Thermochemical system and method

A thermochemical system & method may be configured to convert an organic feedstock to various products. A thermochemical system may include a solid material feed module, a reactor module, an afterburner module, and a solid product finishing module. The various operational parameters (temperature, pressure, etc.) of the various modules may vary depending on the desired products. The product streams may be gaseous, vaporous, liquid, and/or solid.

FIELD OF THE INVENTION

The present disclosure is related to organic material and methods and apparatuses used in the processing of those organic materials.

No federal funds were used to develop or create the invention disclosed and described in the patent application.

BACKGROUND

Generally, a reactor for processing an organic feedstock (e.g., biomass) is configured to convert the feedstock into a variety of products, such as gas, liquid, and solid products via pyrolysis or other reactions. The conversion rate to each product may be manipulated by several factors, such as the feedstock that is used, the temperature at which the reactor operates, and the amount of oxygen or reacting gases present in the reactor. Any of the products from pyrolysis may be further processed (e.g., the solid products may be activated, the liquid products may be collected, isolated and filtered, etc.).

Various patents exist on biomass reactors to produce gases, oils and biochar via pyrolysis. For example, U.S. Pat. No. 8,361,186 discloses a pyrolysis unit that converts biomass into gas, liquid, and solid products. However, the prior art has several shortcomings, which include but are not limited to being cumbersome, requiring significant energy input, limited to operation with a specific type of feedstock, moisture content, particle size, sensitivity to foreign materials (e.g., rocks, metals, non-uniform sizes or shapes of feedstock), complicated to operate, requiring various operators or sophisticated automation controls, restrictive as to products produced, and/or a lack of mobility/portability.

DETAILED DESCRIPTION

Before the present methods and apparatuses are disclosed and described, it is to be understood that the methods and apparatuses are not limited to specific methods, specific components, specific arrangements, or to particular implementations. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments/aspects only and is not intended to be limiting.

“Aspect” when referring to a method, apparatus, and/or component thereof does not mean that limitation, functionality, component etc. referred to as an aspect is required, but rather that it is one part of a particular illustrative disclosure and not limiting to the scope of the method, apparatus, and/or component thereof unless so indicated in the following claims.

The present methods and apparatuses may be understood more readily by reference to the following detailed description of preferred aspects and the examples included therein and to the Figures and their previous and following description. Corresponding terms may be used interchangeably when referring to generalities of configuration and/or corresponding components, aspects, features, functionality, methods and/or materials of construction, etc. those terms.

It is to be understood that the disclosure is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “front”, “back”, “up”, “down”, “top”, “bottom”, and the like) are only used to simplify description, and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as “first”, “second”, and “third” are used herein and in the appended claims for purposes of description and are not intended to indicate or imply relative importance or significance.

The present thermochemical system & method may be comprised of modular units, which may be fitted in shipping containers or truck trailers such that it may be mobile, transportable, and may be adaptable to many configurations. Different and/or additional components (e.g., a piece of equipment) may be integrated with and assembled to the thermochemical system10for one configuration and may be removed and disassembled from the thermochemical system10in another configuration. Because the supply of many organic feed materials (e.g., biomass) is scattered, transportation of the organic feed materials may be cost-prohibitive. Accordingly, the thermochemical system & method disclosed herein may effectively allow a user/operator to bring the processing facility to the field, where the organic feed material is located.

Referring now toFIG. 1, which provides a schematic view of various products and processes that may be made from or included with the thermochemical system & method, organic material, which organic material may be comprised of, biomass, coal, tires, plastic, municipal waste, manures, industrial waste, diatomaceous earth or other filtration medias containing organic components, slurries of up to 70 percent by weight moisture, other organic material with approximately 5 MJ/kg energy content or more, and/or combinations thereof without limitation unless otherwise indicated in the following claims, may be used as a primary feedstock. It is contemplated that for embodiments of a thermochemical system10and method described below that may be configured to sustain a chemical reaction without an external heat source17(but which external heat source17may be required to start the chemical reaction) the feedstock may have an energy content of at least 5 MJ/kg in order to produce enough thermal energy to sustain the reaction without an external heat source17without limitation unless otherwise indicated in the following claims. Various references are made herein to an organic material feed module20, which may be included in various embodiments of a thermochemical system10. However, the use of the term “organic material feed module”20does not limit the composition of the feedstock used for the thermochemical system and method as disclosed herein in any way unless otherwise indicated in the following claims. Accordingly, a feedstock comprised of an inorganic material may be used with an organic material feed module20without limitation unless otherwise indicated in the following claims.

The organic material may undergo a thermochemical process (e.g., pyrolysis) and thereby be converted into one or more products. Generally, the product of a thermochemical process may be classified as a gas, liquid, or solid. As shown inFIG. 1, the solid product stream may be separated from the gas and liquid product stream, and each product stream may undergo further processing as described in detail below. As will be understood by those skilled in the art, certain amounts of gaseous and liquid products may remain in the solid product stream and vice versa. The specific amount of overlap between matter states in any given product stream may vary from one application of the thermochemical system & method to the next and may be dependent at least upon the organic material feedstock used and the operational parameters for the thermochemical system & method. Accordingly, the amount of gaseous and/or liquid product in the solid product stream and vice versa in no way limits the scope of the present disclosure unless so indicated in the following claims.

As previously mentioned, a wide variety of feedstocks may be used with the thermochemical system and method. Additionally, feedstocks having contaminants (soil, sand, gravel, debris, metal, plastic, water, other foreign objects, etc.) therein may be used without limitation unless so indicated in the following claims. Because of the range of temperatures at which the thermochemical system & method may be operated, the organic material feedstock may include (in addition to those previously listed above) but is not limited to sludge, solid wastes, industrial byproducts, biohazardous wastes, and/or combinations thereof unless otherwise indicated in the following claims.

The solid product stream may be pyrolyzed until it becomes biochar, at which point it may be activated and subsequently quenched via cooling. The activation of the biochar may be accomplished through an oxidation process. Other processes may be used to convert the biochar to activated biochar and/or to quench the activation process without limitation unless so indicated in the following claims. When the thermochemical system is used to maximize the reduction of the input or feedstock, the equipment used with the thermochemical system & method may be configured as a combustor/incinerator to minimize the solid product to all or mostly all mineral ash (minimizing the carbon composition of the solid product).

Still referring toFIG. 1, the liquid and/or gaseous product stream may be comprised of non-condensable gases, and/or liquids. The non-condensable gases may be compressed and stored for further use and/or processing, or they may be supplied to other areas adjacent the thermochemical system and used as fuel. In one configuration, the non-condensable gases may be supplied to an area of the thermochemical system adjacent an organic material feed module20to provide fuel to one or more burners to dry and/or otherwise process the organic material. In another configuration, the non-condensable gases (which may include syngas) may be supplied to an afterburner module40for combustion.

The condensable gases may be condensed to liquid and stored for further use and/or processing (e.g., purification), or they may be supplied to other areas adjacent the thermochemical system and used as fuel in a manner as previously described for non-condensable gases. The liquid products may be collected, purified, and/or stored for further use and/or processing, or they may be supplied to other areas adjacent the thermochemical system and used as fuel as previously described for the non-condensable and condensable gases. Alternatively, to increase the biochar yields the liquid products can be introduced to the biomass for secondary polymerization and increased biochar yields. The specific use of any product stream in no way limits the scope of the present disclosure unless so indicated in the following claims.

Referring now toFIG. 2A, which provides a perspective view of the first illustrative embodiment of a thermochemical system & method, the thermochemical system & method may be comprised of several modules. The thermochemical system10may include an organic material feed module20, which inFIG. 2Ais positioned toward the bottom-right corner of the drawing. A more detailed view of the organic material feed module20is shown inFIG. 2C. The organic material feed module20may be comprised of a hopper21having an agitator system22positioned therein to ensure a relatively even and consistent feed of organic material to the thermochemical system10by breaking up large clustered chunks and/or other abnormalities in the organic material feedstock to prevent bridging. A feed module conveying member27may provide the motive force to convey the organic material from the organic material feed module20to the reactor module30. In the illustrative embodiment pictured herein, the feed module conveying member27may be configured as an auger, but any suitable conveying member may be used without limitation unless so indicated in the following claims including but not limited to paddles, screws, belts, chain conveyors, drums, etc. The feed module conveying member27may receive rotational energy from a motor12, which may be mounted external to the hopper21and at a terminal end of the feed module conveying member27.

The thermochemical system10may be configured to operate using a wide variety of organic materials and/or combinations thereof as a feedstock, which materials include but are not limited to various types of biomass (e.g., cellulosic-based plant material, lignocellulosic-based plant material, pulp, and/or combinations thereof). Accordingly, the specific configuration of the organic material feed module20(including but not limited to the hopper21, agitator system22, and/or feed module conveying member27) may vary from one application of the thermochemical system10to the next without limitation unless so indicated in the following claims.

A reactor module30may be positioned adjacent the organic material feed module20, as shown inFIGS. 2A-2D. The reactor module30may be configured such that all or a majority of a thermochemical reaction and/or conversion (e.g., pyrolysis) of a portion of the organic material feedstock takes place within the reactor module30. The reactor module30may be configured such that it is comprised of one or more horizontal sections30a. One or more horizontal sections30amay comprise one or more zones31a,31b, and/or31cas shown at least inFIGS. 2B & 2C. Each zone31a,31b, and/or31cmay be defined by a specific temperature and/or temperature range, residence time (which may be dependent on at least length, auger pitch, rotational speed, etc.) and/or defined by a specific conversion to a specific product. As shown inFIGS. 2A-2D, the illustrative embodiment of a thermochemical system10depicted therein may be comprised of at least three zones31a,31b, and/or31c.

Referring still toFIGS. 2A-2Dand alsoFIGS. 3A & 3B(which provide cross-sectional depictions of two illustrative embodiments of a reactor module30), the thermochemical system10may be configured such that zone one31ais comprised of two horizontal sections30a, wherein zone one31amay operate primarily to dry the organic material feed and begin the thermochemical process. However, for configurations of the thermochemical system10in which the organic material feedstock is relatively dry initially, zone one31amay be used to initialize a thermochemical process. Heat may be added to the organic material feed immediately upon entering zone one31afrom the afterburner module40, combustion of gases and/or vapors (e.g., syngas) within the ventilation/combustion chamber38, and/or an external heat source17as further described in detail below. Moisture, vapor, liquid, and/or gases may exit the reactor vessel33through one or more apertures34formed therein, which may be on the top of the reactor vessel33to reduce the pressure therein. Additionally, the apertures34may be sized, spaced, and/or shaped to mitigate and/or eliminate the elutriation of particles, which may increase the yield of the thermochemical system10while simultaneously reducing particulate matter in emissions. Generally, but without limitation unless otherwise indicated in the following claims, the mass percentage of solid material within the reactor vessel33may increase in a direction from right to left in the orientation shown inFIGS. 2B-2D. That is, the mass percentage of solid material in the organic material feed module20may be less than that in zone one31a, which may be less than that in zone two31b, and so one. The organic material exiting zone one31aand entering zone two31bmay be between 400 and 900 C, and in some embodiments may be at a temperature of approximately 700 C.

An external heat source17, which may be configured as any suitable heat source including but not limited to an electric heating element, a propane, natural gas, syngas, liquid fuel burner, etc. (unless otherwise indicated in the following claims) may be configured to add heat to the organic material feed module20and/or reactor module30to start and/or sustain combustion of gases, liquids, and/or vapors released during the thermochemical process. It is contemplated that after a certain amount of time (e.g., one hour) the external heat source17may be disengaged, and the combustion of the gases and/or vapors released via the thermochemical process (e.g., syngas) may provide the required thermal energy to sustain and/or complete the thermochemical process. The illustrative embodiment inFIG. 2Bshows two external heat sources17, one near the interface of zone three31cof the reactor module30and the solid product finishing module60and another near the interface between zone one31aand zone two31b. However, in other embodiments more external heat sources17may be used (such as one positioned within the afterburner module40), and in still other embodiments the external heat source17adjacent the interface between zones one and two31a,31bmay be eliminated. Accordingly, the scope of the present disclosure is not limited by the specific number and/or placement of external heat sources unless otherwise indicated in the following claims.

The thermochemical system10may be configured such that zone two31bis also comprised of two horizontal sections30aand may operate primarily to begin and/or sustain a thermochemical process on the organic material within the reactor vessel33, such that various liquids, gases, and/or vapors are released from the organic material through a plurality of apertures34formed in the reactor vessel33. The organic material exiting zone two31band entering zone three31cmay be between 200 and 750 C, and in some embodiments may be at a temperature of approximately 400 C. As the organic material passes through zone two31b(from right to left using the orientation shown inFIGS. 2B & 2C), the thermochemical process may proceed, and the temperature of the organic material may decrease from as high as 900 C at the interface between zone one31aand zone two31bto as low as 250 C at the interface between zone two31band zone three31c. In one embodiment, the temperature gradient within zone two31bmay be from 1250 to 250 C (in a direction from right to left for the orientation shown inFIGS. 2B & 2C).

The thermochemical system10may be configured such that zone three31cis also comprised of two horizontal sections30aand may operate primarily to sustain and/or finish a thermochemical process on the organic material within the reactor vessel33, such that various gases, vapors, and/or liquids are released from the organic material through a plurality of apertures34formed in the reactor vessel33. It is contemplated that in some applications liquid may be released through apertures34formed in the bottom half of the reactor vessel33and gases and/or vapors may be released through apertures34formed in the top half of the reactor vessel33such that gravity aides in the separation process. However, other configurations may be used without limitation unless so indicated in the following claims.

The organic material exiting zone three31cand entering the solid product finishing module60may be between 150 and 1300 C, and in some embodiments may be at a temperature of approximately 200 C. Generally, air may enter the reactor module through zone three31c, such the ambient air may cool zone three31cresulting in a relatively lower temperature than other areas of the reactor module30. However, when configured for certain products, the temperature of zone three31cmay be relatively high, as described in further detail below.

As the organic material passes through zone three31c(from right to left using the orientation shown inFIGS. 2B & 2C), the thermochemical process may be completed and the organic material may be allowed to cool, and the temperature of the organic material may decrease from as high as 900 C at the interface between zone two31band zone three31cto as low as 150 C at the interface between zone three31cand the solid product finishing module60. In one embodiment, the temperature gradient within zone three31cmay be from 400 to 200 C (again moving right to left), and in another embodiment, the temperature within zone three31cmay be relatively constant at approximately 700 C.

In some applications, it may be desirable to cool the solid product (and/or slowly aerate the solid product) to a temperature between 40 and 100 C (and in some applications to about 60 C) before the solid product passes through the solid product outlet64. The heat exchanger/insulator62may function to remove thermal energy from the solid product within the solid product finishing module60and transfer all or a portion of that thermal energy to other components of the thermochemical system10(e.g., the organic material feed module20, the reactor module30, etc.) for increased efficiency. The heat exchanger/insulator62may be configured as a shell-and-tube heat exchanger utilizing air, water, or other fluids as a heat transfer fluid. Alternatively, the heat exchanger/insulator62may be configured with a vacuum or insulating gases therein to maintain the temperature of the moving mass within the solid product finishing module60.

Although temperature ranges for the various zones31a,31b,31care given above, those ranges are for illustrative purposes only and in no way limit the scope of the present disclosure unless so indicated in the following claims. The optimal temperature of any zone31a,31b,31cand/or other portion of the thermochemical system10may be dependent on various factors, including but not limited to the desired properties for the solid, liquid, and gas product stream. For example, in a configuration in which the thermochemical system is optimized to produce solid char, the temperature of the reactor module30may be relatively consistent along its entire length (e.g., at a temperature of approximately 400 C). Whereas in another configuration in which the thermochemical system is optimized to produce higher gas yields, the temperature of the reactor module30may be relatively consistent at higher temperatures approximately 800 C. For example, in a configuration in which the thermochemical system10is optimized to produce a solid product of a specific type of activated carbon, the temperature may reach as high as 1200 C in the presence of oxidizing gases to modify its surface chemistry. Table 1 below provides various product streams and ratios thereof by mass for a given feedstock and set of operational parameters for the thermochemical system10having the same components. The variety of products that may be produced and the variety of usable feedstocks serve to further demonstrate the flexibility of the thermochemical system & method according to the present disclosure.

Additionally, the properties of the solid product (e.g., carbon content, amount of volatiles, fixed carbon, ash, elemental analysis, energy content, etc.) may be modified based on other features of the thermochemical system10, which include but are not limited to unless so indicated in the following claims, organic carbon content, H:Corgratio, cation or anion exchange capacity, pH, particle density, porosity, pore size distribution, average pore size, crystallinity structure, particle size distribution, surface area, iodine number, surface area per mass, and/or adsorption capacity. The solid product may be cooled in a variety of manners, such through the use of the heat exchanger/insulator62, water spraying, addition of previously cooled material, adding combusted gaseous products with low oxygen content or inert gases in any state of matter, storing in high vacuum environments, re-condensed steam from a dryer, addition of other materials (e.g., nutrients, microbes, organic additives, pH adjusters, compost, manures, etc.) and may be further processed for storage, transport, and/or later use (e.g., grinding, pelletizing, classification, etc.). In one illustrative embodiment, the solid product may be cooled via introduction of an inert gas in a liquid or solid state of matter (e.g., liquid argon, helium, nitrogen, carbon dioxide, solid nitrogen or carbon dioxide, etc.), which may increase the safety of operating the thermochemical system10. It is contemplated that such cooling may quench and/or arrest any chemical reaction within the solid material, which may further contribute to increased safety of the thermochemical system10and method. The solid product may be allowed to be kept at high temperatures for longer periods of time and cool at a relatively slow rate, effectively increasing the residence time of the solid product within the solid product finishing module60or on a separate high temperature storage bin, which increased residence time may in turn increase the degree of carbon crystallization in the solid product.

The thermochemical system10may allow for sequestration of carbon dioxide within the solid product. When biomass is pyrolyzed at more than 350 C the carbon molecules organize in a recalcitrant carbon form which prevents microbes and abiotic factors to decompose and oxidize the solid carbon into carbon dioxide or other forms of labile carbon. This form of carbon typically is arranged in polymers of aromatic benzene rings and can stay unaltered for hundreds to thousands of years. As the plant absorbs the carbon dioxide from the air and turns it into biomass, processes such as pyrolysis carried out in the thermochemical system10can effectively “lock” that carbon contained in the biomass and turn it into a recalcitrant and stable form that could have various uses besides the carbon sequestration feature.

Additionally, the liquid, gas, and/or vapor components released at various points along the length of the various zones31a,31b,31cmay vary from one configuration of the thermochemical system10to the next. In one illustrative embodiment, the majority of liquid, gas, and/or vapor products exiting the reactor vessel33in zone one31ais moisture, which may lead to increased quality of biooil condensate in later sections/zones31a,31b,31c. The majority of liquid, gas, and/or vapor products exiting the reactor vessel33in zone two31bmay be heavier phenolic oligomers, and the majority of liquid, gas, and/or vapor products exiting the reactor vessel33in zone three31cmay be non-condensable gases.

Generally, the longer the thermochemical process is allowed to proceed on the organic material, the higher the yield of gases and/or vapors and the lower the yield of solids. It is contemplated that for many organic material feedstocks comprised of organic material, the majority of gases and/or vapors released during the thermochemical process may be combustible. However, it is contemplated that for a thermochemical system10configured with a reactor module30designed for pyrolysis, a certain amount of steam and carbon dioxide may be released throughout the process in various quantities. A portion of these gases and/or vapors may be consumed within the reactor module30and provide the energy required to sustain the thermochemical process.

Referring specifically toFIGS. 3A & 3B, which provide two cross-sectional views of two illustrative embodiments of a reactor module30, a reactor vessel33may be positioned within a vessel shroud32. The reactor vessel33may be positioned within the vessel shroud32near the geometric center of the vessel shroud32and such that the vessel shroud32surrounds or nearly surrounds the entire reactor vessel33. The vessel shroud32may be formed with one or more vents32aalong a bottom surface thereof as shown inFIGS. 2C & 2D. As shown inFIGS. 3A & 3B, the vessel shroud32may be formed such that it has a generally square cross-sectional shape whereas the reactor vessel33may have a generally circular cross-sectional shape without limitation unless otherwise indicated in the following claims. The reactor vessel33may be support by one or more support members36such that the reactor vessel33is elevated with respect to the bottom surface of the vessel shroud32.

The reactor vessel33may be formed as a pipe having a reactor conveying member37positioned therein. The reactor conveying member37may be formed as an auger but any suitable conveying member may be used without limitation unless so indicated in the following claims including but not limited to paddles, screws, belts, chain conveyors, rotating pipes and drums, etc. However, when the configuration of the thermochemical system is inclined or vertically sloped it may not require a conveying mechanism and instead gravity may provide the motive force for the organic material. In a thermochemical system10wherein the reactor vessel33is formed as a pipe, the diameter of the pipe may be from 3 to 36 inches without limitation unless so indicated in the following claims. In one embodiment, the diameter of the reactor vessel33may be 6 inches, and it is contemplated that the diameter of the reactor vessel33may affect the optimal length thereof because the diameter of the reactor vessel33may affect the reaction rate as well as the degree of conversion of the solid material to the desired product(s). Accordingly, the diameter of the reactor vessel33may be proportional to the length thereof for the specific application of the thermochemical system10. However, the reactor vessel33and reactor conveying member37may be different configured (i.e., other cross-sectional shapes, etc.) in other embodiments of the thermochemical system10without limitation unless so indicated in the following claims.

The reactor vessel33may be configured such that a certain amount of mixing of the material within the reactor vessel33occurs as the organic material moves through the reactor vessel33. For example, in one embodiment baffles may be added at various positions along the length of the reactor vessel33. Additionally, the reactor conveying member37may be configured to achieve a certain amount of mixing of the material within the reactor vessel33during operation. The reactor conveying member37may also be configured to provide discrete boundaries between various zones31a,31b,31cwithin the reactor module30, a discrete boundary between the organic material feed module20and reactor module30, and/or a discrete boundary between the reactor module30and solid product finishing module. In an embodiment wherein the feed module conveying member27, reactor conveying member37, and solid product conveying member67are formed as one continuous screw-type conveying member, multiple pieces of fighting may be incorporated on opposite sides of fighting to enhance mixing (e.g., concentric fighting portions that are diametrically opposed to one another). During operation, the gaps in the flighting portions may cause the organic material to form natural plugs, which may create a discrete boundary between modules and/or between zones31a,31c,31c. If specific boundaries are also required for various processing zones, constrictions or reduced diameters of pipe could be implemented as well as the removal for small sections of fighting to create a plug due to the non-conveying portion of the auger (i.e., the portion having flighting removed).

A shield35may be positioned around a portion of the reactor vessel33, which shield35may direct heat back towards the reactor vessel33and mitigate heat loss through the vessel shroud32. As shown inFIGS. 3A & 3B, the shield35may be curved such that it drapes over the reactor vessel33, wherein the shield35may be higher in the middle portion thereof and lower on the end portions thereof. The area between the reactor vessel33and the shield35may generally be referred to as a ventilation/combustion chamber38. The area between the shield33and the vessel shroud32may be configured with insulation positioned therein, and/or additional pipes, tubes, and/or headers through which gases, vapors, and/or liquids may pass. It is contemplated that gases released during the thermochemical process may be combusted within this chamber38, and that the thermal energy from that combustion may provide the energy required to begin, sustain, and/or drive the thermochemical process. Generally, it may be advantageous for this combustion to occur as close as possible to the reactor vessel33to provide the most efficient heat transfer possible to the reactor vessel33, and for some applications the most efficient heat transfer possible to the reactor vessel33may be for gases/vapors released through the apertures34to be combusted immediately or nearly immediately after exiting the reactor vessel33. In some applications it is contemplated that it may be advantageous for the reactor vessel33to be completed engulfed in flames from the combustions of gases/vapors released from the organic material or from an external heat source17. The reactor vessel33may also be formed with one or more fins33athereon and extending outward therefrom for increased thermal efficiencies (e.g., to increase the amount of thermal energy transferred to the reactor vessel33) from one or more heat sources, such as combustion within the ventilation/combustion chamber38. The fins33amay also aide in heat transfer to the reactor vessel33by facilitating a more turbulent flow within the ventilation/combustions chamber38.

Generally, temperature of the material within the reactor vessel may be controlled and/or manipulated through the control of air flow into the ventilation/combustion chamber38as described in further detail herein below. Typically, a greater mass flow rate of air may result in increased combustion, which may in turn result in increased temperature. Positioning pipes, tubes39, and/or headers above the shield35as shown inFIG. 3Bmay allow for the capture some of the escaping heat and may keep air in the ventilation/combustion chamber38hot for better combustion. These pipes, tubes39, and/or headers (air or gas injection) could also be positioned below shield35for maximizing the heating of the air or gases.

The configuration of the fins33amay be uniform or non-uniform along the length of the reactor vessel33. For example, when configuring the fins33ato maximize heat transfer for a specific section of the reactor vessel33, that section having higher heat transfer characteristics may result in increased yield of a specific product. For higher bio-oil yields, faster heating of the biomass is required to prevent catalysis of oils into gases. Accordingly, a thermochemical system10configured to produce a relatively high amount of bio-oil may require a reactor vessel33configured such that the rate of heat transfer to the reactor vessel33is relatively fast.

In the illustrative embodiment of a thermochemical system10, one or more blowers16may be configured to blow gases/vapors within the ventilation/combustion chamber38countercurrent to the flow of organic material. That is, the gases/vapors may move from right to left in the solid product finishing module60and/or reactor module30(and zones31a,31b, and31cthereof, respectively, in the orientation shown inFIGS. 2B & 2C(e.g., in a direction from the solid product finishing module60toward the organic material feed module20). However, in other embodiments the flow of organic material may be concurrent with respect to the flow of gases/vapors within the ventilation/combustion chamber38without limitation unless otherwise indicated in the following claims. In such an embodiment it may be advantageous to position a chimney50(in place of or in addition to the chimney50shown inFIGS. 2A-2C) adjacent the solid product finishing module60.

Any gases/vapors remaining at the interface between zone one31aand the organic material feed module20may pass into an afterburner module40. The afterburner module40may be fluidly connected to zone one31aof the reactor module30adjacent the end of zone one31aclosest to the organic material feed module20(i.e., to the right end of zone one31aas shown in the orientation inFIGS. 2B & 2C). However, as discussed below, in other illustrative embodiments the afterburner module40may be positioned closer to the solid product finishing module60. A blower16may also direct air, gas, and/or vapor flow from right to left in the afterburner module40in the orientation shown inFIGS. 2B & 2C. The afterburner module40may be fluidly connected to a chimney50at the opposite end of the afterburner module40, and the chimney50may vent to the atmosphere. The exhaust of the chimney50and/or afterburner module40may be configured with a filter or catalytic media (e.g., bag filter, solid-packed media filter such as dolomite, calcium chloride, calcium carbonate, char, activated carbon, sand, biomass, etc.) to ensure removal or destruction of unwanted compounds from the exhaust gases. Any other suitable methods and/or structures to ensure emissions control may be used, such as water spray, without limitation unless so indicated in the following claims.

Generally, the afterburner module40may receive thermal energy from an external heat source17and may be operated at a sufficient temperature to ensure that sufficient combustion occurs, such that the amount of volatile organic compounds, particulate matter, and other gases and/or vapors released to the atmosphere through the chimney50are within the applicable environmental regulatory standards. Integrating the afterburner module40with the thermochemical system10allows for a user/operator to control various emissions. For some configurations, the temperature within the afterburner module40may be controlled such that it is at least 800 C to ensure a proper level of combustion, and in other configurations it may be at least 1200 C such that the maximum amount of contaminants (e.g., volatile organic compounds, smoke, particulate material, etc.) are removed and/or combusted prior to exhausting to the atmosphere. The flow characteristics of air and gas and/or vapors from the reactor module30to the afterburner module40may be configured to lean or stoichiometric ratios and to yield a residence time of approximately two seconds (or a residence time of approximately one to six seconds) for certain applications without limitation unless otherwise indicated in the following claims.

In one embodiment, the external heat source17(e.g., a propane burner) may be positioned adjacent the interface between the organic material feeds module20and the after burner module40such that gases and/or vapors are subjected to the external heat source17immediately upon entering the afterburner module40, thereby increasing the likelihood of combusting the gases and/or vapors shortly after they have entered the afterburner module40. However, it is contemplated that after a certain amount of time (e.g., one hour) for many configurations of the thermochemical system10any external heat source17adjacent to the afterburner module40may be disengaged and the thermochemical process may proceed without aide from any external heat source17, and that the afterburner module40may maintain the desired temperature without the external heat source17active. In some configurations, a certain amount of combustion may occur within the chimney50, and in other embodiments more than one chimney50may be employed, as described in further detail below. For some configurations, a blower may assist to control the combustion process inside the afterburner.

In still other embodiments such as that shown inFIGS. 6A & 6Ban adjustable horizontal gate19bmay be positioned at the bottom of the chimney50to fluidly connect the chimney50to the reactor module (which connection may be at the portion of the ventilation/combustion chamber38adjacent the chimney50), thereby allowing an operator to adjust the flow of gases and/or vapors from the ventilation/combustion chamber38to the chimney50, which may affect the temperature of all or a portion of the reactor module30. Generally, but without limitation unless otherwise indicated in the following claims, the horizontal gate19bmay be configured as a plate that is slidable with respect to an opening such that the plate may completely cover the opening in a closed position, the plate may be slid away from the opening so as to completely expose the opening, or the plate may be positioned at any point between a fully open and fully closed position. Other suitable structures and/or methods may be used to provide a user-selected opening between a chimney50and reactor module30, an afterburner module40and a reactor module30, and/or an afterburner module40and a chimney50without limitation unless otherwise indicated in the following claims.

A similarly adjustable vertical gate19a(as shown inFIG. 2C) may be positioned between the afterburner module40and the chimney50to allow an operator to adjust the flow of gases and/or vapors from the afterburner module40to the chimney50. Alternatively, or additionally, a horizontal gate19bmay be positioned at the interface of zone one31aand the afterburner module40. Accordingly, the specific temperature, fluid connectivity, and/or configuration of the afterburner module40and chimney(s)50may vary from one environmental jurisdiction to the next and is therefore in no way limiting to the scope of the present disclosure unless so indicated in the following claims.

Generally, it is contemplated that the temperature of all or a portion of the reactor module30for a given feedstock material may be controlled using the draft, air flow characteristics into the ventilation/combustion chamber38, and feedstock material feed rate. By controlling the amount that the gate(s)19a,19bleading to the afterburner module40are open, the amount of air included in the ventilation/combustion chamber38, the inclination of the reactor vessel33within the ventilation/combustion chamber38, and the operation of the afterburner module40, the hot gases produced by the thermochemical reaction may create a draft and force those gases out of the reactor vessel33, which can be used to control the thermochemical process by controlling the temperature of various portions of the thermochemical system10. The position of the gate(s)19a,19bmay control characteristics (e.g., volumetric flow rate, linear speed, turbulence, etc.) of the combustion products as they travel through the horizontal sections30aof the reactor module30and/or afterburner module40. For example (in reference toFIGS. 2B & 2C), if the middle horizontal gate19b(under chimney50but not shown inFIGS. 2B & 2C) is opened less, combustion products may travel to the right, and with the correct amount of air (e.g., from a blower16), that may prevent further combustion, which may result in lower temperatures on right sections30a. In an extreme case, opening the middle horizontal gate19bto the maximum position may prevent gases from going through the afterburner module40as the draft produced in the chimney50may drive the combustion products to the middle horizontal gate19b.

Generally, the position of the gate(s)19a,19band control of any blowers16may allow a user/operator to manipulate the amount of combustion that takes place in the reactor module30relative to that which takes place in the afterburner module40(if present) relative to that which takes place in the chimney50so as to affect the temperature profile of the reactor module30. If a generally higher temperature is desired within the reactor module30(or a zone31,31b,31cthereof), the speed of a blower16may be increased and any gate19a,19bbetween the reactor module30and a chimney50or afterburner module40may be restricted so that more combustion occurs within the reactor module30and not within a chimney50or after burner module40. Conversely, if a generally lower temperature is desired within the reactor module30(or a zone31,31b,31cthereof), the speed of a blower16may be decreased and any gate between the reactor module30and a chimney50or afterburner module40may be opened so that more combustion occurs within a chimney50or after burner module40and not within the reactor module30. A thermochemical system10comprised of two chimneys50may allow the user to more precisely control the draft and where the combustion occurs within the reactor module30(or a zone31a,31b,31cthereof), the afterburner module40, and/or one of the chimneys50.

An illustrative embodiment of a thermochemical system10configured with two chimneys50is shown inFIG. 6A. InFIG. 6A, various external portions of the thermochemical system10have been shown as transparent so that various internal components may be visible. The same thermochemical system10is shown inFIG. 6Bwherein the chimneys50have been removed and no portions are transparent. Generally, such a thermochemical system10may include an organic material feed module20, a reactor module30, and a solid product finishing module60, and those various components may be comprised of elements that function in a manner similar to those described herein for a thermochemical system10having one chimney50. As shown inFIGS. 6A & 6B, the solid material finishing module60may be shorter in length compared to the solid material finishing module60shown for the thermochemical system10inFIGS. 2A-2D.

In an alternative embodiment shown inFIGS. 6A & 6B, the thermochemical system10may be configured with two chimneys50and no afterburner module40. Each chimney50may be fluidly connected to a portion of the reactor module30at different locations, wherein an adjustable horizontal gate19bat each interface between the chimney50and reactor module30may allow a user/operator to manipulate various operational parameters of the thermochemical process (e.g., temperature profile, combustion properties, inlet air flow characteristics, etc.). In such an embodiment, one chimney50may be positioned adjacent the interface between the organic material feed module20and the reactor module30, and a second chimney50may be positioned adjacent the interface between zone one31aand zone two31bof the reactor module30. Alternatively, the second chimney50may be positioned in zone two31bof the reactor module30in a position that corresponds to the position of the chimney50shown inFIGS. 2A-2C. It is contemplated that for certain applications, one or more chimneys50may be positioned adjacent a portion of the reactor module30with the highest or nearly the highest operating temperature along the length of the reactor module30. However, other configurations may be used without limitation unless otherwise indicated in the following claims.

The solid material may move from the reactor module30to a solid product finishing module60. The solid product finishing module60may be configured with a heat exchanger/insulator62surrounding all or a portion thereof, and a solid product outlet64formed at an end thereof opposite the reactor module30. A solid product conveying member67may provide the motive force to the solid product to urge it through the solid product finishing module60and out the solid product outlet64. The solid product conveying member67may be formed as an auger (as shown at least in the illustrative embodiment of a thermochemical system10shown inFIG. 6A) but any suitable conveying member may be used without limitation unless so indicated in the following claims including but not limited to paddles, screws, belts, chain conveyors, rotating drums, etc. The solid product may be treated in a variety of manners, including but not limited to being wasted with a solvent, water, acid, base, etc. without limitation unless so indicated in the following claims.

The function of the heat exchanger/insulator62may vary depending on the desired solid product from the thermochemical system10. If the thermochemical system10is configured to yield an activated carbon product, the temperature at least within zone three31cand the solid product finishing module60may be higher than the temperature therein if the thermochemical system10is configured to yield biochar or other carbon products. Furthermore, in a configuration configured to produce activated carbon, the length of the solid product finishing module60and heat exchanger/insulator62may be longer to increase the residence time for solid material positioned therein to ensure sufficient time for activation. The heat exchanger/insulator may act merely as an insulator for the solid material within the solid product finishing module60, thereby preventing/mitigating heat loss from the solid material to an external environment. It is contemplated that these higher temperatures may be achieved by using thermal energy from the combustion of various gases and/or vapors released during the thermochemical process as described in further detail below. Additionally, for activated carbon products the thermochemical system10may be configured such that certain additives (e.g., gases and/or vapors for oxidation, such as high-temperature steam) may be introduced to the reactor vessel33and/or solid product finishing module60. In other configurations, the heat exchanger/insulator62may function to cool the solid material within the solid product finishing module60.

In one embodiment, the reactor conveying member37may be coupled to the feed module conveying member27such that they both rotate at the same speed, and such that the motor12(which for many applications may be a variable speed motor12) engaged with the feed module conveying member27provides rotational energy to the reactor conveying member37as shown inFIG. 2B. A second motor12(which may also be configured as a variable speed motor12) may be engaged with the solid product conveying member67as shown inFIG. 2B, and the solid product conveying member67may be coupled to the reactor conveying member37such that they rotate at the same speed. In such a configuration, the torque the reactor conveying member37experiences may be reduced because the motor engaged with the feed module conveying member27may provide rotational energy to a first end of the reactor conveying member37and the motor12engaged with the solid product conveying member67may provide rotational energy to a second end of the reactor conveying member37. Furthermore, in such a configuration the feed module conveying member27, reactor conveying member37, and solid product conveying member67may be formed as one continuous conveying member (e.g., an auger) and the reactor vessel33and area around the solid product conveying member67may be formed as one continuous member (e.g., a pipe into which the continuous auger is positioned), which configuration is shown at least in the illustrative embodiment of a thermochemical system10pictured inFIGS. 6A & 6B. Such a configuration may require a common control for the two motors12to ensure they operate in unison. However, the feed module conveying member27, reactor conveying member37, solid product conveying member67, and/or the structure positioned therearound may be differently configured without limitation unless so indicated in the following claims. The residence time within the thermochemical system10may be modified by adjusting the speed of the motor(s)12engaged with the feed module conveying member27, reactor conveying member37, and solid product conveying member67.

It is contemplated that in various embodiments of a thermochemical system10, features within the reactor vessel33may affect the boundary from one module and/or zone within a module to the next. As will be evident to those skilled in the art in light of the present disclosure, the thermochemical system & method may be separated into distinct modules, regions, and/or zones. The various operational parameters of one region (e.g., temperature, combustion gases and/or characteristics, etc.) may be controlled separately and independently of another region even in the instance the two regions are adjacent one another without limitation unless so indicated in the following claims. This independent and separate control may allow for great flexibility and control over the properties of the end product(s) (solid, liquid, gas, and/or vapor).

The optimal materials for construction of the organic material feed module20, reactor module30, afterburner module40, chimney50, and solid product finishing module60and components thereof (e.g., vessel shroud32, reactor vessel33, fins33a, shield35, and/or reactor conveying member37) may vary depending at least upon the operational parameters for the thermochemical system10. For example, if the thermochemical system10is configured such that the temperature in any zone31a,31b,31creaches 700 C or higher (and in some configurations from 700 to 1300 C), it may be necessary to construct certain portions of the reactor module30and solid product finishing module60(e.g., reactor vessel33, shield35, conveying member37, solid product conveying member67) from a ceramic material, with a ceramic material coating, or other material capable of adequately withstanding such temperatures. In other configurations, metal and/or metallic-based alloys may be used such as RA253or high-temperature stainless steel. Graphite seals may be used along with high-temperature silicone (e.g., RTV) or fiberglass rope. Additionally, various insulators may be used on the reactor module30(e.g., around the exterior of the vessel shroud32) to increase the efficiency of the thermochemical system10. Accordingly, the scope of the present disclosure is in no way limited by the materials of construction for the organic material feed module20, reactor module30, afterburner module40, chimney50, and solid product finishing module60and/or components thereof and/or the placement of insulative materials therein unless otherwise indicated in the following claims.

Various components of the thermochemical system10may be elevated from the ground surface or a flooring structure using one or more support members14, which may be adjustable in height. The support members14may be configured as metallic angle or box supports. The support members14may be configured such that the inclination of the all or a portion of the thermochemical system10may be adjustable (by adjusting the height of one or more support members14relative to other support members14), which may improve natural draft and/or material flow, and which may affect the residence times of the solid material, liquids, gases, and/or vapors. However, in certain applications support members14may not be required, and in other applications they may be differently configured (e.g., bricks, earthen-based, etc.). Accordingly, the presence of support members14and/or the specific configuration thereof in no way limits the scope of the present disclosure unless so indicated in the following claims.

The thermochemical system & process may be configured such that a relatively low amount of instrumentation is required to achieve a desired result. For example, with just one temperature sensor18positioned at or near the reactor module30at the location shown inFIG. 2C, the thermochemical system10may be configured to yield a relatively consistent product. This is because with the configuration of the thermochemical system10shown inFIGS. 2A-2C, knowing the temperature near the interface between zone one31aand zone two31bof the reactor module30provides insight as to the progress and rate of the thermochemical process in zone two31b, zone three31c, and the solid product finishing module60.

Additional temperature sensors allow for increased consistency in the properties of the product(s) as well as increased efficiency of the thermochemical system10. In one embodiment, in addition to the temperature sensor18shown inFIG. 2C, a second temperature sensor18may be positioned in the first horizontal section30aof zone one31, as shown inFIG. 2B. For further control and/or efficiency, another temperature sensor may be positioned in the first horizontal section30aof the zone three31c. Additional temperature sensors18may be positioned in each horizontal section30a, in the afterburner module40, and adjacent the solid product outlet64. However, the specific number and/or position of temperature sensors18and/or any other operational parameter sensor in no way limits the scope of the present disclosure unless so indicated in the following claims. Additional sensors such as UV, carbon dioxide, carbon monoxide, nitrous oxide, pressure, soot, and/or oxygen sensors may be used, as may accelerometers, vibratory sensors, and/or other sensors without limitation unless so indicated in the following claims.

As previously discussed, an illustrative embodiment of a thermochemical system10may include one or more blowers16configured to blow gases/vapors within the ventilation/combustion chamber38countercurrent to the flow of solid material within the reactor vessel33. That is, the gases/vapors may move from right to left in the solid product finishing module60and/or reactor module30(and zones31a,31b, and31cthereof, respectively, in the orientation shown inFIGS. 2B & 2C(e.g., in a direction from the solid product finishing module60toward the organic material feed module20).

Two such blowers16are shown inFIG. 2D, where a first blower16is positioned adjacent the solid product outlet64of the solid product finishing module60and the second blower16is positioned adjacent the interface between the reactor module30and the solid product finishing module60. Each blower16may be configured with a variable speed motor such that an operator may manipulate the volumetric flow rate for each blower16. The thermochemical system10may be configured such that the temperature within various portions thereof may be controlled at least partially based on the settings of one or more blowers16, and specifically the temperature within the reactor module30and/or various zones31a,31b,31c, thereof. With all other settings approximately equal, increasing the airflow from a blower16into the ventilation/combustion chamber38(e.g., increasing the speed of the blower16) may increase the temperature within the reactor module30(and/or zones31a,31b,31c, thereof wherein combustion is occurring) while decreasing the airflow from a blower16into the ventilation/combustion chamber38may decrease the temperature within the reactor module30(and/or zones31a,31b,31c, thereof wherein combustion is occurring). Also, cooling could be performed by adding excess air in an amount greater than that needed to stoichiometrically burn the gases and/or vapors, which excess air may result in an effect similar to cooling down the reactor module.

In certain applications it may be advantageous to provide an upper limit on the allowed speed of one or more blowers16to prevent a chemical reaction within the reactor module from proceeding too fast, as increasing heat within the reactor module may increase the rate at which combustible gases/vapors are released from the organic material, which may increase the amount of combustion occurring within the reactor module30, which may increase the amount of heat therein, etc. In such applications other methods and/or apparatuses may be used to prevent a chemical reaction from occurring faster than desired without limitation unless otherwise indicated in the following claims, including but not limited to the various sensors and controllers disclosed herein.

With reference toFIGS. 2B-2D, the temperature within the ventilation/combustion chamber38may increase in a direction from the left of the figures to the right thereof (i.e., from the solid product finishing module60toward the organic material feed module20) because the blower16may provide ambient air to the solid product finishing module60, which air is then used for combustion within the reactor module30and/or afterburner module40. Accordingly, the temperature of gases within the solid product finishing module60may be less than that of gases within zone three31c, which may be less than that of gases in zone two31b, which may be less than that of gases in zone one31a. Zone one31amay be fluidly connected to the afterburner module40adjacent the right portion thereof (as shown in the orientation ofFIGS. 2B-2D) as previously described above regarding various gates19a,19band/or other methods and/or apparatuses for manipulating the fluid flow characteristics within the thermochemical system10.

Generally, it is contemplated that a thermochemical system10constructed with properly sealed joints between various elements (e.g., horizontal sections30aof the reactor module30, an interface between an afterburner module40and reactor module30, etc.) may not require gates19a,19bas described above to adequately control the temperature profile of the thermochemical system10. Instead, in such thermochemical systems10it is contemplated that the temperature profile may be controlled via one or more blowers16as previously described. This is because properly sealed joints may prevent ambient air from entering the thermochemical system10(which may occur because of a suction effect caused by a draft from combustion) and affecting combustion amount and/or rate. However, gates19a,19bmay be used on thermochemical systems10having adequately sealed joints without limitation unless otherwise indicated in the following claims.

The temperature within the reactor vessel33(and consequently the temperature of the solid material within the thermochemical system10) may have a different temperature profile along the length thereof than previously described for the gases/vapors, and the temperature of the solid material may depend at least upon the organic material feedstock and desired products. In one application the temperature of the solid material within the solid material finishing module60may be relatively low, such as 50 to 100 C, the temperature of the solid material within the reactor vessel33may increase from the solid material finishing module60to zone three31c, and may increase further from zone three31cto zone two31b, wherein the solid material may reach its peak temperature. The temperature of the solid material may decrease from zone two31bto zone one31aand decrease further from zone one31ato the solid material feed module20, wherein the solid material may be generally at ambient temperature.

Generally, configuring the thermochemical system10such that combustion of gases/vapors occurs outside of the reactor vessel33but very near thereto (i.e., in the ventilation/combustion chamber38immediately adjacent the reactor vessel33) may allow for easier and more efficient pyrolysis within the reactor vessel33. Because heating of the organic material within the reactor vessel33may provide greater than ambient pressure within the reactor vessel33, and because gases and/or vapors may be exiting the reactor vessel33through apertures34, no air (or a negligible amount of air) may enter the reactor vessel33. Additionally, controlling the temperature of the reactor module30(and/or zone31a,31b,31cthereof), which may be done by controlling the amount of combustion within the reactor module30(and/or zone31a,31b,31cthereof) may be very important to yield the desired product(s). For example, too much heat (which may be caused by too much combustion) may burn the solid material, whereas too little heat (which may be caused by too little combustion) may not sustain the desired chemical reaction such that the desired product(s) are not produced or not produced with the desired yield(s).

Referring now toFIGS. 4-5B, which provide a simplified schematic representation (or process flow diagram) of a thermochemical system & method, for illustrative purposes the thermochemical system & method may be visualized as three portions: (1) a dryer portion; (2) a reactor portion; and, (3) a finishing portion. The dryer portion may correspond to a first portion of the reactor module30(such as zone one31a, or zones one and two31a,31b), the reactor portion may correspond to a second portion of the reactor module30(such as zone two31b, or zones two and three31b,31c), and the finishing portion may correspond to the solid product finishing module60(all as previously described above). Generally, the dryer portion is shown in more detail inFIG. 5A(and is shown in the upper left-hand area ofFIG. 4) and the reactor and finishing portions are shown in more detail inFIG. 5B(wherein the reactor portion is shown in the middle ofFIG. 4and the finishing portion is shown in the lower right-hand area ofFIG. 4). For certain configurations of a thermochemical system10, a dryer portion may not be required, such as when the thermochemical system10is used with an organic material feedstock that is relatively dry initially. In such a configuration, the dryer portion may instead constitute a zone31a,31b,31cof the reactor module30.

Referring specifically toFIG. 5A, the organic material used as a feedstock for the thermochemical system10may undergo various pretreatment steps, which pretreatment steps include but are not limited to magnetic separator, sieves, screen shaker, grinder, chopper, chemical treatment (e.g., addition of catalyzing agent), and/or combinations thereof unless so indicated in the following claims. In the dryer portion, the flow of the organic material may be opposite that of the drying fluid, which drying fluid may comprise flue gas, combusted products, air, and/or combinations thereof without limitation unless so indicated in the following claims. It is contemplated that to make the thermochemical system10more efficient, it may be advantageous to use excess heat from elsewhere in the thermochemical system10(e.g., exhaust gases from the afterburner module40, which may be at a temperature between 400 and 1300 C) to aide in drying the organic material in the dryer portion as previously described above and as shown inFIG. 4. Generally, it is contemplated that it may be advantageous to provide this excess heat from elsewhere in the thermochemical system to the ventilation/combustion chamber38to facilitate a large amount of heat transfer via convection. However, other heat transfer modes and/or structures therefor may be used without limitation unless so indicated in the following claims.

As shown, a blower may be fluidly connected to the dryer portion to facilitate vapor and/or gas flow from the dryer portion. Any gas and/or vapor removed from the organic material may be condensed and/or otherwise collected for later processing, use, and/or disposal, as shown by the upward and right-facing arrow at the right-hand part of the dryer portion. In one illustrative embodiment, steam collected from the dryer portion may be used in the finishing portion as further described in detail below. In one illustrative embodiment, the exhaust from a blower pulling vapor and/or gas from the dryer portion may be routed to the afterburner module40(as shown at least inFIG. 5B).

Still referring toFIG. 5A, the dried organic material may exit the dryer portion (as represented by the downward arrow) and enter the reactor portion. As shown inFIGS. 4 and 5B, an air lock may be positioned between the dryer portion and the reactor portion. It is contemplated that when adding gas, vapor, chemicals, vacuum, etc. into the reactor portion it may be advantageous to utilize an airlock. However, the advantage of utilizing an airlock may vary at least depending on the desired properties of the final solid product and/or sensitivity of one or more products and/or the thermochemical process required to produce same to ambient environment conditions. For example, if the desired product solid product is relatively sensitive to environmental gases or needs to be air tight, a series of tight knife valves or air locks may be incorporated in both input (dryer portion) and output (activation portion) to prevent and/or mitigate egress of gases from thermochemical system10and/or ingress of air and/or moisture thereto. Accordingly, the presence of air locks is in no way limiting to the scope of the present disclosure unless so indicated in the following claims.

Referring now toFIG. 5B, the inlet ports shown in the reactor portion may be used to inject any number of substances, including but not limited to nitrogen, syngas, combustion products, steam, water, carbon dioxide, other gases, vapors, chemicals, and/or combinations thereof into the reactor vessel33and/or ventilation/combustion chamber38in a controlled and predetermined manner. Injection of a substance into the reactor vessel33and/or ventilation/combustion chamber38may serve to allow increased control of the temperature within the ventilation/combustion chamber38. By allowing a user/operator to increase the temperature within the reactor vessel33and/or ventilation/combustion chamber38, the thermochemical system10may allow the user/operate to increase the rate at which the organic material within the reactor vessel33is processed. Injection of such substances may also allow a user/operator to manipulate the thermochemical reaction in a manner that affects the chemical properties of the end products (solid, liquid, gas, and/or vapor). Depending on the desired properties of the end product(s), the substances and flow thereof may be adjusted to optimize those properties. In other illustrative embodiments of the thermochemical system10such inlet ports are not present.

Heat generated via combustion (or other exothermic chemical reactions) in the afterburner module40may be captured via a coil positioned therein, wherein a portion of the thermal energy may be transferred to a fluid medium (e.g., air, oil, water, compressed steam, etc.). Additionally, another coil may be included in the afterburner module40to further process the syngas by exposing any tar (or other relatively long chain hydrocarbons) to relatively high temperatures, which may further breakdown the tars present with the syngas. That is, the elevated temperatures may cause the tars to break down into gas products. The fluid medium may then be moved to another area of the thermochemical system10and/or externally thereto for further use. In one illustrative embodiment air may be used as a fluid medium and after it is heated in the coil of the afterburner module40it may provide additional thermal energy to the finishing portion via directly injecting the heated air via one or more injection ports formed in the reactor vessel33and/or ventilation/combustion chamber38of the solid process finishing module60and/or zone three31cof the reactor module30. Additionally, or alternatively, all or a portion of the exhaust gases from the afterburner module40may be routed (with or without a blower) to one or more injection ports formed in the solid process finishing module60.

Liquids, gases, and/or vapors may be released from the organic material in the reactor portion and collected for later use and/or disposal as shown schematically by the downward arrows extending from the thermochemical reactor inFIG. 5B. A portion of the liquids, gases, and/or vapors may be combusted in the afterburner module40. The optimal ratio of liquids, gases, and/or vapors that are collected and/or disposed of compared to those that are combusted may vary from one application of the thermochemical system10to the next, and may depend at least upon the organic material feedstock and desired properties of the solid product. Accordingly, that ratio is in no way limiting to the scope of the present disclosure unless otherwise indicated in the following claims.

The finishing portion (which corresponds to the solid product finishing module60as previously described above) may be configured to affect various properties of the solid product. For example, in one illustrative embodiment the finishing portion may be configured such that the solid product is activated carbon, and in another illustrative embodiment it may be configured such that the solid product is carbon black. In still another illustrative embodiment it may be configured such that the solid product is amorphous carbon.

The thermochemical system10may be configured such that the solid product may be dry biomass, biochar, activated carbon, black/amorphous carbon, charcoal, and/or combinations thereof, and such that the liquid, gas, and/or vapor products may be bio-oil, green chemicals such as (phenolic, furans, sugars, organic acids, etc.), syngas, energy dense gases, combusted products, and/or combinations thereof. Accordingly, the scope of the present disclosure is in no way limited by the specific solid, liquid, gas, and/or vapor product of the thermochemical system & method unless otherwise indicated in the following claims.

An airlock may be positioned adjacent the solid product outlet of the finishing portion as shown inFIG. 5B, but the advantages of such an airlock will vary from one application of the thermochemical system10to the next and the presence thereof is therefor in no way limiting to the scope of the present disclosure unless so indicated in the following claims. It is contemplated that configurations of the thermochemical system10in which it may be advantageous to remove a relatively high amount of thermal energy from the solid product after it has passed through the finishing portion may benefit from an airlock so positioned.

Liquids, gases, and/or vapors may be released from the solid material in the finishing portion, and all or a portion of those liquids, gases, and/or vapors may be routed to the afterburner module40for combustion and/or collected for later use, purification, and/or disposal.

It will be apparent to those skilled in the art in light of the present disclosure that the thermochemical system & method may be operated in a continuous manner (as opposed to a batch-style operation). Accordingly, the multiple advantages and/or features of a continuous-operation process may be imparted to the thermochemical system and method. One such advantage is that the feedstock may be processed and/or converted in a matter of minutes instead of hours, and another such advantage is that the thermochemical system10may be operated at steady state.

The reactor module30of the thermochemical system30may be configured to yield various solid, liquid, gas, and/or vapor products as previously mentioned. These various configurations may be achieved via adjusting specific operational parameters of the thermochemical system30without changing the components of the thermochemical system10, or the various configurations may be achieved via alternative combinations/configurations of the components of the thermochemical system10. The reactor module30may be configured as a pyrolysis reactor, and multiple reactions may be occurring simultaneously within different portions of the reactor module30and/or other portions of the thermochemical system10(e.g., combustion in the ventilation/combustion chamber38and/or afterburner module40, activation in the solid product finishing module60, gasification, torrefaction, carbonization, etc.). Accordingly, the scope of the present disclosure is not limited by the specific solid, liquid, gas, and/or vapor products produced by the thermochemical system & method unless otherwise indicated in the following claims.

Generally, and again with reference to Table 1 above, a thermochemical system10according to the present disclosure may be versatile in various operating conditions, with various thermochemical processes, and used to make various products from a wide variety of feedstocks. The thermochemical system10is capable of many configurations to perform drying, torrefaction, pyrolysis, gasification, activation, combustion, incineration, etc. The thermochemical system10as disclosed herein may be more efficient than those found in the prior art and simultaneously more simple to construct and/or operate than those found in the prior art, both of which advantages may primarily be due to the thermochemical system being able to sustain a thermochemical reaction without an external energy source (after an external energy source has been used to start the thermochemical reaction). Combusting gases and/or vapors emitted from the organic material immediately adjacent the reactor vessel33in the ventilation/combustion chamber38may serve to increase efficiency and simplicity of the thermochemical system10because no plumbing is required to move gases and/or vapors, nor is any plumbing required to effectuate heat transfer from the combustion of the gases to the material within the reactor vessel33.

The versatility and adaptability of the thermochemical system10may be due at least in part to the modularity of the illustrative embodiments thereof. The thermochemical system10may be configured for use as a drier utilizing one or more external heat sources17. Alternatively, the thermochemical system10may be configured for torrefaction of organic material by heating an organic feedstock to achieve dry the feedstock and sustain mild decomposition and partially transform the feedstock. The thermochemical system10may be configured for pyrolysis of an organic feedstock (which may produce a solid product comprised of biochar, a liquid product comprised of bio-oils and/or condensable gases/vapors, and a gaseous product of non-condensable gases). The thermochemical system10may be configured for gasification of an organic feedstock in applications wherein air is introduced into the reactor vessel33at various points. The thermochemical system10may be configured for activation of an organic feedstock wherein various gases, steam, and/or other chemicals may be introduced into the reactor vessel33at various points. The thermochemical system10may be configured for incineration of an organic feedstock wherein the residence time of the organic feedstock within the reactor vessel33and a sufficient quantity of air is supplied to the reactor vessel33cooperate to ensure all or nearly all organics have been burned (which may be advantageous for cleaning and recycling diatomaceous earth).

Additionally, the temperature of the ventilation/combustion chamber38and the temperature of the reactor vessel may be controlled by the amount and/or degree of combustion of gases/vapors released from the organic material in the reactor vessel is performed in the ventilation/combustion chamber38of the reactor module30relative to the amount and/or degree performed outside the reactor module30(e.g., in an afterburner module40and/or a chimney50). Controlling and/or manipulating these relative amounts and/or degrees of combustion of released gases/vapors may be done through providing additional air using one or more blowers16and/or via modifying the draft (which may be done using one or more vertical gates19aor horizontal gates19b). The position of the air inlet (either via natural fluid or from a blower16) and adjusted draft may contribute to efficient combustion of gases/vapors and simultaneously relatively clean emissions. As previously described, excess thermal energy (which may be in the form of combustion exhaust) may be used for drying a feedstock, for activating char, to provide thermal energy to other portions of the thermochemical system10, and/or to produce electricity.

The thermochemical system10as disclosed herein may provide a user with a high degree of modularity. Additional components may be added, rearranged, etc. with relative ease such that the thermochemical system10may be configured to yield different products, increase efficiency, increase safety, provide mobility, and/or accommodate different organic material feedstocks. For example, additional horizontal sections30amay be added to increase the length of the reactor vessel33(and potentially the residence time of solid material therein), the location and/or number of the chimney(s)50and afterburner module(s)40may be adjusted, etc. It is contemplated that multiple components of a thermochemical system10may be configured to be positioned within one or more standard-sized shipping containers (such as intermodal shipping containers) such that the shipping containers with the components therein may be relocated with relative ease and a minimal amount of disassembly of the thermochemical system10.

Generally, a thermochemical system10may be assembled in one “train” (e.g., one continuous system having a beginning section and an end section with one or more inputs and/or outputs along the length thereof), and a user may configure the thermochemical system10such that various processes may be completed in series using different components. For example, one thermochemical system10may be configured dry an organic material in a first section (which may constitute zone one31aof a reactor module30), cause the organic material to undergo a chemical reaction in a second section (which may constitute zone two31bof a reactor module30), cause activation of the organic material in a third section (which may constitute zone three31cof a reactor module or which may constitute a solid product finishing module60), cause cooling and/or other post treatment (e.g., adding nutrients or other chemicals, adjusting pH, etc.) in a fourth section (which may constitute another zone of a reactor module or which may constitute a solid product finishing module60), and so on. The various sections may be discreet hardware modules20,30,40,60as disclosed in detail herein, and may be rearranged, adjusted, differently configured, etc. for a specific application or specific processing requirement. This may enhance the versatility of the thermochemical system10by increasing the variety of products it may be configured to produce, by increasing the variety of feedstocks that may be used, and by increasing the range of temperatures that may be achieved at various points within the thermochemical system10. Additionally, the modularity and discreetness of the hardware modules20,30,40,60may allow for a relatively mobile thermochemical system10by easing transportation and adaptation to various configurations.

The thermochemical system10may be integrated with batteries, generators, solar panels, an electrical grid, etc. in remote locations due to the modularity and simplicity of the design. Additionally, multiple thermochemical systems10may be employed in parallel to increase the scale. In one configuration, another module (all or a portion of which also may be positioned in a shipping container, such as an intermodal container) may constitute an electricity generation module70(shown schematically inFIG. 5C), in which an internal combustion (alternatively, micro turbines, Peltier, Rankine cycle or heat engine) may be located. The electricity generation module70may provide electricity for various components of the thermochemical system10(e.g., motor(s)12, external heat sources17, etc.) or to external devices, such as an electrical grid as mentioned above. The electricity generation module70may be operated with syngas, fossil fuels (e.g., propane, diesel, gasoline) or other fuels without limitation unless so indicated in the following claims.

The thermochemical system10may be equipped with one or more communication modules such that certain aspects of the thermochemical system10may be remotely operated and/or controlled. Such a communication module may be wireless (e.g., 2G, 3G, 4G, or 5G mobile protocols, WiFi protocols, Bluetooth, etc.) and may also facilitate automated data logging, increased security via virtual private network (VPN) and remote lockouts and/or video cameras, automated SMS or email messages in certain situations, etc.

As a continuous process, the thermochemical system10may be fully automated from startup to shutdown. For example, with a sufficient supply of feedstock on hand, the user/operator may simply engage a start button that engages an external heat source17to begin the combustion and/or reaction, which may also engage one or more motors12on the various conveying members27,37,67, and which may also engage one or more blowers to use heat generated by the thermochemical process in an efficient way within the thermochemical system10. The control of gases and/or vapors (e.g., syngas) released within the organic material feed module20and/or reactor module30and combustion thereof may be automated via temperature sensors, blowers, and draft control, which may allow a user/operator to achieve a desired level of emissions.

The thermochemical system & method may be safer to operate than those of the prior art. Various factors that may lead to increases safety include but are not limited to: (1) the entire thermochemical system10may operate at ambient or near-ambient pressure (which also reduces the cost of the thermochemical system10compared to reactors that require one or more pressure-rated vessels); (2) various components of the thermochemical system10may be positioned within a structure (e.g., a standard-sized, intermodal shipping container) and the access to that structure may be controlled; (3) the power requirements for the entire thermochemical system (e.g., thermal energy to start the reaction and/or combustion of gases and/or vapors, electrical energy to power the feed module conveying member27, reactor conveying member37, solid product conveying member67, etc.) may be relatively low; and, (4) the operation of the thermochemical system & method may be entirely automated.

As will be evident to those skilled in the art in light of the present disclosure, the thermochemical system & method may be separated into distinct modules, regions, and/or zones. The various operational parameters of one region (e.g., temperature, combustion gases and/or characteristics, etc.) may be controlled separately and independently of another region even in the instance the two regions are adjacent one another without limitation unless so indicated in the following claims. This independent and separate control may allow for great flexibility and control over the properties of the end product(s) (solid, liquid, gas, and/or vapor).

Although specific operating parameters or ranges of operating parameters for the organic material feed module20, reactor module30, zones31a,31b, and/or31cthereof (e.g., temperature, pressure), afterburner module40, chimney50, and solid product finishing module60are provided above, such parameters are for illustrative purposes only and in no way limit the scope of the present disclosure unless so indicated in the following claims. Additionally, the border between one zone31a,31b, and/or31cand another zone31a,31b, and/or31c, between the organic material feed module20and reactor module30, and/or between the reactor module30and solid product finishing module60may not be discrete, and the precise transition from one zone31a,31b, and/or31cto an adjacent zone31a,31b, and/or31c, from the organic material feed module20to the reactor module30, and/or from the reactor module30to solid product finishing module60may vary during a single thermochemical process, and is therefore in no way limiting to the scope of the present disclosure unless so indicated in the following claims. Furthermore, drying, thermochemical reactions, combustion, and/or other processes may occur to a certain extent in any zone31a,31b, and/or31cand/or module20,30,60without limitation unless so indicated in the following claims.

The thermochemical system & method as disclosed herein may be configured to yield a variety of gas, liquid, and solid products. Such gas products include but are not limited to biogases, and such liquid products include but are not limited to biooils. The solid products include but are not limited to char, biochar, activated carbon, carbon black, amorphous carbon, graphite, and/or combinations thereof. The solid product stream may comprise from 5-40% by weight of the total product stream, liquids (including but not limited to biooils) may comprise 0-70% thereof, and gases and/or vapors may comprise 15-95% thereof.

The thermochemical system and method disclosed herein may be configured to recycle thermal energy released in one portion of the thermochemical system to another portion of the thermochemical system for increased efficiency. Integrating the dryer portion (e.g., zone one31a, or zone one31aand a portion of zone31b) with the thermochemical system10allows for a local use of thermal energy that might otherwise be wasted. The various thermal energy recycling schemes for increased efficiency may be utilized independently from one another and to varying degrees without limitation unless so indicated in the following claims. Furthermore, the components required for a thermochemical system10according to the present disclosure may be considerably less expensive than the components of the prior art (including but not limited to the necessary instrumentation as previously described above).

It is understood that the present disclosure extends to all alternative combinations of one or more of the individual features mentioned, evident from the text and/or drawings, and/or inherently disclosed. All of these different combinations constitute various alternative aspects of the present disclosure and/or components thereof. The embodiments described herein explain the best modes known for practicing the apparatuses, methods, and/or components disclosed herein and will enable others skilled in the art to utilize the same. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.

The materials used to construct the apparatuses and/or components thereof for a specific process will vary depending on the specific application thereof, but it is contemplated that polymers, synthetic materials, metals, metal alloys, ceramics, natural materials, and/or combinations thereof may be especially useful in some applications. Accordingly, the above-referenced elements may be constructed of any material known to those skilled in the art or later developed, which material is appropriate for the specific application of the present disclosure without departing from the spirit and scope of the present disclosure unless so indicated in the following claims.

Having described preferred aspects of the various processes, products produced thereby, and/or apparatuses, other features of the present disclosure will undoubtedly occur to those versed in the art, as will numerous modifications and alterations in the embodiments and/or aspects as illustrated herein, all of which may be achieved without departing from the spirit and scope of the present disclosure. Accordingly, the methods and embodiments pictured and described herein are for illustrative purposes only, and the scope of the present disclosure extends to all processes, apparatuses, products, and/or structures for providing the various benefits and/or features of the present disclosure unless so indicated in the following claims.

While the thermochemical system & method, process steps, components thereof, apparatuses therefor, and products produced thereby have been described in connection with preferred aspects, illustrative embodiments, and specific examples, it is not intended that the scope be limited to the particular embodiments and/or aspects set forth, as the embodiments and/or aspects herein are intended in all respects to be illustrative rather than restrictive. Accordingly, the apparatuses, methods, processes, and embodiments pictured and described herein are no way limiting to the scope of the present disclosure unless so stated in the following claims.

Although several figures are drawn to accurate scale, any dimensions provided herein are for illustrative purposes only and in no way limit the scope of the present disclosure unless so indicated in the following claims. It should be noted that the thermochemical system & method, apparatuses and/or equipment therefor, and/or products produced thereby are not limited to the specific embodiments pictured and described herein, but rather the scope of the inventive features according to the present disclosure is defined by the claims herein. Modifications and alterations from the described embodiments will occur to those skilled in the art without departure from the spirit and scope of the present disclosure.

Any of the various features, components, functionalities, advantages, aspects, configurations, process steps, process parameters, etc. of a thermochemical system & method may be used alone or in combination with one another depending on the compatibility of the features, components, functionalities, advantages, aspects, configurations, process steps, process parameters, etc. Accordingly, a nearly infinite number of variations of the present disclosure exist. Modifications and/or substitutions of one feature, component, functionality, aspect, configuration, process step, process parameter, etc. for another in no way limit the scope of the present disclosure unless so indicated in the following claims.