IP Library › Granted Patent US 12,291,760
Granted Patent B2
US 12,291,760 · App. 17/485,365 · Granted May 6, 2025

Bio-reduction of metal ores integrated with biomass pyrolysis

Inventors: James A. Mennell (Brighton, UT); Daren Daugaard (Newburg, MO); Dustin Slack (Gwinn, MI)
Assignee: Carbon Technology Holdings, LLC
C22B1/2406C10B53/02C21B5/008C21B13/004C22B1/005C22B5/12C22B15/0021C22B23/02
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Quick Facts
Patent No.
US 12,291,760
App. No.
17/485,365
Granted
May 6, 2025
Kind
B2
Abstract

Some variations provide a composition for reducing a metal ore, the composition comprising a carbon-metal ore particulate, wherein the carbon-metal ore particulate comprises at least about 0.1 wt % to at most about 50 wt % fixed carbon on a moisture-free and ash-free basis, and wherein the carbon is at least 50% renewable carbon as determined from a measurement of the 14 C/ 12 C isotopic ratio. Some variations provide a process for reducing a metal ore, comprising: providing a biomass feedstock; pyrolyzing the feedstock to generate a biogenic reagent comprising carbon and a pyrolysis off-gas comprising hydrogen or carbon monoxide; obtaining a metal ore comprising a metal oxide; combining the carbon with the metal ore, to generate a carbon-metal ore particulate; optionally pelletizing the carbon-metal ore particulate; and utilizing the pyrolysis off-gas to chemically reduce the metal oxide to elemental metal, such as iron.

Claims (20)

1. A composition for reducing a metal ore, the composition comprising a carbon-metal ore particulate, wherein the carbon-metal ore particulate comprises at least about 0.1 wt % to at most about 50 wt % fixed carbon on a moisture-free and ash-free basis; and wherein the fixed carbon is at least about 50% renewable carbon as determined from a measurement of the 14 C/ 12 C isotopic ratio of the carbon.

2. The composition of claim 1 , wherein the measurement of the 14 C/ 12 C isotopic ratio of the fixed carbon utilizes ASTM D6866.

3. The composition of claim 1 , wherein the metal ore is selected from iron ore, copper ore, nickel ore, magnesium ore, manganese ore, aluminum ore, tin ore, zinc ore, cobalt ore, chromium ore, tungsten ore, molybdenum ore, or a combination thereof.

4. The composition of claim 1 , wherein the metal ore is iron ore.

5. The composition of claim 1 , wherein the metal ore is a combination of copper ore and nickel ore.

6. The composition of claim 1 , wherein the composition is in the form of objects selected from fines, lumps, pellets, nuggets, or a combination thereof.

7. The composition of claim 1 , wherein the carbon-metal ore particulate comprises at least about 0.5 wt % to at most about 25 wt % fixed carbon on a moisture-free and ash-free basis.

8. The composition of claim 7 , wherein the carbon-metal ore particulate comprises at least about 1 wt % to at most about 15 wt % fixed carbon on a moisture-free and ash-free basis.

9. The composition of claim 8 , wherein the carbon-metal ore particulate comprises at least about 2 wt % to at most about 10 wt % fixed carbon on a moisture-free and ash-free basis.

10. The composition of claim 9 , wherein the carbon-metal ore particulate comprises at least about 3 wt % to at most about 6 wt % fixed carbon on a moisture-free and ash-free basis.

11. The composition of claim 1 , wherein the fixed carbon is at least about 90% renewable carbon as determined from measuring the 14 C/ 12 C isotopic ratio of the carbon.

12. The composition of claim 11 , wherein the fixed carbon is at least about 99% renewable carbon as determined from measuring the 14 C/ 12 C isotopic ratio of the carbon.

13. The composition of claim 12 , wherein the fixed carbon is about 100% renewable carbon as determined from measuring the 14 C/ 12 C isotopic ratio of the carbon.

14. The composition of claim 1 , wherein the carbon-metal ore pellet comprises an additive.

15. The composition of claim 14 , wherein the additive comprises a binder.

16. The composition of claim 1 , wherein the carbon-metal ore pellet consists essentially of carbon and the metal ore.

17. The composition of claim 1 , wherein the fixed carbon is characterized by a BET surface area of at least 400 m 2 /g.

18. The composition of claim 17 , wherein the fixed carbon is characterized by a BET surface area of at least 800 m 2 /g.

19. The composition of claim 1 , wherein the fixed carbon is characterized by a mesopore volume of at least 0.5 cm 3 /g.

20. The composition of claim 19 , wherein the fixed carbon is characterized by a mesopore volume of at least 1 cm 3 /g.

Assignments (5)
SECURITY INTEREST Recorded Feb 5, 2025
From: CARBON TECHNOLOGY HOLDINGS, LLC
To: ALTER DOMUS (US) LLC
Reel/Frame 070114/0775 →
RELEASE OF SECURITY INTEREST Recorded Feb 4, 2025
From: FORTRESS CREDIT CORP.
To: CARBON TECHNOLOGY HOLDINGS, LLC
Reel/Frame 070608/0239 →
SECURITY INTEREST Recorded Feb 12, 2024
From: CARBON TECHNOLOGY HOLDINGS, LLC
To: FORTRESS CREDIT CORP.
Reel/Frame 066552/0001 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 18, 2022
From: MENNELL, JAMES A.; DAUGAARD, DAREN; SLACK, DUSTIN
To: CARBON TECHNOLOGY HOLDINGS, LLC
Reel/Frame 058674/0528 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 16, 2021
From: MENNELL, JAMES A.; DAUGAARD, DAREN; SLACK, DUSTIN
To: CARBON TECHNOLOGY HOLDINGS, LLC
Reel/Frame 058119/0218 →
Continuity (2)
Provisional Application 63083223 · Sep 25, 2020
Related Publication 20220098685A1 · Mar 31, 2022
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