# US 2011/0003686 A1 · Coal Heat-Treatment Process and System > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2011/0003686 A1 - Document ID: US20110003686A1 - Status: Published application - Kind: A1 - Application number: 12/626,458 - Filed: 2009-11-25 - Published: 2011-01-06 - Earliest claimed: 2009-07-02 - Assignees: Pneumatic Processing Technologies, LLC - Inventors: Michael A. Jones - Web page: https://patentgrep.com/patent/US20110003686A1 ## CPC - F23K 1/00: Preparation of lump or pulverulent fuel in readiness for delivery to combustion apparatus - C01B 32/33: from distillation residues of coal or petroleum; from petroleum acid sludge - C01B 32/342: characterised by non-gaseous activating agents - C01B 32/366: by physical processes, e.g. by irradiation, by using electric current passing through carbonaceous feedstock or by using recyclable inert heating bodies - F23K 1/04: Heating fuel prior to delivery to combustion apparatus - F23K 2201/505: with additives - F23K 2203/201: using pneumatic means - F23K: FEEDING FUEL TO COMBUSTION APPARATUS (fuel feeders specially adapted for fluidised bed combustion apparatus F23C10/22) - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} ## Abstract Methods and systems for producing activated carbon from a particulate coal feedstock that include the introduction of an activation medium such that the water content of the coal feedstock is equal to or greater than that of the feedstock's naturally occurring state. Different methods and system configurations allow the production of activated carbon or other heat-treated carbons while concurrently avoiding adverse reaction conditions. ## Claims ### Claim 1 A method for producing activated carbon from a particulate coal suitable for forming same, comprising the steps of: a. loading a particulate coal feedstock with an activation medium such that the water content of said particulate coal feedstock is equal to or greater than that of said coal feedstock's naturally occurring state; b. conveying the particulate coal feedstock of step (a) into a heat treatment system; and c. heat treating said particulate coal feedstock such that at least partial activation occurs. ### Claim 2 (depends on 1) The method of claim 1, wherein said particulate coal feedstock undergoes at least one additional heat treatment after said at least partial activation occurs. ### Claim 3 (depends on 1) The method of claim 1, wherein said particulate coal feedstock undergoes devolatilization and at least partial activation in one reactor or reaction vessel. ### Claim 4 (depends on 1) The method of claim 1, where said particulate coal feedstock is at least partially heated by a waste gas from said heat treatment system. ### Claim 5 (depends on 1) The method of claim 1, wherein the particulate coal feedstock of step (a) is flowable in a conveying gas. ### Claim 6 (depends on 1) The method of claim 1, further comprising the step of providing a secondary activation of a heat-treated carbon formed by the particulate coal feedstock in step (c). ### Claim 7 (depends on 6) The method of claim 6, further comprising the step of providing a binder co-currently with said heat-treated carbon during said secondary activation. ### Claim 8 (depends on 7) The method of claim 7, wherein said binder is lignin or lignin compound. ### Claim 9 (depends on 1) The method of claim 1, wherein a heat-treated carbon formed by the particulate coal feedstock in step (c) is physically conveyed within an indirect cooler. ### Claim 10 (depends on 1) The method of claim 1, wherein said particulate coal feedstock is loaded with said activation medium for at least 30 seconds prior to activation. ### Claim 11 (depends on 6) The method of claim 6, wherein said activation medium is disposed upon the heat-treated carbon prior to or co-currently with said secondary activation step. ### Claim 12 (depends on 1) The method of claim 1, further comprising the step of providing a co-product industrial mineral co-currently with said particulate coal feedstock prior to activation in step c. ### Claim 13 (depends on 1) The method of claim 1, further comprising the step of providing an enhancer co-currently with said particulate coal feedstock prior to activation in step c. ### Claim 14 (depends on 1) The method of claim 1, further comprising the step of providing an additive to the heat-treated carbon formed by the particulate coal feedstock after activation in step c. ### Claim 15 (depends on 1) The method of claim 1, further comprising the step of re-circulating at least a portion of a heat-treated carbon formed by the particulate coal feedstock in step (c) through an additional heat treatment in said heating system. ### Claim 16 A method for producing activated carbon from a particulate coal suitable for forming same, comprising the steps of: a. mixing a particulate coal feedstock with an activation medium in a mixer such that the water content of said particulate coal feedstock is equal to or greater than that of said coal feedstock's naturally occurring state; b. pneumatically conveying the particulate coal feedstock with said water content from the mixer into a heat treatment system; and c. heat treating said particulate coal feedstock such that at least partial activation occurs. ### Claim 17 (depends on 16) The method of claim 16, wherein a heat-treated carbon formed by said particulate coal feedstock undergoes at least one additional heat treatment after said at least partial activation occurs. ### Claim 18 (depends on 16) The method of claim 16, wherein said particulate coal feedstock undergoes devolatilization and at least partial activation in one reactor or reaction vessel. ### Claim 19 (depends on 16) The method of claim 16, where said particulate coal feedstock is at least partially heated by a waste gas from said heat treatment system. ### Claim 20 (depends on 16) The method of claim 16, further comprising the step of providing a secondary activation of a heat-treated carbon formed by the particulate coal feedstock in step (c). ### Claim 21 (depends on 20) The method of claim 20, further comprising the step of providing a binder concurrently with said heat-treated carbon during said secondary activation. ### Claim 22 (depends on 21) The method of claim 21, wherein said binder is lignin or lignin compound. ### Claim 23 (depends on 16) The method of claim 16, wherein a heat-treated carbon formed by the particulate coal feedstock in step (c) is physically conveyed within an indirect cooler. ### Claim 24 (depends on 16) The method of claim 16, wherein said particulate coal feedstock is loaded with said activation medium for at least 30 seconds prior to activation. ### Claim 25 (depends on 20) The method of claim 20, wherein said activation medium is disposed upon the heat-treated carbon prior to or co-currently with said secondary activation step. ### Claim 26 (depends on 16) The method of claim 16, further comprising the step of providing a co-product industrial mineral co-currently with said particulate coal feedstock prior to activation in step c. ### Claim 27 (depends on 16) The method of claim 16, further comprising the step of providing an enhancer co-currently with said particulate coal feedstock prior to activation in step c. ### Claim 28 (depends on 16) The method of claim 16, further comprising the step of providing an additive to a heat-treated carbon formed by the particulate coal feedstock after activation in step c. ### Claim 29 (depends on 16) The method of claim 16, further comprising the step of re-circulating at least a portion of a heat-treated carbon formed by the particulate coal feedstock that has undergone said at least partial activation through an additional heat treatment in said heating system. ### Claim 30 A system for producing activated carbon from a particulate coal feedstock, comprising: a. a mixing chamber with an activation medium inlet; b. a heating chamber having a heat source; c. a cyclone; and d. a conveying means that conveys said particulate coal feedstock and is in connection with said mixing chamber, heating chamber, and cyclone. ### Claim 31 (depends on 30) The system of claim 30, further comprising an indirect cooling chamber in connection with said cyclone. ### Claim 32 (depends on 31) The system of claim 31, wherein said indirect cooling chamber contains a physical conveying means that transports a heat-treated carbon formed from said particulate coal feedstock through the indirect cooling chamber. ### Claim 33 (depends on 30) The system of claim 30, further comprising a second cyclone in connection with said cyclone. ### Claim 34 (depends on 33) The system of claim 33, wherein waste gas from said cyclone is in fluid connection with said second cyclone. ### Claim 35 (depends on 30) The system of claim 30, further comprising a second mixing chamber having an activation medium inlet, wherein said second mixing chamber is in fluid connection the cyclone. ### Claim 36 (depends on 35) The system of claim 35, wherein said second mixing chamber includes an auxiliary heat source. ### Claim 37 (depends on 30) The system of claim 30, further comprising a second cyclone, an indirect cooler and a second mixing chamber having an activation medium inlet, wherein the second cyclone, indirect cooler, and second mixing chamber are in connection with each other and the cyclone. ### Claim 38 (depends on 30) The system of claim 30, wherein said conveying means comprises a gas. ### Claim 39 (depends on 30) The system of claim 30, wherein said cyclone is paired with a second mixing chamber having an activation medium inlet, said system further comprising a second cyclone paired with a third mixing chamber having an activation medium inlet, wherein the second mixing chamber is connected to an indirect cooler, the third mixing chamber is connected to the heating chamber, and the cyclone and second cyclone are connected to each other by conveying means.