DOE Bioenergy Technologies Office (BETO) 2021

Project Peer Review

WBS 5.1.2.101 - Torrefaction of sorted MSW

pellets for uniform biopower feedstock

3/12/2021
Feedstock Technologies

Jordan Klinger
Idaho National Lab

This presentation does not contain any proprietary, confidential, or otherwise restricted information
 Project Overview

From within DOE EERE, BETO released a competitive laboratory call

for early-stage R&D.

Goal: “Develop innovations in the use of biomass, municipally-derived

biosolids, and sorted municipal solid waste to improve the economic
potential of biopower production and use in the United States.”

Our Project Objective: Use advanced compositional and

thermophysical characterization methods (INL) to support the
evaluation of novel production pathways (MTU) to biopower
applications under the guidance of an industrial partner operating in
the US power sector (CE).
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 Project Overview

• What are you trying to do?

− Create a uninform feedstock from non-recyclable wastes for use
in bioenergy (solid fuel for biopower) and biomaterials
• How is it done today and what are the limits?
− Currently, the only accepted method is through incineration
• Why is it important?
− Torrefaction and preprocessing strategies can create a uniform
fuel, free of contamination (chlorine) that can be used is other
combustion applications
• What are the risks?
− Feedstock variability, leading to inconsistent product or high
contamination
− Plastic melt properties are incompatible with process equipment

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 1 – Management

• This project was a result of a competitive lab call solicitation

• The scope and approach has been through peer review (FY19, poster review for
scope before project start) as well as annual AOP development and review
• Team (bi-weekly team meetings)
− INL is leading this project, and is performing advanced characterization and
measurement of decomposition kinetics for torrefaction
− Michigan Technological University is a key partner, and is performing kinetic
modeling and pilot scale torrefaction
− Convergen Energy is a commercial partner, is providing relevant waste
feedstock streams, industrial feedback
• Quarterly meetings with BETO management
• Working with INL Feedstock SOT (WBS 1.1.1.2) to evaluate process economics,
and alongside MSW Decontamination (WBS 1.2.1.7) and Biomass Size
Reduction, Drying, and Densification (WBS 1.2.1.2) for waste processing
• Dissemination of Project Impact
− Peer reviewed publications
− Conference meetings, presentations, and trade shows
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 2 – Approach

• Approach
− Use realistic waste stream from industrial partner and
apply torrefaction and densification strategies to make
a uniform, homogenous solid fuel pellet
− Develop models to describe the chemistry of the
torrefaction preprocessing, and use them to target
conditions that minimize chlorine contamination, and
maximize heating value, throughput, and grindability
− Demonstrate operation of novel pilot scale operation
and use process-level data to inform TEA and LCA for
evaluation of the process economics in partnership
with WBS 1.1.1.2
• TEA and LCA is being performed alongside
this work

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 2 – Approach

• Challenges
− Producing a uniform product from a variable feed
• include separations and severe degradation as needed
− Handling and processing plastics at elevated temperatures (plastic softening)
• investigate several systems, including current plastics handling extruders
− Ensuring fuel purity and properties match what is needed by the industrial
boiler
• industry partnerships and materials characterization
• Go/No-go
− Determine if our approach can meet homogeneity and quality metrics
(heating value, chlorine content) for solid fuel pellet. Pivot to investigation of
one method of densification (ring die or extrusion) to best meet these goals.

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 3 – Impact

• The program outcomes are applicable to fuel suppliers and waste collectors and
opens new markets for end-of-life solution to non-recyclable waste materials
• State of technology
− Processing of MSW and wastes to alternative fuels and products is scarce outside incineration
− Combine developing torrefaction technologies with existing compounding/extrusion techniques to
develop a novel pathway for utilization of raw national resources

• Industrial Partner, Convergen Energy

− Investigating torrefaction as a method to make a more uniform and consistent product that be
compatible with a wide range of fuel boilers

• Successful dissemination will include presentations (3 workshop talks) to a

broader industrial/academic audience as well as publications (2 accepted, 1
under review, 1 in preparation) in peer reviewed journals and workshops

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 4 – Progress and Outcomes

• The high-level goal was to develop a more uniform

feedstock from wastes for bioenergy through
torrefaction development
• The progress will show the scientific development that
enables industrial and economic preparation of these
materials

Plastic Clean solid fuel

Composite >90% purity and
material uniformity are
targeted

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 4 – Progress and Outcomes

Coarse Fine
Loading Continuous Plattco® Dryer &
Pre-sorting shredding shredding Sifting
Station Hopper Airlock Crammer
(4”) (1/16”)

To Air Condenser Cyclone Gas Reactor- Heat

Demister DSI
Treatment – 1 to 4 – 1 and 2 Fraction Extruder

Liquid Solid Extruded

Fractions, Particles Rods
Water
Cutter
• High level block diagram of process to produce Air
uniform fuel or feedstock from wastes. Pellets
• Initial TEA of the process estimates the fully
To User Counter-
burdened cost of production at approximately Pellet
flow Airlock
$50/ton, while preprocessing is $22/ton. Storage
Cooler
Odor Trapping
To Air
Baghouse Blower Cyclone
Treatment

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 4 – Progress and Outcomes
$22/ton total
Pre-processing Cost breakdown
• Baseline cost of preprocessing MSW is
estimated at $50.15/dry ton (2020$). Heat Management
Conveyor to System Gauges and
• The crammer-torrefier unit accounts for Storage
1%
5% Analyzers
5%
Loader
6%
Infeed Belt
Cooler 0%
$9.14/dry ton (nearly 42%) of the Bucket Elevator 2 1%
preprocessing costs ($22/ton). 1%
Pellet Collector
Cutter
• Sensitivity analysis shows costs range 1%
2%

between $47 and $53/dry ton.

Three Stage
Cost ($/dry ton) Shredder
35%
Preprocessing cost per dry ton $ 22.00
Installation cost per dry ton $ 8.62
Labor cost per dry ton $ 15.08 Crammer and
Maintenance cost per dry ton $ 4.45 Torrifier Live Bottom
42% Hopper
Total cost per dry ton $ 50.15
1%
Distributor Bucket Elevator 1
0% 0%

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 4 – Progress and Outcomes
Operational pilot system testing and validating project
analytical findings

Condensation system

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 4 – Progress and Outcomes

• Analytical developments have:

1. Shown improvements to
homogeneity
2. Demonstrated interaction between
material components to accelerate
conversion
3. Developed advanced models to
represent the chemical kinetics of
the process to inform industrial
operation

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 4 – Progress and Outcomes
FTIR: 2mm plastic crumbles Avg FTIR spectra comparison

Crumbles
Compounded
cm-1
cm-1
500 1000 1500 2000 2500 3000 3500 4000 500 1500 2500 3500
• Chemical (and physical/mechanical)
FTIR: Compounded plastics signature for mixed waste is highly
variable
• Combinations of size reduction and
compounding can homogenize the
macro- and meso-scale properties and
cm-1 composition of the materials
500 1000 1500 2000 2500 3000 3500 4000
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 4 – Progress and Outcomes
Homogenizing by Crumbling and Compounding

0.5 400 0.06 400 0.08 400

±30% ±10% ±2%
0.4 N=19 300 N=19 300 0.06 N=19 300

Temp (°C)

Temp (°C)
Mass Loss

Temp (oC)
0.04

Mass Loss
Mass Loss
0.3
200 200 0.04 200
0.2 0.02
0.1 100 100 0.02 100
As received fluff Compounded
Crumbled to 2mm
0 0 0 0 0 0
0 2000 4000 6000 8000 0 2000 4000 6000 8000 0 2000 4000 6000 8000
Time (s) Time (s) Time (s)

• Extent of reaction (mass loss) with processing time at 300°C

• No processing (fluff) is highly variable in what product you will end up with
• Size reduction help create a more uniform degradation rate
• Compounding and size reduction create a uniformly processed product
(93% more uniform than using no preprocessing)

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 4 – Progress and Outcomes
8% 400
• Size reduction alone is not
enough to make a uniform
material 6% 300
• For the case of a torrefaction

Temp (°C)
Mass Loss
feed, compounding the material 4% 200
enables uniform preprocessing
• The physical and chemical
intimacy of the material after 2% 100
preprocessing enhance
degradation rate
0% 0
0 4000 8000
Time (s)

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 4 – Progress and Outcomes

50
• Certain feedstock mixtures and reactor
1:1 Mixed
conditions exhibited decomposition
40 plastic waste
synergy led to accelerated processing
with fiber
• This could imply that analytically 250°C

Mass Loss
30
informed selection of conditions could
reduce capital equipment size, increase
throughput and decrease energy 20
consumption
10

Xu, Z. et al. Bypassing Energy Barriers in Fiber-Polymer 0

Torrefaction. Frontiers in Energy Research. Special Issue.
0 5000 10000 15000
Accepted for publication.
Time (s)

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 4 – Progress and Outcomes
0.0004
Develop kinetic models
based on high-fidelity
• To better understand how the material experimental data

Rate (1/s)
attributes and processing impacts the
conversion and product quality, a 0.0002
series mechanism was used to
develop chemical kinetics
1.0 Total Mass 0
A
Mass Fraction

A1 0 2000 4000 6000 8000

Time (s)
A2
A3
0.5 A4
Predict quality (composition, heating value,
chlorine content) based on chemical
understanding
0.0
0 2000 4000 6000 8000
Time (s)
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 0.09 300 1.0
0.06 200
225 °C Exp. 0.5

4 – Progress and Outcomes

0.03 Model 100
Temp
0 0 0.0
0.3 0 5000 10000 15000300 1.0 0 5000 10000 15000
0.2 200
250 °C Exp. 0.5
0.002 0.1
0
Model
Temp
100
0 0.0
0 5000 10000 15000300 1.0 0 5000 10000 15000
Mass Loss Rate (1/s)

0.6
275 °C
225 °C 0.4 Experiment 200
Model 100
0.5
0.2
250 °C 0
Temp
0 0.0
275 °C 0.8
0.6
0 5000Time (s)
10000 15000400
300
1.0 0 4000 8000
Title 12000

Temperature (°C)

Mass Fraction
300 °C
0.001 300 °C 0.4 Experiment 200
Model
0.5

Mass Loss
0.2 Temp
100
325 °C 0
0.8 0 5000 10000
0
15000400
0.0
1.0 0 5000 10000 15000
350 °C 0.6
0.4 325 °C
300
Experiment 200 0.5
375 °C 0.2 Model
Temp 100
0 0 0.0
1 0 5000 10000 15000400 1.0 0 5000 10000 15000
0.8 300
0.6 Experiment 200
350 °C 0.5
0.000 0.4
0.2
Model
Temp 100
0 0 0.0
0 1000 2000 3000 4000 1 0 5000 10000 15000400 1.0 0 5000Time (s)10000 15000
Time (s) 0.8
0.6 375 °C
300
Experiment 200 0.5
0.4 Model
1 0.2 Temp 100
6000 0.0
Molar Weight Ratio

Molar Weight (g/mol) 0 0

0.8 1 0 5000 10000 15000500 1.0 0 5000 10000 15000
0.8 400
0.6 4000 0.6 Experiment 300
0.4 400 °C 200 0.5
Model
0.4 0.2 Temp 100
2000 0 0 0.0
0.2 0 5000 10000 15000 0 5000Time (s)10000 15000
Time (s)
0 0
0 1 2 3 4 5 6 7 8
Product
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 4 – Progress and Outcomes
100%

Norm Energy Retained

• Demonstrated product characterization along the 80%
degradation pathway also connection material and 60%
processing conditions
40%
• up to 100% chlorine removal Low Chlorine
20%
• energy density up to 40% higher High Chlorine
0%
0% 20% 40% 60%
100% 40 Mass Loss
Removal Effiency
Organic Chlorine

80% Heat Content (MJ/kg) 35

Xu, Zhuo, et al. "Properties of torrefied US
60%
Waste blends." Frontiers in Energy
30
Research 6 (2018): 65.
40%
Xu, Zhuo, et al. "Chlorine Removal from
20% 25 Low Chlorine US Solid Waste Blends through
High Chlorine Torrefaction." Applied Sciences 10.9
0% 20 (2020): 3337.
0% 20% 40% 60% 0% 20% 40% 60%
Mass Loss Mass Loss
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 Summary
Goal: “Develop innovations in the use of biomass, municipally-derived biosolids, and sorted
municipal solid waste to improve the economic potential of biopower production and use in the
United States.”
• This work has:
1. Shown improvements to homogeneity (>90%
improvement)
2. Discovered interaction between material
components to accelerate conversion leading to
reduced processing costs
3. Developed advanced models to represent the
chemical kinetics of the process to inform industrial
operation, and predict product quality attributes
from fundamental experiments and models
4. Demonstrated pilot scale production and novel
process configuration
• Process development and TEA in partner project has shown and technical and
economically feasible way to generate a uniform feedstock and fuel from wastes

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 Publications and Presentations

Publications
Presentations
Accepted
1. Xu, Z., Kolapkar, S. S., Zinchik, S., Bar-Ziv, E., 2020, BETO Waste Workshop
Ewurum, L., McDonald, A. G., Klinger, J., Fillerup, E.,
Schaller, K., Pilgrim, C. (2021). Bypassing energy Advancing the Bioeconomy: From Waste to Conversion-Ready
barriers in fiber-polymer torrefaction. Frontiers in Feedstocks Workshop
Energy Research. Just accepted.
2. Zinchik, S., Xu, Z., Kolapkar, S. S., Bar-Ziv, E., & 1. Klinger, J. Quality by Design Case
McDonald, A. G. (2020). Properties of pellets of
torrefied US waste blends. Waste Management, 104, Study: Densification of Municipal
130-138.
Solid Wastes and Residues.
Under Review
1. Xu, Z., Kolapkar, S. S., Zinchik, S., Bar-Ziv, Klinger, 2. Bar-Ziv, E. Feedstock Preparation
J., Fillerup, E., Schaller, K., Pilgrim, C. (2021). Kinetic
Study of Paper Waste Thermal for MSW Valorization.
Degradation. Polymer Degradation and Stability.
In Preparation 3. Hansen, T. MSW Handling and
1. Maintaining structural properties of recycled carbon Feedstock Challenges.
fiber composites.

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 Quad Chart Overview (Competitive Project)
Timeline Project Goal
• Project Start: 10/1/2019 Use preprocessing to make non-recyclable
wastes clean and resemble the fuel properties
• Project End: 9/30/2021 of coal for use as a solid fuel
End of Project Milestone
FY20
Total Award Optimize continuous torrefaction and
Costed pelletization at >10 kg/hr scale for the same
Year 1 MSW composition range to match or
DOE
$246,500 $495,615 exceed heat content of sub-bituminous coals
Funding (24-35MJ/kg) as well as 50% reduction in
sulfur and chlorine content compared to non-
torrefied MSW. Determine conditions that
achieve product uniformity (+/-10%) as
determined by measuring the heating value
and composition of 10 random samples.
Project
$105,643 $212,406 Developed methods will be applied to at least
Cost 1 mixed biomass feedstock.
Share

Project Partners Funding Mechanism

• Michigan Technological University DE-LC-000L045
Topic Area 1: Advances in Biomass and MSW
• Convergen Energy Torrefaction

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 Additional Slides

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