Process Development Unit

A modular, fully integrated, full-size biomass preprocessing system

P
oor feed handling is The PDU allows industry PDU OVERVIEW
one of the primary partners to test a variety The PDU processes a variety
reasons commercial of size reduction, milling, of feedstocks at up to 5
plants that process bulk drying, pelletizing, tons per hour. Since its
solids often operate at a cubing, torrefaction, and construction in 2009, it
fraction of design capacity mechanical and chemical has processed more than
The PDU allows during their first year. separation options. 1,500 tons of feedstocks.
industry partners to
test a variety of size A single feed handling The PDU’s flexible Examples of PDU capabilities:
reduction, milling,
drying, pelletizing,
problem—anything from a configuration allows for • Toll processing for research
plugged auger to a broken insertion of third-party and development
cubing, torrefaction,
conveyer—may bring the equipment and a wide
and mechanical and • Feedstock supply sourcing
chemical separation plant to a standstill until range of process designs
and custom blends
options. the problem is resolved. so biorefineries can
minimize or eliminate feed
• Industrial feedstocks
Researchers at the developed at commercial
handling problems before
Department of Energy’s specifications
costly setbacks occur.
Biomass Feedstock National • Validation and testing of
User Facility (BFNUF) The PDU and its third-party technology
specialize in scale up and counterparts—the
• Multiple sources of the
integration of biomass Characterization Laboratory
same feedstock type for
preprocessing facilities. The and the Bioenergy
variability comparisons
BFNUF’s primary capability Feedstock Library— offer
is the Process Development the bioenergy industry
• Full-scale control and
equipment test bed
Unit (PDU), a full-size, a world-class feedstock
fully integrated feedstock preprocessing research and
preprocessing system. development resource.
 Drying
• Three-pass rotating drum
• Variable heat furnace
• Variable blower
The PDU offers
solutions for more
• Torrefaction
than natural materials • Pneumatic conveyance
like pine residue and
corn stover. Municipal
• Drag chain, belt and
solid waste can also be screw conveyors
processed at INL’s PDU. • Plenum chamber:
pneumatic-assisted
grinding, dust collection
and control
• Metering bin: decouples
upstream and downstream
Examples of feedstocks Decomposition feed-handling rates
tested at the PDU: • Bale deconstruction with Densification
• Agricultural residues: bale capacity of up to Densifies ground material
corn stover, wheat straw, 4-by-4- foot cross sections to more than 40 pounds
sugar cane bagasse • Shredding of bulk per cubic foot
• Grasses: switchgrass, materials like municipal • Pellets, cubes or briquettes
miscanthus, energy solid waste • Cooler improves quality
sorghum, reed » plastics and durability
canary grass
» electronics • Super sacks
• Woody biomass: tree
» food scraps • Compression bags
chips, logging residues
• • Bulk loading
• Municipal solid waste Size reduction for bales
The PDU’s control room has
• Cellulosic coproduct and bulk material through
screens ranging from two computer workstations,
• Circuit boards and other
6 inches to 3/16 inch which allow operation of
electronic wastes
• Wood chipping integrated equipment via a
MODULAR DESIGN Distributed System Manager.
FOR MORE INFORMATION
• Compression milling
A data logger records
The PDU is comprised of • Attrition milling
measurements from various
multiple modules including
Technical contact decomposition, sorting/ Sorting/Fractionation instrument sensors and
Neal Yancey fractionation, milling, drying • Air classification at motor current draws. These
208-526-5157 and densification. The multiple scales measurements allow the
[email protected] modular system provides • Robotic sorting operator to track and record
easy reconfiguration allowing • Gravity or density important variables such as
General contact users to conduct process separation moisture and grinding energy
Abby Todd to help partners understand
development, design and • Contaminant removal
trade-offs during commercial-
208-526-6166 scale up of preprocessing by rock trap
[email protected] and feed-handling systems scale preprocessing.
• Magnetic separation
at INL’s 27,000-square-foot
www.inl.gov high bay in Idaho Falls or
• Mechanical separation
Battelle Energy Alliance manages INL for the U.S. Department
or screening of Energy’s Office of Nuclear Energy. INL is the nation’s center for
at partner locations.
nuclear energy research and development, and also performs
Milling research in each of DOE’s strategic goal areas: energy, national
• Hammer, knife and security, science and the environment.
A U.S. Department of Energy shear milling
National Laboratory

22-50380_R3 (Updated: 2022)