The invention provides a method of sequential pyrolysis and carbon deposition to produce a composite carbonaceous product, the method comprising: a pyrolysis process step comprising pyrolyzing a pyrolyzable organic feed at a pyrolysis temperature in a first reaction zone in the presence of a non-oxidising gas to produce hot char and pyrolysis gas, wherein the pyrolysis gas and the non-oxidising gas combine to form a gas mixture; discharging the gas mixture from the first reaction zone to a combustion zone and combusting at least a portion of the pyrolysis gas therein, wherein heat produced by the combusting of the pyrolysis gas is transmitted from the combustion zone to the first reaction zone to provide at least a portion of the heat of pyrolysis; and a decomposition process step comprising contacting a hydrocarbon-rich organic gas with the hot char directly after its production in the pyrolysis process step, wherein the hydrocarbon-rich organic gas catalytically decomposes on the hot char at a decomposition temperature which is higher than the pyrolysis temperature, thereby producing gaseous decomposition products comprising hydrogen and a composite carbonaceous material comprising the char with carbon deposits thereon.

The invention provides a method of sequential pyrolysis and carbon deposition to produce a composite carbonaceous product, the method comprising: a pyrolysis process step comprising pyrolyzing a pyrolyzable organic feed at a pyrolysis temperature in a first reaction zone in the presence of a non-oxidising gas to produce hot char and pyrolysis gas, wherein the pyrolysis gas and the non-oxidising gas combine to form a gas mixture; discharging the gas mixture from the first reaction zone to a combustion zone and combusting at least a portion of the pyrolysis gas therein, wherein heat produced by the combusting of the pyrolysis gas is transmitted from the combustion zone to the first reaction zone to provide at least a portion of the heat of pyrolysis; and a decomposition process step comprising contacting a hydrocarbon-rich organic gas with the hot char directly after its production in the pyrolysis process step, wherein the hydrocarbon-rich organic gas catalytically decomposes on the hot char at a decomposition temperature which is higher than the pyrolysis temperature, thereby producing gaseous decomposition products comprising hydrogen and a composite carbonaceous material comprising the char with carbon deposits thereon.

A method is provided for reducing foaming within a coke drum of a delayed coking unit. The method may include forming a plastic mixture including a plastic material and a carrier. The method may also include injecting the plastic mixture into the coke drum during operation of the coke drum.

A method is provided for reducing foaming within a coke drum of a delayed coking unit. The method may include forming a plastic mixture including a plastic material and a carrier. The method may also include injecting the plastic mixture into the coke drum during operation of the coke drum.

A catalyst is illustrated, which has 70-90 parts by weight of mica, 1-10 parts by weight of zeolite, 5-15 parts by weight of titanium dioxide, 1-10 parts by weight of aluminum oxide, 1-5 parts by weight of sodium oxide and 1-5 parts by weight of potassium oxide. The present disclosure also illustrates a pyrolysis device using the catalyst, and further illustrates a pyrolysis method using the catalyst and/or the pyrolysis device for thermally cracking an organic polymer.

A catalyst is illustrated, which has 70-90 parts by weight of mica, 1-10 parts by weight of zeolite, 5-15 parts by weight of titanium dioxide, 1-10 parts by weight of aluminum oxide, 1-5 parts by weight of sodium oxide and 1-5 parts by weight of potassium oxide. The present disclosure also illustrates a pyrolysis device using the catalyst, and further illustrates a pyrolysis method using the catalyst and/or the pyrolysis device for thermally cracking an organic polymer.

In some variations, the disclosure provides a renewable biocarbon composition comprising from 50 wt% to 99 wt% total carbon, wherein the biocarbon composition is characterized by a base-acid ratio selected from 0.1 to 10, an iron-calcium ratio selected from 0.05 to 5, iron-plus-calcium parameter selected from 5 to 50 wt%, a slagging factor selected from 0.001 to 1, and/or a fouling factor or modified fouling factor selected from 0.1 to 10. Some variations provide a process comprising: providing a biomass feedstock; pyrolyzing the biomass feedstock to generate an intermediate biocarbon stream; washing or treating the intermediate biocarbon stream with an acid, a base, a salt, a metal, H.sub.2, H.sub.2O, CO, CO.sub.2, or a combination thereof, and/or introducing an additive in the process, to adjust a base-acid ratio or other compositional parameter; and recovering a biocarbon composition comprising from 50 wt% to 99 wt% total carbon and optimized for a compositional parameter.

This disclosure provides a method of making a high-fixed-carbon material comprising pyrolyzing biomass to generate intermediate solids and a pyrolysis vapor; condensing the pyrolysis vapor to generate pyrolysis liquid; blending the pyrolysis liquid with the intermediate solids, to generate a mixture; and further pyrolyzing the mixture to generate a high-fixed-carbon material. A process can comprise: pyrolyzing a biomass-comprising feedstock in a first pyrolysis reactor to generate a first biogenic reagent and a first pyrolysis vapor; introducing the first pyrolysis vapor to a condensing system to generate a condenser liquid; contacting the first biogenic reagent with the condenser liquid, thereby generating an intermediate material; further pyrolyzing the intermediate material in a second pyrolysis reactor to generate a second biogenic reagent and a second pyrolysis vapor; and recovering the second biogenic reagent as a high-yield biocarbon composition. The process can further comprise pelletizing the intermediate material. Many process and system configurations are disclosed.

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.