Solvent consumption in supercritical ethanol, propanol or butanol treatment of either refined pre-extracted lignin or comparatively impure lignin-rich solid residual from hydrothermally pretreated lignocellulosic biomass can be minimized by conducting the reaction at very high loading of lignin to solvent. Comparatively impure, crude lignin-rich solid residual can be directly converted by supercritical alcohol treatment to significantly diesel-soluble lignin oil without requirement for pre-extraction or pre-solubilisation of lignin or for added reaction promoters such as catalysts, hydrogen donor co-solvents, acids, based or H2 gas. O:C ratio of product oil can readily be obtained using crude lignin residual in such a process at levels 0.20 or lower.

A process for cleaning and beneficiating biomass is described which may allow removal of entrained salts and light volatiles from biomass materials. The process may also minimize energy use through capturing steam and flue gases for re-use. The process may generally comprise the following steps: prewashing and/or preheating a biomass, pressurizing the biomass in a steam explosion vessel, rapidly depressurizing the steam explosion vessel, releasing the steam from the steam explosion vessel entrained with fine lignin-enriched particles into a cyclone-type gas expansion vessel, routing the steam from the gas expansion vessel to the input hopper, subjecting the biomass to a second washing step, mechanically removing a portion of the water from the biomass, and evaporatively heating the biomass.

A system for processing a material includes a pre-processing module configured to receive the material, mechanically stress the received material, and output the mechanically stressed material. The system also includes a pyrolysis module communicatively coupled to the pre-processing module and downstream of the pre-processing module. The pyrolysis module is configured to receive the mechanically stressed material from the pre-processing module and to perform a pyrolysis process on the received mechanically stressed material, thereby to produce one or more pyrolysis products.

A fuel production system includes a first modular unit and a second modular unit. The first modular unit includes a first housing, a process vessel, an agitator rotor assembly, a first drivetrain, an extrusion screw, a second drivetrain, a first separation vessel, and a product shaping system. The second modular unit includes a second housing, a thermal fluid heater system, a condenser, a second separation vessel, and a vacuum pump. The second modular unit is configured to be coupled to the first modular unit. At least a portion of each of the process vessel, the agitator rotor assembly, the first drivetrain, the extrusion screw, the second drivetrain, the first separation vessel, and the product shaping system are contained in the first housing. At least a portion of each of the thermal fluid heater system, the condenser, the second separation vessel, and the vacuum pump are contained in the second housing.

A fuel production system includes a first modular unit and a second modular unit. The first modular unit includes a first housing, a process vessel, an agitator rotor assembly, a first drivetrain, an extrusion screw, a second drivetrain, a first separation vessel, and a product shaping system. The second modular unit includes a second housing, a thermal fluid heater system, a condenser, a second separation vessel, and a vacuum pump. The second modular unit is configured to be coupled to the first modular unit. At least a portion of each of the process vessel, the agitator rotor assembly, the first drivetrain, the extrusion screw, the second drivetrain, the first separation vessel, and the product shaping system are contained in the first housing. At least a portion of each of the thermal fluid heater system, the condenser, the second separation vessel, and the vacuum pump are contained in the second housing.

Clean, safe and efficient methods, systems, and processes for utilizing thermolysis methods to processes to convert various carpet, rug, polymeric materials and other waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like into a Clean Fuel Gas and Char source are disclosed. The invention processes the carpet, rug, polymeric material to effectively shred and/or grind the waste source, such as post-consumer carpet remnants and waste, and then process using thermolysis methods to destroy and/or separate halogen and other dangerous components to provide a Clean Fuel Gas and Char source. Additional waste sources, such as solid waste, tires, manure, auto shredder residue, glass and carbon fiber composite materials, municipal solid wastes, medical wastes, waste wood and the like, are suitable for the processing of the invention disclosed.

A system for torrefaction of waste material comprising biogenic material and plastic material may comprise a material pre-processing system, a heating and compaction unit, a reactor system comprising a reaction portion and an extrusion portion, and a cutting unit adjacent an outlet of the reactor system. A method for operating a system for torrefaction of waste material comprising biogenic and plastic material may comprise processing the waste material to generate waste material having an aspect ratio between 0.8:1 and 1.2:1 and a largest dimension of less than 4 millimeters (mm); compressing and heating the pre-processed waste material in the heating and compaction unit; heating the compacted waste material in the reactor system to a temperature of 280° C.-500° C.; extruding material from the reactor system; and cutting the extruded material into pellets.

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.

Systems and methods of processing biomass include a conveyor unit associated with an inlet and/or outlet, a microwave generator, a microwave guide connecting the microwave generator to the conveyor unit that includes a microwave opening configured to receive microwave energy via the microwave guide, and a microwave suppression system including a tunnel associated with the material inlet and/or outlet, and including at least one flexible and/or movable microwave reflecting component within the tunnel, the microwave reflecting component configured to be deflected as biomass material passes through the tunnel and then returning to a resting, closed position when the biomass material is no longer passing through the tunnel. The conveyor unit is configured to receive and process the biomass material, including heating the biomass material to at least a first temperature by applying microwave energy to the biomass material.

The invention relates to a method for the purification of lignin, cellulose and hemicellulose obtained from purines, which can be burned in compliance with environmental standards as a substitute for wood. The method of the invention produces a novel bio-fuel.