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Steam pyrolysis of birch wood: Process modelling mass and energy using
Microsoft Excel

Conference Paper · November 2016

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STEAM PYROLYSIS OF BIRCH WOOD:
PROCESS MODELLING MASS AND
ENERGY USING MICROSOFT EXCEL
J. B. Lad, P. Blanco-Sanchez, A. V. Bridgwater

European Bioenergy Research Institute (EBRI), Aston University, Aston

Triangle, Birmingham, B4 7ET, United Kingdom

ABSTRACT: Optimisation of the right conditions for the physical and thermochemical
fractionation of biomass will help to provide much needed competition for the fossil fuels
industry for the production of high value chemical precursors, fuels and energy. Cellolignin
is a natural cellulose-containing material which has been pre-hydrolysed with dilute
mineral acids to reduce the hemicellulose content. It can be pyrolysed around 400 °C in
the presence of steam to produce high value pre-cursors such as high quality char and
anhydrosugars such as levoglucosan (LG) and 1, 6-anhydroglucofuranose. The resulting
anhydrosugars can be hydrolysed to produce fermentable sugars such as glucose and
fructose for the production of bio-fuels namely bio-ethanol and bio-butanol and the char
has a variety of high and low value applications. A techno-economic analysis (TEA) is
essential to any commercially driven process not only for economic evaluation but to
obtain information on the overall process inputs and operational feasibility. This study
investigates the design of a single process stage – fast steam pyrolysis of pre-treated birch
wood in an integrated biorefinery to optimise the operating conditions in terms of mass and
energy with a particular view for process scale up. The fast steam pyrolysis of pre-treated
birch wood stage represents a single process module within the biorefinery, which is
modelled using Microsoft Excel. The fast steam pyrolysis module is interconnected with
other pre- and post- modules such as pre-treatment, anhydrosugar hydrolysis, effluent
processing and disposal, steam generation and heat and power production. Although the
designed model can be used for any scale, this study uses experimental data from a
50 kg/h pilot plant, together with reported literature data, engineering assumptions, and
user defined logic. It is important to use accurate conversion data, yields and property data
(chemical and physical), and also incorporate clear and accurate logic and functionality.
The model in this study is used to estimate the relative quantities and components within
process streams; the energy demands; the influence of changing conditions and effect of
scale.

KEYWORDS: biomass, cellolignin, steam, pyrolysis, model, excel

Proceedings Venice2016, Sixth International Symposium on Energy from Biomass and Waste,
14 - 17 November 2016
Great School of St. John the Evangelist, Venice, Italy
ã 2016 by CISA Publisher, Italy
VENICE2016
Sixth Internationail Symposium on Energy from Biomass and Waste

1. INTRODUCTION

Pyrolysis of biomass in the presence of steam, is a promising method for simultaneous

production of liquid fuels and/or chemicals and activated carbon. Kantarelis reports that the
bio-oil from steam pyrolysis has a lower oxygen content than conventional fast pyrolysis and
the gas quality is higher at the expense of lower char yields. The latter is reportedly of good
quality for making activated carbon or combustion (Kantarelis 2014). Fast pyrolysis at
atmospheric pressure with superheated steam causes the removal of oxygen from the system
and lowers the partial pressure of the volatile product vapours. Of the products produced
through pyrolysis, levoglucosan (LG) has the greatest value potential along with the other
anhydrosugars: 1,6-anhydroglucofuranose, cellobiosan, cellubiose, 1,4:3,6-dianhydro-α-D-
glucopyranose and levoglucosenone. In order to model, optimise and eventually scale up a
process, it is imperative to have good understanding of the process and the dynamics of
changing conditions for the system. This must be backed up by reliable experimental data
supported by strong engineering assumptions, some literature and/or other means of
validation.
When modelling any chemical process for scale up, typically a techno economic
assessment (TEA) is carried out which characteristically involves: mass, energy and cost
assessment. The advantage of a sound TEA is that it can quantitatively and qualitatively
illustrate the valorisation potential of the technologies under investigation. According to
Kuppens, there are increasing numbers of TEAs being carried out, however there are no
accepted guidelines on how to perform a TEA (Kuppens 2015). This study includes two of the
three elements required for a TEA, namely mass and energy balances. The cost assessment
which includes capital expenditure (CAPEX) and operational expenditure (OPEX) is to be
carried out in the next stage of research. The model is a multifunctional tool which is manually
configured by the user with the following objectives:
§ Helping to optimise the module in terms of performance for variable operating conditions,
§ Determining the energy demands of the process (thermal, cooling and electrical) and
matching these to available waste, residues and/or by-products.
The model will then be used to develop capital, operating and production costs so the fast
steam pyrolysis stage can be evaluated more accurately to determine the feasibility and
economic viability of the process stage.

2. STEAM PYROLYSIS

Piskorz reports that when solid cellolignin particles are subjected to fast steam pyrolysis with a
solid residence time of 0.6-1.8 s at 360-400 °C, the ratio of reduced substances (RS) such as
aromatics, aldehydes, ketones and acids to LG in the condensate is maximised at up to
0.70-0.80 (Piskorz 1989). With longer solid residence times (8-10 s) the LG/RS ratio is only
0.20-0.30, thus increasing the yield of RS and reducing the effectiveness of the process. This
increase is explained by the presence of intermediate compounds; percursors of the LG
pathway which are not fully converted (Piskorz 1989). In terms of increasing LG selectivity
during steam pyrolysis, Oudenhoven reports that a low ash content in the biomass feedstock
not only increases selectivity of reaction pathways (shown in Figure 1) toward LG, but the
VENICE2016
Sixth Internationail Symposium on Energy from Biomass and Waste

liquid yield increases at the expense of gas and char (Scott 2000). Furthermore, a low level of
minerals in the ash reduces problems in subsequent applications, e.g. poisoning of the
catalyst and minimising low temperature melting ash in the char. The presence of ash in the
feed material affects the depolymerisation of cellulose into anhydrosugars and increases
fragmentation reactions (Oudenhoven 2013).
Decarbonylation
Hydroxyacetaldehyde,
formaldehyde, acetol,
methylglyoxal, glyoxal
CELLULOSE Fast >450 ˚C, low
Slow <300 ˚C, depolymerisation
heterolytic
Depolymerisation
Levoglucosan, cellobiosan,
other anhydrosugars, higher
Char, gas, oligomers
water
Figure 1. Reaction pathways for the thermal decomposition of cellulose by fast pyrolysis
(Reproduced from: Scott et al).

Anhydrosugars constitute more than 40 % of the depolymerisation products from the

pyrolysis of cellulose (Abella 2007). Thermal degradation of cellulose proceeds in two stages:
an abrupt decrease in the degree of polymerisation of the chain molecules; responsible for the
production LG and or 1,4-D-glucopyranose followed by the competitive reactions such as
dehydration reactions which account for char formation.
Levoglucosan formation begins at 320 °C and requires rapid heating at low pyrolysis
temperatures (320-400 °C) with minimum ash to avoid unwanted dehydration reactions.
Superheated steam provides the heating medium as it has a high heat capacity and provides
the transportation of the partially carbonised material and removes the volatiles from the
reaction zone (Pernikis 1997)., Low char yields are attributed to steam adsorption on the
surface of the solid biomass matrix which react with the char. The char yield during steam
pyrolysis is affected by two factors:
§ The adsorbed steam inhibits the adsorption of tar vapours whilst simultaneously helping to
desorb and extract the volatile matter, thus secondary tar cracking reactions which are
associated with char formation (Giudicianni 2013).
§ The ash content of the material is important as the greater the inorganics content (alkali and
alkaline metals) the lower the temperature char is formed and greater the catalytic effect for
its formation (Zhurinsh 2013).
The char produced during conventional fast and steam pyrolysis, has a morphology similar
to the parent material. During conventional fast pyrolysis the solid biomass matrix softens, the
pores becomes clogged up and the gases inside the structure generate an overpressure
leading to the formation of bubbles that consequently burst and destroy the porous network.
The presence of steam during pyrolysis is believed to contribute to the rapid removal of low
molecular weight compounds on the surface. At low temperatures it results in less clogging
thus yielding a highly active porous char by-product (Kantarelis 2014).
VENICE2016
Sixth Internationail Symposium on Energy from Biomass and Waste

3. PROCESS MODELLING

The overall process model when completed will comprise of user interface module, an
assumptions list module; a biomass reception; storage and handling module; a pretreatment or
fractionation module to remove hemicellulose; a fast steam pyrolysis module to maximize LG
and other anhydrosugars; a hydrolysis module to convert anhydrosugars to glucose; a heat
and power module to supply the process; and a waste management module. This paper
focuses on the fast steam pyrolysis module.

3.1 Building the pyrolysis module

Microsoft Excel was used to model a multi-stage biomass fractionation process, however this
study focuses on the fast steam pyrolysis stage. Figure 1 shows a simplified process flow
diagram for fast steam pyrolysis of pre-treated birch wood using dilute acid and the pre- and
post- processing stages into and out of fast steam pyrolysis. The model defines the mass and
energy balance, using user defined logic to connect to upstream and downstream modules.
The model was based on pilot plant data, engineering assumptions and reported literature
data.

3.2 Inputs and assumptions

Table 1 shows the feed composition entering the fast steam pyrolysis module after the
biomass was pre-treated as shown in Figure 2. As shown in Table 1, the fast steam pyrolysis
inlet stream has a high cellulose and lignin content, with a combined total of 76.3 wt % (dry
basis) compared to 65.0 wt % for the fresh biomass. Table 1 also includes the range of
operating conditions and highlights the main reactions modelled.

Table 1. Composition of the pre-treated biomass feed stream into fast steam pyrolysis, operating
conditions and main reactions modelled.
Fast steam pyrolysis input composition
Component wt % (dry basis)
Water (10 wt % water wet basis) -
Acids 6.4 %
C5 sugars 4.0 %
Cellulose 46.0 %
Lignin 30.3 %
Non-volatile solids 11.0 %
Other 2.4 %
TOTAL 100.0 %
Operating conditions
Fast steam pyrolysis temperature: 370 – 410 ˚C
Fast steam pyrolysis pressure: Atmospheric
Feed birch wood particle size : 1 – 2 mm
Solid residence time: 0.8 – 10 s
Quantity of superheated steam to dry biomass
2.5 – 8.5 kg of steam / kg of dry feed
feed (kg steam /kg dry biomass feed):
Main reactions and yields defined
Cellulose à Levoglucosan
Cellulose à Other anhydrosugars
Cellulose à Gases
Cellulose à C1-C3 acids, ketones and humins
VENICE2016
Sixth Internationail Symposium on Energy from Biomass and Waste

Cellulose à Char
Cellulose à Acetic acid
Cellulose à Unconverted cellulose
Lignin à Phenolics
Lignin à Char
Phenolics à CO
Phenolics à CO2
VENICE2016
Sixth Internationail Symposium on Energy from Biomass and Waste

Fast steam pyrolysis stage

Pre-treated biomass
Exhaust
1
2 7 Gases
Heat exchanger Conveyor belt dryer
Cyclone
Pre-treated biomass: 3 8
4 5
Post biomass
Dilute acid Air Blower
Fast steam pyrolysis Liquid processing: Acid
(hemicellulose) condensate
twin screw reactor hydrolysis of liquid
hydrolysis + washing
condensate (stream 8)
(stream 1) Condenser
6

Steam in Solids

Condensate return Cooling water out to boiler

Cooling water in from boiler
Boiler
Water

Figure 2. A simplified process flow diagram for fast steam pyrolysis of pre-treated birch wood and the pre- and post processing stages into and out of
fast steam pyrolysis.
VENICE2016
Sixth Internationail Symposium on Energy from Biomass and Waste

4. RESULTS AND DISCUSSION

4.1 Mass balance

A mass balance was carried out for fast steam pyrolysis of pre-treated birch wood as shown in
Figure 2 – from the pre-treated biomass inlet to the liquid condensate outlet whilst considering
the respective operational assumptions for each process item e.g. fraction of solids leaving the
cyclone. Although the model uses real pilot plant data, not all data sets were complete,
therefore these areas were modelled using reported literature data e.g. the pyrolysis reactions
products breakdown of C1-C3 acid, ketones and humins fraction into: formic acid, acetic acid,
glycolaldehyde, hydroxylaldehyde, formaldehyde, hydroxyacetone, methylglyoxal, furfural, 5-
hydroxymethylfurfural and so on. Compared to the fast steam pyrolysis feed composition
shown in Table 1, Table 2 shows the final fast steam pyrolysis product composition. In the
product stream under the conditions considered there is approximately:
§ 67 wt % (dry basis) of valuable products which consists of 31 wt % C5 + C6 sugars and
36 wt % fuel source in the form of combustable char and non-condensible gases which can
be used to heat and power the process,
§ 20 wt % of unwanted dry matter termed ‘non-volatile solids’, which includes non-soluble
extractables fraction, silica and humins,
§ 13 wt % of organic liquid by-products e.g. acetic acid, formaic acid, hydroxylacetaldehyde,
glyoxal and furfural.
Overall approximately, 62 % of the [C5 sugars + cellulose] stream into the fast steam
pyrolysis module, is converted into the main [C5 + C6 sugars] product with the rest contributing
to other fractions [31.2 wt % / 50 wt % - cellulose to C5 + C6 sugar conversion (dry basis).

Table 2. Fast steam pyrolysis product composition.

Fast steam pyrolysis product composition
Component wt % (dry basis)
Reaction water (80 wt % water wet basis) [Waste] -
C5 + C6 Sugars [Main product] 31.2 %
C1-C3 acids and ketones [By-product] 13.2 %
Char [By-product] 30.0 %
Gases [By-product] 5.5 %
Non volatile solids [Waste] 19.3 %
Other [Waste] 0.8 %
TOTAL 100.0 %

4.2 Energy balance

In terms of energy balance the model produces two outputs:
§ The temperature and quantity of superheated steam needed to fast steam pyrolyse the
biomass at the required temperatures,
§ The energy consumption for each process item shown in Figure 2, assuming no losses.
In terms of the first output two assumptions were made: the superheated steam has a
temperature of 500 ˚C and the fast steam pyrolysis feed inlet temperature is 120 ˚C. As an
example Table 3 shows the results of a possible operational scenario for energy output one.
Table 3 shows the amount of superheated steam required to pyrolyse ~25.0 kg/h of dry
biomass was 86.0 kg/h ignoring energy losses.
In terms of energy output two: the overall heating and cooling requirement for the module
VENICE2016
Sixth Internationail Symposium on Energy from Biomass and Waste

was carried out using heat balance equations and the electrical consumption was determined
using an equipment loading list for the respective scale. For each electrically rated item a
power factor of 0.85 was assumed and a transformer impedance loss of 6 % is included in
each calculation to determine the actual consumption.
Table 4 shows the energy consumption for fast steam pyrolysis of pre-treated birch wood in
terms of the heating, cooling and electrical consumption. Under the conditions considered it
can be seen that thermal heating requires the most energy input for fast steam pyrolysis.

Table 3. An example calculation to show the energy transferred by superheated steam and amount of
superheated steam required to pyrolyse pre-treated birch wood.
Energy/quantity of superheated steam Quantity Units
kJ/kg of
Energy released by superheated steam at 1 bar pressure to pyrolyse
superheated
biomass (assuming superheated steam at 500 ˚C and fast pyrolysis 209.4
steam
at 400 ˚C)

Energy needed to remove water in biomass (120-400 ˚C) 1550.3 kJ/kg

Energy required to raise preheated biomass temperature (120 ˚C)
16463.7 kJ/kg
to fast steam pyrolysis temperature (400 ˚C)
TOTAL ENERGY REQUIRED 18014.0 kJ/kg
Amount of superheated steam required: ignoring losses 86.0 kg/h

Table 4. Energy consumption in terms of heating cooling and electrical for fast steam pyrolysis of pre-
treated birch wood for a 50 kg/h pilot plant.
Energy type Energy percent (%) Energy (kW)
Thermal heating 55.1 114.0
Cooling 24.4 50.5
Electrical 20.5 42.3
TOTAL 100.0 % 206.8

5. CONCLUSIONS

A technical assessment was carried out for a 50 kg/h fast steam pyrolysis pilot plant of pre-
treated birch wood. The following conclusions were obtained from the model:
§ 44.4 wt % of the steam fast pyrolysis liquid product consists of 31.2 wt % liquid
anhydrosugars and 13.2 wt % liquid by-products. The latter will require separation from the
anhydrosugar product using methods such as crystallisation. The anhydrosugar product
can be hydrolysed to produce fermentable sugars.
§ 5.5 wt % of non-condensible gases are formed which can be used to heat and power the
process, thus reducing the external/non-renewable fuel needs.
§ 50.1 wt % of char and non-volatile solids are formed which can be used to heat and power
the process, thus reducing the external/non-renewable fuel needs.
§ The total energy demand for the module in terms of heating, cooling and electrical
consumption was estimated to be ~207 kW for a 50 kg/h pilot plant, of which over half the
quantity is required for heating (55 %).
 VENICE2016
Sixth Internationail Symposium on Energy from Biomass and Waste

ACKNOWLEDGEMENTS

This research is kindly funded by Nova Pangaea Technologies, UK, and Aston University. The
authors gratefully acknowledge their funding, technical information and support.

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