Auger Reactor for Biomass Fast Pyrolysis:

Design and Operation

Leena Kapoor1, Aditya Mekala2 and Debajyoti Bose3
1
Department of Chemical Engineering
2,3
Department of Electrical, Power & Energy
University of Petroleum & Energy Studies
Uttarakhand, Dehradun 248007, India
{lkapoor, dbose}@ddn.upes.ac.in

Abstract - Pyrolysis represents a process of renewable energy of biomass to mobility is however subject to controversy in
recovery, using thermochemical methods of combustion it is the public and in professional circles [3]. However, without
possible to heat biomass i.e. residues such as sawdust, bagasse any doubt, liquid fuels are far more promising as they have
and pine wood to obtain a liquid fuel known as bio-oil. This bio- high energy densities which will continue to make a
oil finds application in Chemical industry and suitable
significant contribution particularly in the transport sector.
upgradation can make it a petroleum substitute. The byproduct
of this process is a solid residue known as bio-char, which has Pyrolysis is the thermal degradation of complex organic
the potential to be used as an excellent climate change molecules in an oxygen-free environment [4]. It is a thermo-
mitigation tool if mixed with soil, acts as an excellent chemical process of biomass conversion where the first step is
amendment. This paper highlights the work done with a Twin gasification and combustion; compared to other biomass
screw reactor or auger reactor, temperature profiles of near conversion processes has low temperature profile [5].
500°C has been studied, biomass used has been sawdust and
bagasse. Analysis for the solid bio-fuel i.e. biochar has been In present study, the detailed physiochemical characteristics,
given along with proximate and ultimate analysis of biomass availability and suitability of the selected biomasses through
feedstocks. System limitation has been profiled and issues
proximate and ultimate analysis to access the bio oil potential
related to bio-oil production have been addressed. Design
changes have been suggested in the existing system using
were investigated. The objective of this work is to propose
Solidworks software to optimize the existing design where this suitable design changes for twin screw reactor to carry out the
experimentation has been done. It is believed the design changes intermediate pyrolysis for the production of bio oil.
would make the facility more efficient. Nitrogen gas has been Investigation on heating schedule employed such as slow
used to maintain velocity profile of the biomass particles inside heating rate (SHR) pyrolysis and the high heating rate (HHR)
the reactor. This work does not have the food vs fodder conflict pyrolysis has also been studied. This study is favourable for
as it shows biomass feeds used are primarily wood wastes and the development of advanced pyrolysis process.
sugar industry by-products.

Index Terms - Pyrolysis, Screw reactors, Bo-oil, Bagasse, Sawdust. II. THE BACKGROUND OF FAST PYROLYSIS
The greater the extent of biomass particles, the greater the
I. INTRODUCTION
temperature slopes prompting lower temperatures that support
The consistent use of renewable energy components is an development of biomass [6]. Bridgewater [7] evaluated the
effective way to reduce the dependence on fossil fuels (crude standards and routine of biomass quick pyrolysis forms and
oil, natural gas and coal) especially in the industrialized the variables impacting process plan contemplations. Plan
nations. The introduction of renewable energy can make a variables required for quick pyrolysis incorporate the
remarkable contribution to reducing CO2 emissions; which accompanying: bolster drying, molecule size, pre-treatment,
essentially reduces the carbon footprint and thus diminishing reactor design, heat supply, heat exchange, warming rates,
the anthropogenic greenhouse effect. Statistics reveal that the
United States itself was responsible for 15.9% of world-wide response temperature, vapour living arrangement time,
anthropogenic CO2 emissions and economic powerhouses auxiliary breaking, roast partition, powder detachment, and
such as China with 28.03% and India with 5.81% in 2015 fluid accumulation. Every one of the angles was surveyed and
[1]. For example, nearly one-third of the emissions from the talked about. On account of the unpredictability of the
United States due to automobiles [2]. procedure, the impact of working conditions on the bio-oil
properties is extremely process-particular. For more analytical
Among all renewables, biomass is the source which is data about fast pyrolysis essentials, the user ought to peruse
considered carbon neutral. Hence a suitable alternative to be broad literature surveys by Bridgwater [7], Mohan et al. [8],
used in the long run as raw material for production of carbon- Venderbosch et al. [9], and Meier et al. [10].
containing materials and other energy sources. The addition

978-1-5090-3564-9/16/$31.00 ©2016 IEEE

 III. METHOD
In this an auger reactor has been used for pyrolysis of biomass
feed through exothermic reaction to get biofuels. A lot of
research has been done worldwide on biomass pyrolysis using
various types of reactor but not much work has been done in a
screw reactor. This scant knowledge has prompted to foray in
this activity. The process employed is fast pyrolysis, which is
a high-temperature process in absence of oxygen, where
biomass is rapidly heated.
The main components of the reactor system are: Fig. 1. The overall system that was used in this experiment, 1- Nitrogen
1. Biomass feeding assembly cylinder, 2- Rota meter, 3-Screw Feeder, 4- Twin screw reactor, 5 Char
tank, 6- Condenser assembly, 7- Outlet.
2. Heat carrier sub-system
3. Auger (Twin Screw) reactor assembly The equipment that was used for this experimental setup was a
4. Product recovery through condenser and Char twin-screw reactor with a screw length of 565 mm. Figure
tank system 2(design made in SolidWorks 2014) shows the system
Other Utilities: assembled that was studied. There were two sections: the first
1. Frog pumps were installed and related piping section performed the task of feeding and conveying of the
arrangement connecting the condensers to one biomass, and the temperature was monitored using K-type
another and establishing the water circulation thermocouples through various openings on top of the
network through the condensers. extruder. The second portion was used for heating, mixing; the
2. Nitrogen cylinders. temperature was 454°C. Normally, the extruder wall
temperature was 25-30°C less compared to temperature of the
coil used to heat it externally. There are 5 orifices on the
Three biomass sources were explored in this work, Bagasse,
reactor; the diameter for all was 0.78 mm.
Sawdust and Pine wood. All were subjected to proximate and
ultimate analysis, some of the data for it are done with support
from Chemistry Lab here at UPES, and rest is adapted from Cooling water was added into the condenser using a water
literature sources. Gross Calorific Value was determined using pump. The moisture content of sawdust in the extruder was
Bomb Calorimeter. For all of the feed materials that were used maintained at 5.58%. The sawdust was fed by a screw feeder
feed preparation step discussed later explains all experimentations whose rpm was maintained in the range of 18-30 rpm. The
including moisture analysis. This work reports formation of solid
feed rate was highlighted in form of rpm on the control panel.
biofuel which is the biochar for all three feed materials but due to
The calibration is shown in Table 2 to convert the feed rate
technical problems with electrical utilities and the reactor, liquid
from rpm to kg/h for the biomass feed input.
biofuel was not achieved but design changes were made, which
Table 1: Feed rate calibration adopted from [15]
would increase the feasibility of producing liquid bio-fuel using
this system. Screw Feeder (rpm) Feed rate of Biomass Feed (kg/hr)
10 13.92
15 19.50
Pinewood, bagasse and Sawdust were pyrolyzed at 450ºC
(reactor temperature) with a nitrogen stream rate of 526 20 24.78
mL/min at air weight. Upon these conditions the nitrogen
25 32.88
temperature at its channel into the reactor was observed to be
30 44.62
65 ± 4 ºC. The rotational speed of the screw was held at 55
rpm. The tests were directed with biomass tests of 50 g
legitimately arranged as portrayed in segments later. The III. FEED MATERIAL
temperature of the refrigerant liquid (water) was kept at 10°C. The Biomass material used for experiments was locally
The test conditions depended on trial concentrates on sourced from inside Dehradun. Bagasse and sawdust came in
completed preceding directing the test runs. The trial natural form. Before each test on the pyrolysis reactor,
contemplates brought up the above conditions as the most samples of each feedstock were properly prepared. Bagasse
encouraging states of a fast pyrolysis process with the most was brought from Doiwala Sugar Plant in Dehradun,
elevated yields of bio-oil, without trading off its properties. Uttarakhand whereas simple wooden sawdust and pinewood
Process yields biochar, analysis are given later. sawdust were procured from local carpenters at Saharanpur
Chowk, Dehradun; Uttarakhand.
These raw materials were then screened at approximately 2
mm and then analyzed, given below are its proximate analysis
and Gross Calorific value (GCV).
 vitality (by means of bio-oil and syngas that are in this way
Table 2: Proximate analysis of biomass feeds used in the system
used to run steam turbines) and the intentionally delivered
material "biochar."

III. REACTOR
The main body of the reactor is a horizontal pipe made of
AISI 316 steel. Inside the main pipe, assembled two screws go
all along the pipe length. At both the ends, gear arrangement is
done with the screw imposing a rotation movement on it. The
rotation of the screw carries the biomass sample from the
biomass inlet towards the heating/reaction zone till the
products collection point at the other end of the pipe. An
electrical resistance coiled over main pipe provides heat for
the reaction and defines the reaction zone. The temperature is
monitored using thermocouples located along the pipe.
Ultimate analysis was done for the feeds; it was found that the
Nitrogen is used as inert and carrier gas. After reaction, char is
sulphur content is very low; hence it has been represented
quickly collected in an enclosed flask and bio-oil is collected
jointly with other gases present in the system. Oxygen content
is highest in bagasse and Carbon content is high with Sawdust, in flasks by rapid condensation of the hot vapors in two
meaning sawdust is preferable over bagasse and pine wood. condensation stages. The non-condensable gases proceed their
way to an exhaust system.

Fig. 2. Reactor shell designed in SolidWorks 2014

For a lab-based fast pyrolysis system, the feed rate was studied
between 0.5 kg/hr – 2.0 kg/hr. Hence, a calculated biomass
feed rate of 1.0 kg/hr was decided for carrying out all the
experiments. Heat carrier was sand, mixed with biomass (1:1)
All of the biomass feeds were first screened and 2mm particle and charged into the feed hopper. The SolidWorks 2014
size was kept constant for all materials. Then moisture Professional software was used extensively during the design
removal was done to facilitate proper pyrolysis, followed by phase for liquid bio-fuel.
storage and then accordingly use for the auger reactor.
Simultaneously a bomb calorimeter was used for determining Table 5: Reactor Dimensions Dimensions Units
the gross calorific value of the samples as well. Dimensioning
reactor L 50 Cms
Table 4: GCV of biomass feeds used in the system housing I.D. vertical 3 Cms
Sawdust Bagasse Pine Wood
Gross I.D. Horizontal 4 Cms
Calorific 3
Volume 471.29 Cm
Value 2071.86 3965.18 8365.6
(Kcal/Kg)

Analysis shows pine wood having the highest calorific value

and by a significant margin, this shows more potential of pine
wood to be used especially as the solid bio-fuel or bio-char, There are two routes for the vapor to travel after the reaction,
which can further explain the use of biomass for making one is downstream from the product outlet tube of the reactor
biochar. The utilization of biomass as feedstock from which to into the condenser and the same line is connected from the
create vitality is not a new idea [11]. Be that as it may, char tank with 0.7 in (1.77 cm) OD stainless steel tubing.
innovation exists where these assets are utilized to give vitality There is however no facility maintained to filter the fine bio-
and in the meantime the chance to sequester C from the char particles. Biochar is collected in a 4.5 liters capacity
environment [12]. The pyrolysis of biomass serves to give Stainless steel canister. Through the condenser the cooling
fluid of liquid water is flowing to condense the volatile gases
into a liquid.

Fig. 3. The Pyrolysis System on which experiments were conducted

After the product stream enters a set of three water cooled

brass condensers, they are expected to be condensed, using V. RESULTS AND DISCUSSIONS
water as the cooling fluid at a temperature of 10°C. The An equal proportion of sand and biomass mixed was charged
condensers are single tube heat exchangers with quick-clamp inside the reactor through the feed hopper. Sand was used as a
tubing. There is an assembly of three condensers. Bio-oil heat carrier, in principle using a heat carrier like sand should
formed to be collected in glass beakers. not be a problem, but problems related to wear has been
reported. However Char or the solid biofuel is formed
successfully in the present system within the residence time of
8 seconds.

Biochar is a carbon rich material from the pyrolysis of

biomass. The use of biochar to soil is a noteworthy long haul
sink of barometrical carbon dioxide in physical biological
systems. The part of biochar in carbon sequestration in
decreasing the emanation of nursery gasses, and enhancing
soil ripeness prompted the suggestion of biochar as an
alteration of soils. Also, biochar offers a basic, manageable
device for turning so as to oversee rural and urban squanders it
into significant items [13]. Consolidation of biochar in soil can
apply both short and long haul impact on its wellbeing.
Transient advantages incorporate a liming impact for soils
with low pH and long haul impacts incorporate expanded
supplements and water maintenance limit of soil that can
influence the harvest efficiency [14]. The reason for applying The theoretical establishments of biochar as an air CO2
biochar to soil mostly falls into four general classes: evacuation component lie in the photosynthetic procedures
agricultural gainfulness; management of contamination and that create the biomass to be utilized for biochar generation.
eutrophication danger to nature; degraded Land Restoration As biomass develops it uproots air CO2. The creation of
and sequestration of Carbon from the air. biochar changes over relatively labile C (Carbon) present in
the biomass into stubborn C intensifies that oppose
IV. TWIN SCREWS mineralization. Thusly the rate of return of C to the climate is
extraordinarily restrained. It is the contrast between the
Given is the design of the screw made in SolidWorks.
(moderately quick) rate of air CO2 sequestration into biomass
contrasted with the ensuing (generally moderate) rate at which
biochar C is mineralized that offers ascend to net stockpiling
of C; and by this token the chance to create warmth and force
by C-negative means.
For the setup that has been demonstrated here we found that the outlets. The gas is collected from the three slots and further
passage of nitrogen was often obstructed, and the gas formed after combined as 1 slot and then it is condensed through a
heating of the biomass found it very difficult to travel to the condenser and is converted into oil. This oil is the final
condenser and got accumulated mostly inside the char tank, product of the project. Some work based on suggested design
although it has to be mentioned that some leaks were detected in and insulation has been done at a workshop in Delhi, work
the system that contributed to the condensable and uncondensed includes but not restricted to, improve functioning of the
gases escaping from the system. impeller at the sand preheating section, new heating coils, new
clamp fittings, char tank capacity now increased to 6.5 liters
Based on the aforementioned observations the following (initially it was 4.8 liters), MCV changed (connection related),
design improvements are suggested: Char tank inlet from reactor is 25 mm (initially it was 18mm).
1. Inlet to the condenser is connected from the reactor Also temperature profiles for study will be 600-700°C with
instead of the char tank. new temperature coils used.
2. Present char tank has the capacity of 5.84 liters it is
proposed to increase the capacity of it.
3. Separate screw feeders for the entry of biomass and
sand into the system.
4. Present system has some problems with gases
escaping through leakages, those have to be
compromised.
5. Temperature ranges of above 500°C has to be
investigated, present system uses glass wool for
insulation for the reactor.
6. Installation of a cyclone separator to remove the
suspended particles through vortex separation.

This work infers that the formation of the pyrolysis oil or bio- Fig. 7. Char tank before modification (left) with 4.84 lit capacities after
modification with 6.5 lit capacity (right)
oil is a tricky process, and this proposed design is presently
being worked upon, given below are the dimensions in inches
VI. CONCLUSION
for the system that is being designed presently.
Present work ends here with the possibility of bio-oil
production from this new improved design, this work has
demonstrated the system is feasible for producing biofuel, and
hence it can be speculated to have this design take a future
leap from R &D to commercialization, with help of platforms
such as the National Biofuel Policy pyrolysis units can cater to
the needs of alternative fuel. It is believe the fast pyrolysis of
biomass has the potential to meet the global need for liquid
fuels in terms of petroleum substitute and, also for other
chemicals. However, the complex mechanism of the feeding
system coupled with variability makes it difficult to come up
with a definitive standard process. The investigated
parameters were the reactor temperature of 350–450°C by
means of heating coils, the initial flow rate and the residence
time of the solids of 2–4 kg/h and 6-8 seconds, to examine the
effect of the heating rate on the process, and it is reported that
in this setup solid bio-char is formed successfully but the
liquid product requires further system integration, suitable
changes has been proposed and being developed presently to
continue this study further which would lead to production of
liquid biofuel or bio-oil from this system. It is believed that
The Figure 6 shows the top view of the reactor. Starting from bio-oil would contribute significantly for transportation,
the bottom of the figure the first opening is for the Sand feed heating, or electricity generation of the future.
with a motor is given. Then the second opening is given for
the Biomass feed. Then the small slots which are given and
are of dia 0.3 inch are given for thermocouples for measuring
temperatures. The remaining three slots are given for the Gas
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