IP Library › Granted Patent US 12,404,455
Granted Patent B2
US 12,404,455 · App. 17/731,194 · Granted Sep 2, 2025

Biocarbon blends with optimized fixed carbon content, and methods for making and using the same

Inventors: James A Mennell (Brighton, UT); Dustin Slack (Gwinn, MI); Daren Daugaard (Newburg, MO)
Assignee: Carbon Technology Holdings, LLC
C10B53/02C04B35/532C04B35/62204C04B35/62695C04B35/636C10B57/02C10B57/06C10B57/10C04B2235/422C04B2235/48
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Quick Facts
Patent No.
US 12,404,455
App. No.
17/731,194
Granted
Sep 2, 2025
Kind
B2
Abstract

In some variations, the invention provides a biocarbon composition comprising a low fixed carbon material with a fixed carbon concentration from 20 wt % to 55 wt %; a high fixed carbon material with a fixed carbon concentration from 50 wt % to 100 wt % (and higher than the fixed carbon concentration of the low fixed carbon material; from 0 to 30 wt % moisture; from 0 to 15 wt % ash; and from 0 to 20 wt % of one or more additives (such as a binder). Some variations provide a process for producing a biocarbon composition, the process comprising: pyrolyzing a first biomass-containing feedstock to generate a low fixed carbon material; separately pyrolyzing a second biomass-containing feedstock to generate a high fixed carbon material; blending the low fixed carbon material with the high fixed carbon material, thereby generating an intermediate material; optionally, blending one or more additives into the intermediate material; optionally, drying the intermediate material; and recovering a biocarbon composition containing the intermediate material or a thermally treated form thereof.

Claims (55)

1. A biocarbon composition comprising:

(a) at least about 1 wt % to at most about 99 wt % of a low-fixed-carbon material, wherein the low-fixed-carbon material comprises a first fixed-carbon concentration, and wherein the first fixed-carbon concentration is at least about 10 wt % to at most about 55 wt % fixed carbon on an absolute basis;

(b) at least about 1 wt % to at most about 99 wt % of a high-fixed-carbon material, wherein the high-fixed carbon material comprises a second fixed-carbon concentration, wherein the second fixed-carbon concentration is at least about 50 wt % to at most about 100 wt % fixed carbon on an absolute basis, and wherein the second fixed-carbon concentration is greater than said first fixed-carbon concentration;

(c) at least 0 wt% to at most about 30 wt% moisture;

(d) at least 0 wt% to at most about 15 wt% ash; and

(e) at least 0 wt% to at most about 20 wt% of one or more additives.

2. The biocarbon composition of claim 1 , wherein said low-fixed-carbon material and said high-fixed-carbon material are present in said biocarbon composition as a homogenous physical blend.

3. The biocarbon composition of claim 1 , wherein said first fixed-carbon concentration is uniform throughout said biocarbon composition.

4. The biocarbon composition of claim 1 , wherein said second fixed-carbon concentration is uniform throughout said biocarbon composition.

5. The biocarbon composition of claim 1 , wherein said first fixed-carbon concentration and said second fixed-carbon concentration are both uniform throughout said biocarbon composition.

6. The biocarbon composition of claim 1 , wherein said low-fixed-carbon material and said high-fixed-carbon material are present in said biocarbon composition as a heterogeneous physical blend.

7. The biocarbon composition of claim 1 , wherein said low-fixed-carbon material and said high-fixed-carbon material are present in said biocarbon composition as distinct layers.

8. The biocarbon composition of claim 1 , wherein the low-fixed-carbon material is comprised within a shell or a coating around a core, wherein the core comprises the high-fixed-carbon material.

9. The biocarbon composition of claim 1 , wherein the high-fixed-carbon material is comprised within a shell or a coating around a core, wherein the core comprises the low-fixed-carbon material.

10. The biocarbon composition of claim 1 , wherein said high-fixed-carbon material is in the form of particulates in a continuous phase of said low-fixed-carbon material.

11. The biocarbon composition of claim 1 , wherein said low-fixed-carbon material is in the form of particulates in a continuous phase of said high-fixed-carbon material.

12. The biocarbon composition of claim 1 , wherein the biocarbon composition comprises at least about 10 wt% to at most about 90 wt% of the low-fixed-carbon material.

13. The biocarbon composition of claim 1 , wherein the biocarbon composition comprises at least about 10 wt% to at most about 90 wt% of the high-fixed-carbon material.

14. The biocarbon composition of claim 1 , wherein a weight ratio of the low-fixed-carbon material to the high-fixed-carbon material is at least about 0.1 to at most about 10.

15. The biocarbon composition of claim 1 , wherein the first fixed-carbon concentration is at least about 15 wt% to at most about 40 wt%.

16. The biocarbon composition of claim 1 , wherein the first fixed-carbon concentration is at least about 20 wt% to at most about 50 wt%.

17. The biocarbon composition of claim 1 , wherein the first fixed-carbon concentration is at least about 30 wt% to at most about 55 wt%.

18. The biocarbon composition of claim 1 , wherein the second fixed-carbon concentration is at least about 80 wt% to at most about 100 wt%.

19. The biocarbon composition of claim 1 , wherein the second fixed-carbon concentration is at least about 70 wt% to at most about 95 wt%.

20. The biocarbon composition of claim 1 , wherein the second fixed-carbon concentration is at least about 60 wt% to at most about 90 wt%.

21. The biocarbon composition of claim 1 , wherein an unweighted average of the first fixed-carbon concentration and said second fixed-carbon concentration is at least about 30 wt% to at most about 90 wt%.

22. The biocarbon composition of claim 1 , wherein the biocarbon composition contains an overall fixed-carbon concentration of at least about 25 wt% to at most about 95 wt% on an absolute basis.

23. The biocarbon composition of claim 1 , wherein the low-fixed-carbon material contains at least about 45 wt % to at most about 80 wt% volatile carbon on an absolute basis.

24. The biocarbon composition of claim 1 , wherein the high-fixed-carbon material contains at least about 0 to at most about 50 wt% volatile carbon on an absolute basis.

25. The biocarbon composition of claim 1 , wherein the biocarbon composition comprises at least about 0.1 wt% to at most about 20 wt% moisture.

26. The biocarbon composition of claim 1 , wherein the biocarbon composition comprises at least about 0.1 wt% to at most about 10 wt% ash.

27. The biocarbon composition of claim 1 , wherein the biocarbon composition comprises at least about 0.1 wt% to at most about 18 wt% of the one or more additives.

28. The biocarbon composition of claim 1 , wherein the one or more additives comprise a renewable material.

29. The biocarbon composition of claim 1 , wherein the one or more additives comprise a material that is capable of being partially oxidized or combusted.

30. The biocarbon composition of claim 1 , wherein the one or more additives comprise a binder.

31. The biocarbon composition of claim 30 , wherein said binder is selected from starch, thermoplastic starch, crosslinked starch, starch polymers, cellulose, cellulose ethers, hemicellulose, methylcellulose, chitosan, lignin, lactose, sucrose, dextrose, maltodextrin, banana flour, wheat flour, wheat starch, soy flour, corn flour, wood flour, coal tars, coal fines, met coke, asphalt, coal-tar pitch, petroleum pitch, bitumen, pyrolysis tars, gilsonite, bentonite clay, borax, limestone, lime, waxes, vegetable waxes, baking soda, baking powder, sodium hydroxide, potassium hydroxide, iron ore concentrate, silica fume, gypsum, Portland cement, guar gum, xanthan gum, polyvidones, polyacrylamides, polylactides, phenol-formaldehyde resins, vegetable resins, recycled shingles, recycled tires, derivatives thereof, or any combinations of the foregoing.

32. The biocarbon composition of claim 31 , wherein said binder is selected from starch, thermoplastic starch, crosslinked starch, starch polymers, derivatives thereof, or any combinations of the foregoing.

33. The biocarbon composition of claim 1 , wherein the one or more additives reduce the reactivity of said biocarbon composition compared to an otherwise-equivalent biocarbon composition that does not comprise the one or more additives.

34. The biocarbon composition of claim 33 , wherein the biocarbon composition has lower self-heating compared to the otherwise-equivalent biocarbon composition that does not comprise the one or more additives.

35. The biocarbon composition of claim 1 , wherein the one or more additives is present and is pore-filling within the low-fixed-carbon material.

36. The biocarbon composition of claim 1 , wherein the one or more additives is present and is pore-filling within the high-fixed-carbon material.

37. The biocarbon composition of claim 1 , wherein the one or more additives is present and is pore-filling within both of said low-fixed-carbon material and the high-fixed-carbon material.

38. The biocarbon composition of claim 1 , wherein the one or more additives is present and is disposed on an outer surface of the biocarbon composition.

39. The biocarbon composition of claim 1 , wherein the one or more additives is comprised within the low-fixed-carbon material or the high-fixed-carbon material.

40. The biocarbon composition of claim 1 , wherein said biocarbon composition is in the form of powder.

41. The biocarbon composition of claim 1 , wherein said biocarbon composition is in the form of pellets.

42. The biocarbon composition of claim 41 , wherein the one or more additives comprise a binder.

43. The biocarbon composition of claim 41 , wherein said pellets utilize said low-fixed-carbon material as a binder within said pellets.

44. The biocarbon composition of claim 41 , wherein the pellets are characterized by a Hardgrove Grindability Index of at least about 30 to at most about 100.

45. The biocarbon composition of claim 41 , wherein said pellets are characterized by a Pellet Durability Index of at least about 80%.

46. The biocarbon composition of claim 1 , wherein said biocarbon composition is characterized as non-self-heating when subjected to a self-heating test according to Manual of Tests and Criteria , Seventh revised edition 2019, United Nations, Page 375, 33.4.6 Test N.4: “Test method for self-heating substances”.

47. The biocarbon composition of claim 1 , wherein at least one of the low-fixed-carbon material or the high-fixed-carbon material comprises biogenic carbon.

48. The biocarbon composition of claim 47 , wherein the low-fixed-carbon material is selected from unpyrolyzed biomass, pyrolyzed biomass, unpyrolyzed polymers, pyrolyzed polymers, coal, pyrolyzed coal, or a combination thereof.

49. The biocarbon composition of claim 47 , wherein the high-fixed-carbon material is selected from pyrolyzed biomass, coal, pyrolyzed coal, coke, petroleum coke, metallurgical coke, activated carbon, carbon black, graphite, graphene, pyrolyzed polymers, or a combination thereof.

50. The biocarbon composition of claim 1 , wherein total carbon is at least 50% renewable as determined from a measurement of the 14 C/ 12 C isotopic ratio of said total.

Assignments (4)
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 Sep 26, 2022
From: MENNELL, JAMES A.; SLACK, DUSTIN; DAUGAARD, DAREN
To: CARBON TECHNOLOGY HOLDINGS, LLC
Reel/Frame 061210/0727 →
Continuity (2)
Provisional Application 63180240 · Apr 27, 2021
Related Publication 20220396529A1 · Dec 15, 2022
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