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

In some variations, the invention provides a biocarbon composition comprising a low fixed carbon material with a fixed carbon concentration from 20 wt % to 55 wt %; a high fixed carbon material with a fixed carbon concentration from 50 wt % to 100 wt % (and higher than the fixed carbon concentration of the low fixed carbon material; from 0 to 30 wt % moisture; from 0 to 15 wt % ash; and from 0 to 20 wt % of one or more additives (such as a binder). Some variations provide a process for producing a biocarbon composition, the process comprising: pyrolyzing a first biomass-containing feedstock to generate a low fixed carbon material; separately pyrolyzing a second biomass-containing feedstock to generate a high fixed carbon material; blending the low fixed carbon material with the high fixed carbon material, thereby generating an intermediate material; optionally, blending one or more additives into the intermediate material; optionally, drying the intermediate material; and recovering a biocarbon composition containing the intermediate material or a thermally treated form thereof.

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

A method to create a natural charcoal briquette is described herein. A wood material is collected and impurities are removed from the wood material. The wood material is dried at a temperature in a range of approximately 150° C. to approximately 200° C. to reach a moisture level in a range of approximately 3.7% to approximately 5.0%. The dried wood material is compressed in a shaped mold at approximately 300° C. and under 40 tons of pressure to form a charcoal briquette. The charcoal briquette is carbonized at a temperature in a range of approximately 700° C. to approximately 800° C. in a range of approximately 14 days to approximately 17 days. The charcoal briquette is then cooled for approximately 2 days prior to use or packaging.

Embodiments of the present invention may provide managing waste including providing non-sorted solid waste (1), processing non-sorted solid waste in a waste handling system (21), shredding (26) non-sorted solid waste to create shredded non-sorted solid waste (27) in a waste handling system; introducing shredded non-sorted solid waste into a thermochemical conversion reactor (4); heating and even chemically converting a shredded non-sorted solid waste; producing hydrochar (22) and a recyclable materials fraction (23); recycling water (24) used in the heating and chemically processing of the shredded non-sorted solid waste in a thermochemical conversion reactor in said waste handling system; sorting (25) the recyclable materials fraction; fueling (28) a thermochemical conversion reactor with hydrochar (22); and perhaps even recycling heat from a thermochemical conversion reactor in the waste handling system.

The present disclosure includes a process for pelletizing a spent bleaching earth (SBE) into a clay-biocarbon composite including classifying the SBE based on at least one parameter of the SBE, selecting at least one filler compound and mixing the at least one filler compound with the SBE to make a mixture, forming a plurality of pellets out of the mixture, and pyrolyzing the pellets to produce the clay-biocarbon composite. Pyrolyzing a pelleted spent bleaching earth (SBE) may include advancing the pelleted SBE with a distributer to a first thermal chamber for providing even thermal processing, releasing the pelleted SBE to an auger to cool to room temperature, and condensing at least one volatile compound emitted from the pelleted SBE during thermal processing to produce a condensate for reuse.

A method to create a natural charcoal briquette is described herein. A wood material is collected and impurities are removed from the wood material. The wood material is dried at a temperature in a range of approximately 150° C. to approximately 200° C. to reach a moisture level in a range of approximately 3.7% to approximately 5.0%. The dried wood material is compressed in a shaped mold at approximately 300° C. and under 40 tons of pressure to form a charcoal briquette. The charcoal briquette is carbonized at a temperature in a range of approximately 700° C. to approximately 800° C. in a range of approximately 14 days to approximately 17 days. The charcoal briquette is then cooled for approximately 2 days prior to use or packaging.

A system for producing biocoal and biochar includes at least one rotary compression unit (RCU) having a barrel, a compression screw housed within the barrel, a feed for receiving biomass and at least one exit for releasing biochar and gasses formed in the RCU. A first exit stream is produced that includes biochar and a portion of the remaining gasses, and a second exit stream is produced that includes biocoal. A gas crossover is provided that connects the first and second exit stream having a mechanism for transporting gasses from the first exit stream to the second exit stream thereby condensing a portion of the remaining gasses into the biocoal. In one form two RCUs are included connected to two condensers.

The present invention describes a method for the energy efficient production of metals and alloys by carbothermic reduction of minerals and ores in electric reduction reactors, said method comprising at least the following steps: conveying a wood containing material to at least one pyrolysis step for producing charcoal; conveying said produced charcoal, possibly other carbon-containing reduction materials and metal containing raw materials to the at least one reactor for producing metal or alloy; conveying off-gas from said at least one pyrolysis step and off-gas from said at least one reactor to at least one energy recovery step.

The invention relates to a method for producing a biofuel from an aqueous mixture of carbonized biomass obtained by means of a method for the hydrothermal carbonization of biomass, characterized in that it comprises: (a) grinding the aqueous mixture of carbonized biomass until a maximum size of less than 500 micrometers of the particles contained in the mixture is obtained; (b) applying a method for the physical separation of inorganic substances; and (c) reducing the moisture content until a water content of between 25 and 55 wt. % is reached. The invention also relates to the biofuel obtained by said method, and to the use thereof in various applications.