Biochar aggregate particles

• US 10,322,389 B2
• Filed: 02/02/2017
• Issued: 06/18/2019
• Est. Priority Date: 10/01/2014
• Status: Active Grant

• Current Assignee: Carbon Technology Holding LLC
• Original Assignee: Cool Planet Energy Systems, Inc.
• Inventors: Malyala, Rajashekharam, Traxler, Vern, Smith, Matthew William, Kim, Han Suk, Bontchev, Ranko Panayotov, Belcher, Richard Wilson
• Primary Examiner(s): Langel, Wayne A
• Application Number:
  US15/423,563
• Publication Number:
  US 20170197192A1
• Time in Patent Office: 866 Days
• Field of Search: None
• CPC Class Codes: A23K 10/30 from material of plant origin, e.g. roots, seeds or hay; from material of fungal origin, e.g. mushrooms obtained by microbiological or biochemical processes, e.g. using yeasts or enzymes, A23K10/10
• CPC Class Codes: A23K 20/10 Organic substances
• CPC Class Codes: A23K 20/158 Fatty acids; Fats; Products containing oils or fats
• CPC Class Codes: A23K 20/163 Sugars; Polysaccharides
• CPC Class Codes: A23K 20/20 Inorganic substances, e.g. oligoelements
• CPC Class Codes: A23K 20/28 Silicates, e.g. perlites, zeolites or bentonites
• CPC Class Codes: A23K 20/30 Oligoelements
• CPC Class Codes: A23K 40/10 by agglomeration; by granulation, e.g. making powders
• CPC Class Codes: A23K 50/90 for insects, e.g. bees or silkworms
• CPC Class Codes: A61K 33/44 Elemental carbon, e.g. charcoal, carbon black
• CPC Class Codes: A61K 9/1611 Inorganic compounds
• CPC Class Codes: A61K 9/1652 Polysaccharides, e.g. alginate, cellulose derivatives; Cyclodextrin homeopathic globules A61K9/1623
• CPC Class Codes: A61K 9/1682 Processes
• CPC Class Codes: A61L 9/012 characterised by being in a special form, e.g. gels, emulsions A61L9/048 takes precedence
• CPC Class Codes: A61L 9/014 containing sorbent material, e.g. activated carbon
• CPC Class Codes: B01J 2/00 Processes or devices for granulating materials , e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
• CPC Class Codes: B01J 2/12 in rotating drums
• CPC Class Codes: B01J 2/28 using special binding agents
• CPC Class Codes: B01J 20/12 Naturally occurring clays or bleaching earth
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/24 : Naturally occurring macromolecular compounds, e.g. humic acids or their derivatives
• CPC Class Codes: B01J 20/28019 : Spherical, ellipsoidal or cylindrical
• CPC Class Codes: B01J 20/3007 : Moulding, shaping or extruding
• CPC Class Codes: B01J 20/3028 : Granulating, agglomerating or aggregating
• CPC Class Codes: B01J 20/3042 : Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent
• CPC Class Codes: B01J 20/3078 : Thermal treatment, e.g. calcining or pyrolizing
• CPC Class Codes: C01B 32/05 : Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
• CPC Class Codes: C05B 17/00 : Other phosphatic fertilisers, e.g. soft rock phosphates, bone meal
• CPC Class Codes: C05C 5/00 : Fertilisers containing other nitrates
• CPC Class Codes: C05D 9/00 : Other inorganic fertilisers
• CPC Class Codes: C05F 11/00 : Other organic fertilisers
• CPC Class Codes: C05G 3/80 : Soil conditioners
• CPC Class Codes: C05G 5/12 : Granules or flakes
• CPC Class Codes: C09K 17/04 : applied in a physical form other than a solution or a grout, e.g. as granules or gases
• CPC Class Codes: C09K 17/48 : Organic compounds mixed with inorganic active ingredients, e.g. polymerisation catalysts
• CPC Class Codes: C09K 17/50 : the organic compound being of natural origin, e.g. cellulose derivatives

Abstract

Biochars and methods for producing biochar aggregate particles where the method for producing the aggregate particles comprise the steps of (i) producing or collecting biochar fines; (ii) adding a binding agent to the biochar fines; and (iii) forming the biochar fines and binding agent into solid aggregate particles.

Claims

1. A method for producing biochar aggregate particles, the method comprising the steps of (i) producing or collecting biochar fines;

(ii) treating the biochar fines with a surfactant solution (iii) adding a binding agent to the biochar fines; and

(iv) forming the biochar fines and binding agent into solid aggregate particles.

2. The method of claim 1 where a dewatering step follows the addition of a binding agent to create a biochar paste and the biochar paste is then formed into solid aggregate particles.

3. The method of claim 2 where the step of forming the biochar paste into solid aggregate particles includes passing the biochar paste through an extruder.

4. The method of claim 2 where the step of forming the biochar paste into solid aggregate particles includes creating a biochar pellet.

5. The method of claim 2 where the step of forming the biochar paste into solid aggregate particles includes creating a biochar agglomeration.

6. The method of claim 1 where the fines are produced and collected to be a generally uniform size to maintain biochar pore structure.

7. The method of claim 1 where the binding agent is a starch.

8. The method of claim 1 where the binding agent is a clay.

9. The method of claim 1 where the binding agent includes a polymer, lignin or cellulose.

10. The method of claim 1 further including the step of drying the aggregate particles.

11. The method of claim 10 where the step of drying the aggregate particles includes air drying the particles.

12. The method of claim 1 further including the step of adding an additive to either the fines or the aggregate particles.

13. The method of claim 1, where the produced or collected biochar fines are treated by infusing a liquid into the pores of the biochar fines.

14. The method of claim 1, where the produced or collected biochar fines are treated using centrifuge extraction.

15. The method of claim 1, where the produced or collected biochar fines are treated using a vacuum.

16. A method for producing biochar aggregate particles, the method comprising the steps of (i) collecting biochar fines;

(ii) adding a binding agent and a surfactant solution to the biochar fines;

(iii) adding an additive to the biochar fines;

(iv) de-watering the fines to yield a biochar paste;

(v) heat activating the binding agent;

(vi) passing the biochar paste through an extruder to yield aggregate particles; and

(vii) drying the aggregate particles.

17. The method of claim 16 where the step of collecting the fines further includes treating the fines with a pH adjusting solution.

18. The method of claim 16 where the binding agent and additive are in solution together and added to the biochar fines.

19. The method of claim 16 where 95% of the biochar fines are between 0.1-0.5 mm in equivalent diameter.

20. A method for producing biochar aggregate particles, the method comprising the steps of (i) collecting treated biochar fines where the treated biochar fines are collected in a solution used to treat a batch of biochar;

(ii) separating the treated fines from the solution (iii) adding a binding agent to the fines;

(iv) forming the fines and binding agent into solid aggregate particles; and

(v) drying the solid aggregate particles.

21. The method of claim 20 where the step of forming the fines and binding agent into solid particles is performed by a processor which is an extruder, a pelletizer, a briquetter, a granulator or other system capable of forming the paste into solid shapes.

22. A method for producing biochar aggregate particles, the method comprising the steps of (i) collecting biochar fines;

(ii) adding a binding agent to the fines;

(iii) de-watering the fines to yield a biochar paste;

(v) freezing the biochar paste and passing the biochar paste through a processor to create solid aggregate particles; and

(vi) drying the solid aggregate particles.

23. The method of claim 22 where freezing the biochar paste includes lyophilizing the paste.

24. A method for producing biochar aggregate particles, the method comprising the steps of (i) producing or collecting biochar fines;

(ii) adding a binding agent and surfactant solution to the biochar fines;

(iii) de-watering the biochar fines to create a biochar paste; and

(vi) forming the biochar paste into solid aggregate particles in the shape of spikes.

25. A method for producing biochar aggregate particles, the method comprising the steps of grinding biochar into a powder and mixing the powder in a rotary drum with a binder and a surfactant solution to create spherical biochar aggregate particles.

26. A method for producing biochar aggregate particles comprising:

drying and grinding raw or treated biochar fines and/or larger biochar particles into smaller particle sizes or powder and mixing the smaller particle sizes or powder with a binder, water and a surfactant in a rotary drum to create uniform spherical biochar aggregate particles.

27. A method for producing biochar aggregate particles, the method comprising the steps of (i) collecting biochar fines;

(ii) adding a binding agent and a surfactant solution to the biochar fines;

(iii) forming the biochar fines, binding agent and surfactant solution into aggregate particles; and

(vi) drying the aggregate particles.