Battelle engineers and scientists have developed a mobile device that can use catalytic pyrolysis to convert unwanted biomass materials (such as wood chips or agricultural waste) into valuable bio-oil. In its current configuration, the Battelle-funded device can convert one ton of pine chips, shavings and sawdust into up to 130 gallons of wet bio-oil per day. 

This intermediate bio-oil can then be upgraded to a gas/diesel mixture or jet fuel by hydroprocessing. The conversion of bio-oil into advanced biofuels is a key element of Battelle's research. Extensive testing of bio-based gasoline substitutes produced by Battelle has shown that it can be blended with existing gasoline and can help fuel producers meet their renewable fuel requirements. 

Another use of Battelle bio-oil is to convert it into bio-polyols, which can replace petroleum-derived polyols in chemical manufacturing. Battelle's biopolyols have been verified as viable alternatives by third-party polyurethane manufacturers.  

Battelle is evaluating the one-ton-per-day system at its plant in West Jefferson, Ohio. The pilot scale system is the culmination of the second phase of Battelle's mobile pyrolysis technology development. In the first phase of the past four years, Battelle created a desktop machine that can convert 50 pounds of wood waste a day to demonstrate this novel concept. The next step will be to cooperate with strategic partners/investors to produce a tenth-scale demonstration unit.  

Currently, Battelle experts mainly use pine waste in transportable pyrolysis units, although high-tech machines can be modified to use other types of unwanted farmland residues called stranded biomass, including corn stalks, switchgrass, and miscanthus. 

In addition, all waste materials generated in the process of this installation—liquid, solid and gas—have been taken into account. The liquid waste stream is water that can be safely recycled or treated, the solid coke contains inorganic substances that can be used for fertilizer, and the exhaust gas is safely monitored.

Due to its small size, the pyrolysis unit is mounted on the trailer of an 18-wheel flatbed truck, which makes it mobile and can therefore be transported to waste. This feature makes it an ideal choice for obtaining woody biomass that often remains in agricultural areas far away from industrial facilities. This may have a significant cost advantage compared to the competitive process represented by a large facility that needs to transport biomass from its location.

"We have something very compelling," said Kathya Mahadevan, Battelle's energy and environmental business unit manager. "We have allowed it to produce oil and have proven its viable applications. As we scale up, we will be able to further improve efficiency, such as heat consumption and output."

The Battelle bio-oil produced by the mobile pyrolysis unit is similar to natural petroleum collected from the ground. The hydrotreated and upgraded fuel complies with the Renewable Fuel Standard (RFS) established by the U.S. Environmental Protection Agency.