Project Completion Report on

Torrefaction of Bamboo

October, 2006

Advanced Bioresidue Energy Technologies Society (ABETS)

Combustion, Gasification & Propulsion Laboratory (CGPL)
Department of Aerospace Engineering
Indian Institute of Science
Bangalore 560 012
Web site: http://cgpl.iisc.ernet.in
email: [email protected]

1
 Acknowledgement

ABETS, CGPL, IISc expresses sincere thanks to National Mission for Bamboo
Application (NMBA), Department of Science and Technology (DST), Govt. of India
under whose auspices this project entitled “Torrefaction of Bamboo” has been
successfully carried out.

2
 Contents

Executive Summary 4
Background of the project 5
Introduction & Literature Survey 6
Exploratory Studies 8
Laboratory Scale Studies 10
The Pilot Plant 19
Characterizing Torrefied Bamboo 24
Techno-economics 26
Plant Dimensions for higher throughput 27
Conclusions 28

3
 Executive Summary

This project was taken to enhance the storability of bamboo and also generate a product which
can be a cheaper substitute for applications where black charcoal is currently being used. Bamboo
is a fast growing fibrous plant grown in abundance the country. In India, one particular species of
bamboo namely ‘Melocanna baccifera’, estimated to represent over a sixth of the
country’s growing stock of bamboo, is facing the threat of gregariously flowering between 2004 -
08. The flowering of Melocanna Baccifera is an event of great significance wherein large tracts of
land are affected, as bamboo forests burst into bloom and then die. This sudden death of bamboo
in huge quantity is expected to significantly increase the rodent population and therefore there is
an urgent need to identify ways and means by which several tons of bamboo could be put to
effective use in short span of time. So there is definite need to immediately use or preserve or
extend the shelf life of the bamboo. The current practices of bamboo usage can only consume a
part of the excess bamboo generated on account of this gregarious flowering thereby opening
possibility for other usages. Torrefaction of bamboo is seen as one such possibility that apart from
energy densification makes the product resistant to fungal attack thereby enhancing its storability.

Under the project sponsored by NMBA, DST, Govt. of India, torrefaction of bamboo has been
successfully attempted wherein trails have been conducted in a kiln of 1 ton/day input capacity.
Prior to conceiving the design of the kiln, basic studies have been conducted wherein the effect
on torrefaction temperature (180 to 350° C) and residence time has been thoroughly investigated.
The torrefied bamboo has been characterized for calorific value and elemental balance such as
carbon, hydrogen and oxygen. Based on the analysis it is found that there is an enhancement in
energy density by 20% against green bamboo between torrification temperatures of 250 and 260°
C. The effect on residence time both on energy density and yield is found to be marginal. Apart
from energy densification, torrefaction process makes the material hydrophobic, the moisture
absorption over a long duration of observation is found to be between 3 and 5% against 10 and
12% with sun dried bamboo. The product from the process of torrefaction is referred as ‘Grey
Charcoal”

The thermal energy required for torrefaction process is derived from ‘green energy fuel’ –
generated from the gasification of bamboo and its waste. The kiln is designed to allow re-
circulation of hot flue gases thereby making the torrefaction process efficient. The volatiles
released in the process of torrefaction is fed back to the combustion chamber thereby making the
entire process clean and does not contribute to atmospheric pollution. This batch-type kiln has
completed successful trials at the laboratory is being shifted to Nagaland Bamboo Development
Agency, Dimapur, Nagaland for field trials.

This consolidated report contains details of exploratory work, lab scale plant and pilot plant of 1
ton/day. The last chapter contains plant dimensions for 10 and 20 ton/day throughput. As a part of
the project it was felt appropriate to conduct a survey on the current charcoal/activated charcoal
consumption in North-Eastern states of the country. This was expected to provide input on the
volume of charcoal traded and the possibility of replacing it with grey charcoal generated from
bamboo. As the survey didn’t elicit much response this aspect is not reported here. However,
economics based on 1 ton/day plant is brought out.

4
 Background of the Project

Bamboo is a fast growing fibrous plant grown in abundance in India. It is a versatile material
finding usage in structural, construction, wood substitute, composite and energy production. In
India, one particular species of bamboo namely ‘Melocanna baccifera’, estimated to represent
over a sixth of the country’s growing stock of bamboo, is facing the threat of gregariously
flowering between 2004 and 08. The flowering of Melocanna baccifera is an event of great
significance wherein large tracts of land are affected, as bamboo forests burst into bloom and then
die. This sudden death of bamboo in huge quantity is expected to significantly increase the rodent
population and therefore there is an urgent need to identify ways and means by which several tons
of bamboo could be put to effective use in short span of time. So there is definite need to
immediately use or preserve or extend the shelf life of the bamboo. The current practices of
bamboo usage can only consume a part of the excess bamboo generated on account of this
gregarious flowering thereby opening possibility for other usages. Methods need to be devised to
capture as much of this material for productive uses of the society. Several approaches are already
under consideration at present. Torrefaction of bamboo is seen as one such possibility that apart
from energy densification makes the product resistant to fungal attack.

Torrefaction is mild pre-treatment of any biomass (including bamboo) at a temperature between

200 and 250° C. During torrefaction the properties of bamboo undergo changes, wherein the end
product has much better fuel quality compared to biomass for combustion application. The
decomposition reactions during this process results in bamboo becoming completely dry and
loose its tenacious structure, also the hygroscopic nature of the biomass is changed to
hydrophobic material. Besides this, the process increases the calorific value of the end product.
The actual weight loss in this period would be about 20 to 25 % whereas 90 % of the energy of
the parent dry material is preserved in the torrefied matter. The combustion process of this matter
has less problematic volatiles and hence the process is closer to that of charcoal. It can therefore
be used as an alternate to charcoal in many applications. It also makes the material immune to
attack by fungi. Hence long term storage without degradation is possible.

A project to enhance the storability of bamboo has been sanctioned by NMBA. This exploratory
and development work has been carried out at Combustion Gasification and Propulsion
Laboratory, IISc, Bangalore. The duration of the project was for nine months and involved
exploratory work and development of a 50 kg/hr pilot scale equipment for the manufacture of
torrefied bamboo. The objectives the project is briefly given below:

1. Conduct tests on a pilot scale version to establish the design parameters and characterize
the principal properties with bamboo from selected sites

2. To provide the design details of a large scale system (to handle15000 to 17000 tonnes per
year of as-received bamboo) for its establishment at one location and conduct tests to
prove the performance at the field level

3. Establish the techno-economics of this approach.

5
 Introduction and Literature Survey

Torrefaction involves mild treatment of biomass between 200 to 300° C in an inert

atmosphere. Untreated biomass particularly agricultural waste has low energy density, high
moisture content. These features make transport relatively expensive. Just drying would be
insufficient as the biomass can regain moisture and rot during storage. Increasing the energy
density such as torrefaction process can be seen as an attractive proposition. The product of
torrefaction process is a solid product, which is torrefied biomass, has attractive properties
such as improved heating value, low moisture content and ease of size reduction. The
properties of torrefied biomass are as follows:

1. Lower moisture content and therefore higher heating value compared to biomass,
Due to lower moisture content, it is cheaper to transport the torrefied biomass
2. Hydrophobic nature: the material does not gain humidity in storage and therefore
unlike charcoal and biomass, it is stable and is resistant to fungal attack.
3. Easy burning and less smoke formation when burnt
4. Suitable for various application such as for cooking fuel, residential heating, raw
material for manufacturer of fuel pellets, reducer in smelters - steel industry,
manufacture of charcoal or activated carbon, gasification, co-firing with other fuels in
boilers etc.

Literature does not contain information on bamboo torrefaction per se, nevertheless there is
large amount of research conducted on biomass torrefaction. Research as early as in 1930 is
reported in France, but there does not seem to be any publications available. Research work
on torrefaction at a fundamental level has been reported by Mark J Prins [1] in his PhD thesis
entitled “Thermodynamic analysis of biomass gasification and torrefaction”, however it does
not contain details of industrial torrefaction process technology.

Literature reports that in the 1980’s, a commercial plant with a capacity of 14,000 ton/year
was operated in France for the production of barbecue fuel [2], but the plant is no more in
operation. Similarly Bourgois and Doat [3] have published torrefaction work using two
tropical wood samples. This research is reported to have resulted in the building of a
continuous wood torrefaction plant in 1987, the torrefied wood was used as a reducer in the
production of silicon metal.

Bergman et al [4] reports the benefits of torrefaction process in terms of reduced electricity
requirement for size reduction and production technology for the production of pellets.
Similarly Pach et al [5] discusses the torrefaction process performed in a laboratory unit using
two species of wood, birch, pine and sugar cane bagasse.

The above compiled literature study clearly reveals the work done at the fundamental level
but there is no information about industrializing the process. Since the mandate of the project
taken up involved development of a pilot scale plant, the current work was more focused on
development and less on basic research work. The available information in the literature was
used as guidance in realizing of the goal.

6
List of Reference:

1. Mark J Prins, Thermodynamics analysis of biomass gasification and torrefaction,

PhD thesis, Technical University Eindhoven, 2005.

2. Girard P, Shah N, Recent developments on torrefied wood, an alternative to charcoal

for reducing deforestation, REUR Technical series 20: 101 – 114

3. Bourgois J P , Doat J, Torrified wood from temperature and tropical species,

advantages and prospects In: Egneus H, Ellegard A, Bioenergy 84, London, Elsevier
Applied Science Publishers, p 153 – 159.

4. Patrick C A Bergman and Jacob H A Kiel, Torrefaction for biomass upgrading, 14th
European Biomass Conference and Exhibition, Paris, October 2005.

5. M, Pach, R Zanzi and E Bjornbom, Torrefied biomass a substitute for wood and
charcoal, 6th Asia Pacific International symposium on combustion and energy
utilization, 2002.

7
 Exploratory Studies
The first phase of the activity involved conducting lab scale studies and establishing of design
parameters for scaling-up activity. Towards this a 100 kg/hr (based input feed capacity) was
designed and tested in the laboratory. Prior to commencement of this work, exploratory work was
conducting in identifying the temperature regime for torrefaction of bamboo. A series of
experiments were conducted where the bamboo sample was subjected to temperatures between
100 and 250° C in an electrically heated oven. The bamboo species used for experiments was
'Bambusa bambos', - a thorny bamboo and one of the three major species of the country,
extensively found in Central and Peninsular India - with a preference for rich and moist soils.
These weigh about 3.0 – 3.5 kg/m and are shown in Plate – 1.

Plate 1: Bambusa bambos - Thicker variety bamboo sourced from the neighboring market

0.8

s 0.7 Material become fragile above 200 o C

s
o
L
t
h 0.6
g
i
e
W
l
a
n 0.5
o
it
c
a
r
F 0.4

0.3
100 150 200 250 300
Temperature, o C
Fig. 1 Fractional weight loss vs Temperature, torrefaction regime for bamboo identified.

8
The results of the experiments are shown in Fig. 1. It is evident from the results that the critical
temperature regime for torrefaction of bamboo is around 200° C. At about 200 – 205° C, the
bamboo looses its tenacity and becomes fragile in nature. The bamboo samples during various
stages of heating between 100 and 210° C is shown in Plate – 2.

Plate 2: Bamboo samples during various stages of heating. At about 205° C the bamboo
losses its tenacity and becomes brittle, indicating bamboo is torrefied

9
 Laboratory Scale Studies

A laboratory scale plant with an input feed capacity of 100 kg/hr (batch type) was built
for the initial trials. The heat source for torrefaction was obtained by combusting producer gas +
air mixture in the combustor. The producer gas was in turn generated in a gasifier system using
waste wood as the feedstock. The hot gas temperature at the entry to the torrefaction chamber was
maintained at varying temperatures between 200 and 350° C. The combustor and the torrefaction
chamber were fitted with thermocouples to record the bed temperature in the chamber. To
enhance the efficiency of the torrefaction process the hot flue gas was recirculated. The
combustor, torrefaction chamber, blower and all connecting ducts were insulated to reduce heat
loss. The schematic of the torrefaction process is shown in Fig. 2. The photograph of the lab plant
is shown in Plate 3 and 4.

Blower

Air
Hot Flue
Gas Tor (with moisture & volatile)
Fuel gas Combustor Chamber
source Hot Flue Recirculation
(200 - 300 C) Blower

Burner

Biomass drier

Fig. 2 Schematic of Torrefaction Process

One of the most important parameters that were to be established in the above process
was the residence time. The only sure way of determining this was through experimental trials.
Therefore experimental trials were conducted using cut green bamboo of 0.6 m length (50 – 60
mm diameter) with an initial moisture content between 9 and 47 % (on wet basis). Two types of
bamboo, namely thin and thick bamboo were tried for experiments. Most of the trials were
conducted using thin bamboo (Bamboosa-Bamboosa species). About 5 tons of Bamboo was
procured for these trials from Dandeli forest in Karnataka. These bamboos measured about 6 m
length with a mean diameter of 80 – 140 mm at the bottom to about 50-80 mm at the top. The
typical wall thickness was about 10 mm. The moisture and ash content of the green bamboo was
about 47% and 2 % on wet basis respectively.

10
 Plate 3: Laboratory Scale Plant Arrangement for Torrefaction Process

Flue Gas Recirulation

Air

P Gas

Air Air

Plate 4: Combustion Chamber for Generation of Hot Flue Gases for Torrefaction Process

11
 Raw Bamboo (50% Moisture wb)

Bamboo Post-drying at 100° C

Torrefied Bamboo

Plate 5: Bamboo during various stages - lab scale testing

12
 It took about 2 to 3 trials to establish the operational procedure. During these exploratory
trials the combustor was operated at power level of about 20 – 25 kWth. The hot gas entry to the
torrefaction chamber was maintained at about 200 to 225° C. First set of experiments were
conducted in non-recirculation mode and the dryer efficiency was found to about 7%. This was
followed by experiments in part-recirculation mode wherein the operation was carried for about
3.5 hours, the efficiency of system turned out to be about 14%. The process was further optimized
wherein the flue gas recirculation rate was increased such that there is no flame quenching in the
combustor, this resulted in an efficiency of about 30 - 35%.

Further trials were conducted between temperatures of 200 and 350° C and at varying
residence times (1- 3 hours). Other than maintaining of flue gas temperature at the entry to the
torrefaction chamber, roughly inert conditions (oxygen < 2- 3%) were maintained at all times in
order to prevent combustion of volatiles/biomass in the torrefaction chamber. The temperature
during the torrefaction process was continuously monitored by recording the bamboo temperature
at three/four tiers. In each of the tier, one bamboo had a provision for thermocouple insertion.
Thermocouples were inserted to measure the surface, pulp and core on each of the identified
bamboo. During the initial process there was large variation observed in temperature at various
levels and also temperature within the bamboo. With time the non-uniformity used to reduce and
by the time of completion of the trial the temperature was more or less uniform (variation by
about 25 C). Upon achieving of the desired temperature by the top tier bamboo, the trial was
stopped.

On the whole more than thirty trials were conducted and results of important ones are
summarized in Table 1. It is evident from the Table that as the operating temperature is increased
the loss of volatile matter is higher and consecutively the yield of solid matter is lower. The
dependency on temperature appears to be much stronger than the residence time. In the
temperature range of 180 to 220° C, the yield of solid matter is about 83% and as the temperature
is increased to 350° C, the yield comes down to about 45%. The solid yield at varying
torrefaction temperature is summarized in Table 2. The residence time at higher temperature is
lower in some case because of initial moisture content being low in the raw bamboo. Lower
initial moisture content would therefore need lower residence time.

There was inconsistency in the results of some of the trials due to incorrect estimation of
initial moisture content in the bamboo. Initial estimation of moisture content had become some
what problematic as there some variation observed in the moisture content along the length of the
bamboo and moreover the procured green bamboo started to loose moisture. Therefore getting the
right representative sample for estimating the initial moisture had become difficult. This was
resolved in the subsequent trials by adopting a more elaborate procedure.

Fig. 3 shows the temperature profile at the exit of the combustor and the entry of the
torrefaction chamber – grate entry, The temperature of the flue gas is maintained between 220
and 250 °C right through the process. The flue gas exit temperature slowly increases from
ambient to about 230 °C by the completion of the process. Similarly Fig. 4 shows the temperature
profile measured at three locations within a given bamboo – surface, inner and hollow. It is
evident from this figure that the heating rate is between 0.5 to 1.0 °C/min. The temperature
throughout the cross section of a given bamboo is more or less uniform at any point of time
through the process. This uniformity in temperature ensures generation of uniform and consistent
product.

13
Fig. 3 Temperature at various points in the chamber during the process

Fig. 4 Temperature in the bamboo during the Process

14
 Table – 1: Summary of the Lab Studies

volatile Total Duration >

Bamboo loss solid yield Duration Temp 180° C
% % Min °C hour
thick 15 85 525 207 -222 1
thin 17 83 400 199 - 222 1
thin 17 83 310 190-219 2
split 17 83 280 188 -216 2.5
thin 42 58 250 196 -223 1
thin 39 61 375 213 - 222 3
thin 22 78 400 232 - 236 3
thin 29 71 555 230 - 248 6
thin 30 70 380 230 - 248 6
thin 57 43 320 300 - 325 2.5
thin 28 72 205 250-283 2
thin 47 53 110 225-280 2
thin 37 63 180 270-300 1.5
thick 34 66 390 246-283 3.1
thin 50 50 330 250-318 3.25
thin 66 34 385 245-296 3.45
thin 45 55 195 270-280 2.15
thin 41 59 215 270-300 2
thin 22 78 400 250-270 3
thin 21 79 440 250-270 3
thin 18 82 325 215-234 1
thin 10 90 395 210-220 1.1
thin 55 45 295 300-350 1
there is inconsistency in the results shown in italics due to wrong estimation of initial moisture
content

Table -2 Solid Yield at Varying Torrefaction Temperature

Temperature, °C Residence Time, Solid yield, %

hour
180-220 5.0 – 6.5 81 – 83
225-250 6.0 - 7.0 70 – 78
250-280 6.0 66 -72 (55 – 79)
280-300 4.0 55 -63 (50 – 66)
300-350 5.0 – 6.0 43 – 45

15
 During torrefaction process decomposition reactions results in bamboo becoming
completely dry and loose its tenacious structure. Also, the hygroscopic nature of the biomass is
transformed to become hydrophobic. Besides this, the process increases the calorific value of the
end product.

The challenging part of the development process was to identify a criterion for the
completion of the torrefaction process. The extent to which the end product has become
hydrophobic was found to be the only valid criteria. . Towards this the end product was subjected
to humidity tests by exposing it (a) to atmosphere for prolonged duration of time (b) humidity
above 95% for 24, 48 and 72 hours. The outcome of these studies is shown in Fig. 5 and 6. Under
ambient conditions, the maximum absorption of moisture is less than 4% against nearly 10% in
the case of raw bamboo. Similarly studies under humid conditions of over 95% indicate moisture
absorption of about 6% against 11% with raw bamboo. These studies clearly emphasize achieving
of hydrophobicity during torrefaction process.

Fig. 5 Moisture absorption test: raw and torrefied bamboo exposed to ambient

Plate 6 shows the bamboo that was used for the experimentation. Plate 7 shows the process
sequence to obtained grey charcoal from bamboo. Plate 8 shows the products obtained by
subjecting the bamboo at varying temperatures.

16
Fig. 6 Moisture absorption test: raw and torrefied bamboo exposed to humid environment
(95-98% Relative Humidity)

Plate 6: Bamboo procured for the trails

17
 Plate 7: The Process Sequence

Plate 8: Torrefied Bamboo at Varying Temperatures

18
 The Pilot Plant

Design & Description of Test Plant

The test plant of 50 kg/hr plant shown in Plate -9 & 10 was commissioned in May 2006.
The test plant is an extension of the batch type lab scale system, wherein initial trials were
conducted. The pilot plant is designed for continuous operation and meant for production of
torrified bamboo. The test plant comprises of six identical chambers (each measuring 1 x 0.55 x
0.85 m) juxtaposed to each other with adequate thermal insulation. Each of the chambers has
provision for hot flue gas entry at the bottom and exit at the top. The entry part of all the
chambers are connected to one common manifold whose other end forms the exit of the
combustion chamber. Similarly exit of all the chambers are connected to another common
manifold whose other end is connected to a recirculation blower. There is isolation valves
provided on the entry and exit side of each of the chambers. The details of test plant is
schematically is shown in Fig. 7.

Plate 9: The 50 kg/hr pilot plant

19
 Gas inlet
Gas inlet
Flare Flare

Hot flue
gas exit

Recuperated air
Torrefaction Torrefaction Torrefaction Torrefaction Torrefaction Torrefaction
Torefaction Chamber 1 Chamber 2 Chamber 3 Chamber 4 Chamber 5 Chamber 6 For view port
Chambers GAS GAS GAS GAS GAS

GAS
GAS
GAS Combustion
Chamber

GAS

Blower 1
Side View

Blower 2
Blower 2
GAS

GAS
GAS

GAS

GAS

GAS

GAS
GAS
Blower 1 GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS

View from side Hot flue Elevation Gas inlet

gas entry

Combustion
Flare
GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS GAS

Chamber
GAS

GAS

GAS

GAS

GAS

GAS
GAS

GAS

GAS

GAS

GAS

GAS
Ignition Valve

- Gate Valve
Torrefaction
Chambers
- Ball Valve

GAS GAS
- Gas inlet to combustion chamber

Blower 2
Blower 1
- Ambient air OR recuperated air to combustion chamber
- Recirculation Pipe from chamber

- Recirculation from blower2

Top view
Blower 1 - For fresh air
Fresh air valve
Blower 2 - For recirculation

Fig 7 Schematic of the Pilot Plant

20
 Plate 10: Thermocouple instrumentation on the Torrefcation Chambers

The heat source for torrefcation was obtained by combusting producer gas + air mixture
in the combustor. The producer gas was generated in a gasifier system using waste wood as the
feedstock. A 30 kg/hr capacity gasifier would suffice the requirement. The air for combustion was
supplied by a separate blower, which had provision for supply of air either from the ambient or
hot air (recuperated heat) sucked through the chambers undergoing cooling process. In order to
achieve this, provision was made for fresh air entry to each of the chambers to facilitate heat
recovery. The complete system including the blowers were insulated and cladded to reduce heat
loss and improve the overall efficiency of the system. The connected electrical load of the two
blowers was about 4 – 5kWe. Each of the torrefaction chambers was provided with thermocouple
(see Plate 10) for temperature measurement and display. Similarly is the case with the
combustion chamber. The temperature data was acquired on to a PC during lab trials and this
would not be required for field trials since a temperature display is supplied along with the
equipment. Also, the system is equipped to measure the gas flow rate, re-circulation rate etc.

Each of the chamber is designed for 0.47 m3 (1 x 0.55 x 0.85 m) capacity and therefore
can hold an input charge of about 70 kg of sun dried bamboo sticks (moisture ~ 10%) and 90 -
110 kg of raw bamboo (35 to 45% moisture). The plant is designed for 6-7 hours of heating and 4
hours of cooling time (estimated), which would complete one cycle. This works out to about
handling of 50 kg/hr of raw bamboo and 35 kg/hr of sun-dried bamboo in a continuous mode of
operation.

21
Operational Procedure

The system is designed for continuous operation, wherein one or more chambers are
subjected to torrefcation process. The torrefcation process needs to be conducted under controlled
heating rate conditions in order to achieve the best results. The optimum process time to reach a
targeted temperature of 250° C is about 6 – 7 hours, followed by cooling to ambient condition.
This optimum heating rate has been arrived on the basis of pilot scale studies conducted earlier.
The required hot flue gas needs to be supplied from the combustion chamber, wherein it should
be ensured that the oxygen content in the flue gas is maintained below 2 - 3% to prevent
combustion of the charge or volatiles released during the process. The heating rate can be ensured
by maintaining a certain temperature profile of the hot flue gas entering the chambers. This could
be controlled by varying the amount of producer gas + air mixture combusted. Also, major part of
the hot gases is recirculated to improve the overall efficiency of the process. Some part of the hot
gas (equivalent of air + producer gas) needs to be let out to the ambient in order to permit
operation of the combustion chamber. These gases invariably contain volatiles and therefore can’t
be allowed to escape unburnt leading to air pollution. The hot gas containing volatiles can’t
sustain combustion as it is fuel lean and therefore requires some support fuel. This can be
achieved by burning a small quantity of producer gas (a separate stream taken out from the
gasifier) as the support fuel (in a flare). The heat generated by this process could probably be used
for drying of biomass that is fed as feedstock in the gasifier. In the current development this issue
is not being addressed and the burnt products from the flare is being let out to the atmosphere.

After the completion of torrefcation process (after 6 – 7 hours of heating), the first set of
chambers are isolated by closing appropriate valves and simultaneously the next set of chambers
are initiated into the torrefcation process. So the combustion chamber supplies hot flue gases to
the next set of chambers. Provision is made for heat recovery from the chambers that is
undergoing cooling process; this is achieved by drawing cold air through hot bed of charge and
the hot air supplied to the combustion chamber. This operation is expected to improve the overall
efficiency of the process.

The Trials

Four trials were successfully conducted with the pilot plant at the laboratory. The first
trial was essentially conducted in batch mode in order to understand and establish the operational
procedure. There was an issue of air ingress into the torrefcation chamber that was subsequently
rectified by using better quality gaskets. Similarly provision was made to combust some of the
volatiles before they are let out to the ambient as mentioned earlier. One trial was conducted in a
continuous mode for about 30 hours, wherein about 600 kg of raw bamboo was loaded in 22
hours.

The mode of operation was as follows: Three chambers were loaded with raw bamboo of
10% initial moisture content (about 70 kg per chamber) and subjected to gradual heating for
about 7 hours to attain a temperature of 220° C. Later the flue gas supply was cut-off to these
chambers and supplied to the remaining three chambers. The first three chambers were allowed to
cool, but due to air ingress into the chamber the temperature increased to about 270 – 300° C in
two of the chambers and therefore the cool off period was longer than anticipated. The cooling
period stretched to 300 – 350 min against 240 min that was planned. In the manner the heating-
cooling cycle of the chambers were continued for about 30 hours. The average torrefied bamboo
yield was about 16 kg/hr (solid yield about 65 – 70%). In one of the subsequent trial, the cooling
cycle could be completed within 240 min. The Plate - 11 shows the torrefied bamboo generated
from the test plant.

22
 Plate 11: Torrefied Bamboo from the Test Plant

A long duration trial of 76 hour duration was conducted wherein bamboo with 42% initial
moisture was used. The heating time was about 7 hours and cooling time was reduced to about
4.5 hours. The cooling process was shortened by adapting a two step cooling strategy wherein
initial cooling for about 3 hours was done by allowing the chambers to cool out naturally and
once the temperature reached below 160 – 170 °C, cold air was sucked through the bed. This
reduced the cooling time from 6 hours to about 4.5 hours.

23
 Characterization of Grey Charcoal from Bamboo
The torrefied bamboo or grey charcoal was further characterized in terms of its
composition and calorific value. Both proximate and ultimate analysis was conducted. Proximate
analysis was conducted to determine the fraction of volatile and fixed carbon content. The results
of the proximate analysis on moisture and ash free basis are shown in Fig. 7, wherein it is evident
that increasing the temperature reduces the volatile fraction and increases the fixed carbon. The
raw bamboo has about 85% volatiles and 10% fixed carbon is transformed to contain about 73%
volatiles and 27% fixed carbon after subjecting to a torrefaction process at 250 – 275° C. The
process when carried at 350 °C results in higher fixed carbon content up to 64%

Fig. 7 Proximate Analysis (on ash and moisture free basis) of the Torrefied Bamboo at
Varying Temperatures.

Further the samples were subjected to ultimate analysis where the elemental constituents
like hydrogen, carbon, oxygen and ash were determined. Fig. 8 shows the elemental analysis
wherein there is a reduction in oxygen element and correspondingly increase in the hydrogen and
carbon content with the increase in temperature. Therefore torrefaction process results in
reduction in O/C ratio, which essentially contributes to increase in the calorific value. The ash
content in the raw bamboo is about 2.5% and increases to about 5.5% with grey charcoal at 350
°C.
A very important property is the increase in energy density of the torrefied bamboo
compared to raw/untreated bamboo as shown in Fig. 9. The gross heating value of torrefied
bamboo was found to increase with temperature: a 20% increase was observed at 250-260 °C
(from 17.6 to 21.1 MJ/kg on dry basis). If the heating value of raw bamboo is corrected for the

24
heat of evaporation of the moisture present, the actual increase brought out by torrefcation would
be much higher.

Fig. 8 Ultimate Analysis of Torrified Bamboo

Fig. 8 Energy Density of the Torrefied Bamboo at Varying Temperatures. The reference
measurement is the Gross Calorific Value of raw bamboo which is 17.6 MJ/kg on dry basis.

25
 Techno-economics

Assumptions:

Cost of green bamboo: 250 Rs/ton

Biomass cost for Gasifier: 1000 Rs/ton
Electricity: Rs 3.50/kWh

Calculations:

Nature of Expense kg/hr or kWh kg or kWh in 24 hr Cost, Rs

Raw bamboo 50 kg/hr 1000 kg 250

Fuel - biomass 25 kg/hr 600 kg 600
Electricity 6.75 kWh 162 kWh 567
Manpower lump sum 700

Total cost 1867

Production cost for a production of 459 kg of torrefied bamboo 4.07/kg

7 – 8/kg
Market rate for black charcoal

26
 Plant dimensions of higher throughput

Plant Dimensions for 10 Ton/day:

Bamboo to be processed kg/day 10000

No. of batches/day 2
Batch capacity kg/batch 5000
Density of bamboo kg/m3 450
Total Volume of chambers m3 12.7
Chambers No. 6
Volume of each chamber m3 2.12
LxBxH m 1.28
Capacity of each chamber kg 952.5
Recirculation blower of 200 mm head m3/hr 16000
Gasifier Rating kg/hr 300

Plant Dimensions for 20 Ton/day:

Bamboo to be processed kg/day 20000

No. of batches/day 2
Batch capacity kg/batch 10000
Density of bamboo kg/m3 450.00
Total Volume of chambers m3 25.40
Chambers No. 6
Volume of each chamber m3 4.23
LxBxH m 1.62
Capacity of each chamber kg 1905
Recirculation blower of 200 mm head m3/hr 32000
Gasifier Rating kg/hr 600

27
 Conclusions
The following are the conclusions arrived at the completion of the project:

1. Torrefaction of bamboo has been successfully demonstrated and grey charcoal generated
with an increment of calorific value by 20% corresponding to a torrefaction temperature
of 250 °C.

2. Around 250 °C bamboo is found to have lost its tenacity and turning out brittle. So
around 250 °C could be identified as the torrefaction temperature for that particular
species bamboo.

3. The grey charcoal from bamboo is also found to have become hydrophobic, with
maximum moisture absorption of about 6% against 12% with raw bamboo.

4. The pilot plant has been successfully tested and the designed throughput of 1 ton/day
(based on input raw bamboo) has been achieved.

5. The pilot plant is being shifted to Nagaland Bamboo Development Agency (NBDA),
Dimapur, Nagaland for field trials where this hardware would be integrated with the
existing 135 kg/hr gasifier.

28