 removal filter mixed gas outlet and a thermal oxidizer
through the tail gas recycle loop. The method may comprise
recycling heat. Recycling heat may further comprise recycling heat
generated from the tail gas by the thermal oxidizer. The method may
comprise applying the heat generated from the tail gas by the
thermal oxidizer to the processing chamber.
[0120] Various direct biochar cooling implementations may achieve
one or more technical effect. For example, some direct biochar
cooling implementations may reduce installation, component, or
maintenance cost. This facilitation may be a result of a direct
biochar cooling implementation designed to directly cool biochar
using cool gas comprising steam or hydrocarbons, without a need for
additional components to cool the biochar, such as, for example, a
heat exchanger, or a cooling tower. Some direct biochar cooling
implementations may reduce operation cost. Such reduced operation
cost may be a result of a direct biochar cooling implementation
designed to directly cool biochar using cool gas comprising steam
or hydrocarbons, without requiring additional energy inputs to cool
the biochar using additional cooling components. In some direct
biochar cooling designs, valuable byproducts may be produced. For
example, biochar produced by steam direct cooling may be valued at
a higher price point than standard biochar produced by indirect
cooling, and the biochar produced by steam direct cooling may be a
competitive alternative to activated carbon. Such higher-valued
biochar produced by steam direct cooling may be a result of greater
biochar surface area relative to standard biochar produced by
indirect cooling.
[0121] Some direct biochar cooling implementations may produce
biochar valued as a high-grade carbon manufacturing input. For
example, biochar produced by some hydrocarbon direct cooling
implementations may be valued at a higher price point than standard
biochar. This facilitation may be a result of high grade carbon
growth from the decomposition of CH.sub.4 in the gas, produced by
hydrocarbon direct cooling of the biochar. Some direct biochar
cooling implementations may produce a value-add chemical byproduct.
Such a value-add chemical byproduct may be a result of recycling
and selling cooled hydrocarbon captured from an exemplary
hydrocarbon direct cooling implementation. Various direct biochar
cooling implementations may enhance biochar quality. Such enhanced
biochar quality may be a result of directly cooling hot biochar
resulting from gasification. Some direct biochar cooling
implementations may capture hydrogen resulting from gasification.
Such captured hydrogen production may enhance the efficiency of
transition from a carbon-based economy, and improve the usefulness
of gasification technology.
[0122] In the case of hydrocarbon direct biochar cooling, a portion
of the hydrocarbon gas may decompose with carbon attaching to
biochar and hydrogen flowing through in the hot hydrocarbon mixed
gas. The hot hydrocarbon mixed gas may be cooled, and hydrogen may
be stripped out or captured with a filter. In an illustrative
example, ten percent or more hydrogen may be required to
commercially apply such an exemplary filtration approach and
recycle the cooled hydrocarbon mixed gas back to the direct cooling
step, with make-up from the pipeline, wellhead, digester, or the
like, to repeat the process. In an illustrative example, this
recovered hydrogen may be sold as a value-add chemical byproduct of
an exemplary hydrocarbon direct biochar cooling system.
[0123] In an illustrative example, a direct biochar cooling
implementation in accordance with the present disclosure may
directly cool hot biochar resulting from gasification, and in the
process, enhance the biochar quality, or enhance the biochar
quality and generate hydrogen.
[0124] In some implementations, an exemplary biochar and bio fly
ash cooling apparatus may be a counter flow, direct contact
exchange system operating on principles similar to a standpipe. An
exemplary apparatus may include a metal cylinder of an appropriate
composition for the conditions, but may require a refractory or
other lining for high temperature operation. In various examples
illustrative of the design and usage of various biochar cooling
implementations in accordance with the present disclosure, solids
may enter the top of an exchanger and flow via gravity through the
cooler, exiting at the bottom. In such an example, the gas stream
may enter the cooler near the bottom of the cooler, and flow upward
through the solids. The gas may also serve to fluidize the solids,
enhancing the solids' flow through the cooler. In various exemplary
implementations, the method of introducing the gas may vary
depending on, for example, flow and cooler size, however the method
of introducing the gas may either utilize a gas distributor in
larger systems, or fluidization nozzles at the wall for smaller
coolers. The gas may exit near the top of the cooler. Depending on
application, a separation device, such as a small cyclone or
filter, may be needed to disengage the gas and solids at the gas
exit.
[0125] In another aspect, a method to activate and cool biochar may
comprise: receiving biochar (809) into a processing vessel (803)
configured with multiple independently temperature-controlled
chambers and counter-flow steam injection; controlling activation
levels of the biochar (809) by moving the biochar (809) through the
processing vessel (803) and adjusting the temperature of the
biochar (809) by steam (831) injection into at least one
temperature-controlled chamber of the processing vessel (803);
recovering volatiles driven off through dehydration using a thermal
oxidizer (505); cooling the biochar (809) to a desired discharge
temperature using steam (831) and retention time; and discharging
an activated biochar product (833).
[0126] Receiving biochar (809) may further comprise receiving
biochar (809) from a downdraft gasifier (600).
[0127] The processing vessel (803) may further comprise a calciner,
a rotary calciner, or a kiln.
[0128] The method may further comprise sweeping volatile gases to a
thermal oxidizer (505) using a vacuum system and counter-flow
saturated steam (831).
[0129] The multiple independently temperature-controlled chambers
configured in the processing vessel (803) may further comprise a
processing vessel heating section (824) and a processing vessel
cooling section (827).
[0130] The temperature range of the processing vessel heating
section (824) may be (750.degree. F.-2200.degree. F. or 400.degree.
C.-1200.degree. C.).
[0131] The processing vessel (803) may further comprise a
processing vessel inlet (806) disposed at a processing vessel head
(1100) wherein the processing vessel inlet (806) is configured to
be fluidly coupled with the processing vessel heating section
(824), and a processing vessel outlet (830) disposed at a
processing vessel tail (1120) wherein the processing vessel outlet
(830) is configured to be fluidly coupled with the processing
vessel cooling section (827).
[0132] Receiving biochar (809) may further comprise receiving
biochar (809) into the processing vessel heating section (824).
[0133] Discharging the activated biochar product (833) may further
comprise discharging the activated biochar product (833) from the
processing vessel cooling section (827).
[0134] The processing vessel (803) may further comprise a control
system (925) configured to adjust the temperature of biochar (809)
using the processing vessel heating section (824).
[0135] The control system (925) may further comprise configuration
to govern retention time of biochar (809) in the processing vessel
(803) based on controlling fluid coupling of the processing vessel
heating section (824) with the processing vessel cooling section
(827).
[0136] The control system (925) may further comprise configuration
to determine the temperature in the at least one
temperature-controlled chamber of the processing vessel (803).
[0137] Adjusting the temperature of the biochar (809) retained by
at least one temperature-controlled chamber of the processing
vessel (803) may further comprise using the control system (925) to
release biochar (809) from the processing vessel heating section
(824) into the processing vessel cooling section (827) in response
to the control system (925) determining the temperature in the
processing vessel heating section (824) is at least a predetermined
minimum temperature.
[0138] Adjusting the temperature of the at least one
temperature-controlled chamber of the processing vessel (803) may
further comprise using the control system (925) to retain biochar
(809) in the at least one temperature-controlled chamber of the
processing vessel (803) until the control system (925) determines
the temperature of the at least one temperature-controlled chamber
of the processing vessel (803) satisfied at least a predetermined
minimum temperature for at least a predetermined minimum period of
time.
[0139] Adjusting the temperature of the at least one
temperature-controlled chamber of the processing vessel (803) may
further comprise cooling the biochar (809) based on increasing
biochar (809) retention time in the at least one
temperature-controlled chamber of the processing vessel (803) using
the control system (925).
[0140] The control system (925) may further comprise configuration
to adjust the temperature of biochar (809) using the processing
vessel (803) heating section (824) to heat the biochar (809) to a
predetermined target temperature in response to the control system
(925) determining the biochar (809) temperature is less than a
predetermined minimum.
[0141] The control system (925) may further comprise configuration
to adjust the temperature of biochar (809) using the processing
vessel (803) cooling section (827) to cool the biochar (809).
[0142] Adjusting the temperature of the biochar (809) retained by
at least one temperature-controlled chamber of the processing
vessel (803) may further comprise heating the at least one
temperature-controlled chamber of the processing vessel (803) using
processing vessel heating means (905).
[0143] The processing vessel heating means (905) may further
comprise an electric heating element.
[0144] The processing vessel heating means (905) may further
comprise recovered process heat.
[0145] Receiving biochar (809) may further comprise receiving
biochar (809) from a cyclone (812).
[0146] The method may further comprise heating biochar (809) using
a processing vessel heating means (905) to heat a processing vessel
heating section (827).
[0147] The method may further comprise cooling biochar (809) by
injecting steam (831) into a processing vessel cooling section
(827).
[0148] The processing vessel (803) may be configured with three
distinct temperature-controlled sections comprising a heating
section (824), a steam injection/activation chamber, and a cooling
chamber (827).
[0149] The processing vessel (803) may be configured to cause
received biochar (809) to flow in a direction from a processing
vessel inlet (806) to a processing vessel outlet (830) while
flowing through, in sequence, a heating section (824), a steam
injection/activation chamber, and a cooling chamber (827).
[0150] The method may further comprise enhancing and controlling
activation levels of carbon in the biochar (809) using steam (831)
injected into the processing vessel (803).
[0151] The method may further comprise sweeping volatile gases from
the biochar (809) using the injected steam (831).
[0152] The method may further comprise decomposing the volatile
gases swept from the biochar (809) using a thermal oxidizer
(505).
[0153] The method may further comprise injecting steam (831)
further comprising saturated steam.
[0154] The method may further comprise forming additional macro and
micro pores in the activated biochar product (833) using the
injected steam (831).
[0155] The method may further comprise adjusting an injection rate
of the injected steam (831) to control the size and number of macro
and micro pores in the activated biochar product (833), using the
control system (925).
[0156] The activated biochar product (833) may further comprise
graphene.
[0157] The activated biochar product (833) may further comprise
activated carbon.
[0158] The method may further comprise the processing vessel (803)
is configured to cause received biochar (809) to flow in a
direction from a processing vessel inlet (806) to a processing
vessel outlet (830).
[0159] The method may further comprise the processing vessel (803)
is configured to cause injected steam (831) to flow in a direction
counter to the biochar (809) flow.
[0160] Throughout this disclosure, the term "fluid" is used
interchangeably with the term "gas." For example, an element that
is "fluidly coupled" or "fluidly connected" or in "fluid
communication" is capable to or would be capable to be in a
coupled, connected, or communication mode with respect to gas,
fluid, gas and fluid, gas or fluid, or any combination or mixture
of gas or fluid. Throughout this disclosure, an element that is
"fluidly coupled" or "fluidly connected" or in "fluid
communication," as the terms are used herein, is also capable to or
would be capable to be in a coupled, connected, or communication
mode with respect to fluid, solids, fluid and solids, fluid or
solids, or any combination or mixture of fluid or solids.
[0161] The details of various aspects are set forth in the
accompanying drawings and the description below. Other features and
advantages will be apparent from the description and drawings, and
from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0162] FIG. 1 depicts a schematic of exemplary catalytic methane
decomposition.
[0163] FIG. 2 depicts a schematic of exemplary nanocarbon and
hydrogen gas creation.
[0164] FIG. 3 depicts a schematic of exemplary direct cooling of
hot biochar with cool dry steam as the hot biochar exits a gasifier
or cyclone, enhancing the surface area of the biochar.
[0165] FIG. 4 depicts a schematic of exemplary direct cooling of
hot biochar with cool hydrocarbon gas as the hot biochar exits a
gasifier or cyclone, enhancing the high-quality carbon content of
the biochar with nano tube type carbon formation on the biochar
[chemical vapor deposition], and producing a gas stream that may be
filtered to recover hydrogen.
[0166] FIG. 5 depicts a schematic of exemplary direct cooling of
hot biochar with cool hydrocarbon gas as the hot biochar exits a
gasifier or cyclone, with exemplary tail gas recycling.
[0167] FIG. 6 depicts an exemplary downdraft gasifier
implementation in accordance with the present disclosure.
[0168] FIG. 7 depicts an exemplary fluidized bed gasifier
implementation in accordance with the present disclosure.
[0169] FIG. 8 depicts a schematic view of an exemplary biochar
activation and cooling system implementation in accordance with the
present disclosure.
[0170] FIG. 9 depicts a schematic view of an exemplary biochar
cooling and activation processing vessel implementation in
accordance with the present disclosure.
[0171] FIG. 10 depicts a plan view of an exemplary biochar
activation and cooling system implementation in accordance with the
present disclosure.
[0172] FIG. 11 depicts a schematic view of an exemplary biochar
cooling and activation processing vessel implementation in
accordance with the present disclosure.
[0173] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0174] To aid understanding, this document is organized as follows.
First, catalytic methane decomposition and creation of nanocarbon
tubes [chemical vapor deposition] and hydrogen gas are briefly
introduced with reference to FIGS. 1-2. Second, with reference to
FIGS. 3-5, the discussion turns to exemplary implementations that
illustrate direct biochar cooling designs. Specifically, direct
biochar cooling implementations designed to cool biochar based on
steam and hydrocarbon gas applied directly to biochar are
disclosed. Then, with reference to FIGS. 6-7, illustrative
downdraft and fluidized bed gasifier implementations are presented,
to explain applications of direct biochar cooling technology.
Finally, with reference to FIGS. 8-11, exemplary biochar activation
and cooling designs are disclosed, to present improvements in
biochar processing technology.
[0175] It is to be understood that the specific devices and
processes illustrated in the attached drawings and described in the
following specification are exemplary implementations of the
inventive concepts defined in the appended claims. Hence, specific
dimensions and other physical characteristics relating to the
implementations disclosed herein are not to be considered as
limiting, unless the claims expressly state otherwise.
[0176] FIG. 1 depicts a schematic of exemplary catalytic methane
decomposition. In FIG. 1, the exemplary catalytic methane
decomposition process comprises low-temperature cracking of
methane, producing CON-free hydrogen and solid carbon. Catalytic
methane decomposition has the unique potential to make the swift
transition for a fully decarbonized economy and beyond: the methane
decomposition of biomethane removes CO.sub.2 from the atmosphere at
competitive cost.
[0177] FIG. 2 depicts a schematic of exemplary nanocarbon and
hydrogen gas creation. In FIG. 2, gas comprising methane is
decomposed by methane decomposition. The gas comprising methane may
be decomposed by methane decomposition as a result of being run
over a catalyst containing carbon in a heated reactor, to produce
hydrogen and carbon nanotubes/nano-onions/graphite. Examples of
catalysts commonly used for methane decomposition may include at
least nickel, cobalt, iron ore, or hematite iron ore. The gas
comprising methane may be decomposed by methane decomposition as a
result of being run over a thermochemically converted carbonaceous
material in a heated vessel, which decomposes the methane into
hydrogen and carbon. The hydrogen may remain in gaseous form. The
hydrogen may be recovered. The carbon may aggregate in solid form
with carbonaceous residue. The carbon may be recovered.
Gasification is a thermochemical process in which the reactions
between fuel and the gasification agent take place and syngas (also
known as producer gas, product gas, synthetic gas, or synthesis
gas) is produced. The syngas may be mainly composed of CO, H.sub.2,
N.sub.2, CO.sub.2, and some hydrocarbons (CH.sub.4, C.sub.2H.sub.4,
C.sub.2H.sub.6, and the like).
[0178] FIG. 3 depicts a schematic of exemplary direct cooling of
hot biochar with cool dry steam as the hot biochar exits a gasifier
or cyclone, enhancing the surface area of the biochar. In the steam
direct biochar cooling implementation 300 depicted by FIG. 3, hot
carbonaceous solid residue ("hot biochar") 335 is expelled from a
gasifier. The gasifier may be a downdraft gasifier. The gasifier
may be a fluidized bed gasifier. The downdraft gasifier may be, for
example, the exemplary downdraft gasifier 600 described at least
with reference to FIG. 6. The fluidized bed gasifier may be, for
example, the exemplary fluidized bed gasifier 700 described at
least with reference to FIG. 7. The gasifier may be operably
connected with the steam direct biochar cooling implementation 300
by the flange 330. In an illustrative downdraft gasifier example,
hot carbonaceous residue from the downdraft gasifier ("hot
biochar") 335 may be expelled from the downdraft gasifier through
the flange 330. In an illustrative fluidized bed gasifier example,
hot carbonaceous residue from the gasifier ("hot biochar") 335 may
be expelled from the gasifier cyclone through the flange 330. In
the illustrated example, the hot biochar 335 is expelled from the
gasifier through the flange 330 and the feed mechanism 320 to the
solid residue discharge valve 315 directing the biochar flow 325
into the cooling chamber 305. In the example depicted by FIG. 3,
the cooling chamber 305 is configured with the direct steam 360
input interface valve 340 fed by recycled steam from the steam
recycling loop 350. In the illustrated example, steam from the
alternative steam makeup 352 port is injected into the steam
recycling loop 350.
[0179] The steam 360 injected into the cooling chamber 305 cools
the hot carbonaceous solid residue ("biochar") 335 in the cooling
chamber 305. In the depicted example, the cooled biochar 335 is
then directed from the bottom of the cooling chamber 305 into the
drying chamber 310 through the discharge valve 315. During an
exemplary cooling step, moisture from the steam 360 may be
physically caught in the cooling biochar 335 depending on the pore
space and reactivity of the biochar 335. In the illustrated
example, the cooling steam 360 stream is directed from the cooling
chamber 305 through the particulate steam filter 345 to remove
particulates from the steam 360. The particulate steam filter 345
may be a hot gas ceramic or sintered metal particulate filter. In
the depicted example, the steam 360 filtered by the particulate
steam filter 345 is cooled in the steam recycling loop 350 using
steam to liquid heat exchange between the steam recycling loop 350
and the environment. The heat exchange may be enhanced by the heat
sink 355 configured in the steam recycling loop 350. The heat
exchange may be enhanced by the steam injected from the steam
makeup port 352 into the steam recycling loop 350. For example, the
steam makeup port 352 steam may be a different temperature than the
steam 360 in the steam recycling loop 350, to enhance cooling in
the steam recycling loop 350. The steam makeup port 352 steam may
be provided from the facility. In the depicted example, the cooled
steam 360 is re-routed through the steam recycling loop 350 to the
cooling chamber 305. Heat from the steam to liquid heat exchange in
the steam recycling loop 350 may be captured from the heat sink 355
and used to produce thermal energy for steam, power, or co-heat and
power applications within the facility.
[0180] In the example depicted by FIG. 3, the drying chamber 310 is
configured with the direct inert gas 370 input interface fed by the
recycled supply of dry inert gas 370 from the gas loop 380. During
an exemplary drying step, moisture caught in the biochar may be
swept away, producing the dried cooled biochar 375. In the
illustrated example, the inert gas 370 moistened in the drying
chamber 310 is directed through the particulate gas filter 365 to
remove particulates from the inert gas 370. The particulate gas
filter 365 may be a hot gas ceramic or sintered metal filter. In
the depicted example, the moistened inert gas 370 from the
particulate gas filter 365 is cooled in the gas loop 380. The
moistened inert gas 370 from the particulate gas filter 365 may be
cooled in the gas loop 380 using a chiller. The moistened inert gas
370 from the particulate gas filter 365 may be cooled in the gas
loop 380 using heat exchange between the gas loop 380 and the
environment. The moistened inert gas 370 from the particulate gas
filter 365 may be cooled in the gas loop 380 using heat exchange
enhanced by the heat sink 355 configured in the gas loop 380. Heat
from the heat exchange in the gas loop 380 may be captured from the
heat sink 355 and used to produce thermal energy for steam, power,
or co-heat and power applications within the facility. Makeup inert
gas may be injected into the gas loop 380 from makeup inert gas
port 372 to enhance cooling the gas 370 or enhance moisture removal
from the gas 370. The makeup inert gas injected from makeup inert
gas port 372 may have a different moisture level than the gas in
the gas loop 380. The makeup inert gas injected from makeup inert
gas port 372 may be a different temperature than the gas in the gas
loop 380, to enhance cooling in the gas loop 380. In the depicted
example, the filtered and cooled inert gas 370 is recycled through
the gas loop 380 back to the drying chamber 310. Following the
drying chamber 310, the resultant biochar 375 may be directed to
existing biochar sizing, handling and storage for 3rd party sale or
internal use.
[0181] In the example depicted by FIG. 3, the inlet flange 330 that
connects the cooling chamber 305 to the gasifier and/or the cyclone
via the discharge valve 315 represents the point at which the
exemplary steam direct biochar cooling implementation 300 begins.
Various steam direct biochar cooling implementation 300 designs may
include: i) one or more discharge valve 315 from the gasifier
and/or the cyclone(s), ii) one or more feed mechanism 320 from the
discharge valve 315 to the cooling chamber 305, iii) the cooling
chamber 305, iv) one or more hot gas ceramic or sintered metal
filter 345 for the removal of particulates from the steam post
cooling, v) the steam recycling loop 350 system with heat exchange
and steam makeup port 352, vi) the drying chamber 310, vii) one or
more hot gas ceramic or sintered metal filter 365 for the removal
of particulates from the inert gas post drying, viii)) the inert
gas loop 380 recycling system with heat exchange and gas make-up
372, and ix) piping, conduit, wiring, and control systems to
effectuate all of the described functions.
[0182] In the depicted example, the drying chamber 310 is connected
by the outlet discharge valve 315 with the outlet flange 330
through which the cooled carbonaceous solid residue ("cooled
biochar") 375 is expelled. In the illustrated example, the
particulate steam filter 345 or the particulate gas filter 365 may
be configured with a particulate removal valve connected with the
filters by a flange 330 (not shown). In the depicted example, the
steam recycling loop 350 or the gas loop 380 may be configured with
a heat exchanger comprising one or more heat sink 355. The heat
exchanger configured in the steam recycling loop 350 may be
connected with the particulate steam filter 345 by a flange 330
(not shown). The heat exchanger configured in the gas loop 380 may
be connected with the particulate gas filter 365 by a flange 330
(not shown). In an example illustrative of various steam direct
biochar cooling implementations in accordance with the present
disclosure, the flange 330 connections proximal to the drying
chamber 310, flange 330 connections to the filters, the steam
makeup port 352, and the inert gas makeup port 372 represent points
at which the exemplary steam direct biochar cooling implementation
300 may end.
[0183] In an illustrative example, the depicted steam direct
biochar cooling implementation 300 may permit a more cost-effective
means of cooling gasification hot carbonaceous solid residues.
[0184] For example, a steam direct biochar cooling implementation
in accordance with the present disclosure may take advantage of the
physical and compositional properties of the gasification hot
carbonaceous solid residue and the compositional properties of the
steam and inert gas, to augment the resultant hot carbonaceous
solid residue that renders the resultant biochar more suitable for
certain product applications, increasing the biochar's overall
commercial value.
[0185] Various steam direct biochar cooling implementations in
accordance with the present disclosure may utilize recycling loops
to minimize water and inert gas resource inputs, and improve the
efficiency of energy usage by biochar cooling.
[0186] Some steam direct biochar cooling implementations in
accordance with the present disclosure may be configured with one
or more heat exchanger designed to maximize process heat recovery,
and minimize energy resource inputs.
[0187] A steam direct biochar cooling implementation in accordance
with the present disclosure may include a dutchman style feed
system setup on the bottom of the discharge valve(s) to provide
flow variances between the gasifier and the cooling chamber. Some
steam direct biochar cooling implementations in accordance with the
present disclosure may include hot gas particulate removal systems,
such as, for example, a bag house system, or quench scrubber
system, applied as an alternative to a hot gas ceramic or sintered
metal filter.
[0188] In an illustrative example, a steam direct biochar cooling
implementation in accordance with the present disclosure may be
configured to receive independently produced and heated biochar,
using the biochar as a means to convert that heated biochar into a
biochar different in composition and physical format from the
original biochar, for specific product applications.
[0189] In an illustrative example, pre-cooling of the cooling gas
media prior to cooling chamber injection may be employed to ensure
the stream is sufficiently cooled to reduce the temperature of the
gasification hot carbonaceous solid residue (hot biochar). Some
implementations may adjust the moisture content of the stream to
prevent the stream from becoming too wet. A stream that is too wet
may cause the creation of a residue slurry that cannot be
effectively dried by inert gas drying, if, for example, the inert
gas is not dry enough to sweep the caught moisture from the
gasification cooled carbonaceous solid residue (cooled biochar); or
if carry over of too many particulates in the steam post cooling or
inert gas post drying impede the filtration systems' ability to
effectively remove particulates prior to the recycling loops.
[0190] In an illustrative example, component parts may comprise
sufficient quality steel material to account for the pressures
(1-500 psig/1-35 Bar), temperatures (212.degree.-1500.degree. F. or
100.degree.-800.degree. C.) and corrosiveness of the substances
involved. In an illustrative example, one could expect to utilize
at least some component parts comprising stainless steel in an
exemplary implementation in accordance with the present disclosure,
to account for the operational pressures and temperatures
expected.
[0191] An exemplary steam direct biochar cooling implementation may
take advantage of temperature, pressure, and composition of the
gasification hot carbonaceous material (hot biochar), the cooling
steam and the drying inert gas, to create cooled biochar with high
value application opportunities.
[0192] FIG. 4 depicts a schematic of exemplary direct cooling of
hot biochar with cool hydrocarbon gas as the hot biochar exits a
gasifier or cyclone, enhancing the high-quality carbon content of
the biochar with nano tube type carbon formation on the biochar,
and producing a gas stream that may be filtered to recover
hydrogen. FIG. 5 depicts a schematic of exemplary direct cooling of
hot biochar with cool hydrocarbon gas as the hot biochar exits a
gasifier or cyclone, with exemplary tail gas recycling.
[0193] In FIG. 4, the depicted hydrocarbon gas direct biochar
cooling implementation 400 is configured to cool hot biochar 335
based on direct application of heat, pure hydrocarbon gas streams,
or mixed gas streams (such as, for example, natural gas, biogas,
well head gas and coal bed methane, or the like) to produce the
cooled biochar 375 that is different in composition and physical
format from biochar produced by indirect processing and cooling. In
an illustrative example, this resultant cooled biochar 375 produced
based on direct application of heat, pure hydrocarbon gas streams
or mixed gas streams to the hot biochar 335 may be more suitable
for certain product applications. For example, in various
hydrocarbon gas direct biochar cooling implementations in
accordance with the present disclosure, the processing and cooling
media may be purified and refined as the hot carbonaceous solid
gasification residue is processed and cooled. In an example
illustrative of various hydrocarbon gas direct biochar cooling
implementation designs, the CO.sub.2 content of the cooling gas
stream may be extracted utilizing filtration technology adapted
from the sour gas and biogas upgrading industry applications. The
hydrogen content of the cooled gas stream may be extracted
utilizing filtration technology used in hydrogen production
technologies. In FIG. 5, the depicted hydrocarbon gas direct
biochar cooling implementation 500 further comprises exemplary tail
gas recycling features with the direct biochar cooling features
described with reference to the hydrocarbon gas direct biochar
cooling implementation 400 described with reference to FIG. 4.
[0194] In the hydrocarbon gas direct biochar cooling implementation
400 depicted by FIG. 4 and the hydrocarbon gas direct biochar
cooling with tail gas recycling implementation 500 depicted by FIG.
5, hot carbonaceous solid residue ("hot biochar") 335 is expelled
from a gasifier. The gasifier may be a downdraft gasifier. The
gasifier may be a fluidized bed gasifier. The downdraft gasifier
may be, for example, the exemplary downdraft gasifier 600 described
at least with reference to FIG. 6. The fluidized bed gasifier may
be, for example, the exemplary fluidized bed gasifier 700 described
at least with reference to FIG. 7. The gasifier may be operably
connected by the flange 330 with the hydrocarbon gas direct biochar
cooling implementation 400 depicted by FIG. 4, or the hydrocarbon
gas direct biochar cooling with tail gas recycling implementation
500 depicted by FIG. 5.
[0195] In the hydrocarbon gas direct biochar cooling implementation
example depicted by FIG. 4, hot carbonaceous solid gasification
residue (biochar) 335 is directed into the processing chamber 405
as the residue (biochar) 335 is expelled from the downdraft
gasifier at the solid residue discharge valve(s) 315, or from the
downdraft gasifier or the fluidized bed gasifier at the cyclone
solid residue discharge valve(s) 315. In the examples depicted by
FIGS. 4 and 5, the processing chamber 405 includes the heating
element 415. The heating element 415 may be an indirect heating
element. The indirect heating element 415 may be a gas/liquid to
gas heat exchange that can boost the solids temperature from
400.degree.-800.degree. C. or higher, if necessary, to achieve
gasification hot carbonaceous solid residue (biochar) 335
processing temperatures.
[0196] In an exemplary cooling step, the hot carbonaceous solid
residues (biochar) 335 are next directed to the cooling chamber
410. In the example depicted by FIG. 4, the cooling chamber 410 is
configured with the direct gas 425 input interface. The direct gas
425 input interface may be fed, for example, by hydrocarbon gas
streams (natural gas, biogas, well head gas and coal bed methane,
and the like) from a facility processing unit or a pipeline
interconnection. In an illustrative example, the hydrocarbon direct
gas 425 reacts with the hot carbonaceous solid residue (biochar)
335 in the cooling chamber 410, cooling the residue (cooling
biochar) 335 creating cooled biochar 375 (also known as bio fly ash
when recovered from a cyclone) that is then directed from the
bottom of the cooling chamber 410. In the depicted example, the
processing chamber 405 is configured to receive recovered process
heat 420 to enhance the hydrocarbon direct gas 425 reaction with
the hot carbonaceous solid residue (biochar) 335 in the cooling
chamber 410. The cooled biochar 375 may be directed to a biochar
recovery sizing, storage, or packaging system for distribution. In
some implementations, the heating element 415 may be deactivated in
response to determining the recovered process heat 420 reaches at
least a predetermined minimum temperature. In an illustrative
example, the heating element 415 may be used to heat biochar 335 in
the processing chamber 405. The biochar 335 may be heated in the
processing chamber 405 using process heat 420. An exemplary biochar
cooling implementation may initially heat biochar 335 in the
processing chamber 405 using the heating element 415, deactivate
the heating element 415 when the process heat 420 reaches at least
a predetermined minimum temperature, and continue heating biochar
335 in the processing chamber using only, or substantially only,
process heat 420. In an illustrative example, the process heat 420
may be generated by a thermal oxidizer supplied with tail gas
filtered from gas released from the cooling chamber 410.
[0197] In various hydrocarbon gas direct biochar cooling
implementations in accordance with the present disclosure, during
an exemplary cooling step, compounds and elements within the
cooling gaseous media such as carbon, hydrogen sulfide, siloxanes,
and the like may be physically captured in the cooling carbonaceous
solid residue (biochar) 335 or chemically bound in the cooled
carbonaceous solid residue (biochar) 375 depending on the pore
space or reactivity of the carbonaceous solid residue (biochar)
335, augmenting the compositional aspects of the resultant cooled
biochar 375. During the cooling step, physical expansion and
reduction activities may alter the physical nature of the resulting
carbonaceous solid residue (cooled biochar) 375. Such augmentations
may enhance the applicability of the biochar 375 for certain
product applications that may take advantage of these physical or
compositional aspects of the resultant biochar 375, such as greater
surface area, greater cat ion exchange capability, or nano
structure carbon formations.
[0198] During the cooling step, the temperature of the carbonaceous
solid residue (cooling biochar) 335 and/or the catalytic properties
of the compositional make-up of the cooling biochar 335 may
facilitate chemical reactions with the hydrocarbon gas 425, such
as, for example, methane decomposition, forming a resulting mixed
gaseous stream suitable for recovery of valuable gas streams, such
as, for example, CO.sub.2, or hydrogen. In the depicted examples,
the resulting mixed gaseous stream exiting the cooling chamber 410
is then directed via the valve 430 through the hot gas ceramic or
sintered metal particulate gas filter 365 to remove particulates
from the post cooling gaseous media. In the illustrated examples,
the valve 430 is a three-way valve configured to permit coupling
the gas chromatograph 435 to the valve 430 to measure the chemical
composition of the mixed gaseous stream exiting the cooling chamber
410. In the depicted examples, after particulates are filtered from
the post cooling gaseous media, the filtered mixed gaseous stream
is directed to various filtration systems for the capture,
recovery, and beneficial use of these valuable gas streams. In the
depicted examples, the filtered mixed gaseous stream is directed
from the particulate gas filter 365 output to the CO.sub.2 removal
filter 440, resulting in the carbon dioxide 445 stream at the
CO.sub.2 removal filter 440 carbon dioxide output. The carbon
dioxide 445 stream filtered from the mixed gaseous stream may be
recovered, distributed, or sold. In the depicted examples, the
mixed gaseous stream filtered by the CO.sub.2 removal filter 440 is
directed from the CO.sub.2 removal filter 440 mixed gaseous stream
output to the H.sub.2 removal filter 450, resulting in the tail gas
stream 455 and the hydrogen stream 460. In various exemplary
hydrocarbon gas direct biochar cooling implementations in
accordance with the present disclosure, residual tail gas from the
tail gas stream 455 may be recycled within the system, to improve
biochar cooling efficiency and reduce harmful impact to the global
human environment. In the example depicted by FIG. 5, residual tail
gas from the tail gas stream 455 may be cooled via heat exchange
and the tail gas may recycled via the tail gas recycle loop 520
back to the cooling chamber 410. In the example illustrated by FIG.
5, residual tail gas from the tail gas stream 455 may also be
cooled via heat exchange and directed to the thermal oxidizer 505.
In the example depicted by FIG. 5, the tail gas stream 455 directed
to the thermal oxidizer 505 permits the thermal oxidizer 505 to
produce thermal energy. The thermal energy 510 produced by the
thermal oxidizer 505 may then be recovered from the exhaust gas 525
via the heat exchanger 530. In various implementations, the thermal
energy 510 recovered from the thermal oxidizer 505 may be employed
to heat the processing chamber 405. The processing chamber 405 may
be heated by alternate heat source 515. In some implementations,
the thermal energy recovered from the thermal oxidizer 505 may be
employed to produce thermal energy for heat, power, or co-heat and
power applications.
[0199] In the examples depicted by FIGS. 4 and 5, the inlet flange
330 that connects the processing chamber 405 to the gasifier and/or
the cyclone via the discharge valve 315 represents the point at
which the exemplary hydrocarbon gas direct biochar cooling
implementations may begin. Various hydrocarbon gas direct biochar
cooling implementation 400 or 500 designs may include i) one or
more discharge valve 315 from the gasifier and/or the cyclone(s),
ii) one or more feed mechanism 320 from the discharge valve 315 to
the processing chamber 405 and the cooling chamber 410, iii) the
processing chamber 405 and the cooling chamber 410, iv) a biochar
recovery sizing, storage, and packaging system (not shown), v) the
incorporation/utilization of the hot gas ceramic or sintered metal
filter 365 for the removal of particulates from the post cooling
gaseous media, vi) the incorporation/utilization of the CO.sub.2
removal filter 440 and hydrogen removal filter 450 for the recovery
of these gas streams from the post cooling gaseous media, vii), the
heat exchange cooling and recycle loop 520, viii) the
incorporation/utilization of the thermal oxidizer 505 and the
exhaust gas 525 heat exchanger 530 to recover thermal energy 420
from the residual tail gas, to provide process heat 415 to the
processing chamber 405 via gas to gas heat exchange, or for the
production of heat, power, or co-heat and power and ix) all piping,
conduit, and wiring control systems to effectuate all of the
described functions.
[0200] Various exemplary hydrocarbon gas direct biochar cooling
implementations in accordance with the present disclosure may
permit more cost-effective processing and cooling of gasification
hot carbonaceous solid residue. Such improved gasification hot
carbonaceous solid residue processing and cooling cost
effectiveness may be a result of a biochar cooling implementation
designed to take advantage of the physical and compositional
properties of the gasification hot carbonaceous solid residue and
the compositional properties of the hydrocarbon gas to cost
effectively augment the resultant hot carbonaceous solid residue
with elements and compounds that render the resultant biochar more
suitable for certain product applications, increasing the biochar's
overall commercial value.
[0201] An exemplary hydrocarbon gas direct biochar cooling
implementation in accordance with the present disclosure may take
advantage of the physical and compositional properties of the
gasification hot carbonaceous solid residue and the hydrocarbon gas
to cost effectively purify and refine the hydrocarbon gas into
purified and refined gas streams that may comprise, for example,
CO.sub.2 or hydrogen, that, through the use of filtration
technology, can be captured and recovered for high value beneficial
use applications or beneficial sequestration in the context of
CO.sub.2.
[0202] Some exemplary hydrocarbon gas direct biochar cooling
implementations in accordance with the present disclosure may
include a dutchman style feed system setup on the bottom of the
discharge valve(s) to provide flow variances between the gasifier
and the processing chamber.
[0203] In an exemplary hydrocarbon gas direct biochar cooling
implementation in accordance with the present disclosure, the
processing chamber and cooling chamber may be configured as one
piece of equipment, with a top to bottom gasification hot
carbonaceous solid residue flow characteristic.
[0204] Alternative hot gas particulate removal systems, such as,
for example, a bag house system, or a quench scrubber system, could
be applied to the post cooling gaseous media used in some exemplary
hydrocarbon gas direct biochar cooling implementations, as an
alternative to a hot gas ceramic or sintered metal filter.
[0205] In an illustrative example, an alternative gas recovery
systems could be applied to the purified and refined cooling gas
stream in some hydrocarbon gas direct biochar cooling designs, such
as pressure swing adsorption, temperature swing adsorption, amine
scrubbing, biological scrubbing, or the like, to capture, recover,
and beneficially use the valuable gas streams inherent therein.
[0206] In an illustrative example, an exemplary hydrocarbon gas
direct biochar cooling implementation in accordance with the
present disclosure may be configured to independently heat cooled
biochar and use the heated biochar as a means to convert that
heated biochar using heat, pure hydrocarbon gas streams, or mixed
gas streams (natural gas, biogas, well head gas and coal bed
methane, or the like) into a biochar different in composition and
physical format from the original biochar, for specific product
applications. Various exemplary hydrocarbon gas direct biochar
cooling designs may also be used to cost effectively purify and
refine hydrocarbon gas streams (natural gas, biogas, well head gas
and coal bed methane, or the like) into valuable gas streams for
the capture and recovery of CO.sub.2 or hydrogen for useful
applications or beneficial sequestration in the context of
CO.sub.2.
[0207] Various exemplary hydrocarbon gas direct biochar cooling
designs may include pre-cooling of the hydrocarbon prior to cooling
chamber injection, to ensure the hydrocarbon is sufficiently cooled
to reduce the temperature of the gasification hot solid residue. In
an illustrative example, the temperature of gasification hot solid
residue (biochar) will have an impact on the biochar's capabilities
associated with purifying and refining the cooling media.
[0208] In an illustrative example, component parts may comprise
sufficient quality steel material to account for the pressures
(1-500 psig/1-35 Bar), temperatures (212.degree.-1500.degree. F. or
100.degree.-800.degree. C.) and corrosiveness of the substances
involved. In an illustrative example, one could expect to utilize
at least some component parts comprising stainless steel in an
exemplary implementation in accordance with the present disclosure,
to account for the operational pressures and temperatures
expected.
[0209] An exemplary hydrocarbon gas direct biochar cooling design
may take advantage of temperature, pressure, and composition of the
gasification hot carbonaceous material (hot biochar) and the
hydrocarbon gas to create cooled biochar with high value
application opportunities, and enable the capture and recovery of
purified and refined high value gas streams for beneficial use,
products, production, or sequestration. This facilitation may be a
result of a direct biochar cooling implementation designed to avoid
sweeping the heat away in the form of a hot transfer media which
then must be cooled via a cooling tower arrangement, or discharged
as a waste stream in once through cooling applications, which may
be disadvantages related to indirect cooling designs that may cool
biochar based on heat exchange.
[0210] In an illustrative example, an exemplary hydrocarbon gas
direct biochar cooling implementation may be employed wherever a
gasification system exists. Other applicable industries for the
disclosed steam direct and hydrocarbon gas direct biochar cooling
technologies include, for example, producers of biochar interested
in augmenting their biochar product for higher value applications;
producers of purified gas streams for beneficial use applications
or sequestration; wastewater treatment plants and biosolid
aggregators; wood and agricultural processors and biomass/biomass
waste aggregators; consumers that are looking for specialty carbon
materials for advance bioproduct manufacturing; and land
remediators, water pollution control system providers, and odor
control system providers.
[0211] FIG. 6 depicts an exemplary downdraft gasifier
implementation in accordance with the present disclosure. Disclosed
is a gasifier comprising a plurality of conjoined and vertically
positioned tubes. The tubes have an interior wall and exterior wall
and a proximal and distal end wherein the proximal end provides an
inlet and the distal end provides an outlet. The gasifier has three
separate reaction zones: (1) a Pyrolysis Zone; (2) an Oxidation
Zone beneath the Pyrolysis Zone; and (3) a Reduction Zone beneath
the Oxidation Zone. A rotating and vertically adjustable grate is
located below, but not attached to, the Reduction Zone. Unlike
other gasifiers, this is a partially open core gasifier without an
airtight seal on the distal end of the gasifier. The Producer Gas
exits through the grate and is collected by collection vents on the
sides of the collection chutes.
[0212] In FIG. 6, arrows depict an exemplary gasification process
in the exemplary downdraft gasifier 600. Three types of Oxidant
Streams enter the gasifier through three separate, corresponding
inlet points: Purge Oxidant Streams, Bed Oxidant Streams and Plano
Oxidant Streams. The Purge Oxidant Stream is the Oxidant Stream
that is introduced to the feedstock and enters the gasifier with
the feedstock through a Pressure Lock. The Purge Oxidant Stream
also prevents tarry gases from back-flowing into the Pressure Lock.
The Bed Oxidant Stream enters the gasifier through inlets 611
located at the top of the gasifier. The Plano Oxidant Streams enter
the gasifier through the Plano Air Inlets 631, 632 located in rings
around the perimeter of the Oxidation Zone 630. In the depicted
example, an exemplary Control System monitors and adjusts each of
these Oxidant Streams to control the total amount of Oxygen in each
zone of the gasifier and the rate of Producer Gas being generated.
The Control System can adjust the volume and velocity of this
Oxidant Stream to adjust for feedstock having differing moisture
contents, bulk densities, or even because of changes in the BTU
value of a feedstock. The Control System allows for the changes to
be made while the gasifier is in operation, so that it does not
need to be shut down or be reconfigured. In the depicted
implementation, the gasifier includes the Pyrolysis Zone 620, the
Oxidation Zone 630, and the Reduction Zone 640 with a grate located
underneath the gasifier. Below the gasifier are gas collection
vents, and Biochar collection chutes.
[0213] The Oxidation Zone 630 is the zone in the gasifier leading
up to and away from the Oxidation Band 650 or the general step of
the method including formation of the Oxidation Band 650. The
Oxidation Zone 630 is where the Oxidation Band 650 forms and
represents the hottest step in the gasification process and is
where the cellulosic fraction of the feedstock converts from a
solid to a gas. The more Oxygen fed to the gasifier the faster the
feedstock is gasified in the Oxidation Zone 630. The faster the
reaction, the more Biochar is produced and accumulates in the
Reduction Zone 640.
[0214] During operation, the flow of an Oxidant Stream through
Pyrolysis Zone 620 induces a feedstock gradient to form (1)
vertically, beginning toward the top of the outside wall of the
Pyrolysis Zone 620 and ending down at a lower ring of Plano Air
Inlets 631, 632 in the Oxidation Zone 630 and (2) horizontally,
beginning in the center of the gasifier and ending at the wall of
the gasifier (the "Induced Feedstock Gradient"). This Induced
Feedstock Gradient is an increasing and differential density of
feedstock becoming denser toward the perimeter of the gasifier wall
and above the Oxidation Band 650 (the "Densest Portion") formed by
at least four factors acting in concert: (1) the Pressure Wave from
the Oxidation Band 650 pressing feedstock against the interior wall
of the gasifier; (2) the geometry of the Pyrolysis Zone 620 and the
Oxidation Zone 630 (i.e., angles of the walls); (3) the total
volume of the Oxidant Stream flowing into the Pyrolysis Zone 620
and the Oxidation Zone 630; and (4) the relative volume of the
Oxidant Stream flowing into each of the Pyrolysis Zone 620 and the
Oxidation Zone 630. The Densest Portion of the Induced Feedstock
Gradient is illustrated at 660. As Biochar leaves the Oxidation
Band 650, the diameter of the Oxidation Zone 630 narrows to
approximately the same size as the inlet to the Oxidation Zone 630.
The Pressure Wave from the Oxidation Band 650 pushes the Biochar
against the narrowing wall of the Oxidation Zone. The Densest
Portion of this Entrained Biochar Gradient is illustrated at 670.
The Pressure Wave slows the movement of the Densest Portion of the
Biochar in the Entrained Biochar Gradient 670 relative to
Biochar.
[0215] Implementing a Control System for variable control of the
Bypass 649 and the Oxidant Stream in the gasifier also ensures the
consistency and quality of the Producer Gas. The Bypass 649
functions to control Producer Gas flow out of the Reduction Zone
640, the Bypass 649 acting similar to a valve. For example, a short
Bypass increases resistance to Producer Gas flow through the grate
and causes pressure to build in the gasifier.
[0216] There are several different redundant control methods used
in the gasifier, and most function as a means by which more precise
control can be achieved throughout the process. In one embodiment,
an effective control method is to monitor the thermal gradient, or
profile, as indicated by the temperatures of each zone. These
temperatures are obtained by way of embedded thermocouples inside
of the lined wall of the gasifier. This temperature gradient, or
profile, is a very good indicator of where each zone is and where
it is moving toward within the gasifier. In one embodiment, the
Control System uses this information to change the balance of
Oxidant Stream at any given zone or to physically change the height
of the bed of Biochar in the Reduction Zone 640 by way of the grate
rotation and bypass 649 to help maintain and/or sustain each zone
above it.
[0217] One embodiment improves the consistency of the Producer Gas
by lining the entire gasifier with silica carbide, silica oxide,
aluminum oxide, refractory alloy, other ceramics or another
material that is stable at high temperatures. This lining helps to
evenly distribute and conduct heat out from the Oxidation Band 650
and allows the use of thermocouples while protecting them from the
reactions occurring inside the gasifier.
[0218] The Control System may use all of the different methods and
combine said methods into an algorithmic controller. The latter
does not only allow for redundancy throughout the Control System
but also ensures much greater reliability and efficiency. It
furthermore ensures that the Producer Gas is of constant and high
quality.
[0219] The application and method of gasification described above
also provides an effective way of controlling the height of the
Reduction Zone 640. In one embodiment of this gasifier, the
Oxidation Band 650 can move up into the Pyrolysis Zone 620 or down
into the Reduction Zone 640 and still be controlled and/or
maintained by way of where the Control System allows the Oxidant
Stream to be placed and amount of Biochar being removed. Disruption
to the height of the feedstock, or the differential pressure across
the gasifier can therefore be controlled by way of the grate
rotation without risking the Oxidation Band 650 collapse.
[0220] FIG. 7 depicts an exemplary fluidized bed gasifier
implementation in accordance with the present disclosure. FIG. 7
depicts the exemplary small and large-scale fluidized bed gasifier
700 designed to gasify biosolids; wherein the large-scale gasifier
includes a reactor vessel with a pipe distributor and at least two
fuel feed inlets for feeding biosolids into the reactor vessel at a
desired fuel feed rate of more than 40 tons per day with an average
fuel feed rate of about 100 tons per day during steady-state
operation of the gasifier. The fluidized bed in the base of the
reactor vessel has a cross-sectional area that is proportional to
at least the fuel feed rate such that the superficial velocity of
gas is in the range of 0.1 m/s (0.33 ft/s) to 3 m/s (9.84 ft/s). In
operation, biosolids are fed into a fluidized bed reactor and
oxidant gases are applied to the fluidized bed reactor to produce a
superficial velocity of producer gas in the range of 0.1 m/s (0.33
ft/s) to 3 m/s (9.84 ft/s). The biosolids are heated inside the
fluidized bed reactor in an oxygen-starved environment having a
sub-stoichiometric oxygen level, whereby the biosolids are
gasified. In an implementation, the internal diameter of the
reactor is configured to ensure that the fluidized bed is able to
be fluidized adequately for the desired fuel feed rate and the flow
rate of the fluidizing gas mixture at different operating
temperature, yet prevent slugging fluidization as media is
projected up the freeboard section. Other factors may be used in
the design and sizing of the gasifier, including internal diameter
of the bed section, internal diameter of a freeboard section,
height of the freeboard section, bed depth and the bed section
height to reach the targeted fuel feed rate.
[0221] In the example depicted by FIG. 7, the exemplary gasifier
700 is a scaled-up implementation of a bubbling type fluidized bed
gasifier 700. In an implementation, the bubbling fluidized bed
gasifier 700 will include a reactor 799 operably connected to the
feeder system (not shown) as an extended part of the standard
gasifier system 700. A fluidized media bed 704A such as but not
limited to quartz sand is in the base of the reactor vessel called
the reactor bed section 704. The fluidized sand is a zone that has
a temperature of 1150.degree. F.-1600.degree. F. Located above the
reactor bed section 704 is a transition section 704B and above the
transition section 704B is the freeboard section 705 of the reactor
vessel 799. Fluidizing gas consisting of air, flue gas, pure oxygen
or steam, or a combination thereof, is introduced into the
fluidized bed reactor 799 to create a velocity range inside the
freeboard section 705 of the gasifier 700 that is in the range of
0.1 m/s (0.33 ft/s) to 3 m/s (9.84 ft/s). The biosolids are heated
inside the fluidized bed reactor to a temperature range between
900.degree. F. and 1600.degree. F. in an oxygen-starved environment
having sub-stoichiometric levels of oxygen, e.g., typically oxygen
levels of less than 45% of stoichiometric. In another embodiment,
the fluidized sand is a zone that has a temperature of 1150.degree.
F.-1600.degree. F.
[0222] The reactor fluidized bed section 704 of a fluidized
bubbling bed gasifier 700 is filled with a fluidizing media 704A
that may be a sand (e.g., quartz or olivine), or any other suitable
fluidizing media known in the industry. Feedstock such, as but not
limited to sludge, is supplied to the reactor bed section 704
through fuel feed inlets 701 at 40.degree. F.-250.degree. F. In one
embodiment the feedstock is supplied to the reactor bed section 704
through fuel feed inlets 701 at 215.degree. F.; with the gas inlet
703 in the bubbling bed receiving an oxidant-based fluidization gas
such as but not limited to e.g., gas, flue gas, recycled flue gas,
air, enriched air and any combination thereof (hereafter referred
to generically as "gas" or "air"). In one embodiment the air is at
about 600.degree. F. The type and temperature of the air is
determined by the gasification fluidization and temperature control
requirements for a particular feedstock. The fluidization gas is
fed to the bubbling bed via a gas distributor. An oxygen-monitor
709 may be provided in communication with the fluidization gas
inlet 703 to monitor oxygen concentration in connection with
controlling oxygen levels in the gasification process. An inclined
or over-fire natural gas burner (not visible) located on the side
of the reactor vessel 799 receives a natural gas and air mixture
via a port 702. In one embodiment, the natural gas air mixture is
77.degree. F. which may be used to start up the gasifier and heat
the fluidized bed media 704A. When the minimum ignition temperature
for self-sustaining of the gasification reactions is reached (about
900.degree. F.), the natural gas is shut off. View ports 706 and a
media fill port 712 are also provided.
[0223] In one embodiment, a freeboard section 705 is provided
between the fluidized bed section 704 and the producer gas outlet
710 of the gasifier reactor vessel 799. As the biosolids thermally
decompose and transform in the fluidized bed media section (or sand
zone) into producer gas and then rise through the reactor vessel
799, the fluidizing medium 704A in the fluidized bed section 704 is
disentrained from the producer gas in the freeboard section 705
which is also known as and called a particle disengaging zone. A
cyclone separator 707 may be provided to separate material
exhausted from the fluidized bed reactor 799 resulting in clean
producer gas for recovery with ash exiting the bottom of the
cyclone separator 707 alternatively for use or disposal.
[0224] An ash grate 711 may be fitted below the gasifier vessel for
bottom ash removal. The ash grate 711 may be used as a sifting
device to remove any large inert, agglomerated or heavy particles
so that the fluidizing media and unreacted char can be reintroduced
into the gasifier for continued utilization. In one embodiment, a
valve such as but not limited to slide valve 713 which is operated
by a mechanism to open the slide valve 714 is located beneath the
ash grate 711 to collect the ash. In one embodiment, a second valve
713 and operating mechanism 714 (not shown) are also located below
the cyclone separator 707 for the same purpose. That is, as a
sifting device to remove any large inert, agglomerated or heavy
particles so that the fluidizing media and unreacted char can be
reintroduced into the gasifier for continued utilization. In one
embodiment the ash grate 711 may be a generic solids removal device
known to those of ordinary skill in the art. In another embodiment,
the ash grate 711 may be replaced by or combined with the use of an
overflow nozzle.
[0225] The producer gas control 708 monitors oxygen and carbon
monoxide levels in the producer gas and controls the process
accordingly. In one embodiment a gasifier feed system (not shown)
feeds the gasifier reactor 799 through the fluidized fuel inlets
701. In one embodiment, the gasifier unit 700 is of the bubbling
fluidized bed type with a custom fluidizing gas delivery system and
multiple instrument control. The gasifier reactor 799 provides the
ability to continuously operate, discharge ash and recycle flue gas
for optimum operation. The gasifier reactor 799 can be designed to
provide optimum control of feed rate, temperature, reaction rate
and conversion of varying feedstock into producer gas.
[0226] A number of thermocouple probes (not shown) are placed in
the gasifier reactor 799 to monitor the temperature profile
throughout the gasifier. Some of the thermal probes are placed in
the fluidized bed section 704 of the gasifier rector 799, while
others are placed in the freeboard section 705 of the gasifier. The
thermal probes placed in the fluidized bed section 704 are used not
only to monitor the bed temperature but are also control points
that are coupled to the gasifier air system via port 702 in order
to maintain a certain temperature profile in the bed of fluidizing
media. There are also a number of additional control instruments
and sensors that may be placed in the gasifier system 700 to
monitor the pressure differential across the bed section 704 and
the operating pressure of the gasifier in the freeboard section
705. These additional instruments are used to monitor the
conditions within the gasifier as well to as control other
ancillary equipment and processes to maintain the desired operating
conditions within the gasifier. Examples of such ancillary
equipment and processes include but are not limited to the cyclone,
thermal oxidizer and recirculating flue gas system and air delivery
systems. These control instruments and sensors are well known in
the industry and therefore not illustrated.
[0227] An optional ash grate 711 may be fitted below the gasifier
vessel for bottom ash removal. The ash grate 711 may be used as a
sifting device to remove any agglomerated particles so that the
fluidizing media and unreacted char can be reintroduced into the
gasifier for continued utilization. In one embodiment, a slide
valve 713 operated by a mechanism to open the slide valve 714 is
located beneath the ash grate 711 to collect the ash. In one
embodiment, a second slide valve 713 and operating mechanism 714
are located below the cyclone separator 707.
[0228] As with the small format fluidized bed gasifier, some
unreacted carbon is carried into the cyclone separator 707 with
particle sizes ranging from 10 to 300 microns. When the solids are
removed from the bottom of the cyclone, the ash and unreacted
carbon can be separated and much of the unreacted carbon recycled
back into the biogasifier, thus increasing the overall fuel
conversion to at least 95%. Ash accumulation in the bed of
fluidizing media may be alleviated through adjusting the
superficial velocity of the gases rising inside the reactor.
Alternatively, bed media and ash could be slowly drained out of the
gasifier base and screened over an ash grate 711 before being
reintroduced back into the biogasifier. This process can be used to
remove small, agglomerated particles should they form in the bed of
fluidizing media and can also be used to control the ash-to-media
ratio within the fluidized bed.
[0229] A feedstock such as but not limited to biosolid material can
be fed into the gasifier by way of the fuel feed inlets 701 from
more than one location on the reactor vessel 799 and wherein said
fuel feed inlets 701 may be variably sized such that the desired
volumes of feedstock are fed into the gasifier through multiple
feed inlets 701 around the reactor vessel 799 to accommodate a
continuous feed process to the gasifier. For the present invention
and in one embodiment, the number of fuel feed inlets is between
2-4. The minimum number of feed inlets 701 is based, in part, on
the extent of extent of back mixing and radial mixing of the char
particles in the bed and on the inside diameter of the reactor bed
section 704. For bubbling fluidized beds, one feed point could be
provided per 20 ft.sup.2 of bed cross sectional area. For example,
and in one embodiment, if the reaction bed section has an internal
diameter of 9 ft, the reactor vessel 799 will have at least 3 feed
inlets 701 (located equidistant radially to maintain in-bed mixing.
Feed inlets 701 may be considered all on one level, or on more than
one level or different levels and different sizes.
[0230] FIG. 8 depicts a schematic view of an exemplary biochar
activation and cooling system implementation in accordance with the
present disclosure. In FIG. 8, the exemplary integrated biochar
activation and cooling system 800 is configured to produce a
controlled activation level enhanced surface area biochar product
based on adjusting biochar temperature, cooling biochar with
injected steam, and recovering volatiles driven off through
dehydration, using the depicted processing vessel 803. In the
depicted implementation, the processing vessel 803 is a calciner.
The processing vessel 803 may be rotary calciner. The processing
vessel 803 may be a rotary kiln. In the depicted implementation,
the processing vessel 803 is configured with the processing vessel
inlet 806. The processing vessel inlet 806 is configured to be
fluidly coupled with the depicted gasifier system comprising
gasifiers 600a,b,c. In the depicted implementation each of the
gasifier 600a, the gasifier 600b, and the gasifier 600c is a
downdraft gasifier. In the depicted implementation, the gasifier
system 600a,b,c supplies the gasifier flow to cyclone 810 to the
cyclone 812. In the depicted implementation the processing vessel
803 receives biochar 809 from the depicted gasifier system
600a,b,c, and the cyclone 812. The depicted gasifier system
600a,b,c receives feedstock 815 delivered by the feedstock delivery
means 816. In the depicted implementation, the feedstock delivery
means 816 is a motor vehicle comprising a truck. The feedstock
delivery means 816 may comprise, for example, a conveyor system,
pipeline, or other delivery means as would be known to one of
ordinary skill. In the depicted example, the feedstock 815 is
transferred to the feedstock receiving hopper 818 and ingested by
the gasifier system 600a,b,c from the feedstock storage bins 819
with air 821. In the depicted implementation, the processing vessel
803 includes the processing vessel heating section 824 and the
processing vessel cooling section 827. In the depicted
implementation, the processing vessel 803 is configured to receive
biochar 809 using the processing vessel inlet 806, control
activation levels of the biochar 809 by moving the biochar through
the processing vessel 803, adjust the temperature of the biochar
809 by injecting steam 831 into at least one temperature-controlled
chamber of the processing vessel 803, and discharging at the
processing vessel outlet 830 an enhanced surface area biochar
product 833 with a desired activation level. In the depicted
implementation, the discharged activated biochar product 833 is
collected in the activated carbon storage/loadout bin 836 for
transport by the biochar product transport means 839. In the
depicted implementation, the biochar product transport means 839 is
a motor vehicle comprising a truck. The biochar product transport
means 839 may comprise, for example, a conveyor system, pipeline,
or other delivery means as would be known to one of ordinary skill.
Volatiles driven off through dehydration in the processing vessel
803 may be recovered using the thermal oxidizer 505 supplied with
ambient air 840. In the depicted implementation, the thermal
oxidizer 505 supplies process heat 842 to the first heat recovery
exchanger 845, emission control device 848, and second heat
recovery exchanger 851 to reduce emissions and recover energy
before exhaust to the stack 854. In the depicted implementation,
spent sorbent 857 from the emission control device 848 is collected
for transport by the spent sorbent transport means 860. In the
depicted implementation the spent sorbent transport means 860 is a
motor vehicle comprising a truck. The spent sorbent transport means
860 may comprise, for example, a conveyor system, pipeline, or
other delivery means as would be known to one of ordinary skill. In
the depicted implementation, the first heat recovery exchanger 845
and second heat recovery exchanger 851 are operably coupled to
exchange heat with the organic Rankine cycle 863 to generate the
electric energy to grid 866 also supplied to the processing vessel
803 as recovered process electric energy 869. In an illustrative
example, the processing vessel 803 may use the recovered process
electric energy 869 to provide electrical power to the processing
vessel heating section 824, to power a control system configured to
govern operation of the implementation to perform steps of an
exemplary process, or to power a rotary inner cylinder configured
to move biochar 809 through the processing vessel.
[0231] FIG. 9 depicts a schematic view of an exemplary biochar
cooling and activation processing vessel implementation in
accordance with the present disclosure. In FIG. 9, the exemplary
processing vessel 803 includes the processing vessel heating
section 824 and the processing vessel cooling section 827. In the
depicted implementation, the processing vessel heating section 824
is configured in fluid coupling with the processing vessel inlet
806 to receive biochar 809. The biochar 809 may be received from a
gasifier. The received biochar may, for example, have a temperature
in the range 750.degree. F.-850.degree. F. In the depicted
implementation, the processing vessel cooling section 827 is
configured in fluid coupling with the processing vessel outlet 830
to discharge the activated biochar product 833. The depicted
processing vessel 803 is a rotary calciner. In the depicted
implementation, the processing vessel 803 is configured with the
rotating processing vessel cylinder 900 designed to move the
biochar 809 through the processing vessel 803. The rotating
processing vessel cylinder 900 moves the biochar 809 through the
multiple independently temperature-controllable processing vessel
sections or chambers, comprising the processing vessel heating
section 824 and the processing vessel cooling section 827. In the
depicted implementation, the processing vessel heating means
905a,b,c,d comprise electric heating elements configured to heat
the processing vessel heating section 824. In the depicted
implementation, counter-flow saturated steam 831 injected at a
target temperature of 250.degree. F. flows opposite the biochar 809
flow direction to sweep the off gas to thermal oxidizer 910 and
sweep gas 915 from the processing vessel cylinder 900. In the
depicted implementation the processing vessel cooling section 827
may be cooled using the cooling water/air 920. The depicted
processing vessel 803 includes the control system 925 configured to
govern the fluid coupling between the processing vessel heating
section 824 and the processing vessel cooling section 827. The
control system 925 is configured to govern the temperature of the
processing vessel heating section 824 and the processing vessel
cooling section 827. The control system 925 may use electricity or
hot air/exhaust gas for heating the processing vessel heating
section 824 to a target temperature range of 800.degree.
F.-1100.degree. F. determined by the control system 925. The
control system 925 is configured to govern the retention time of
biochar 809 in the processing vessel heating section 824 and the
processing vessel cooling section 827, based on controlling the
fluid coupling between the processing vessel heating section 824
and the processing vessel cooling section 827. In the depicted
implementation, the target residence time of biochar 809 in the
processing vessel heating section 824 may be in the range of 20-30
minutes determined by the control system 925. The control system
925 may indirectly heat or cool biochar 809 based on adjusting the
temperature and retention time of biochar 809 in the heating
section 824 and/or the cooling section 827. The activated biochar
product 833 may have a target temperature range of 100.degree.
F.-200.degree. F. determined by the control system 925.
[0232] FIG. 10 depicts a plan view of an exemplary biochar
activation and cooling system implementation in accordance with the
present disclosure. In FIG. 10, the exemplary integrated biochar
activation and cooling system 800 includes the downdraft gasifier
600 operably coupled with the cyclone 812, the processing vessel
803, and the thermal oxidizer 505 to produce an activated biochar
product for collection in the activated carbon storage/loadout bin
836. The depicted processing vessel 803 receives biochar from
downdraft gasifier 600 biochar outlets 1000a,b via the biochar
conveyor 1005 and the gasifier cyclone biochar outlet 1010. In the
depicted implementation, the processing vessel 803 is configured
with the rotating processing vessel cylinder 900 designed to move
biochar through the processing vessel 803 heating section 824 and
cooling section 827 to the tube chain conveyor 1015 for collection
in the activated carbon storage/loadout bin 836.
[0233] FIG. 11 depicts a schematic view of an exemplary biochar
cooling and activation processing vessel implementation in
accordance with the present disclosure. In FIG. 11, the exemplary
processing vessel 803 includes the features and ranges described
with reference to FIGS. 8, 9, and 10. FIG. 11 shows the processing
vessel inlet 806 disposed at the processing vessel head 1100
proximal to the heating section 824. In the depicted implementation
the direction of solids flow 1105 from the processing vessel head
1100 is opposite the direction of the counter-flow gas 1110 from
the processing vessel tail 1120. In the depicted implementation the
cooling manifold 1115 supplies water or air for cooling to the
cooling section 827.
[0234] Although various features have been described with reference
to the Figures, other features are possible. For example, catalytic
methane decomposition is a promising pathway for the energy
transition to a decarbonized economy. Catalysts and reactor designs
are being optimized to increase reaction stability. In addition,
carbon is a valuable by-product with the potential creation of new
markets, and catalyst regeneration may be employed and optimized
for long-term stability. In combination, such exemplary lines of
research may reduce CO.sub.2 emissions based on gradually replacing
fossil fuels by a hydrogen-based economy.
[0235] A direct biochar cooling system implementation in accordance
with the present disclosure may produce biochar having enhanced
carbon content with increased surface area, and a hydrogen stream
byproduct. In the case of hydrocarbon direct biochar cooling, the
resultant biochar may have high grade carbon growth from the
decomposition of CH.sub.4 in the gas, which has a higher price
point than standard biochar as a high-grade carbon manufacturing
input.
[0236] An implementation in accordance with the present disclosure,
of steam direct biochar cooling or hydrocarbon gas direct biochar
cooling may cost less to install and operate, and produce more
valuable byproducts, than an indirect biochar cooling
implementation. In the case of steam direct biochar cooling, the
resultant biochar may have a greater surface area, which has a
higher price point than standard biochar, and may be a competitive
alternative to activated carbon.
[0237] In illustrative examples, low-cost biochar produced from
biomass products (wood and wood residues, agricultural and
agricultural residues, sludges, biosolids, and other suitable
organic materials) is growing in importance and application across
a variety of industries. Various Aries downdraft and fluidized bed
gasifier system implementations may produce a hot carbonaceous
solid residue that, when cooled, is commonly referred to as biochar
(also referred to as "bio fly ash" when recovered from a
cyclone).
[0238] In illustrative examples, biochar may be favorable as a
terrestrial carbon sink, fertilizer, soil supplement, composting
supplement, solids, water or gas filtration media for
neutralization, odor control, purification and/or refinement,
bioproduct manufacturing input, renewable building material
manufacturing input, and solid catalyst input.
[0239] In an illustrative example, some implementations of Aries'
prior art indirect biochar cooling designs may process and cool hot
carbonaceous solid gasification residue indirectly utilizing a
water fed cooling screw. In contrast, an Aries direct biochar
cooling design in accordance with the present disclosure may
provide an alternative approach to cooling hot carbonaceous solid
gasification residues utilizing direct application of gas
comprising steam or hydrocarbon gas to produce a biochar different
in composition and physical format to biochar produced by indirect
cooling. This resultant biochar produced based on cooling utilizing
direct application of gas comprising steam or hydrocarbon gas may
be more suitable for certain product applications.
[0240] Various examples in accordance with the teaching of the
present disclosure relate to a cost-effective means to cool hot
biochar produced through gasification using direct application of
cool gases made up of H.sub.2O or CH.sub.4. In one aspect of the
present disclosure, direct cooling of hot biochar with steam as the
hot biochar exits the gasifier or cyclone creates an economical way
to cool biochar while enhancing the surface area of the biochar
resulting in a byproduct that is comparable to activated carbon. In
another aspect of the present disclosure, direct cooling of hot
biochar with hydrocarbon gas as the hot biochar exits the gasifier
or cyclone creates an economical way to cool biochar while
enhancing the high-quality carbon content of our biochar with nano
tube type carbon formation on the biochar while producing a gas
stream that can be filtered for high value chemical (specifically
hydrogen) recovery.
[0241] In illustrative examples, a biochar activation and cooling
implementation in accordance with the teaching of the present
disclosure may integrate a processing vessel with a gasifier to
activate biochar produced by the gasifier. In some implementations
the processing vessel may be a rotary type calciner or kiln
attached to a downdraft gasifier system to activate biochar
produced by the gasifier system. The gasifier system may comprise a
plurality of gasifiers. An exemplary biochar activation and cooling
implementation may receive hot biochar, discharged and recovered
from a cyclone dip leg into the front end of an indirect fired type
of rotary calciner. In an illustrative example of using an indirect
calciner, the indirect calciner rotating drum is enclosed in a heat
shroud or furnace to keep the material and heating medium separate.
This heat shroud externally heats the rotating drum, and the
material is subsequently heated through contact with the drum shell
interior. In an illustrative example, an indirect calciner rotating
drum may be a cylinder that spins inside a heating/cooling chamber
to perform indirect thermochemical processing within a controlled
atmosphere. Depending upon the temperature of biochar as the
biochar enters the calciner cylinder, the biochar may be indirectly
heated in the initial sections (high temperature sections) of the
rotary calciner's heating/cooling chamber to achieve the optimal
thermochemical processing temperature. The biochar will flow
through the rotary calciner, and the biochar will be cooled to the
desired discharge temperature through steam injection as the
biochar progresses through the cylinder. The biochar will exit the
tail end of the cylinder at a predetermined design control
temperature suitable for handling, storage and load out. At the end
of the high temperature sections of the calciner, low temperature
saturated steam will be injected counterflow into the cylinder
cooling the biochar and sweeping any released volatile gases from
the biochar. The gas effluent will exit the cylinder via a fan
driven vacuum port at the front end of the rotary calciner and will
be directed to a thermal oxidizer. The initial sections of a rotary
calciner (high temperature sections) may be heated using
electricity, natural gas, waste heat recovered via hot thermal
liquids, or hot gases. The cooling chamber sections (low
temperature sections) of the rotary calciner may be cooled using
air, water, waste cooling via cool thermal liquids or cool
gases.
[0242] An exemplary biochar activation and cooling implementation
in accordance with the teaching of the present disclosure may use a
processing vessel that may be a calciner or kiln integrated with a
biochar source to activate and cool biochar received from the
biochar source. The biochar source may be a gasifier. The gasifier
may be a downdraft gasifier or a downdraft gasifier system
comprising a plurality of gasifiers. In an illustrative scenario
exemplary of various biochar activation and cooling
implementations' design and usage, a system in accordance with the
present disclosure may cool biochar in the controlled environment
of a processing vessel such as a calciner or kiln so that volatiles
and moisture present in the biochar, to the extent they are
released from the biochar as the biochar progresses through the
calciner, are recovered and oxidized reducing emissions and
generating waste heat for use; alternatively the recovered gases
may be processed for sale.
[0243] An implementation in accordance with the present disclosure
may cool biochar in part using saturated steam which facilitates
the potentiality for a water gas shift reaction generating mixed
gases enriched with H.sub.2, CO and CO.sub.2 that are recovered and
oxidized rather than being released to the atmosphere, reducing
emissions, and generating waste heat for use; alternatively, the
recovered gases may be processed for sale. Cooling the biochar at
least in part using saturated steam facilitates the formation of
additional macro and micro pores in the biochar as moisture and
volatiles are driven off through dehydration, thermochemical
conversion, and or/decomposition reactions, advantageously
increasing the biochar's surface area.
[0244] In illustrative examples, a biochar activation and cooling
implementation in accordance with the teaching of the present
disclosure may augment an external steam injected counter current
cooling chamber to cool biochar with utilization of a suitable
processing vessel such as a calciner configured to provide indirect
biochar heating and cooling capability. Such indirect biochar
heating and cooling capability provides capability to boost the
temperature of the biochar using indirect heat within the high
temperature zone of the processing vessel to an optimal
thermochemical processing temperature while maintaining the
controlled environmental integrity of the biochar in the inner
cylinder. Boosting the temperature of the biochar may or may not be
required depending upon the temperature of the biochar as the
biochar enters the processing vessel from the biochar source. Being
able to control the thermochemical processing temperature of the
biochar increases the opportunity to maximize certain
biochar-related chemical properties within the processing vessel,
such as, for example, dehydration, calcination, and/or
decomposition. In an illustrative example, various implementations
may advantageously increase the surface area of the resultant
biochar by optimizing these chemical reactions, rendering the
resultant biochar a more valuable input material for certain
biobased product applications such as water purification filtration
media, gas filtration media, and environmental remediation media.
Using a biochar activation and cooling implementation in accordance
with the teaching of the present disclosure, biochar may be cooled
while at the same time directing the ancillary thermochemical
reactions so as to achieve desired biochar product property
outcomes. Various biochar activation and cooling implementations in
accordance with the teaching of the present disclosure may control
desired producer gas and biochar product outcomes determined as a
function of the control system adjusting temperatures in an inner
cylinder and multiple section temperature control exterior
chambers, in a system configured to permit controlling temperatures
in various parts of the processing vessel to adjust the producer
gas and biochar products. Some biochar activation and cooling
implementations in accordance with the teaching of the present
disclosure may produce a final product comprising graphene. Some
biochar activation and cooling implementations in accordance with
the teaching of the present disclosure may produce a final product
comprising activated carbon.
[0245] An exemplary biochar activation and cooling implementation
in accordance with the teaching of the present disclosure may
comprise a downdraft gasifier, a cyclone, piping, an indirect fired
rotary calciner with an inner cylinder and multiple section
temperature control external chambers, counterflow saturated steam
injection, a vacuum driven producer gas sweep system from the head
of the calciner, and associated control systems configured to
perform the steps of the integrated process using the
implementation.
[0246] A biochar activation and cooling implementation in
accordance with the teaching of the present disclosure may
advantageously provide the ability to control the temperature of
the biochar and the rate at which the biochar cools. Various
exemplary designs contemplate integrating a rotary calciner with
countercurrent steam injection as the mechanism for cooling the
resultant hot biochar from a downdraft gasification process.
[0247] In an illustrative example, an exemplary biochar activation
and cooling implementation may be configured to use steam injection
in the form of, for example, a lance, steam nozzles, or steam
injectors. The calciner heating and cooling systems can take many
forms. An optimal steam input system may be evaluated and selected
using experimentation and testing techniques accessible to one of
ordinary skill in the art, and a desired level of control and/or
availability and price of the different utility inputs will likely
dictate which approach is optimal in a particular
implementation.
[0248] A biochar activation and cooling implementation in
accordance with the teaching of the present disclosure may replace
the inner cylinder cooling agent steam with, for example, carbon
dioxide, methane, nitrogen, natural gas or other hydrocarbon gases.
Various gases or mixtures of gases may result in different
thermochemical reactions within the processing vessel or calciner,
and such may be desired in tuning the producer gas product and
biochar product. In an illustrative example, certain compounds
could be added to the organic matter input pre-gasification or to
the biochar pre-calcination or to the steam input to facilitate
product quality adjustments or additional thermochemical processes
within the processing vessel or calciner. Some implementations may
include a biochar sizing step such as grinding or milling
pre-calcining if particular particle size distributions and/or
product uniformity inside the processing vessel or calciner needs
to be ensured.
[0249] In an illustrative example, a biochar activation and cooling
implementation in accordance with the teaching of the present
disclosure may include a calciner or processing vessel of certain
inner cylinder diameter to receive the outflows from the respective
gasifiers. This inner cylinder diameter is a function of the output
of the gasifier and the desired throughput of the calciner. The
length of the calciner or processing vessel inner cylinder must be
such that it can allow for the optimal cooling and thermochemical
processing of the biochar; too short, and the inner cylinder may
not function as desired. Testing of processing vessels or calciners
with biochar produced in gasifiers may be employed by one of
ordinary skill to determine the appropriate sizing of system
components to meet the desired process control outcomes.
[0250] In an illustrative example, rotary calciners are high
temperature machines that process materials into a desired form by
changing the state or composition of a material or removing
moisture. Indirect rotary calciners are heated from the outside of
an enclosed chamber and gives them the ability to process materials
that are fine or dusty, susceptible to contamination or combustion,
sensitive to oxidation, or thermally sensitive.
[0251] In the Summary above and in this Detailed Description, and
the Claims below, and in the accompanying drawings, reference is
made to particular features of various implementations. It is to be
understood that the disclosure of particular features of various
implementations in this specification is to be interpreted to
include all possible combinations of such particular features. For
example, where a particular feature is disclosed in the context of
a particular aspect or implementation, or a particular claim, that
feature can also be used--to the extent possible--in combination
with and/or in the context of other aspects and implementations,
and in an implementation generally, whether or not such embodiments
are described with and whether or not such features are presented
as being a part of a described embodiment. Thus, the breadth and
scope of the present disclosure should not be limited by any of the
above-described exemplary implementations.
[0252] While multiple implementations are disclosed, still other
implementations will become apparent to those skilled in the art
from this detailed description. Disclosed implementations may be
capable of myriad modifications in various obvious aspects, all
without departing from the spirit and scope of the disclosed
implementations. Accordingly, the drawings and descriptions are to
be regarded as illustrative in nature and not restrictive.
[0253] It should be noted that the features illustrated in the
drawings are not necessarily drawn to scale, and features of one
implementation may be employed with other implementations as the
skilled artisan would recognize, even if not explicitly stated
herein. Descriptions of well-known components and processing
techniques may be omitted so as to not unnecessarily obscure the
implementation features.
[0254] In the present disclosure, various features may be described
as being optional, for example, through the use of the verb "may;"
or, through the use of any of the phrases: "in some
implementations," "in some designs," "in various implementations,"
"in various designs," "in an illustrative example," or, "for
example." For the sake of brevity and legibility, the present
disclosure does not explicitly recite each and every permutation
that may be obtained by choosing from the set of optional features.
However, the present disclosure is to be interpreted as explicitly
disclosing all such permutations. For example, a system described
as having three optional features may be implemented in seven
different ways, namely with just one of the three possible
features, with any two of the three possible features or with all
three of the three possible features.
[0255] In various implementations, elements described herein as
coupled or connected may have an effectual relationship realizable
by a direct connection or indirectly with one or more other
intervening elements.
[0256] In the present disclosure, the term "any" may be understood
as designating any number of the respective elements, that is, as
designating one, at least one, at least two, each or all of the
respective elements. Similarly, the term "any" may be understood as
designating any collection(s) of the respective elements, i.e. as
designating one or more collections of the respective elements, a
collection comprising one, at least one, at least two, each or all
of the respective elements. The respective collections need not
comprise the same number of elements.
[0257] While various implementations have been disclosed and
described in detail herein, it will be apparent to those skilled in
the art that various changes may be made to the disclosed
configuration, operation, and form without departing from the
spirit and scope thereof. In particular, it is noted that the
respective implementation features, even those disclosed solely in
combination with other implementation features, may be combined in
any configuration excepting those readily apparent to the person
skilled in the art as nonsensical. Likewise, use of the singular
and plural is solely for the sake of illustration and is not to be
interpreted as limiting.
[0258] The Abstract is provided to comply with 37 C. F. R. .sctn.
1.72(b), to allow the reader to quickly ascertain the nature of the
technical disclosure and is submitted with the understanding that
it will not be used to interpret or limit the scope or meaning of
the claims.
[0259] In the present disclosure, all descriptions where
"comprising" is used may have as alternatives "consisting
essentially of" or "consisting of" In the present disclosure, any
method or apparatus implementation may be devoid of one or more
process steps or components. In the present disclosure,
implementations employing negative limitations are expressly
disclosed and considered a part of this disclosure.
[0260] Certain terminology and derivations thereof may be used in
the present disclosure for convenience in reference only and will
not be limiting. For example, words such as "upward," "downward,"
"left," and "right" would refer to directions in the drawings to
which reference is made unless otherwise stated. Similarly, words
such as "inward" and "outward" would refer to directions toward and
away from, respectively, the geometric center of a device or area
and designated parts thereof. References in the singular tense
include the plural, and vice versa, unless otherwise noted.
[0261] Terms and phrases used in this document, and variations
thereof, unless otherwise expressly stated, should be construed as
open ended as opposed to limiting. As examples of the foregoing:
the term "including" should be read as meaning "including, without
limitation" or the like; the term "example" is used to provide
exemplary instances of the item in discussion, not an exhaustive or
limiting list thereof; the terms "a" or "an" should be read as
meaning "at least one," "one or more" or the like; and adjectives
such as "conventional," "traditional," "normal," "standard,"
"known" and terms of similar meaning should not be construed as
limiting the item described to a given time period or to an item
available as of a given time, but instead should be read to
encompass conventional, traditional, normal, or standard
technologies that may be available or known now or at any time in
the future. Likewise, where this document refers to technologies
that would be apparent or known to one of ordinary skill in the
art, such technologies encompass those apparent or known to the
skilled artisan now or at any time in the future.
[0262] The term "comprises" and grammatical equivalents thereof are
used herein to mean that other components, ingredients, steps,
among others, are optionally present. For example, an
implementation "comprising" (or "which comprises") components A, B
and C can consist of (i.e., contain only) components A, B and C, or
can contain not only components A, B, and C but also contain one or
more other components.
[0263] Where reference is made herein to a method comprising two or
more defined steps, the defined steps can be carried out in any
order or simultaneously (except where the context excludes that
possibility), and the method can include one or more other steps
which are carried out before any of the defined steps, between two
of the defined steps, or after all the defined steps (except where
the context excludes that possibility).
[0264] The term "at least" followed by a number is used herein to
denote the start of a range beginning with that number (which may
be a range having an upper limit or no upper limit, depending on
the variable being defined). For example, "at least 1" means 1 or
more than 1. The term "at most" followed by a number (which may be
a range having 1 or 0 as its lower limit, or a range having no
lower limit, depending upon the variable being defined). For
example, "at most 4" means 4 or less than 4, and "at most 40%"
means 40% or less than 40%. When, in this specification, a range is
given as "(a first number) to (a second number)" or "(a first
number)-(a second number)," this means a range whose limit is the
second number. For example, 25 to 100 mm means a range whose lower
limit is 25 mm and upper limit is 100 mm.
[0265] Many suitable methods and corresponding materials to make
each of the individual parts of implementation apparatus are known
in the art. One or more implementation part may be formed by
machining, 3D printing (also known as "additive" manufacturing),
CNC machined parts (also known as "subtractive" manufacturing), and
injection molding, as will be apparent to a person of ordinary
skill in the art. Metals, wood, thermoplastic and thermosetting
polymers, resins and elastomers as may be described herein-above
may be used. Many suitable materials are known and available and
can be selected and mixed depending on desired strength and
flexibility, preferred manufacturing method and particular use, as
will be apparent to a person of ordinary skill in the art.
[0266] Any element in a claim herein that does not explicitly state
"means for" performing a specified function, or "step for"
performing a specific function, is not to be interpreted as a
"means" or "step" clause as specified in 35 U.S.C. .sctn. 112 (f).
Specifically, any use of "step of" in the claims herein is not
intended to invoke the provisions of 35 U.S.C. .sctn. 112 (f).
Elements recited in means-plus-function format are intended to be
construed in accordance with 35 U.S.C. .sctn. 112 (f).
[0267] Recitation in a claim of the term "first" with respect to a
feature or element does not necessarily imply the existence of a
second or additional such feature or element.
[0268] The phrases "connected to," "coupled to" and "in
communication with" refer to any form of interaction between two or
more entities, including mechanical, electrical, magnetic,
electromagnetic, fluid, and thermal interaction. Two components may
be functionally coupled to each other even though they are not in
direct contact with each other. The terms "abutting" or "in
mechanical union" refer to items that are in direct physical
contact with each other, although the items may not necessarily be
attached together.
[0269] The word "exemplary" is used herein to mean "serving as an
example, instance, or illustration." Any implementation described
herein as "exemplary" is not necessarily to be construed as
preferred over other implementations. While various aspects of the
disclosure are presented with reference to drawings, the drawings
are not necessarily drawn to scale unless specifically
indicated.
[0270] Reference throughout this specification to "an
implementation" or "the implementation" means that a particular
feature, structure, or characteristic described in connection with
that implementation is included in at least one implementation.
Thus, the quoted phrases, or variations thereof, as recited
throughout this specification are not necessarily all referring to
the same implementation.
[0271] Similarly, it should be appreciated that in the above
description, various features are sometimes grouped together in a
single implementation, Figure, or description thereof for the
purpose of streamlining the disclosure. This method of disclosure,
however, is not to be interpreted as reflecting an intention that
any claim in this or any application claiming priority to this
application require more features than those expressly recited in
that claim. Rather, as the following claims reflect, inventive
aspects may lie in a combination of fewer than all features of any
single foregoing disclosed implementation. Thus, the claims
following this Detailed Description are hereby expressly
incorporated into this Detailed Description, with each claim
standing on its own as a separate implementation. This disclosure
is intended to be interpreted as including all permutations of the
independent claims with their dependent claims.
[0272] A system or method implementation in accordance with the
present disclosure may be accomplished through the use of one or
more computing devices. As descried, for example, at least with
reference to FIGS. 3, 4, 5, 8, 9, 10, and 11 one of ordinary skill
in the art would appreciate that an exemplary control system or
algorithmic controller appropriate for use with an implementation
in accordance with the present application may generally include
one or more of a Central processing Unit (CPU), Random Access
Memory (RAM), a storage medium (e.g., hard disk drive, solid state
drive, flash memory, cloud storage), an operating system (OS), one
or more application software, a display element, one or more
communications means, or one or more input/output devices/means.
Examples of computing devices usable with implementations of the
present disclosure include, but are not limited to, proprietary
computing devices, personal computers, mobile computing devices,
tablet PCs, mini-PCs, servers, or any combination thereof. The term
computing device may also describe two or more computing devices
communicatively linked in a manner as to distribute and share one
or more resources, such as clustered computing devices and server
banks/farms. One of ordinary skill in the art would understand that
any number of computing devices could be used, and implementation
of the present disclosure are contemplated for use with any
computing device.
[0273] In various implementations, communications means, data
store(s), processor(s), or memory may interact with other
components on the computing device, in order to effect the
provisioning and display of various functionalities associated with
the system and method detailed herein. One of ordinary skill in the
art would appreciate that there are numerous configurations that
could be utilized with implementations of the present disclosure,
and implementations of the present disclosure are contemplated for
use with any appropriate configuration.
[0274] According to an implementation of the present disclosure,
the communications means of the system may be, for instance, any
means for communicating data over one or more networks or to one or
more peripheral devices attached to the system. Appropriate
communications means may include, but are not limited to, circuitry
and control systems for providing wireless connections, wired
connections, cellular connections, data port connections,
Bluetooth.RTM. connections, or any combination thereof. One of
ordinary skill in the art would appreciate that there are numerous
communications means that may be utilized with implementations of
the present disclosure, and implementations of the present
disclosure are contemplated for use with any communications
means.
[0275] Throughout this disclosure and elsewhere, block diagrams and
flowchart illustrations depict methods, apparatuses (i.e.,
systems), and computer program products. Each element of the block
diagrams and flowchart illustrations, as well as each respective
combination of elements in the block diagrams and flowchart
illustrations, illustrates a function of the methods, apparatuses,
and computer program products. Any and all such functions
("depicted functions") can be implemented by computer program
instructions; by special-purpose, hardware-based computer systems;
by combinations of special purpose hardware and computer
instructions; by combinations of general purpose hardware and
computer instructions; and so on--any and all of which may be
generally referred to herein as a "circuit," "module," or
"system."
[0276] While the foregoing drawings and description may set forth
functional aspects of the disclosed systems, no particular
arrangement of software for implementing these functional aspects
should be inferred from these descriptions unless explicitly stated
or otherwise clear from the context.
[0277] Each element in flowchart illustrations may depict a step,
or group of steps, of a computer-implemented method. Further, each
step may contain one or more sub-steps. For the purpose of
illustration, these steps (as well as any and all other steps
identified and described above) are presented in order. It will be
understood that an implementation may include an alternate order of
the steps adapted to a particular application of a technique
disclosed herein. All such variations and modifications are
intended to fall within the scope of this disclosure. The depiction
and description of steps in any particular order is not intended to
exclude implementations having the steps in a different order,
unless required by a particular application, explicitly stated, or
otherwise clear from the context.
[0278] Traditionally, a computer program consists of a sequence of
computational instructions or program instructions. It will be
appreciated that a programmable apparatus (that is, computing
device) can receive such a computer program and, by processing the
computational instructions thereof, produce a further technical
effect.
[0279] A programmable apparatus may include one or more
microprocessors, microcontrollers, embedded microcontrollers,
programmable digital signal processors, programmable devices,
programmable gate arrays, programmable array logic, memory devices,
application specific integrated circuits, or the like, which can be
suitably employed or configured to process computer program
instructions, execute computer logic, store computer data, and so
on. Throughout this disclosure and elsewhere a computer can include
any and all suitable combinations of at least one general purpose
computer, special-purpose computer, programmable data processing
apparatus, processor, processor architecture, and so on.
[0280] It will be understood that a computer can include a
computer-readable storage medium and that this medium may be
internal or external, removable, and replaceable, or fixed. It will
also be understood that a computer can include a Basic Input/Output
System (BIOS), firmware, an operating system, a database, or the
like that can include, interface with, or support the software and
hardware described herein.
[0281] Implementations of the system as described herein are not
limited to applications involving conventional computer programs or
programmable apparatuses that run them. It is contemplated, for
example, that implementations of the disclosure as claimed herein
could include an optical computer, quantum computer, analog
computer, or the like.
[0282] Regardless of the type of computer program or computer
involved, a computer program can be loaded onto a computer to
produce a particular machine that can perform any and all of the
depicted functions. This particular machine provides a means for
carrying out any and all of the depicted functions.
[0283] Any combination of one or more computer readable medium(s)
may be utilized. The computer readable medium may be a computer
readable signal medium or a computer readable storage medium. A
computer readable storage medium may be, for example, but not
limited to, an electronic, magnetic, optical, electromagnetic,
infrared, or semiconductor system, apparatus, or device, or any
suitable combination of the foregoing. More specific examples (a
non-exhaustive list) of the computer readable storage medium would
include the following: an electrical connection having one or more
wires, a portable computer diskette, a hard disk, a random access
memory (RAM), a read-only memory (ROM), an erasable programmable
read-only memory (EPROM or Flash memory), an optical fiber, a
portable compact disc read-only memory (CD-ROM), an optical storage
device, a magnetic storage device, or any suitable combination of
the foregoing. In the context of this document, a computer readable
storage medium may be any tangible medium that can contain or store
a program for use by or in connection with an instruction execution
system, apparatus, or device.
[0284] Computer program instructions can be stored in a
computer-readable memory capable of directing a computer or other
programmable data processing apparatus to function in a particular
manner. The instructions stored in the computer-readable memory
constitute an article of manufacture including computer-readable
instructions for implementing any and all of the depicted
functions.
[0285] A computer readable signal medium may include a propagated
data signal with computer readable program code encoded therein,
for example, in baseband or as part of a carrier wave. Such a
propagated signal may take any of a variety of forms, including,
but not limited to, electromagnetic, optical, or any suitable
combination thereof. A computer readable signal medium may be any
computer readable medium that is not a computer readable storage
medium and that can communicate, propagate, or transport a program
for use by or in connection with an instruction execution system,
apparatus, or device.
[0286] Program code encoded by a computer readable medium may be
transmitted using any appropriate medium, including but not limited
to wireless, wireline, optical fiber cable, RF, etc., or any
suitable combination of the foregoing.
[0287] The elements depicted in flowchart illustrations and block
diagrams throughout the figures imply logical boundaries between
the elements. However, according to software or hardware
engineering practices, the depicted elements and the functions
thereof may be implemented as parts of a monolithic software
structure, as standalone software modules, or as modules that
employ external routines, code, services, and so forth, or any
combination of these. All such implementations are within the scope
of the present disclosure.
[0288] Unless explicitly stated or otherwise clear from the
context, the verbs "execute" and "process" are used interchangeably
to indicate execute, process, interpret, compile, assemble, link,
load, any and all combinations of the foregoing, or the like.
Therefore, implementations that execute or process computer program
instructions, computer-executable code, or the like can suitably
act upon the instructions or code in any and all of the ways just
described.
[0289] The functions and operations presented herein are not
inherently related to any particular computer or other apparatus.
Various general-purpose systems may also be used with programs in
accordance with the teachings herein, or it may prove convenient to
construct more specialized apparatus to perform the required method
steps. The required structure for a variety of these systems will
be apparent to those of skill in the art, along with equivalent
variations. In addition, implementations of the disclosure are not
described with reference to any particular programming language. It
is appreciated that a variety of programming languages may be used
to implement the present teachings as described herein, and any
references to specific languages are provided for disclosure of
enablement and best mode of implementations of the disclosure.
Implementations of the disclosure are well suited to a wide variety
of computer network systems over numerous topologies. Within this
field, the configuration and management of large networks include
storage devices and computers that are communicatively coupled to
dissimilar computers and storage devices over a network, such as
the Internet.
[0290] A number of implementations have been described.
Nevertheless, it will be understood that various modifications may
be made. For example, the steps of the disclosed techniques may be
performed in a different sequence, components of the disclosed
systems may be combined in a different manner, or the components
may be supplemented with other components. Such modifications are
to be considered as included in the following claims unless the
claims by their language expressly state otherwise. Variations
described for exemplary implementations of the present disclosure
may be realized in any combination desirable for each application.
Accordingly, other implementations are contemplated, within the
scope of the following claims.
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