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This study demonstrates a failure identification methodology applied to a preprocessing facility generating conversion-ready feedstocks from biomass meeting conversion process critical quality attribute (CQA) specifications. Failure Modes and Effects Analysis (FMEA) was used as an industrially relevant risk analysis approach to evaluate a logging residue preprocessing system to prepare feedstock for pyrolysis conversion. Risk evaluations considered both system-level and operation unit-level assessments considering process efficiency, product quality, cost, sustainability, and safety. Key outputs included estimations of semi-quantitative risk scores for each failure, identification of the failure impacts, identification of failure causes associated with material attributes and process parameters, ranking success rates of failure detection methods, and speculation of potential mitigation strategies for decreasing failure risk scores. Results showed that deviations from moisture specifications had cascading consequences for other CQAs along with process safety implications. Failures linked to fixed carbon specifications carried the highest risk scores for product quality and process efficiency impacts. As increased throughput can be inversely related to meeting product quality specifications; achieving throughput and other material-based CQAs simultaneously will likely require system optimization or prioritization based on system economics. Ultimately, this work successfully demonstrates FMEA as a risk analysis approach for other bioenergy process systems. [ABSTRACT FROM AUTHOR]

A discrete element method (DEM) based approach is used to study the relationships between material attributes (MAs), processing parameters (PPs), and quality attributes (QAs) for the knife milling of maize stalks. An approximate DEM shape model was conceptualized based on real maize stalks and calibrated based on experimental bending test data for flexural properties (elastic bending stiffness, elastic bending angle limit, elastoplastic ratio, etc.). DEM simulations of maize stalk comminution in a Jordan Reduction Solutions ("JRS") knife mill were performed to investigate the relationships between the MAs (maize stalk size and breakage stress limit), PPs (impeller rotational speed), and QAs (mass throughput and output particle size distribution (PSD)). The DEM results suggest that stalk length has little influence on mass throughput and PSD, whilst stalks with larger cross sections tend to generate larger sizes of milled particles given the same breakage stress limit. Both the DEM and experimental results show that faster impeller rotation (or higher power) does not necessarily generate higher throughput or smaller output PSD, especially for maize stalks of higher breakage stress limit. The correlations between these MAs, PPs and QAs are found highly stochastic, though breakage stress limit dictates mass throughput, regardless of stalk size. The DEM-predicted output particle size tended to match the experimental data with coarse PSDs based on sieve size but showed weakened fidelity with finer material, indicating the potential for further model improvement. [Display omitted] • Novel DEM model is introduced for simulation of knife milling of maize stalks. • Stalk shell breakage stress limit dictates mass throughput, regardless of stalk size. • Milled particle size is influenced by stalk cross-section area but not stalk length. • Faster impeller rotation may not produce higher throughput or smaller particle size. • DEM predictions match experiments on higher end of milled particle size distribution. [ABSTRACT FROM AUTHOR]

An extended population balance model (PBM) and a deep learning-based enhanced deep neural operator (DNO+) model are introduced for predicting particle size distribution (PSD) of comminuted biomass through a large knife mill. Experimental tests using corn stalks with varied moisture contents, mill blade speeds, and discharge screen sizes are conducted to support model development. A novel mechanism in the extended PBM allows for including additional input parameters such as moisture content, which is not possible in the original PBM. The DNO+ model can include influencing factors of different data types such as moisture content and discharge screen size, which significantly extends the engineering applicability of the standard DNO model that only admits feed PSD and outcome PSD. Test results show that both models are remarkably accurate in the calibration or training parameter space and can be used as surrogate models to provide effective guidance for biomass preprocessing design. [Display omitted] • An extended population balance model (PBM) is developed for biomass comminution. • Biomass feed moisture is added in the PBM as a new input parameter. • An enhanced deep neutral operator (DNO+) model is developed for biomass comminution. • DNO+ allows for influencing factors such as moisture and screen size as extra inputs. • Both models are remarkably accurate in the calibration or training parameter space. [ABSTRACT FROM AUTHOR]