PROCESSES AND SYSTEMS FOR RECAPTURING CARBON FROM BIOMASS PYROLYSIS LIQUIDS

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

pyrolyzing a first feedstock in a first pyrolysis reactor, thereby generating a biogenic reagent and a pyrolysis vapor;

introducing the pyrolysis vapor to a condensing system, thereby generating a condenser liquid and a condenser vapor;

contacting a second feedstock with the condenser liquid, wherein the second feedstock comprises biomass, thereby generating the first feedstock, wherein the first feedstock comprises the second feedstock and the condenser liquid; and

recovering the biogenic reagent as a biocarbon composition.

2 . The process of claim 1 , wherein the biomass is selected from softwood chips, hardwood chips, timber harvesting residues, 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 and/or demolition waste, railroad ties, lignin, animal manure, municipal solid waste, municipal sewage, or a combination thereof.

3 . The process of claim 1 , further comprising pelletizing the biogenic reagent.

4 . The process of claim 3 , wherein the pelletizing the biogenic reagent comprises introducing a binder to the biogenic reagent.

5 . The process of claim 4 , wherein the 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 a combination of the foregoing.

6 . The process of claim 3 , wherein the pelletizing the biogenic reagent does not comprise introducing an external binder to the biogenic reagent.

7 . The process of claim 1 , wherein the condensing system comprises multiple condenser stages.

8 . The process of claim 7 , wherein the condenser liquid is a condensed product of a first stage of the multiple condenser stages.

9 . The process of claim 8 , wherein the condenser liquid is a condensed product of a plurality of stages of the multiple condenser stages, and wherein optionally the plurality of stages does not include the final stage of the multiple condenser stages.

10 . The process of claim 1 , wherein the contacting comprises spraying the condenser liquid onto the biomass.

11 . The process of claim 1 , wherein the first feedstock comprises the condenser liquid adsorbed onto a surface of the biomass.

12 . The process of claim 1 , wherein the first feedstock comprises the condenser liquid absorbed into a bulk phase of the biomass.

13 . The process of claim 1 , further comprising thermally treating the biogenic reagent in a thermal-treatment unit, wherein if the biogenic reagent is subjected to pelletizing, the thermally treating is before, during, or after the pelletizing.

14 . The process of claim 13 , wherein the thermal-treatment unit is a second pyrolysis reactor operated at a second pyrolysis temperature of at least about 250° C., and wherein the second pyrolysis reactor is configured for pyrolyzing the biogenic reagent.

15 . The process of claim 13 , wherein the thermal-treatment unit is operated at a temperature selected from about 80° C. to about 250° C.

16 . The process of claim 13 , wherein the thermal-treatment unit contains an internal oxygen-free environment.

17 . The process claim 13 , wherein an inert gas is introduced to the thermal-treatment unit.

18 . The process claim 13 , wherein the thermal-treatment unit is operated under vacuum.

19 . The process of claim 13 , wherein the thermal-treatment unit is configured for drying the biogenic reagent.

20 . The process of claim 13 , further comprising drying of the biocarbon composition after the thermally treating.

21 . The process of claim 14 , wherein the first pyrolysis reactor is distinct from the second pyrolysis reactor.

22 . The process of claim 14 , wherein the first pyrolysis reactor and the second pyrolysis reactor are the same unit, and wherein the pyrolyzing and the thermally treating are conducted at different times.

23 . The process of claim 1 , wherein the condenser liquid comprises total carbon, and wherein the process further comprises converting at least 25 wt % of the total carbon comprised within the condenser liquid to fixed carbon comprised within the biogenic reagent.

24 . The process of claim 1 , wherein the condenser liquid comprises total carbon, and wherein the process further comprises converting at least 50 wt % of the total carbon comprised within the condenser liquid to fixed carbon comprised within the biogenic reagent.

25 . The process of claim 1 , wherein the condenser liquid comprises total carbon, and wherein the process further comprises converting at least 75 wt % of the total carbon comprised within the condenser liquid to fixed carbon comprised within the biogenic reagent.

26 . The process of claim 1 , wherein at least about 10 wt % to at most about 80 wt % of fixed carbon in the biogenic reagent is derived from the condenser liquid.

27 . The process of claim 1 , wherein at least about 20 wt % to at most about 60 wt % of fixed carbon in the biogenic reagent is derived from the condenser liquid.

28 . The process of claim 1 , wherein all of the condenser liquid is contacted with the second feedstock.

29 . The process of claim 1 , wherein less than all of the condenser liquid is contacted with the second feedstock.

30 . The process of claim 1 , wherein the condenser liquid is contacted with the second feedstock without any intermediate chemical processing.

31 . The process of claim 1 , wherein the condenser liquid is chemically processed prior to contacting with the second feedstock.

32 . The process of claim 31 , wherein the condenser liquid is subjected to a purification step prior to contacting with the second feedstock.

33 . The process of claim 31 , wherein the condenser liquid is subjected to a reaction step prior to contacting with the second feedstock.

34 . The process of claim 29 , further comprising introducing a portion of the condenser liquid to the biogenic reagent.

35 . The process of claim 14 , wherein the pyrolyzing the biogenic reagent generates an off-gas, and wherein the off-gas is recycled to the condensing system.

36 . The process of claim 1 , wherein the pyrolyzing in the first pyrolysis reactor is conducted at a first pyrolysis temperature of at least about 250° C. to at most about 1250° C.

37 . The process of claim 36 , wherein the first pyrolysis temperature is at least about 300° C. to at most about 700° C.

38 . The process of claim 14 , wherein the second pyrolysis temperature is at least about 250° C. to at most about 1250° C.

39 . The process of claim 38 , wherein the second pyrolysis temperature is at least about 300° C. to at most about 700° C.

40 . The process of claim 1 , wherein the pyrolyzing in the first pyrolysis reactor is conducted for a first pyrolysis time of at least about 10 seconds to at most about 24 hours.

41 . The process of claim 14 , wherein the pyrolyzing the biogenic reagent is conducted for a second pyrolysis time of at least about 10 seconds to at most about 24 hours.

42 . The process of claim 1 , further comprising oxidizing the condenser vapor, thereby generating heat.

43 . The process of claim 42 , further comprising oxidizing an off-gas derived from the thermal-treatment unit, thereby generating heat.

44 . The process of claim 1 , further comprising milling the biogenic reagent using a mechanical-treatment apparatus, wherein the mechanical-treatment apparatus is 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.

45 . The process of claim 3 , wherein the pelletizing the biogenic reagent 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.

46 . The process of claim 1 , further comprising drying the biogenic reagent, and further comprising pelletizing the biogenic reagent to generate pellets, wherein the pelletizing the biogenic reagent occurs prior to the drying, during the drying, or after the drying.

47 . The process of claim 1 , wherein the biocarbon composition comprises at least 50 wt % fixed carbon.

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

49 . The process of claim 1 , wherein the biocarbon composition comprises at least 70 wt % fixed carbon.

50 . The process of claim 1 , wherein the biocarbon composition comprises at least 80 wt % fixed carbon.

51 . The process of claim 1 , wherein the biocarbon composition comprises at least 90 wt % fixed carbon.

52 . The process of claim 1 , wherein the biocarbon composition comprises less than 10 wt % ash.

53 . The process of claim 1 , wherein the biocarbon composition comprises less than 5 wt % ash.

54 . The process of claim 1 , wherein the biocarbon composition comprises less than 1 wt % ash.

55 . The process of claim 1 , wherein the condenser liquid comprises less than 1 wt % ash.

56 . The process of claim 1 , wherein the condenser liquid comprises less than 0.1 wt % ash.

57 . The process of claim 1 , wherein the condenser liquid comprises essentially no ash.

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

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

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

61 . The process of claim 1 , wherein the biocarbon composition is characterized by a bulk density of at least about 5 lb/ft 3 on a dry basis.

62 . The process of claim 1 , wherein the biocarbon composition is characterized by a bulk density of at least about 10 lb/ft 3 on a dry basis.

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

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

65 . The process of claim 1 , wherein the 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”.

66 . The process of claim 1 , wherein the biocarbon composition is in the form of a pellet.

67 . The process of claim 66 , wherein the pellet is characterized by a bulk density of at least about 10 lb/ft 3 on a dry basis.

68 . The process of claim 66 , wherein the pellet is characterized by a bulk density of at least about 25 lb/ft 3 on a dry basis.

69 . The process of claim 66 , wherein the pellet is characterized by a bulk density of at least about 35 lb/ft 3 on a dry basis.

70 . The process of claim 66 , wherein the pellet is characterized by a Hardgrove Grindability Index of at least 30.

71 . The process of claim 66 , wherein the pellet is characterized by a Hardgrove Grindability Index of at least 50.

72 . The process of claim 66 , wherein the pellet is characterized by a Hardgrove Grindability Index of at least 70.

73 . The process of claim 66 , wherein the pellet is characterized by a pellet compressive strength at 25° C. of at least about 100 lbf/in 2 .

74 . The process of claim 66 , wherein the pellet is characterized by a pellet compressive strength at 25° C. of at least about 150 lbf/in 2 .

75 . A system for producing a biocarbon composition, the system comprising:

a first pyrolysis reactor configured for pyrolyzing a first feedstock to generate a biogenic reagent and a pyrolysis vapor;

a condensing system in flow communication with the first pyrolysis reactor, wherein the condensing system is configured for condensing the pyrolysis vapor to generate a condenser liquid and a condenser vapor;

a mixing unit in flow communication with the condensing system, wherein the mixing unit is configured for contacting a second feedstock comprising biomass with the condenser liquid to generate a first feedstock; and

a system output in flow communication with the first pyrolysis reactor, wherein the system output is configured for recovering the biogenic reagent as a biocarbon composition.

76 . The system of claim 75 , further comprising a pelletizing unit in flow communication with the first pyrolysis reactor, wherein the pelletizing unit is configured for pelletizing the biogenic reagent to generate pellets.

77 . The system of claim 75 , further comprising a thermal-treatment unit in flow communication with the pelletizing unit, if present, or in flow communication with the first pyrolysis reactor.

78 . The system of claim 77 , wherein a thermal-treatment unit is disposed downstream of the pelletizing unit, and wherein the thermal-treatment unit is configured to receive the pellets.

79 . The system of claim 77 , wherein the thermal-treatment unit is disposed between the first pyrolysis reactor and the pelletizing unit, wherein the pelletizing unit is configured to receive a thermally treated biogenic reagent.

80 . The system of claim 75 , wherein the condensing system comprises multiple condenser stages.

81 . The system of claim 75 , wherein the mixing unit is configured to spray the condenser liquid onto the biomass.

82 . The system of claim 75 , wherein the thermal-treatment unit is a second pyrolysis reactor operated at a second pyrolysis temperature of at least about 250° C., and wherein the second pyrolysis reactor is configured for pyrolyzing the biogenic reagent.

83 . The system of claim 82 , further comprising a recycle line configured to recycle pyrolysis off-gas, from the second pyrolysis reactor, to the condensing system.

84 . The system of claim 75 , wherein the thermal-treatment unit is operated at a temperature selected from about 80° C. to about 250° C.

85 . The system of claim 75 , further comprising a mechanical-treatment apparatus configured to mill the biogenic reagent, wherein the mechanical-treatment apparatus is 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.

86 . The system of claim 76 , wherein the pelletizing unit is 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.