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Renewable and Sustainable Energy Reviews 105 (2019) 332–348

Contents lists available at ScienceDirect

Renewable and Sustainable Energy Reviews


journal homepage: www.elsevier.com/locate/rser

The significance of pelletization operating conditions: An analysis of T


physical and mechanical characteristics as well as energy consumption of
biomass pellets
Mohamed E. Mostafaa,d, Song Hua,b, Yi Wanga,b, , Sheng Sua,b, Xun Huc, Saad A. Elsayedd,

Jun Xianga,b,

a
State Key Laboratory of Coal Combustion, School of Energy and Power Engineering, Huazhong University of Science and Technology, Wuhan 430074, Hubei, PR China
b
China-EU Institute for Clean and Renewable Energy at Huazhong University of Science and Technology, Wuhan 430074, Hubei, PR China
c
School of Material Science and Engineering, University of Jinan, Jinan 250022, PR China
d
Mechanical Power Engineering Department, Faculty of Engineering, Zagazig University, 44519 Zagazig, Egypt

ARTICLE INFO ABSTRACT

Keywords: Biomass raw materials are widely regarded as a significant source of renewable energy, which significantly
Biomass reduces the dependence on traditional fossil fuels, especially in the case of countries that are able to obtain
Pellets biomass from various sources. Recently, pelletization has been widely used for mass and energy densification of
Steam explosion biomass to overcome the problems associated with raw material use. As the global pellet market has developed
Torrefaction
quickly, the use of wood residues became no longer sufficient to fulfill the market needs. The standards of pellets
Binders
provide limits for both physical and mechanical characteristics of produced pellets. Characteristics of produced
pellets depend mainly on the feedstock characteristics as particle size and moisture content and operating
conditions as applied pressure and die temperature. Thus, this paper provides rich information on the factors
affecting the physical and mechanical properties of granules included in pellets. The main goal of the paper is to
review the latest and comprehensive research on the physical and mechanical properties of most types of single
and mixed pellets from biomass. The analysis of the effect of properties, adhesives, humidity, pressure and
temperature as well as the physical and mechanical properties of the pellets studied was carried out. In addition,
the critical and optimal values of various factors for different materials in which the following is of importance:
high quality of pellets and biomass from which they are produced were analyzed. The principle and effect of
applying post-production conditions as steam explosion and torrefaction on the characteristics of the pellets
were reviewed in details. Moreover, this study proposes some recommendations for further development of the
pelletization analysis and characteristics.

1. Introduction and transportation [1,14–18]. Burning biomass material in pellets form


for power generation overcomes the drawbacks of traditional use of
Using biomass as the main source for heat and power production biomass as low thermal efficiency [19,20]. Biomass pellets could be
resulted from the depletion of fossil fuels and climate change due to used directly as fuel for residential heating stoves, heating boilers and
CO2 emissions [1–4]. Biomass can reduce CO2 and acidic gas emissions large-scale power plants [21].
and can be used as a continuous source for heat and power [5–8]. Quality of produced pellets is affected by the properties of the raw
Nowadays, thermal energy production using solid fuels as biomass material used as are particle size, moisture content and chemical
materials focused on the densified biofuels to overcome the dis- composition and operating conditions as die temperature, applied
advantages of raw biomass as irregular shape, low bulk density and pressure, holding time and die geometry [10,14,22–24]. The main types
high moisture content which make it difficult and expensive to handle, of biomass feedstocks are agricultural residues [25–30] and forest
transport and store it [9–13]. Densification process of raw material wastes [31–33]. In recent years, different types of biomass materials
increases its bulk density which reduces the cost of handling, storage had been used individually and mixed together or with sewage sludge


Corresponding authors at: State Key Laboratory of Coal Combustion, School of Energy and Power Engineering, Huazhong University of Science and Technology,
Wuhan 430074, Hubei, PR China.
E-mail addresses: alenwang@hust.edu.cn (Y. Wang), xiangjun@mail.hust.edu.cn (J. Xiang).

https://doi.org/10.1016/j.rser.2019.01.053
Received 25 June 2018; Received in revised form 7 January 2019; Accepted 26 January 2019
Available online 15 February 2019
1364-0321/ © 2019 Elsevier Ltd. All rights reserved.
M.E. Mostafa, et al. Renewable and Sustainable Energy Reviews 105 (2019) 332–348

for producing high quality pellets [6,15,31–43]. Characteristic para- Fig. 1. The applied load is controlled by a computer program that able
meters of various biomass pellets had been studied under different to record the change of displacement versus the load until reaching the
operating conditions [12,37,40,44–48]. desired pressure as illustrated in Fig. 1c.
The price of woody materials increased and its availability in
market decreased which weakened market competitiveness of pellets 2.2. Densified solid biofuel standards
[36,43]. Using non-woody biomass waste into pellets production be-
came environment friendly and helped in facing the problem of raw It is necessary to fulfill and achieve the requirements of customers
material high price and shortage in the market. Mixed pellets are found regarding pellet quality and emissions generated by combustion
to have sufficient hardness and heating values nearly similar to that of [21,66]. Due to mechanical failure of the pellets that results during
wood pellets [11]. Therefore, a lot of previous studies have focused on production, transportation and storage, fines and dust that have
the production of raw and mixed pellets [15,19,27,41,43,49–58]. Ser- harmful effect as fire hazards are formed [67,80]. These fines nega-
ious problems as combustor corrosion and greenhouse gases emission tively affect the process of automatic feeding system and the high
are produced when mixed biomass pellets are used in energy produc- temperature resulted from their rapid combustion enhances the ash
tion due to the presence of sulfur and chlorine [11,59]. Therefore, melting [81]. The quality of the produced pellets depends on the raw
specific characteristics for mixed pellets have been established for wood material and operating conditions [14,74,81,82]. To judge the quality
and Agro-waste to be commercialized [11]. Mixing biomass materials of the raw materials used and produced pellets, there are different
with sewage sludge became a new and effective trend for producing standards that provide a clear and specific values of different parameter
pellets [6,17,36,43,60–62]. Sewage sludge contains a significant can be followed. The European Committee for Standardization (CEN)
amount of organic compounds as proteins and carbohydrates which act developed standards for solid biofuels. For instance, the European
as a natural binder that can improve the strength of fiber grid in pellet standard EN 14961-1 [83] for general use including pellets from dif-
[6,43,62]. ferent biomass raw materials, EN 14961-2 [84] for wood pellets for
The available recent review articles related to the area of pelleti- non-industrial use and EN 14961-6 [85] for non-woody pellets for non-
zation focused on the combustion models, kinetics, development of industrial use. The International Organisation for Standardization (ISO)
pellet industry and storage of pellets [11,16,63–65]. These studies have had prepared about 60 standards for solid biofuels [86]. Standards for
to some extent neglected the discussion of factors affecting the char- pellets include: EN ISO 17225-1 [87] for general requirements, EN ISO
acteristics of biomass pellets. Thus, there is a need for updated in- 17225-2 [88] for graded wood pellets for industrial and nonindustrial
formation on the issue of the physical and mechanical characteristics of use and EN ISO 17225-6 [89] for graded non-woody pellets. EN ISO
the single and mixed biomass pellets and a need for up-to-date analysis 17225 series has replaced EN 14961 to become the national standard in
of the factors affecting these characteristics as well as the energy con- Europe.
sumption. This paper first provides a comprehensive overview of the
various characteristics of pellets, then prescribes the factors influencing
3. Physical and mechanical properties of pellets
these characteristics accompanied by the critical and optimal values of
various factors at which high quality pellets are produced and finally
3.1. Pellet size (diameter and length)
discusses the future prospects of the pellet production technology. Also,
a new vision about the future development of the pelletization process
The diameter and length of produced pellets are standardized which
is introduced.
made it easy to choose the feeding and furnace facilities. As stated by
EN ISO 17225-2 [88], the length of produced pellets is set to be no more
2. Pellets production
than 40 mm. After the production of pellets and during the storage
period, pellets can dry up and expand [44]. The expansion ratio (ER)
Pelletization, briquetting, extrusion, and tumble are the different
could be calculated based on the dimensions of pellets that measured
types of biomass densification [66]. Pelleting can be performed either
immediately and after several days of production according to the fol-
by using a uniaxial piston-cylinder unit to produce single pellets or a
lowing formula in Eq. (1) [45]:
pellet mill that consists of a series of rollers to compress raw material
through a steel die. The procedure of pelletization process consists of a Df D0 Lf L0
ER = /
three main steps; pre-production, pelletizing and post-production. Pre- D0 L0 (1)
production steps depend mainly on the collecting, characterization,
drying, grinding and pre-treatment of the raw material. Pre-treatment where: Df is the final diameter of the pellet after several days (mm), Do
of the raw material includes mixing with additives and conditioned is the initial diameter of the pellet measured immediately after extru-
with steam to increase the temperature and/or moisture level [67]. sion (mm), Lf is the final length of the pellet after several days (mm),
Post-production step includes cooling and screening [63,67,68]. and Lo is the initial length of the pellet measured immediately after
production (mm).
2.1. Pelletization equipment
3.2. Single and bulk densities of produced pellets
Some researchers used the mill design and others used the piston -
cylinder unit. Mill consists of rollers that force the biomass through the The bulk density of produced pellets depends on the pore volume
cylindrical press channels of the perforated flat or ring die from inside and pellet density and it can be calculated by dividing the mass of the
towards the outside [66,69]. Generally, overheating is produced during bulk materials by the volume of the container according to the standard
the pelletization process from the friction between the biomass material EN ISO 17828 [90] which replaced the old one EN 15103 [91]. Bulk
and the walls of the mill [1,69,70]. Resulted temperature and friction in density can be roughly estimated be by dividing the particle density by
the die channels are hard to be controlled which made it difficult to use two. ISO standards for solid biofuels set down 600 kg/m³ as a minimum
a large-scale pellet mill to investigate the effects of operating para- value for bulk density of the produced pellets. The particle pellet den-
meters on the characteristics of pellets [47,71]. So, a single piston-cy- sity is defined as the mass of a pellet divided by its volume. This density
linder unit is the most common method that used by researchers to is determined based on the standard EN ISO 18847 [92] that replaced
study the characteristics of new shapes and types of biomass pellets the old standard CEN/TS 15150 [93]. According to European guide-
[1,6,15,25,36,43,44,46,48,67,72–79]. The load is applied to the piston lines, Emadi et al. [94] stated that the accepted standard range of a
of the piston-cylinder unit by a universal testing machine as shown in single pellet’s density is 1000–1400 kg/m3.

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M.E. Mostafa, et al. Renewable and Sustainable Energy Reviews 105 (2019) 332–348

Fig. 1. Set up, schematic diagram of the pelletization process and hardness test of biomass pellet: (a) compression testing machine; (b) piston cylinder unit; and (c)
recorded force-displacement curve; (d) diametrical compression of the pellet and (e) breaking force versus displacement (i.e. load-deformation curve).

3.3. Moisture content of pellets The pressurized air method (Holmen tester or Ligno Tester) simu-
lates the mechanical stress that result when pumping the pellets from a
The moisture content of pellets could be analyzed based on the ISO truck using about 100 gm of pellets [98]. In the rotational movement
18134–1 standard which limited its value to be less than 10% [95]. In (tumbling can tester), about 500 gm initial mass of the hand sieved
most studies, researchers focused on the moisture uptake of the pellet pellets are tested in rotating chamber. The mechanical durability from
[36,43,67]. Moisture uptake is considered an important parameter be- the two methods could be determined using the formulae presented in
cause it affects the moisture content of the pellet over time especially Eq. (3).
pellets are stored before being used for energy production. Moisture mf
uptake of is measured by placing pellets in a humidity chamber set at Durability = ×100
mi (3)
30 °C and 90% relative humidity for five hours. At the first hour, the
weight of the sample is measured every 10 min followed by every where: mi is the initial mass of pre-sieved pellets before the handling
30 min for the next four hours. The kinetic of moisture sorption is process (gm) and mf is the remaining pellets mass after the handling
calculated according to Eq. (2). process (gm).
M Me For studies that produce pellets using single pelletization unit, it is
=e kt
Mi Me (2) hard to apply these methods to perform the durability test due to the
relatively huge number of pellets required. Therefore, other researchers
where M is the instantaneous moisture content (%), Me is the equili- conducted the durability test by sieving a randomly selected number of
brium moisture content that can be estimated after exposing the pellets produced pellets in a sieve with relatively big screen size (i.e. 3 mm
in the humidity chamber over 48 h (%), Mi is the initial moisture con- wire screen) for a period of time (~ 10–30 min) [49,99]. The durability
tent (%), k is the absorption constant (min−1) and t is the exposure time was calculated by weighting the pellets before and after vibrating
(min). process using the same formulae of the previous methods (see Eq. (3)).

3.4. Durability 3.5. Hardness

Mechanical durability (abrasive resistance) is defined as the ability The pellet hardness (compression strength) is defined as the max-
of pellets to remain intact during handling. High mechanical stresses imum crushing force a pellet can withstand before breaking when it is
that lead to pellet failure are created from pumping, transport snails subjected to a diametrical compression force between two horizontal
and conveyor belts. High durability means high quality pellets [10,37]. metal plates as illustrated in Fig. 1d. The hardness is one of the most
Low durability leads to high amount of fines which change the bulk essential characteristics of commercial pellets that must be taken in
density of the pellets, increase the losses during transport and storage consideration as it affects the mechanical strength of a single pellet and
and make disturbances within the pellet feeding systems. Durability is efficiency of storage and feeding processes [6,14]. Hardness test si-
determined according to the standard EN ISO 17831-1 [96] which re- mulates the compressive stress of pellets on each other during crushing
placed the standard EN 15210-1 [97]. According to ISO 17225-1 [87] in a screw conveyor and storage as a result of the weight of the pellets
for general requirements of solid biofuels, the minimum value of dur- on the top [14].
ability was set to be 97.5%. Some researchers analyzed the Meyer hardness (HM ) of a pellet by
Simulating the mechanical stresses that applied on the pellets from placing it horizontally on a steel plate and subjecting it to a diametrical
different sources is the best way to study the durability of produced compressive force at low speed (nearly 2–6 mm/min) until breakage as
pellets. These mechanical stresses were created either by Ligno Tester shown in Fig. 1d and e [1,6,36,67,72,99]. Meyer hardness (HM ) is de-
[98] or by rotational movement as recommended by ISO 17831–1 [96]. fined as the applied force divided by the projected area as illustrated in

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M.E. Mostafa, et al. Renewable and Sustainable Energy Reviews 105 (2019) 332–348

Eq. (4) [6,36,67]: 4.1.1. Effect of applied pressure on the density of pellets
It was reported that applied pressure has a positive effect on the
F
HM = pellet density [37,48,110–112]. The density of pellets increases with
(Dh h2 ) (4)
increasing the pressure until reaching a certain value beyond which the
where: h is the indentation depth (mm), F is the maximum force at pressure has no longer an effect [113]. Through the literature, this
which the pellet is broken (N) and D is the diameter of the pellet (mm). positive effect was emphasized by drawing the effect of pressure on the
According to Fell & Newton [100], the compression strength ( t ) can pellet density for various materials at different operating conditions as
be used to represent the hardness of the pellet as shown in Eq. (5) shown in Fig. 2. Jiang et al. [6] stated that the pellet density of mixed
[15,25,77,101,102]. sewage sludge with and Chinese fir (CFSP) and rice straw (RSSP) in-
creased with increasing the applied pressure above 55 MPa as shown in
2F
t =
(5) Fig. 2. At high pressure and temperature, protein and lignin of the
DL
materials squeezed out and the sludge particles diffused into the void
where: t is the compressive strength (MPa), F is the maximum force at fractions of biomass particles which increased the density of the pellets.
which when the pellet is broken (N), D is the diameter of the pellet Stelte et al. [76] showed that the density of beech and spruce straw
(mm) and L is the length of the pellet (mm). pellets increases greatly with increasing the compaction pressure as
Some researchers expressed the hardness of the pellets by dividing clear in Fig. 2.
the maximum breaking force by the pellet length [46], while others just
judged the hardness of the pellets by recording the maximum force at 4.1.2. Effect of applied pressure on durability and hardness
which the pellet break [37,40]. Generally, no limits were established The applied pressure during the pelletization process activates the
for hardness in pellets standards. According to the literature, the different binding mechanisms as the natural binders as starch, protein
hardness value of different biomass materials reached 25 kgf and the and lignin in the material are pressed out and produced good inter-
ideal value that ensures high-quality pellets was found to be 22 kgf particle bonding [10,46]. Durable and hard pellets are produced at high
[37,40,103,104]. pressures. The durability of pellets produced from maize residues in-
creased when the compaction pressure increased from 150 to 250 MPa
3.6. Energy consumption [45]. Carone et al. [48] found that there is no difference in the dur-
ability of olive pruning residues pellets when densification process
Applied energy mainly used to compress the biomass material and performed at a pressure between 70 and 175 MPa. Jiang et al. [6] stated
overcome the friction between the material and the cylinder. Therefore, that the hardness of sewage sludge-biomass mixed pellets increased
the energy consumption is defined as the work done by the force during with increasing the applied pressure.
the pelletizing process. During the compression and ejection of the
pellet, the force-displacement data were recorded by the control pro- 4.2. Effect of die temperature
gram that connected to the compression machine as shown in Fig. 1c.
The energy consumption in case of production (Ec, p ) and ejection (Ec, e ) The quality of pellets is determined based on the temperature
of the pellets could be obtained by integrating the force-displacement reached during the pelletization process [74,81,82,116–118]. In-
curve as shown in Eq. (6). creasing the temperature of die helps in softening and activating the
x components of inherent or added binders which affects the self-bonding
Ec =
0
F (x ) dx (6) processes and the pellet quality [14,37,74].

4.2.1. Effect of die temperature on the dimension and density of pellets


4. Effect of different parameters on the characteristic properties of A reduction in expansion ratio of the produced pellets is caused by
pellets increasing the die temperature [37,48]. For maize residue, it was found
that the expansion of pellets at high temperatures (> 60 °C) is lower
The quality and characteristics of produced pellets are determined than that at low temperatures at the same compaction pressure [45]. As
based on different operating conditions as pressure, temperature, the die temperature influences the density of the pellets, it would
moisture content, binder material and particle size. Although the sus- therefore, be interesting to discuss some experimental results on the
tainability of the energy from biomass pellets depends mainly on the temperature and density relationship from previous studies as shown in
quantity of the valid sources of feedstocks as claimed by most re- Fig. 3. High protein content in the component leads to high pellet
searchers, the operating conditions of the pelletization process are density at low pressure and high temperature as protein melts and flow
considered the spine of the sustainability. If these parameters were between the layers of biomass material acting as a binder during the
adapted correctly with different biomass materials, high quality pellets compression process [45,79]. After the produced pellets are left to cool
with good combustion characteristics would be produced which could down, lignin is hardened and protein is re-associated which enhanced
be considered a great economic and environmental gain. Table 1 the strength and density of pellets [48,72]. Jiang et al. [6] found that
summarizes the factors influencing the physical, mechanical and che- the density of mixed pellets increased with increasing die temperature
mical properties of different biomass pellets under different operating in the range of 30–110 °C and then decreased with further increasing of
conditions. die temperature. At low die temperature (i.e. 30 °C), the lignin and
protein contained in raw material didn’t act as a binder. Thus, resulted
4.1. Effect of applied pressure bonding forces were limited to short-range forces as hydrogen bridges,
van der Waals’ force, mechanical interlocking and free chemical bonds
Physical and mechanical properties of pellets are strongly affected which explain the low pellet density at low temperature [101]. On the
by the applied pressure [10,14,74,82]. Any biomass material contains other hand, in some previous studies, the temperature was found to
natural binders as lignin, starch, protein and water soluble carbohy- have a negative effect on density of the pellets [37,119]. Further in-
drate [10,17,36,48]. These binders are strongly affected by the applied creasing in die temperature resulted in lignocellulosic fibers plastici-
pressure during pelletization process. As pressure increases, solid zation which lowered the modulus of elasticity of biomass particles and
bridges, hydrogen bondings and van der Waals’ forces are formed be- made them more flexible. Therefore, empty spaces between and within
cause the binding components inside the material are squeezed the particles were formed which reduced the density of pellets. At ex-
[6,17,105]. tremely high temperature (i.e. 130 or 150 °C), nearly all moisture had

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M.E. Mostafa, et al.

Table 1
Summary of pellets characteristics at various operating conditions for different biomass materials.
Ref. Biomass material Operating parameters Characteristics of produced pellets

P T M dp Dp Lp bulk pellet Mp Ash HHV Du Strength


(MPa) (oC) (%) (mm) (mm) (mm) (kg / m3 ) (kg / m3 ) (%) (%) (MJ/kg) (%)

[40] Olive leaves (OL) Pelletizer Kahl 14–175 ˃60 9.0 < 2.50 6 12.3 < 600 < 1000 ‫ــ‬ ‫ــ‬ 19.64 88.6 13.3*
Olive prunings (OP) ˃60 9.0 2.50–4.00 6 24.0 ˃600 ˃1000 ‫ــ‬ ‫ــ‬ ‫ــ‬ ‫ــ‬ 21.0–24.86*
Olive wood (OW) 40–60 9.0 4.00–5.00 6 28.7 ˃600 ˃1000 ‫ــ‬ ‫ــ‬ 17.53 91.7 21.0–24.86*
[49] mixing moso bamboo with rice straw at ratio Laboratory pellet mill (L-175),
(5:0) ‫ــ‬ 16.0 < 2.00 6 13.8 540 1250 ‫ــ‬ 2.0 18.25 94.1 ‫ــ‬
(4:1) ‫ــ‬ 15.8 < 2.00 6 13.5 560 990 ‫ــ‬ 4.0 18.10 95.3 ‫ــ‬
(3:2) ‫ــ‬ 15.7 < 2.00 6 13.6 570 1000 ‫ــ‬ 6.0 17.5 97.5 ‫ــ‬
(2:3) ‫ــ‬ 15.6 < 2.00 6 13.8 600 1040 ‫ــ‬ 10.0 16.20 99.0 ‫ــ‬
(1:4) ‫ــ‬ 15.8 < 2.00 6 13.4 620 1050 ‫ــ‬ 13.0 16.00 98.7 ‫ــ‬
(0:5) ‫ــ‬ 15.9 < 2.00 6 13.2 635 1350 ‫ــ‬ 16.0 15.40 ‫ــ‬ ‫ــ‬

336
[6,43] Chinese fir-SS (CFSP) ˃55.0 ˃70 10.0–15.0 < 0.45 7 ‫ــ‬ ‫ــ‬ 1110 ‫ــ‬ ‫ــ‬ ‫ــ‬ ‫ــ‬ 5.0***
Camphor-SS (CSP) ˃55.0 ˃70 10.0–15.0 < 0.45 7 ‫ــ‬ ‫ــ‬ 1105 ‫ــ‬ ‫ــ‬ ‫ــ‬ ‫ــ‬ 4.7***
Rice straw-SS (RSSP) ˃55.0 ˃70 10.0–15.0 < 0.45 7 ‫ــ‬ ‫ــ‬ 1180 ‫ــ‬ ‫ــ‬ ‫ــ‬ ‫ــ‬ 5.3***
[67] Softwood Douglas fir 126.0 ˃200 10.0 0.35–0.45 6 21.0 ‫ــ‬ 111 ‫ــ‬ ‫ــ‬ ‫ــ‬ ‫ــ‬ 6.0*
[1] vigorous sugar maple 49–81.5 75–125 8.1–17.2 0.25–1.00 6 ‫ــ‬ ‫ــ‬ 1026 2.1–11.9 ‫ــ‬ ‫ــ‬ ‫ــ‬ 4.03**
Non-vigorous sugar maple 49–81.5 75–125 8.1–17.2 0.25–1.00 6 ‫ــ‬ ‫ــ‬ 1038 2.1–11.9 ‫ــ‬ ‫ــ‬ ‫ــ‬ 46.6**
[106] Mixed garden waste Flat pelletizer 80–90 5.0–35.0 6.25–25.4 12–15 31.1–45.1 ‫ــ‬ 409–1482 ‫ــ‬ ‫ــ‬ ‫ــ‬ 64.6–98.3 3.9–55.1*
[102] Treated wheat straw (TVm4D) ‫ــ‬ 95 ‫ــ‬ 1.00–1.6 6 ‫ــ‬ ‫ــ‬ 969–1036 ‫ــ‬ ‫ــ‬ ‫ــ‬ ‫ــ‬ 0.4–0.7***
[107] Corn cob Flat pelletizer 85 15.0–20.0 3.15 6 ‫ــ‬ 560–690 ‫ــ‬ 10.5–12.0 ‫ــ‬ ‫ــ‬ 70.0–95.0 ‫ــ‬
[108] Corn stover with starch flour Flat pelletizer 50–65 15.0–19.0 2.00–8.00 6 ‫ــ‬ 548–720 ‫ــ‬ 11.0–16.0 ‫ــ‬ ‫ــ‬ 88.0–98.8 ‫ــ‬
Corn cob with starch flour Flat pelletizer 50–65 15.0–19.0 2.00–8.00 6 ‫ــ‬ 510–644 ‫ــ‬ 8.0–15.0 ‫ــ‬ ‫ــ‬ 77.9–99.2 ‫ــ‬
[109] Canola meal Bench-scale extruder ‫ــ‬ ‫ــ‬ 0.35 6 ‫ــ‬ 936 ‫ــ‬ ‫ــ‬ 6.5 ‫ــ‬ >99.0 6.4*
Torrefied canola meal Bench-scale extruder ‫ــ‬ ‫ــ‬ 0.35 6 ‫ــ‬ 747 ‫ــ‬ ‫ــ‬ 7.8 23.50 >99.0 3.8*
[79] microalgae 79.7–111.6 50–100 10.2 6 ‫ــ‬ ‫ــ‬ 1192–1229 ‫ــ‬ 2.5 27.80 82.0–96.5 ‫ــ‬
Sawdust 79.7–111.6 50–100 9.9 0.58 6 ‫ــ‬ ‫ــ‬ 817–1038 ‫ــ‬ 0.1 19.42 29.0–85.8 ‫ــ‬
25% sawdust+ 75 microalgae 79.7–111.6 50–100 ‫ــ‬ 6 ‫ــ‬ ‫ــ‬ 1155–1207 ‫ــ‬ 1.7 25.32 72.4–97.7 ‫ــ‬

* ** ***
Notes: dp the particle size of raw biomass material, Dp the pellet diameter, kgf, N/mm, MPa.
Renewable and Sustainable Energy Reviews 105 (2019) 332–348
M.E. Mostafa, et al. Renewable and Sustainable Energy Reviews 105 (2019) 332–348

Fig. 2. Effect of compaction pressure on the pellet density for different biomass Fig. 4. Effect of die temperature on the durability of pellets for different ma-
materials (produced from data in [43,45,76,114,115]). terials at different operating conditions (produced from data in
[38,45,79,120,124]).

4.2.2. Effect of die temperature on durability


When the die temperature exceeds the glass transition temperature
of the biomass material, wax and lignin move from the inside towards
the outside of the pellet. Wax coats the outside surface of the pellet
while lignin bonds to layers. Too high temperatures could dry the
biomass material leading to blockage of the materials inside the die and
reduction in the durability of the pellet [121]. Natural binding in-
gredients as lignin, hemicellulose, sugar, fat, protein and starch in
biomass materials could be activated at a temperature ranging from 75
to 150 °C [122]. Starch, protein, and lipids binding are caused by the
effect of gelatinization of starch at higher temperature 100–200 °C [45].
Different biomass materials have different values of glass transition
temperature [45,123]. With increasing the die temperature, most re-
searchers found that the durability of produced pellets increases
[23,74] while others noticed a negative effect on the durability
[119,120]. These two effects are summarized in Fig. 4 based on the data
collected from previous studies for various materials. The durability of
maize residues pellets increased when the pelletization temperature
increased from room temperature to 80 °C [45]. The durability of pure
microalgae and mixed microalgae with sawdust increased with in-
creasing the temperature because the protein denaturation and starch
gelatinization of microalgae material acted as a binder during pelleti-
zation [79]. Besides the positive effect of the temperature on the dur-
ability of pistachio pellets, Ramezanzade and Ghazanfari Moghaddam
[120] noticed high durability values of the pellets that heated at higher
moisture levels (i.e. 12%) due to the liberation of the lignin and resins
that formed strong bonds between the particles when contacted with
Fig. 3. Effect of die temperature on pellet density for different materials (pro- the moisture. The negative effect of the temperature on the durability
duced from data in [1,43,45,79,120]).
was noticed by Ishii and Furuichi [38] who noted that the durability of
rice straw pellets decreases with increasing the die temperature as
evaporated, which left a negative impact on the quality and density of
shown in Fig. 4. This phenomenon can be interpreted in light of the
the pellets. These findings are supported by Gilbert et al. [14] who
plasticization of lignocellulosic fibers, low modulus of elasticity of
reported the similar result which showed that pellet density decreased
biomass particles and the formed voids between particles.
at 125 °C.

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Fig. 5. Effect of die temperature on the compression strength of different bio-


mass pellets produced at different conditions (produced from data in
[1,6,74,120,125]).

4.2.3. Effect of die temperature on hardness


At high temperatures, the binding mechanisms are activated which
results in pellets with high strength as illustrated in Fig. 5a for various
types of biomass materials [45,46]. Through the analysis of fracture
surface, Stelte et al. [104] reported that weak bonding appeared be-
tween adjacent particles in pellets at low temperature. Nguyen et al. [1]
ascribed the enhancement of the durability of least and most vigorous
trees pellets, as shown in Fig. 5a, to the presence of hot water ex-
tractives as simple sugars and starches that plasticized and acted as a
binder in the presence of heat and moisture. The increased strength of
pistachio tree pruning pellets was attributed to the extracted resins and
lignin from the cells at elevated temperatures which bond the pellet
particles together with high forces [120]. Jiang et al. [6] stated that the
hardness of RSSP, CFSP and CSP pellets increased at low die tempera-
ture (up to 70 °C) and then decreased at high temperature levels (150
Fig. 6. Effect of pressure, temperature, and moisture content on the energy
°C) especially for RSSP as shown in Fig. 5b. At high temperature, the
consumption of pellets production (produced from data in [43]).
protein became brittle after excessive denaturation and straw materials
had chemical weak boundary layer caused by the wax in the straw
which lowered the compression strength of straw pellets (RSSP) com- elastic when the temperature of the material is lower than the glass
pared to wood pellets (CFSP and CSP) [104]. The compression strength transition temperature and viscoelastic when this temperature becomes
of water hyacinth showed a positive increased at the temperature range near or higher than the glass transition temperature [44]. The con-
of 80–100 °C due to the plastic deformation of biomass material that sumed energy decreases with increasing the die temperature due to the
enhanced the permeant bonding between particles. At high levels of improvement of the plasticity of particles that resulted from the acti-
temperature (>100 °C), charred and discolored water hyacinth pellets vation of lignin, protein and carbohydrate as shown in Fig. 6a [43,69].
were produced which reduced the strength again [125] as shown in Hosseinizand et al. [79] stated that the compression and extrusion
Fig. 5b. energy of mixed sawdust and microalgae pellets decreased with in-
creasing the temperature due to the enhancement of hydrogen bonding
and solid bridges between particles that resulted from gelatinized starch
4.2.4. Effect of die temperature and pressure on energy consumption
and the formation of amine, hydroxyl and carboxyl functional groups.
The temperature of the material affects positively the applied work.
The energy consumption increased with increasing compaction pres-
Lower work and compression pressure are required at high temperature
sure at the same die temperature as shown in Fig. 6b [43]. This effect
as a result of the thermal softening of fibers [43,44]. The reaction of the
could be changed if the pelletization process performed under the
biomass material with respect to the applied pressure is considered

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M.E. Mostafa, et al. Renewable and Sustainable Energy Reviews 105 (2019) 332–348

interaction effect of different operating conditions as pressure, tem- materials due to filling the empty spaces by small particles and greater
perature and moisture. surface area resulted from finely ground materials [6,10,48]. Thus, the
absorption of heat and moisture was facilitated due to the resulted great
4.3. Effect of material characteristics surface area which in turn activates the binding properties of chemical
components. Pellet density of milled material was found to be higher
The type, chemical composition, moisture content and particle size than that of large chopped particles [129].
of biomass materials have an essential effect on the quality of produced The moisture content of the biomass material has a significant effect
pellets [14,37,48,74,82]. Natural binding components as hemi- on the density of the produced pellets [111]. Generally, density in-
celluloses, cellulose, lignin, starch, protein and water soluble carbo- creases with increasing the moisture content until reaches a maximum
hydrate in biomass materials play an important role regarding to phy- value and then decreases with further increasing of moisture
sical properties of produced pellets especially at high pressure and [23,37,44,130]. Until reaching the optimum moisture content, the
temperature [6,36,43]. These natural binders are the main cause of water content fills the pore space between particles and contributes in
solid bridges which creates bonding between particles [17,43,49]. The increasing the mass of the pellet which in turn increases its density
moisture content of the biomass material is considered to be the most [46]. Beyond the optimum value of moisture content, the extra water
important factor that affects the quality of the pellets [105,125,126]. It occupies the volume of the material and increases the volume expan-
acts as a lubricant and binder in the pelleting process [6,43]. The water sion and resistance to compression, which decreases the density
content of any biomass material increases the contact area of the [106,130]. Higher moisture content may stick in the particles and
particles which in turn makes water to be as a film type binder prevent releasing of natural binders due to the incompressibility of
with hydrogen bonding. Denaturation of proteins, gelatinization of water [10]. Fig. 7 shows the effect of raw moisture content on the
starch, thermal softening of biomass and recrystallization of carbohy- density of pellets for various types of biomass materials. In Fig. 7a, it is
drates change with increasing the temperature in the presence of clear that the optimum value of moisture content corresponding to the
water [6,17]. The optimum amount of moisture content that re- maximum pellet density changes when different materials are used
commended for high quality pellets from woody and biomass materials under different conditions. Jiang et al. [6] and Li et al. [43] noted that
at different conditions were found to be in the range of 5–28% 10–15% moisture content was the optimum value to produce high
[1,10,37,38,46,48,69,70,76,105,119,125]. Hydrogen bonds and van quality RSSP, CFSP and CSP pellets with high density. The pellet density
der Walls’ forces are the most common inter-molecular attractive forces of fescue, alfalfa, sorghum, triticale, miscanthus and willow pellets
that produced during densification. Van der Walls’ forces are strongly decreased when the moisture content increased beyond an optimum
affected by the particle size of the biomass material as its value decrease value of 10% due to the increase in the molecular mobility of lignin and
with increasing particle size [7]. hemicelluloses and other extractives [12]. At higher moisture contents
of canola, wheat, barley and oat straw, the density of produced pellets
4.3.1. Effect on the dimension and density of pellets increased [111]. Some studies reported that with increasing the
Increasing the moisture of the biomass material can make particles moisture content of the biomass material the density increases con-
agglomerate better, which in turn provides long pellets [37,48,70]. tinuously, while others reported a reverse effect showing that the
After storing the produced pellets at 4 °C for two weeks, Jiang et al. [6] density decreases as shown in Fig. 7b and c. These results could be
observed a big difference in the resulted expansion ratio when different ascribed to performing the pelletizing experiments using an amount of
materials were used. They found that the expansion ratio of RSSP pel- moisture content lower or higher than the recommended optimum
lets was lower than that noticed for the CSP and CFSP pellets. This value for these materials under specific operating conditions.
result was regarded to the low lignin glass transition temperature of rice
straw material compared to Chinese fir and camphor [127]. Lower 4.3.2. Effect on the moisture content of pellets
volume expansion was noticed for biomass-sludge mixed pellets when Jiang et al. [36] found that the absorption rate (k) of pure biomass
compared with the expansion of pure biomass pellets which indicated pellet was higher than that of the biomass-sludge mixed pellet due to
that the compression deformation of the particles was not entirely the hydroxyl groups of hemicelluloses in biomass materials. For mixed
plastic [36]. pellets, sewage sludge replaced the lignocelluloses and its fat squeezed
Obidziński et al. [128] found that the highest pellet density could be out and coated the surface of mixed pellets which in turn slowed down
obtained when potato pulp added to the buckwheat hulls material with the moisture absorption rate. Compared to woody biomass materials,
a percent of 10%. The bulk density of Moso bamboo pellets increased the equilibrium moisture content of rice straw pellets was found to be
when mixed with rice straw and pine [26,49]. Higher pellet density was higher [36] due to the lower content of hydrophobic lignin and higher
obtained when the sewage sludge material mixed with rice straw content of hydrophilic hemicelluloses in rice straw [131,132]. On other
(RSSP) compared to that obtained when it was mixed with Chinese fir hands, the presence of waxes in straw diffused to the pellet surface the
(CFSP) and camphor (CSP) as shown in Fig. 7a [6]. These results can be lowered the absorption rate which in turn resisted the moisture ab-
ascribed to the presence of the silica in the rice straw and sewage sludge sorption [104]. At high moisture levels, the die cooled down and pre-
[101]. The density of CFSP pellets exceeded that of CSP pellets because vented further evaporation which led to a high moisture content of
the softwood Chinese fir particles are composed of thin strips that can poplar and pine mixed pellets [57].
form more structural gaps in which sewage sludge particles were settled
and formed more compact structure, while camphor particles are like 4.3.3. Effect on durability
square block and have high content of cellulose and hemicellulose that At high temperature and pressure, the ingredients of the raw ma-
weakened the bonds between the particles due to their elasticity and terial are melted, molecular diffusion is enhanced and solid bridges are
stiffness. Returning to Fig. 2, Mani et al. [115] reported that the pellet formed after cooling due to the solidification of the melted ingredients
density of corn stover showed high values at low compaction pressures [44,135]. The durability of bamboo and barley straw increased when
compared to wheat and barley straws and switchgrass pellets due to the rice straw and sawdust were added to the two materials, respectively
high protein content in the corn stover material that melted at high [49,70]. The durability of pellets was improved at lower values of lignin
temperature and acted as a binder during pelletization. The density of content of the biomass material due to the adhesion forces between the
spruce sawdust pellet is higher than that of birch due to the high con- crystallites that resulted from noncrystalline wood polymers [10].
tent of extractives on birch material which formed a weak boundary Comparing with woody materials, lower durability values were ob-
layer and blocked the sites of hydrogen bonding [46]. Regarding the tained when herbaceous materials were used for producing pellets due
effect of particle size, high-density pellets are produced from fine to their lower lignin and higher extracts content that formed a weak

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M.E. Mostafa, et al. Renewable and Sustainable Energy Reviews 105 (2019) 332–348

until reaching its maximum value and then decreases with further
moisture increase. They attributed this claim to the swelling and dis-
integration of the pellets that caused by biphasic mixture (liquid and
solid) which caused the inter-particle forces to disappear entirely. The
durability of garden waste pellets decreased when the moisture content
increased from 25% to 35% due to the formation of surface cracks that
resulted from the reduction in cohesive forces [106]. Ghasemi et al.
[137] also stated that the reduction of the durability after reaching the
optimum amount of moisture content of feedstock could be attributed
to the incompressibility of the mixture that resulted from filling the
voids in the saturated mixture with water that acted as a lubricant film
and prevented the compression. From literature, different studies pre-
sented several claims regarding the effect of moisture content on the
durability of pellets. Some researchers claimed that no effect of the
moisture [49,138] and others stated that the durability increase with
increasing the moisture [15,70]. This contradiction resulted from the
effect of the material used and other conditions applied in different
studies as heat and compaction pressure [15]. The presence of cracks on
the surface of pellets, increases the susceptibility of pellet breakage
which in turn affects negatively on the durability of the pellet [10].
Aragón-Garita et al. [139] explored fewer cracks on the surface of the
pellets that produced at high moisture content compared with that
produced at low moisture levels because the moisture strengthened the
bonds between particles and decreasing its amount reduced the capil-
lary force that maintains the structure of the pellet which in turn leaved
cracks.

4.3.4. Effect on hardness


It was noted that the hardness of the produced pellets improved
with increasing the sewage sludge ratio in the mixture due to the sy-
nergistic effect of protein in the sludge and lignin in the biomass ma-
terials that covered the particles of the pellets that improved the
bonding and solid bridge between particles [6,17,36]. From SEM
graphs, clear gaps and spaces were identified for pellets produced at
20% sludge compared to that produced at 80% sludge which enhanced
the relative movement of particles and reduced the resistance of the
pellet to deformation leading to lower hardness [72]. The presence of
more cross-links in softwood lignin that caused by the absence of
methoxy groups increased its glass transition temperature and hardness
compared to hardwood material [6,127]. The strength of least vigorous
trees pellets weas higher than that of most vigorous trees pellets due to
the high amount of lignin and proteins entrained in least vigorous trees
that softened at all temperature levels and formed strong solid bridges
(See Fig. 5a) [1]. The compression strength of wood and canary grass
pellets were found to be higher than that of wheat straw and birch
pellets due to the high amount of extractives (waxes) that concentred
Fig. 7. Effect of moisture content of different biomass materials on the density on the straw and birch surface that worked against the hydrogen
of produced pellet (produced from data in [1,43,46,105,107,108,111,124, bonding and prevented the binding between particles [46,104]. Com-
125,133,134]).
pared to canola hull, canola meal pellets showed higher strength due to
the binding effects that resulted from the denaturation of protein during
boundary layer and decreased the friction with the die channel [47]. the pelletization process [109]. Decreasing the particle size of material
Cheng et al. [136] observed that the lignite pellets broke up into a improves the compressive strength of the pellets due to the enhance-
powder after abrasive resistance testing compared to wheat straw pel- ment of natural binders flow as lignin and protein and mechanical in-
lets that maintained a flaky structure. They attributed this result to the terlocking between fibers and particles [77,140]. The hardness of the
composition of wheat straw that mainly consists of cellulose, hemi- pellets increases with increasing the moisture content until reaching the
cellulose and lignin, which collapsed together and formed a mechanical optimum value of moisture then decreases as shown in Fig. 8. The
lock that resisted the destructive forces. Different studies claimed that porosity of produced pellets decreases with increasing the moisture
the lower particle size of biomass material had a great effect on en- content of the biomass material. Therefore, a larger bonding area cre-
hancing the durability of the produced pellets [10,47,48] for to the ated, which led to pellet with high strength [46]. The strength of the
same reasons discussed previously in (Section 4.3.1) for the density. pellets decreases at higher moisture content due to the plasticization of
Several researchers found that the durability of pellets increases the polymer and the formation of a thick water layer on the surface
significantly with increasing the moisture of biomass material due to [141]. Lisowski et al. [142] found that the strength of biomass pellets
the film-type binder effect of water that promoted the bonds between decreased at high moisture content (>20%) due to the inability of fi-
individual particles via Van der Walls’ forces [23,37,124]. However, brous biomass to absorb the moisture. Therefore, the water accumu-
other researchers [10,70,106,130,137] confirmed this result, they lated on the surface of the particles causing extra particle-to particle
stated that the durability increases with increasing moisture content lubrication.

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out of the material that increased the viscosity between the pellet and
the inner surface of the die resulting in a reduction in the relative
motion between particles.

5. Interaction effect between operating parameters

It is clear that all operating parameters have different effects on


both the physical and mechanical characteristics of produced pellets.
Different values of pellet characteristics were obtained at nearly the
same range of operating parameters due to the variations on the values
of other fixed conditions. So, judging the effect of individual operating
parameters on the quality and characteristics of produced pellets by
fixing the other conditions can’t express the actual effect of this para-
meter. Therefore, some researchers investigated this interaction effect
by producing pellets at different controllable operating parameters
[1,37,44,46,48,70,102,105,119]. The operating conditions as pressure
(P), temperature (T), moisture (M), particle size (S), die diameter (D),
binder (B), storage time of raw material (tst ), steam treatment (sttr ), and
holding time (H) are considered the independent variables, while the
characteristics of pellets as length (Lp ), diameter (Dp ), pellet density
( p ), bulk density ( b ), moisture (Mp ), durability (DU), percent fines (F),
hardness (H), compression strength ( c ), tensile strength ( t ), modulus
of elasticity (E) and friction (F) are considered the dependent variable.
They proposed different models, as summarized in Table 2, to describe
the effect of these independent variables as shown in Eq. (7).
n n n n
Y = bo + bi x i + bii x i2 + bij x i xj
i=1 i=1 i=1 j=1 (7)

where, Y is the dependent variable, x i and x j are the independent


variables, bo is the intercept coefficient, bi , bii , and bij are the linear,
quadratic, and interaction terms, respectively and n is the number of
Fig. 8. Effect of raw material moisture content on the compression strength of independent variables.
pellets (produced from data in [1,6,46,74,120,125]).
6. Effect of binders

4.3.5. Effect of on energy consumption Lower content of lignin, proteins and starches within the lig-
The higher cellulose and hemicellulose content of the biomass ma- nocellulose matrix may require adding additional binders to improve
terials contributes in increasing the plasticity of the samples which the quality of the produced pellets by making strong inter-particle
lowers the energy consumed during the pelletizing process [43]. The bonding [37,67]. Attention must be paid to binder selection especially
grass biomass materials as rice straw needs less energy compared to its cost and environmental impact [32,144,145]. The most common
woody materials due to the visco-elastic components (hemicelluloses) types of additives for pellets production are organic and inorganic ad-
of rice straw which provided viscous effect among lignin and cellulose, ditives [21]. Organic additives are the primary products of forestry and
reduced the elasticity and increased the plasticity of particles agricultural biomass as for instance maize starch, shredded maize,
[36,67,143]. Increasing the ratio of sawdust in the mixture of pine cocoa shells, corn flour, potato flour and vegetable oil. These binders
sawdust and microalgae increased the total consumed compression are considered to be a reasonable choice due to their availability and
energy due to the fibrous structure of sawdust particles that enhanced low cost [32]. Different types of organic binders as starch, sodium si-
the friction between biomass particles and wall [79]. The lower com- licates, latex, phenol formaldehyde, molasses lignin powder, rapeseed
pression energy was observed in the case of blends containing micro- flour, coffee meal, pine cones and bark were used by various re-
algae due to the enhancement of the pellets' movement that resulted searchers [25,32,37,144,146–151]. According to standards for en-
from the lubricant effect of the oil squeezed out from the microalgae ergetic pellets, 2% (w.t.%) or less are considered the best economically
cells during densification. amount for producing pellets with binder additives [10,37]. Inorganic
Jiang et al. [36] also found that more energy was needed for making additives were handled in some studies [94,99,149,152]. Si et al. [99]
pellets from pure biomass materials compared with that of biomass- used carboxymethyl cellulose (CMC) as a new additive solution due to
sludge mixed pellets because the synergistic effect of protein in sludge its cost-effective and friendly environmental impact when used in low
decreased the modulus of elasticity and increased the plasticity of the proportions (< 5%).
mixture during pelletization. The power consumption for the pelleti- Most binder materials that used previously were found to reduce the
zation process decreased when the content of potato pulp and rapeseed energy consumption and increase the density, strength and durability of
cake increased in the mixture that combines these materials with the produced pellets as shown in Figs. 9 and 10 [5,25,32,37,99,
buckwheat hulls and sawdust, respectively [53,128]. Li et al. [43] 146,148,150–155]. This result was attributed to the behaviour of the
found that the consumed energy decreased when the moisture in- used additives under different conditions. Some reasons are related to;
creased in the range from 5% to 20%, as shown in Fig. 6c, due to the the low particle sized of bentonite and lignosulfonate binders that filled
lubrication and adhesive action effects between particles that resulted in the voids and formed films around biomass particles which resulted
from the added water. They found that the energy consumption raised in particle bonding [25], the high tensile strength of low density
again when the moisture content increased to reach 25% because extra polyethylene (LLDPE) binder that created a strong mechanical inter-
amount of water caused the carbohydrate and protein to be squeezed locking of the biomass particles [92], the agglomeration and

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Table 2
Regression equation models for characteristics of biomass pellets produced from materials.
Ref. P T M D S B
(MPa) ( ) (%) (mm) (mm) (%)

[37] – <50 and >50 12–17 6 and 8 <4 0–2


Rice straw with starch binder pellets
DU = 88.17+13.52M+4.61M2 +11.07S +3.74B2 +3.81T -3.89D2 -6.66MB
H = 20.55+0.93M +0.54M2 +1.37B -0.98MB
b = 639.53+49.87M2 +62.79S +32.33B2 +76.37D -32.63D2
p = 1195.2+102.53BD
Mp = 12.5+3.5M -0.61M2 +1.08S -0.59T -1.02D +0.68MB -1.23MD +0.66 BD
Lp /Dp = 3.59-1.96D +0.76D2
[1] 0.48–0.81 75–125 8.1–17.2 6.25 0.25–1 –
Most vigorous trees pellets
p = 958+40T +93M +70P -36S +10T2 -53M2 -7P2 -16TM -5TP +5TS -10MP
F = 29.6-7.79T +-3.65M +3.47P -7.54S +2.03T2 -1.29M2 +0.73S2 +1.51TM +1.38TS -0.37MP +1.78MS -0.77PS
c = 25.8+12.7T +17.4M +10P -8.1S +2.2T -8.2M +3.3S -3.5TM -2.7TS -1.9MP -1.3PS
2 2 2

Least vigorous trees pellets


p = 992+24T +67M +67P -42S +11T2 -42M2 -8P2 +6S2 -12TM +6TS -10MP
F = 23.8-4.86T +3.58P -5.96S +1.2T2 -1.61M2 +0.72S2 +1.01TM +1.03TS -0.41MP +0.89MS -0.53PS
c = 28.3+15.6T +13.8M +10.4P -7.2S 2.2T -5.8M -0.9P +2.6S -4.9TM +0.9TP -3.6TS -1.8MP -1.3PS
2 2 2 2

[46] 200–400 25 and 80 2–8 12 0.25–0.5 –


Birch (Betula pendula) pellets
p = 869.507+1.433 T +0.418P +6.952M
c = -6.891+0.234T +0.006P +0.315M
Reed canary grass (Phalaris arundinacea) pellets
p = 954.992+1.215 T +0.377P +3.26M
c = -14.068+0.491T +0.036P +1.034M
Spruce (Picea abies) pellets
p = 979.268+1.607 T +0.333P +3.141M
c = -15.149+0.477T +0.019P +0.825M
[105] – – 8.4–13.1 – – –
Pine sawdust pellets
p = 660-99.4M +32.9tst -11.5Sttr +16MSttr -17.2M2 -23tst 2
DU = 94.7-5.5M +8.6tst +1.2Sttr +7.5MSttr -1.3tst Sttr -6.1M2 -5.1tst 2
F = 0.78+0.71M -2.25tst -0.25Sttr +1.13M2 +1.8tst 2
[44] 139.3 and 159.2 60 and 70 8 and 10 8 0.15–0.3 –
Hardwood pellets
Lp = 31.8-1.25M -0.16T -0.326P -0.011H +0.015MT
Softwood pellets
Lp = 21.8-0.479M -0.023T -0.123P -0.005H
139.3 and 159.2 60 and 70 8 and 10 8 0.3–0.425 –
Hardwood pellets
Lp = 40.2-2.19M +0.201T -1.15P -0.009H +0.019MT +0.101MP
Softwood pellets
Lp = 20.1-0.372M -0.016T -0.014H -0.002MH
[48] 71–176 60–150 5–20 6 1–4 –
Olive tree pruning residues pellets
p = 0.31+0.11P +0.62T -0.52M -0.19S -0.09PT -0.04P2 +0.14T2 -0.28M2 -0.14S2 -0.09PM-0.08TM +0.13TS -0.1MS +0.08PTM+0.05TMS +0.02PTMS
E = 0.06P +0.72T -0.58M -0.16S +0.16T2 -0.09M2 -0.08S2 -0.06PM-0.25TM +0.07MS +0.07TMS
[120] – 50–100 8–16 10 1–3 –
Pruning residues of pistachio trees pellets
DU = 1.54+1.126T -0.02S +7.291M -0.0041T2 -1.779S2 -0.1982M2 +0.0127TS -0.0304TM +0.3375M
F = 41.59-0.4277T -4.933S -1.8875M +0.00177T2 +0.7917S2 +0.03802M2 +0.01267TS +0.00717TM +0.0417SM
p = 427.1+4.21T -S +69.32M +0.0091T2 +8.35S2 -1.517M2 -0.514TS -0.283TM -3.171SM
c = -161.48+1.721T -33.33S +14.53M -0.0067T2 -7.075S2 -0.4964M2 -0.0647TS -0.0223TM -0.129SM

recrystallization by molasses and molasses/lime binders that formed Using oil cake and maize starch as binders reduced the energy con-
solid bridge [156], the electrostatic forces between the particles that sumption during pelletization due to the enhanced plasticity of the
resulted from adding GMC which led to the formation of strong bonds biomass material that resulted from the starch and the reduction of the
and polyelectrolytes [97], the higher viscosity of crude Glycerol and friction between particles that resulted from the lubricating ability of
persea kurzii kosterm powder that resulted in forming films around the these additives [148,153].
biomass particles during pellza/etization which caused a stronger par- Si et al. [99] and Hu et al. [144] noticed that the energy consumed
ticle bonding [151], the adhesive properties of lignin in lignin powder for producing biomass and biochar pellets decreased with increasing
and coffee meal and protein in rapeseed flour that plasticized during the the amount of binder materials, as shown in Fig. 9, due to the ce-
pelletization process and acted as a binder between biomass particles mentation of the material particles. Using starch as binder material
[32,146,150,152] and the high viscosity of coal tar residue (CTR) that wasn’t suitable for producing biochar pellets as it didn’t alter the
adsorbed on the surface of biomass particles and formed strong che- strength of the produced pellets as shown in Fig. 9b [144]. Si et al. [99]
mical bonds between adjacent particles similar to solid bridges [136]. noted that the strength and durability of rape straw pellets decreased

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Fig. 9. Effect of the type and amount of binder material on the energy consumption and compressive strength of various biomass pellets (produced from data in
[99,144]).

while the energy consumption increased with increasing the CMC binding properties of lignocellulosic biomass materials [78]. Also, new
content as illustrated in Figs. 9a and 10 a. Also, Ahn et al. [32] observed chemical bonds are formed after steam explosion treatment due to the
the same phenomenon of durability reduction when bark and pine change in the cellulosic structure and lignin activation [158].
cones were used as binders as shown in Fig. 10b. They attributed these A considerable amount of literature has been published from the
results to the presence of wax in the rape straw material that reduced production of pellets from steam-exploded materials [67,143,159,160].
the adhesive and van der Waals forces between adjacent particles re- Researchers claimed that biomass pellets made from steam-exploded
sulting in low bonding effect and the low chemical reactivity of the materials are more dimensionally stable and less hygroscopic compared
tannin entrained in bark and pine cones binders, besides their large to untreated. Different methods and conditions for performing steam
particle size and high moisture content. explosion treatment could be identified form previous studies
[67,78,143,161,162]. The breaking strength of steam-exploded pellets
increases due to the restructure of lignin that resulted from the thermal
7. Special conditioning technologies of raw materials
degradation of hemicellulose [78,159,163]. Lam et al. [67] attributed
the higher hardness of the steam-exploded Douglas Fir pellets to the
7.1. Steam explosion pre-treatment of raw materials
additional bonding strength that caused by the formation of highly
branched polysaccharides by reverse reactions of monosugars during
Sometimes, the natural chemical compounds of biomass materials
pelletization. Extra steam explosion treatment prevents the close con-
are not enough to contribute in generating the binding force between
tact between bonding sites of the lignocellulose particles, thus reduces
particles during the pelletization process. In this situation, there are two
the pellet strength [163,164]. On the other hand, experimental results
ways to be followed. The first one is to use natural and synthetic
revealed that extra steam treatment acts as lubricant and plasticizer
binding agents as discussed in Section 6. The second solution can be
thereby reducing the energy required for making pellets [164].
conducted by making an alteration of the physical/chemical structure
Steam exploded pellets have a higher single pellet density than
of biomass materials to free up the required chemical constituents. This
untreated pellets. This is likely because the binding role of lignin and
alteration is called steam explosion pre-treatment. Some researchers
sugars between particles was enhanced in case of pre-treated materials
named steam explosion process as wet torrefaction process in which the
[67,78,165]. This result also was attributed to the poor adhesion for
biomass material is treated either in a steam chamber or in hot water
untreated pellets due to boundaries and gaps between individual par-
[67,157]. The structure of cellulose-hemicellulose-lignin matrix could
ticles and stacking of particles on each other after compression
be modified by steam pre-treatment processes that enhance the natural

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M.E. Mostafa, et al. Renewable and Sustainable Energy Reviews 105 (2019) 332–348

Fig. 10. Effect of the type and amount of binder on the durability of produced pellets (a) inorganic binder and (b) organic binder (produced from data in
[32,99,146]).

[17,104]. The volumetric contraction of relaxed steam-exploded pellets dust during handling resulting in explosion risk [72,109,175,178].
increased with increasing treatment severity due to the increased These problems were resolved by adopting different torrefaction and
compressibility of particles and the reduced internal stresses and spring pelletization conditions [169,170]. Some researchers improved the
back effect that built during compression [67,78]. Different researchers durability and density of and reduced the energy consumption of tor-
reported that the durability of pellets is improved by steam explosion refied pellets by adding glycerol and bean cake (CAS) as binders and
[67,78,157,161,166]. treating the materials at different torrefaction temperature [153,178].
Lam et al. [67] revealed that the energy consumption of the treated Although the energy consumption increased and strength of the pellets
sample was higher than that of the untreated sample due to the lower decreased with increasing the degree of torrefaction, this effect was
elastic compression of treated sample that caused by the broken cell inversed by adding CAS as a binder material. Azargohar et al. [109]
structures. Also, treating the biomass material with steam destroyed the found that the mechanical strength torrefied canola meal pellets in-
interfacial bonding between cellulose and lignin which acted as a vis- creased significantly with adding alkali lignin as a binder material. As
coelastic interface between them. Thus, the steam exploded material the consumed energy for torrefaction depends on the moisture content
was brittle because the modulus of elasticity in the elastic region in- of the material, pre-drying samples before torrefaction is considered a
creased [165]. They also claimed that the increase in compression en- necessary step. As drying is an energy consuming processes, the torre-
ergy consumption was due to the higher energy required to overcome faction of wet materials is considered impractical. Hydrothermal car-
the friction between the rough steam-treated particles during the bonization (HTC) in a newly developed technique that improves the
packing before the compression stage [167]. In another study per- densification characterization of wet biomass materials without using
formed by Lam et al. [161], it was noted that the energy consumption of binder additives [180]. Ghiasi et al. [176] proposed a new efficient
producing pellets was low in case of steam exploded material compared scheme for producing torrefied pellets by making torrefaction sub-
to untreated material due to the smaller particle size of the steam ex- sequent to pelletization.
ploded material particles, which made it easy to compress the material
into the most packed structure under applied force. The moisture
8. Evaluation and future work of biomass pellets
sorption rate of steam-exploded wood pellets was found to be slower
than of the untreated wood pellets [67,165,168].
8.1. Environmental, policy and techno-economic analysis

7.2. Torrefaction Biomass pelletization technology showed various benefits regarding


the environmental protection due to the low levels of emissions com-
One of the most efficient methods for improving the properties of paring with coal and fossil fuels. As known, there are many countries
biomass material is torrefaction [169–171]. Torrefaction is a pyrolysis that are vigorously polluted as a result of depending on the coal-fired
process that occurs at 200–300 °C in an inert atmosphere as nitrogen plants, as China and India for example, although they possess a huge
[172–174]. Different characteristics of biomass materials are improved amount of agricultural and forest residues. The situation is more ter-
by torrefaction. rible for the countries that rely on importing coal or gas due to the high
Recently, different studies focused on the production of pellets from cost. Thus, the development of densified solid biomass biofuel became a
torrefied biomass [71,153,155,175–179]. Although the characteristics must as they have the ability to minimize the total cost of energy
of torrefied pellets are better than conventional pellets, their strength production, reduce the greenhouse effect, protect the environment ef-
and durability are low which cause them to break and generate fine fectively and has broad development prospects. Actually, the price of

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M.E. Mostafa, et al. Renewable and Sustainable Energy Reviews 105 (2019) 332–348

producing solid biofuel is to some extent high. Therefore, the energy Program of China (No. 2016YFE0204000), the National Natural Science
policy must be adjusted by the government to control and reduce the Foundation of China (NSFC) (Nos. 51576086,51576081). The authors
price of solid biofuels. Form the economic and social view, the large- also acknowledge the extended help from the Analytical and Testing
scale production of solid biofuel will create employment opportunities, Center of Huazhong University of Science and Technology.
increase the income and modernize the agricultural economy.
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