PRODUCING BIOCARBON PELLETS WITH HIGH FIXED-CARBON CONTENT AND OPTIMIZED REACTIVITY, AND BIOCARBON PELLETS OBTAINED THEREFROM

1 . A process for producing a biocarbon pellet, the process comprising:

(a) pyrolyzing, in a first pyrolysis reactor, a biomass-containing feedstock, thereby generating a first biogenic reagent and a pyrolysis vapor;

(b) introducing, to a separation unit, the pyrolysis vapor, thereby generating a pyrolysis precipitate, wherein the pyrolysis precipitate is in liquid, solid, or slurry form;

(c) contacting the first biogenic reagent with the pyrolysis precipitate, thereby generating an intermediate material, wherein the intermediate material comprises the first biogenic reagent and the pyrolysis precipitate;

(d) pelletizing the intermediate material, thereby generating an intermediate pellet;

(e) optionally, drying the intermediate pellet;

(f) separately from step (a), pyrolyzing, in a second pyrolysis reactor, the intermediate pellet, thereby generating a second biogenic reagent and a pyrolysis off-gas, wherein the first pyrolysis reactor and the second pyrolysis reactor are the same reactor or distinct reactors; and

(g) recovering the second biogenic reagent as a biocarbon pellet,

wherein a fixed carbon content of the second biogenic reagent is greater than a fixed carbon content of the first biogenic reagent; and

wherein, according to a thermogravimetric analysis, an oxygen reactivity of the second biogenic reagent is less than an oxygen reactivity of the first biogenic reagent, wherein the thermogravimetric analysis is performed using a 40° C./min temperature ramp from 25° C. to 950° C. in the presence of pure oxygen.

2 . The process of claim 1 , wherein, according to a TGA graph of weight loss versus time from the thermogravimetric analysis, the second biogenic reagent requires at least a 5% longer time to reach 99% carbon oxidation, compared to the first biogenic reagent.

3 . The process of claim 2 , wherein, according to the TGA graph, the second biogenic reagent requires at least a 10% longer time to reach 99% carbon oxidation, compared to the first biogenic reagent.

4 . The process of claim 1 , wherein a TGA graph from the thermogravimetric analysis shows a first carbon-oxidation regime associated with oxidation of volatile carbon, which is succeeded by a second carbon-oxidation regime associated with oxidation of fixed carbon.

5 . The process of claim 4 , wherein a volatile-carbon oxidation time is defined from the onset of the first carbon-oxidation regime to the onset of the second carbon-oxidation regime, and wherein, during the volatile-carbon oxidation time, a mass loss of the first biogenic reagent is at least 25% greater than a mass loss of the second biogenic reagent.

6 . The process of claim 5 , wherein, during the volatile-carbon oxidation time, the mass loss of the first biogenic reagent is at least 50% greater than the mass loss of the second biogenic reagent.

7 . The process of claim 4 , wherein, during the first carbon-oxidation regime, the thermogravimetric analysis shows that a mass loss rate of the first biogenic reagent is at least 25% greater than a mass loss rate of the second biogenic reagent during the first carbon-oxidation regime.

8 . The process of claim 4 , wherein, during the first carbon-oxidation regime, the thermogravimetric analysis shows that a mass loss rate of the first biogenic reagent is at least 50% greater than a mass loss rate of the second biogenic reagent during the first carbon-oxidation regime.

9 . The process of claim 4 , wherein the thermogravimetric analysis shows that the first biogenic reagent has at least 10% higher average rate of mass loss during the first carbon-oxidation regime compared to the second carbon-oxidation regime.

10 . The process of claim 4 , wherein the thermogravimetric analysis shows a first-derivative curve peak within the first carbon-oxidation regime for the second biogenic reagent at a temperature higher than 500° C., and wherein the thermogravimetric analysis shows a first-derivative curve peak within the first carbon-oxidation regime for the first biogenic reagent at a temperature from 200° C. to 500° C.

11 . The process of claim 1 , wherein the biomass-containing feedstock is selected from softwood chips, hardwood chips, timber harvesting residue, tree branches, tree stumps, leaves, bark, sawdust, corn, corn stover, wheat, wheat straw, rice, rice straw, sugarcane, sugarcane bagasse, sugarcane straw, energy cane, sugar beets, sugar beet pulp, sunflowers, sorghum, canola, algae, miscanthus, alfalfa, switchgrass, fruits, fruit shells, fruit stalks, fruit peels, fruit pits, vegetables, vegetable shells, vegetable stalks, vegetable peels, vegetable pits, grape pumice, almond shells, pecan shells, coconut shells, coffee grounds, food waste, commercial waste, grass pellets, hay pellets, wood pellets, cardboard, paper, paper pulp, paper packaging, paper trimmings, food packaging, construction or demolition waste, railroad ties, lignin, animal manure, municipal solid waste, municipal sewage, or a combination thereof.

12 . The process of claim 1 , wherein the separation unit comprises a condensing system.

13 . The process of claim 12 , wherein the condensing system has multiple stages, and wherein the pyrolysis precipitate is a condensed product of a first condenser stage of the multiple stages.

14 . The process of claim 1 , wherein the separation unit is selected from a liquid-vapor cyclone separator, a demister, a distillation unit, a filtration unit, a membrane unit, a scrubbing unit, a chemical precipitation unit, a liquid-liquid extraction unit, an electrostatic precipitation unit, or a combination thereof.

15 . The process of claim 1 , wherein the intermediate material comprises the pyrolysis precipitate adsorbed onto a surface of the first biogenic reagent.

16 . The process of claim 1 , wherein the intermediate material comprises the pyrolysis precipitate absorbed into a bulk phase of the first biogenic reagent.

17 . The process of claim 1 , wherein steps (c) and (d) are integrated.

18 . The process of claim 1 , wherein a binder is introduced to the intermediate material.

19 . The process of claim 1 , wherein step (e) for the drying is conducted.

20 . The process of claim 19 , wherein steps (d) and (e) are integrated.

21 . The process of claim 19 , wherein steps (e) and (f) are integrated.

22 . The process of claim 1 , wherein the first biogenic reagent is milled utilizing a first mechanical-treatment apparatus selected from a hammer mill, an extruder, an attrition mill, a disc mill, a pin mill, a ball mill, a cone crusher, a jaw crusher, or a combination thereof.

23 . The process of claim 1 , wherein the intermediate material is milled utilizing a second mechanical-treatment apparatus selected from a hammer mill, an extruder, an attrition mill, a disc mill, a pin mill, a ball mill, a cone crusher, a jaw crusher, or a combination thereof.

24 . The process of claim 1 , wherein step (d) utilizes a pelletizing apparatus selected from an extruder, a ring die pellet mill, a flat die pellet mill, a roll compactor, a roll briquetter, a wet agglomeration mill, a dry agglomeration mill, or a combination thereof.

25 . The process of claim 1 , wherein the first pyrolysis reactor is distinct from the second pyrolysis reactor.

26 . The process of claim 1 , wherein the first pyrolysis reactor and the second pyrolysis reactor are the same unit, and wherein steps (a) and (f) are conducted at different times.

27 . The process of claim 1 , wherein the first biogenic reagent acts as a catalyst or reaction matrix for fixed-carbon formation reactions of the pyrolysis precipitate.

28 . The process of claim 1 , wherein step (a) is conducted at a first pyrolysis temperature selected from about 250° C. to about 700° C.

29 . The process of claim 1 , wherein step (f) is conducted at a second pyrolysis temperature selected from about 300° C. to about 1250° C.

30 . The process of claim 1 , wherein step (a) is conducted for a first pyrolysis time selected from about 1 minute to about 4 hours.

31 . The process of claim 1 , wherein step (f) is conducted for a second pyrolysis time selected from about 1 minute to about 4 hours.

32 . The process of claim 1 , wherein a pyrolysis non-precipitate is generated in the separation unit, wherein the pyrolysis non-precipitate is optionally recovered and at least partially oxidized to generate heat, and wherein the heat is optionally used within the process.

33 . The process of claim 1 , wherein the pyrolysis off-gas is conveyed to the separation unit.

34 . The process of claim 1 , wherein the pyrolysis off-gas is conveyed to a second separation unit operated under effective precipitation conditions to generate a second pyrolysis precipitate, wherein the second pyrolysis precipitate is in liquid, solid, or slurry form.

35 . The process of claim 34 , wherein the process further comprises contacting the first biogenic reagent with the second pyrolysis precipitate.

36 . The process of claim 34 , wherein the process further comprises contacting the second biogenic reagent with the second pyrolysis precipitate.

37 . The process of claim 1 , wherein the biocarbon pellet comprises at least 60 wt % fixed carbon.

38 . The process of claim 37 , wherein the biocarbon pellet comprises at least 70 wt % fixed carbon.

39 . The process of claim 38 , wherein the biocarbon pellet comprises at least 80 wt % fixed carbon.

40 . The process of claim 1 , wherein the biocarbon pellet comprises at most 10 wt % ash.

41 . The process of claim 1 , wherein the pyrolysis precipitate comprises at most 1 wt % ash.

42 . The process of claim 1 , wherein the pyrolysis precipitate comprises essentially no ash.

43 . The process of claim 1 , wherein the biocarbon pellet comprises at most 20 wt % total volatile matter.

44 . The process of claim 1 , wherein the biocarbon pellet comprises at most 10 wt % total volatile matter.

45 . The process of claim 1 , wherein at least 50 wt % of carbon comprised in the pyrolysis precipitate is converted to fixed carbon in the biocarbon pellet.

46 . The process of claim 1 , wherein from 1 wt % to 50 wt % of fixed carbon in the biocarbon pellet is derived from the pyrolysis precipitate.

47 . The process of claim 1 , wherein the intermediate material further comprises additional pyrolysis precipitate that is not provided from step (b) of the process.

48 . The process of claim 1 , wherein in step (c), less than all of the first biogenic reagent is contacted with the pyrolysis precipitate.

49 . The process of claim 1 , wherein in step (c), less than all of the pyrolysis precipitate is contacted with the first biogenic reagent.

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

51 . The process of claim 1 , wherein total carbon within the biocarbon pellet is at least 90% renewable as determined from a measurement of the 14 C/ 12 C isotopic ratio of the total carbon.

52 . The process of claim 1 , wherein total carbon within the biocarbon pellet is fully renewable as determined from a measurement of the 14 C/ 12 C isotopic ratio of the total carbon.

53 . The process of claim 1 , wherein the biocarbon pellet is characterized by a Hardgrove Grindability Index of at least 30.

54 . The process of claim 1 , wherein the biocarbon pellet is characterized by a bulk density of at least about 20 lb/ft 3 on a dry basis.

55 . The process of claim 1 , wherein the biocarbon pellet has an average pellet size selected from about 1 mm to about 10 cm, calculated as effective diameter of the biocarbon pellet.

56 . The process claim 1 , wherein the biocarbon pellet has a pellet effective diameter that is within 10% of the effective pellet diameter of the intermediate pellet.

57 . The process of claim 1 , wherein the biocarbon pellet has a pellet shape selected from sphere, cylinder, cube, octagon, hexagon, honeycomb, oval, column, bar, pillow, lentil, random granular, or a combination thereof.

58 . The process of claim 1 , wherein the biocarbon pellet is characterized by a pellet compressive strength at 25° C. of at least about 100 lb f /in 2 .

59 . The process of claim 1 , wherein the biocarbon pellet is characterized by a pellet compressive strength at 25° C. of at least about 150 lb f /in 2 .

60 . The process of claim 1 , wherein the biocarbon pellet is characterized by at most 20 wt % water uptake at 25° C. after 24 hours of soaking in water.

61 . The process of claim 1 , wherein the biocarbon pellet 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.”

62 . The process of claim 1 , wherein the process further comprises introducing an additive during the process.

63 . The process of claim 62 , wherein the additive is selected from acids, bases, or salts thereof.

64 . The process of claim 62 , wherein the additive is selected from metals, metal oxides, metal hydroxides, metal halides, or a combination thereof.

65 . The process of claim 62 , wherein the additive is selected from sodium hydroxide, potassium hydroxide, magnesium oxide, hydrogen bromide, hydrogen chloride, sodium silicate, potassium permanganate, magnesium, manganese, aluminum, nickel, chromium, silicon, boron, cerium, molybdenum, phosphorus, tungsten, vanadium, iron halide, iron chloride, iron bromide, dolomite, dolomitic lime, fluorite, fluorospar, bentonite, calcium oxide, lime, titanium dioxide, or a combination thereof.

66 . The process of claim 62 , wherein the additive is selected to adjust filtrate pH of the biocarbon pellet, wherein the filtrate pH is measured by combining 20 grams on a dry basis of the biocarbon pellet, or a powder form thereof, with 100 milliliters of distilled water, to form a mixture; filtering the mixture through filter paper; and measuring pH of the filtrate with a pH meter.

67 . The process of claim 62 , wherein the additive is added to the second biogenic reagent to adjust filtrate pH of the second biogenic reagent, wherein the filtrate pH is measured by combining 20 grams on a dry basis of the second biogenic reagent with 100 milliliters of distilled water, to form a mixture; filtering the mixture through filter paper; and measuring pH of the filtrate with a pH meter.

68 . The process of claim 62 , wherein the oxygen reactivity of the second biogenic reagent is reduced by addition of the additive to the second biogenic reagent.

69 . The process of claim 1 , wherein the process provides an overall carbon yield of at least 50%, calculated as carbon comprised in the biocarbon pellet as a percentage of carbon comprised in the biomass-containing feedstock.

70 . The process of claim 69 , wherein the overall carbon yield is at least 60%.

71 . The process of claim 70 , wherein the overall carbon yield is at least 70%.

72 . The process of claim 71 , wherein the overall carbon yield is at least 80%.

73 . The process of claim 1 , wherein the process is continuous or semi-continuous.

74 . The process of claim 1 , wherein the biocarbon pellet is mechanically treated to generate biocarbon powder.

75 . The process of claim 1 , wherein the biocarbon pellet is combined with another amount of the second biogenic reagent, to generate a biocarbon object.

76 . A process for producing a biocarbon pellet, the process comprising:

(a) pyrolyzing, in a first pyrolysis reactor, a biomass-containing feedstock, thereby generating a first biogenic reagent and a pyrolysis vapor;

(b) providing a carbon-containing condensed-matter material, wherein the carbon-containing condensed-matter material is a liquid, a solid, or a slurry;

(c) contacting the first biogenic reagent with the carbon-containing condensed-matter material, thereby generating an intermediate material, wherein the intermediate material comprises the first biogenic reagent and the carbon-containing condensed-matter material;

(d) pelletizing the intermediate material, thereby generating an intermediate pellet;

(e) optionally, drying the intermediate pellet;

(f) separately from step (a), pyrolyzing, in a second pyrolysis reactor, the intermediate pellet, thereby generating a second biogenic reagent and a pyrolysis off-gas, wherein the first pyrolysis reactor and the second pyrolysis reactor are the same reactor or distinct reactors; and

(g) recovering the second biogenic reagent as a biocarbon pellet,

wherein a fixed carbon content of the second biogenic reagent is greater than a fixed carbon content of the first biogenic reagent; and

wherein the second biogenic reagent has lower oxygen reactivity than the first biogenic reagent according to a thermogravimetric analysis using a 40° C./min temperature ramp from 25° C. to 950° C. in the presence of pure oxygen.