Throughput Conversion to Bio-Oil & Biochar
International BioRefineries (iNBIO) designs and deploys fast pyrolysis systems that convert lignocellulosic and agricultural residues into bio-oil, biochar, and process gas in a compact, modular footprint. This page summarizes typical engineering ranges and options. Final, project-specific specifications are provided on request under NDA.
Key Performance Summary (Typical Ranges)
| Parameter | Typical Range | Notes |
|---|---|---|
| Nominal throughput (per line) | 5–75 metric tons/day | Multiple lines scale to 200+ TPD |
| Reactor temperature | 450–550 °C | Optimized by feedstock |
| Vapor residence time | < 2 seconds | Fast-pyrolysis regime |
| Heating rate | ≥ 200–1,000 °C/s | Reactor-specific |
| Operating pressure | ~ Atmospheric (slightly negative) | Induced-draft control |
| Bio-oil yield (wt % dry feed) | 40–70% | Depends on feed & moisture |
| Biochar yield (wt %) | 15–40% | Tunable via conditions |
| Process gas (wt %) | 7–20% | Recycled for heat after startup |
| Feed moisture (as-received) | ≤ 10–15% (after drying) | Integrated dryer option |
| Feed particle size | ≤ 10–30 mm | Screening recommended |
| Electrical load (per 5–10 TPD module) | 75–150 kW | Varies with auxiliaries |
| Thermal load for startup | Low (LPG/NG/bio-oil) | Then switches to self-heat |
| Typical footprint (per 5–10 TPD module) | 3,500–6,000 ft² | Indoor or covered pad |
Disclaimer: Values above are representative for fast pyrolysis. iNBIO supplies guaranteed figures in final engineering documents based on your feedstock, uptime target, and product specs.
Process Overview
- Feed Preparation: Size reduction, drying to target moisture, metered feeding.
- Thermal Deconstruction: Rapid heating in an oxygen-limited reactor; volatiles form condensable vapor, solids form biochar.
- Vapor Handling & Condensation: Multistage quench/condensation yields bio-oil; non-condensable gas returns to the heater.
- Product Recovery: Biochar is cooled and discharged; bio-oil is filtered and stored; process gas supports thermal demand.
Feedstock Compatibility
- Woody biomass: forestry residues, sawmill fines, urban wood waste (painted/treated wood excluded unless pre-treated).
- Ag residues: corn stover, rice husk, nut shells, cane bagasse, switch grass, poultry litter, cow manure, animal waste
- Spec limits (typical): Moisture ≤ 15% post-drying; Ash ≤ 10% (lower preferred); Alkali index managed via feed blending or additives.
Tip: For best oil yield and stability, target low ash, low alkali feed. iNBIO can run lab screening on your samples.
Product Specifications & Options
Bio-Oil (Pyrolysis Oil)
- Appearance: Dark, oxygenated liquid; HHV ~14–19 MJ/kg (typical).
- Uses: Industrial heat, CHP, refinery co-processing trials, asphalt binder extender, marine fuel, train fuel, and as an intermediate for SAF after hydrotreating/hydro-deoxygenation in third-party units.
- Options: In-line solids filtration, water content tuning, nitrogen blanketing, heated storage.
Biochar
- Properties: Fixed carbon-rich solid; tunable surface area; low PAH process control.
- Applications: Soil amendment, carbon removal credits, storm-water media, filtration, cement/concrete admixture.
- Quality assurance: ASTM/ISO/IBI/EBC testing supported; certification pursued per customer strategy (iNBIO does not claim blanket certification).
Process Gas
- Composition: CO, H₂, light hydrocarbons, CO₂ (no external oxygen).
- Use: Recycled to provide process heat post-startup; excess can support dryers or be flared per permit conditions.
Controls, Safety & Compliance
- Automation: PLC/SCADA with recipe control, trending, and remote monitoring; interlocks for temperature, draft, and oxygen.
- Safety: Inerting/N₂ purge, explosion venting where applicable, hot-surface guarding, NFPA-aligned design practices; PSM applicability reviewed per site inventory.
- Environmental: Designed to meet local air permits with cyclones, hot-gas filtration, and oxidation/thermal treatment on vents as required.
Utilities & Site Requirements
- Power: 480 V three-phase (typical in North America) or per region.
- Heat: Small startup fuel (LPG/NG or bio-oil); after light-off, process gas sustains heat.
- Water: Minimal for closed-loop cooling; dry coolers available; no process wastewater from reactor.
- Footprint: Skid-based modules for fast installation; indoor or covered outdoor layouts supported.
- Staffing: 1–2 operators/shift per line (typical), plus maintenance/QA shared across lines.
Modularity & Scale-Up
- Module sizes: ~5–10 TPD, ~25–40 TPD, and ~50–75 TPD per line.
- Parallel trains: Combine lines to reach 200+ TPD with shared prep, condensation, storage, and utilities.
- Uptime targets: Engineering offered for 7,000+ hours/year depending on feed logistics and maintenance windows.
Data Services & Guarantees
- Front-End Testing: Lab/bench screening of your feed to predict oil/char yields and ash behavior.
- Performance Guarantees: Offered at contract stage with agreed feed envelope and operating window.
- Commissioning Support: On-site startup, operator training, SOPs, and spare-parts package.
Frequently Asked Questions
What makes fast pyrolysis “fast”?
Extremely short vapor residence time (< 2 s) and high heating rates keep vapors from cracking to gas, maximizing liquid yield.
Can iNBIO support SAF pathways?
Yes. iNBIO supplies stabilized bio-oil as a renewable intermediate to be used as Asphalt binder, Marine fuel, or Train fuel. SAF production requires third-party hydrotreating and upgrading; we collaborate with technology partners and refineries to qualify feed specs.
How do we handle high-ash feedstocks like poultry litter?
Expect lower liquid yields; biochar quality can be attractive for nutrient management value chains.
What certifications can biochar carry?
We support testing to IBI/EBC/ASTM protocols. Certifications depend on your feedstock and target market; we help assemble the documentation.
What emissions controls are included?
Cyclones/hot-gas filtration and controlled oxidation on vents as required by permit. Final configurations are site-specific.
How to Specify Your System
- Define feed envelope: species/grade, moisture, ash, expected variability.
- Set product goals: oil vs. char yield priority, target markets (e.g., asphalt, soil, Marine fuel, Train fuel, SAF intermediate).
- Select scale: start with a 5–10 TPD module or go multi-line for 50–200+ TPD.
- Site constraints: power, fuel availability, footprint, indoor/outdoor preference, environmental thresholds.
- Engage iNBIO: We’ll provide a proposal with mass/energy balance, plot plan, and performance terms.