For all experiments, process conditions such as size of the feedstock material, feed rate, pressure, reaction temperature, condensation temperatures, and flow rates of both the heat carrier and the condensate cycle were the same. Naturally, variations within defined limits cannot be avoided. For a test plant such as the process development unit presented here, the acceptable ranges of fluctuation and required times of operation for reproducible experiments need to be calculated and/or determined by experience. For example, the reactor temperature, which is indicated by the temperature of the heat carrier leaving the reactor, is controlled with a standard deviation of 35 °C over the entire course of the reaction from the start of the reaction at full biomass capacity to the stop of biomass feeding (typically around 4 hr). The pressure in the reactor is controlled with a standard deviation of 300–500 Pa. Peaks in pressure are likely to occur due to fluctuations in biomass feeding. It is recommended to adjust the feeding screw system to the biomass material under consideration in order to minimize such fluctuations and ensure a constant biomass flow. The condensation temperature in the first and second condensers was maintained at a standard deviation of 3 °C and 1 °C, respectively.
It should be noted at this point that all experiments presented were conducted at the same reactor temperature (500 °C). This temperature does not necessarily reflect the optimum fast pyrolysis temperature which exists for each specific feedstock22. A variation of the reactor temperature could lead to an optimized pyrolysis temperature with even higher organic oil yields.
The choice of balancing method is not trivial for fast pyrolysis of biomass, especially when applying fractionated condensation and when using biomass with high ash content. Three different types of balancing have been presented in the previous section. Reporting the yields of product fractions on an 'as received' basis is advantageous for practical considerations such as the design of apparatuses and storage capacities as it reports the actual product distribution to be expected. However, these values are obscured by the water and ash contents of the feedstock. Especially for residual biomass — e.g., straw, forestry and pruning residues and biogenic 'waste' — this is an issue as these feedstocks have a wide range of water and inorganic contents, see Table 1.
The common balancing method for biomass processes on a 'dry basis' is in most cases useful for comparisons between different studies as it eliminates the effect of different moisture contents of the feedstock. However, it should be pointed out that these calculated values from experiments with a specific moist feedstock do not necessarily reflect the behavior and yields of this specific feedstock if it was completely dried by physical means prior to the experiment. It is known that moisture affects the yield distribution of pyrolysis23 and this should be kept in mind when evaluating and comparing 'dry' balances.
Furthermore, mass balances on a 'dry basis' are inappropriate for feedstocks with high ash content because minerals end up primarily in the char and obscure the results similarly to the initial moisture content. Similarly to water, minerals affect the actual pyrolysis reaction network because they promote secondary pyrolysis reactions, leading to higher char and lower bio-oil yields. Such effects can only be evaluated on a scientific basis if balances are corrected for the ash content. One way to achieve this is by setting up carbon balances. From the comparison of Figure 2 and Figure 4 it can be seen that the increased solids yield observed after pyrolysis of wheat straw as compared to miscanthus is not only due to inorganic material that is recovered with the char, but also due to an increased fraction of organic solids that were formed during the process.
Another advantage of elemental carbon balances is to show the fate of biogenic carbon, i.e., its distribution in the recovered product fractions. This is important for the evaluation of more complex conversion chains — e.g., pyrolysis, gasification, and synthesis as in the case presented here — because the biogenic carbon should be used as efficiently as possible. One of the most important roles of biomass in a future bio-based economy is to provide biogenic carbon for a wide range of commodities, thus replacing carbon from fossil resources.
The presented protocol for fast pyrolysis in a twin-screw mixing reactor can be realized on different scales with some adjustments. The presented case of a unit with a feed capacity of 10 kg hr-1 has proven to be a feasible compromise between operational complexity and meaningful results for process behavior. It can be applied both for screening of different types of biomass and optimization of process conditions. Testing a specific biomass feedstock is crucial because certain feedstock characteristics might lead to unfavorable process operation if coarse solid residues accumulate in the heat carrier cycle. Such accumulation was not observed for the biomass presented in the results section, but it has been observed for very hard biogenic material with large particle size (>1 mm) which limits the applicability of the presented process. This problem could be reduced with a different design of the heat carrier loop, e.g., by pneumatic transport of the heat carrier with simultaneous partial combustion.