# US 10,121,563 B2 · Systems and methods for producing biochar-based products

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- Number: US 10,121,563 B2
- Document ID: US10121563B2
- Status: Granted
- Kind: B2
- Application number: 15/334,165
- Filed: 2016-10-25
- Published: 2017-02-09
- Granted: 2018-11-06
- Earliest claimed: 2011-10-10
- Applicants: Dino Favetta; Dirk-Jan Rosse; James C. Slattery
- Inventors: Dino Favetta; Dirk-Jan Rosse; James C. Slattery
- Web page: https://patentgrep.com/patent/US10121563B2

## CPC

- H01B 1/04: mainly consisting of carbon-silicon compounds, carbon or silicon
- C01B 32/05: Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
- C10L 5/44: on vegetable substances
- H01G 11/86: specially adapted for electrodes (carbonisation or activation of carbon for the manufacture of electrodes H01G11/34)
- H01M 4/0471: {involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis}
- H01M 4/0483: {by methods including the handling of a melt (H01M4/0438, take precedence)}
- H01M 4/583: Carbonaceous material, e.g. graphite-intercalation compounds or CFx
- Y02E 50/10: Biofuels, e.g. bio-diesel
- Y02E 50/30: Fuel from waste, e.g. synthetic alcohol or diesel
- Y02E 60/10: Energy storage using batteries
- Y02E 60/13: Energy storage using capacitors
- H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K})
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C10L: FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
- H01G: CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE (selection of specified materials as dielectric H01B3/00; capacitors having potential barriers H10D1/62, H10K10/10)
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

An end-to-end system/process for producing advantageous end products from a raw biomass feedstock is provided. The process includes steps for enhancing biomaterial feedstock, biochar generation and end-product fabrication. The method steps may be employed in selecting, treating and handling biomass materials and their additive inputs to tailor their end performance. Each operative step in the process may be employed to enhance the overall effectiveness of biochar generation and use. Charring furnace design and operational parameters are provided that generate desirable biochar material for various applications, including specifically fabrication of ultra-capacitor electrodes and electric battery components.

## Claims

### Claim 1

A method for generating biochar material, comprising:
a. selecting plant material for use in generating biochar based on predetermined criteria;
b. mechanical conversion of the selected plant material;
c. pre-shaping the mechanically converted plant material to a desired net-shape;
d. charring the mechanically converted plant material in the desired net-shape in a furnace to generate biochar material; and
e. fabricating at least one end-product from the net-shaped biochar material.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the plant material is selected at least in part based on at least one of plant species, soil characteristics and mineral content.

### Claim 3 (depends on 1)

The method according to claim 1, further comprising processing steps related to selection of the plant material that include:
a. harvesting of plants;
b. washing of the harvested plants to remove soluble minerals therefrom.

### Claim 4 (depends on 3)

The method according to claim 3, wherein the washing of the harvested plants includes at least one of allowing the harvested to lay fallow so as to be exposed to rain conditions, and manual washing of the harvested plants.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the mechanical conversion is undertaken in an extruder or pelletizer.

### Claim 6 (depends on 1)

The method according to claim 1, wherein conditions associated with the mechanical conversion are sufficient to allow constituent components associated with the selected plant material to melt, reform and react to form the pre-shaped condition.

### Claim 7 (depends on 1)

The method according to claim 1, wherein charring of the selected plant material is undertaken in a charring furnace that includes a heat source.

### Claim 8 (depends on 7)

The method according to claim 7, wherein the heat source is selected from the group consisting of electrical heating, microwave heating, induction heating, hydrocarbon fuel heating, heating from furnace-resident biomaterial-generated off-gas, and combinations thereof.

### Claim 9 (depends on 1)

The method according to claim 1, further comprising using the end-product as an ultra-high capacitor or a battery component.