Redesign and modernization of a biomass pyrolysis skid system to improve durability, meet U.S. industrial standards, and support advanced carbon sequestration process development
A renewable energy technology company sought to modernize an existing biomass pyrolysis skid system that had originally been designed and constructed in Europe as a prototype-style machine. The existing unit relied heavily on European-standard components and lightweight extruded aluminum construction that limited durability and industrial scalability.
The client partnered with Re:Build Optimation to redesign the system using U.S. standard components and industrial design practices while improving reliability, serviceability, and long-term maintainability. The upgraded system would serve as both a testing platform and demonstration unit at the client’s engineering headquarters, enabling ongoing process development without interrupting operations at their primary production system.
The skid processed waste biomass materials, commonly agricultural waste such as corn stalks, and converted them into multiple output products including biochar, quench oil, dry oil, wood vinegar, and wet oil. The resulting biochar was intended for soil nutrient restoration, while the liquid byproducts were used for carbon sequestration through injection into depleted oil wells.
The project introduced several technical challenges. Midway through design, process analysis determined that portions of the system required a Class 1, Division 2 hazardous classification, significantly impacting equipment layout and electrical integration requirements. In addition, the client later expanded the project scope to include a completely updated controls and software package using the CODESYS platform, despite an extremely compressed development timeline.
To meet the aggressive schedule and evolving project requirements, Re:Build Optimation needed to simultaneously execute process safety analysis, mechanical redesign, controls development, and fabrication while maintaining system performance and operational reliability.
Re:Build Optimation began the project with a detailed review of the client’s existing pyrolysis skid design and process requirements. The engineering team evaluated opportunities to improve structural durability, simplify system operation, and convert the design to readily available U.S. industrial components and standards.
A major focus of the project involved process safety evaluation and hazardous area classification analysis. Re:Build Optimation conducted NFPA research and process analysis to determine whether the system could remain general classification or required hazardous classification mitigation measures. The team established the system’s limiting oxygen concentration at 3% based on NFPA 69 requirements and developed layout modifications to accommodate the Class 1, Division 2 designation.
Multiple frame and equipment configurations were evaluated to reposition electrical components outside the classified area while maintaining accessibility and serviceability. The engineering team also simplified portions of the thermal management system by replacing a closed-loop pressurized cooling configuration with an atmospheric vented reservoir design, reducing system complexity and maintenance requirements.
As project scope evolved, Re:Build Optimation’s controls engineering team rapidly adapted to implement a completely new industrial controls architecture using the unfamiliar CODESYS platform. Despite limited development time, the controls team successfully integrated the updated software package, industrial controller hardware, and revised safety protocols into the redesigned system.
Re:Build Optimation delivered a fully redesigned and industrialized pyrolysis skid system optimized for testing, process development, and future scale-up efforts.
Key project upgrades and solutions included:
The completed system provided the client with a significantly more robust and industrialized pyrolysis platform capable of supporting advanced process testing and future commercial development initiatives.
Re:Build Optimation successfully completed the pyrolysis skid redesign and controls modernization project within an accelerated 6 to 7 month timeline.
Despite significant scope expansion, compressed development schedules, and late-stage hazardous classification changes, the project delivered a highly durable and reliable testing platform that exceeded customer expectations.
The redesigned system provided the client with a modern industrial machine utilizing U.S. standard components, improved structural integrity, and enhanced controls reliability. The upgraded industrial controller architecture offered significantly improved operational stability compared to the previous HMI-dependent control system.
The project also established a valuable foundation for future scale-up and commercialization efforts by giving the client a dedicated engineering and testing platform at their headquarters facility, reducing reliance on remote production equipment and minimizing operational disruptions during process development work.
The successful execution of the project led to follow-on software support opportunities and positioned Re:Build Optimation for potential future collaboration as the client continues advancing its carbon sequestration and renewable energy technologies.
The redesigned pyrolysis skid included:
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