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When producing ethanol from lignocellulosic material using hydrolysis combined with fermentation, a large amount of residue consisting of mainly lignin is generated. A significant amount of energy is retained in this residue which may be utilised as a measure for the process to become economically viable. One possibility is as fuel in a gasification process for synthesis gas production, improving the fuel yield and the overall plant efficiency. Furthermore, the pre-treatment method torrefaction has been shown to significantly improve biomass fuel characteristics such as energy density, moisture content, feeding and hydrophobic properties, as well as significantly facilitate particle size reduction. Therefore, the process chain from hydrolysis residue to synthesis gas was investigated and demonstrated in the present work through bench-scale experiments in a batch torrefaction reactor and a bubbling fluidised bed gasifier. The results from the torrefaction work confirmed the improved fuel characteristics and the effects of process variables were evaluated by factorial designed experiments. The torrefaction residence time was identified as the most influential variable. The results from reactivity tests and gasification experiments indicate that hydrolysis residue and corresponding torrefied residue are suitable for synthesis gas production, with some improved feedstock handling characteristics for the latter.

The pre-treatment method torrefaction has been shown to significantly improve biomass fuel characteristics such as energy density, moisture content, milling energy, feeding and hydrophobic properties. These improvements establish torrefaction as a key process in facilitating an expanding market for biomass raw materials. Most of the previous work has focused on evaluating and optimizing the torrefaction process alone. However, to fully explore the maximum energy/exergy and cost efficiency of biomass torrefaction, the entire fuel supply chain and site specific systems must be considered; including logistics, scale and integration with other processes. The present work in progress aims to develop a model that incorporates optimization of the biomass supply chain and process integration systems together with the torrefaction process in order to avoid sub-optimization.

To optimally utilize biomass resources as feedstock for fuels and chemicals production as well as for a potential substantial carbon sink, a dedicated process and system concept is suggested. The desired outcome of the process is a hydrogen-enriched pyrolysis gas and a carbon-enriched char, also retaining the ash-forming elements. To obtain a transport-driven large-scale CO₂ negative system, the char is suggested as co-firing fuel in a facility with carbon capture and storage technology. In the present work, the basis for this Bio²Fuels separation concept was evaluated by 1) analysis of previously published empirical data for pyrolysis, and 2) chemical equilibrium calculations. The former analysis indicated on the potential for a significant separation of H and C to the pyrolysis gas and char respectively, with ~80% of the hydrogen and 40-60% of the carbon from the raw feedstock present in the pyrolysis gas product. Based on analyzed thermochemical driving forces, most of the ash-forming elements can be expected to be retained in the char, and an ash and alkali-free gas may be achieved at temperatures below 500°C. In addition, chemical equilibrium modelling of the pyrolysis gas reforming demonstrated a significantly increased H₂/CO ratio in the syngas compared to gasification of the raw biomass.