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The variations in feedstock characteristics such as moisture and particlesize distribution lead to an inconsistent flow of feedstock from the biomasspre-processing system to the reactor in-feed system. These inconsistenciesresult in low on-stream times at the reactor in-feed equipment. This researchdevelops an optimal process control method for a biomass pre-processing systemcomprised of milling and densification operations to provide the consistentflow of feedstock to a reactor's throat. This method uses a mixed-integeroptimization model to identify optimal bale sequencing, equipment in-feed rate,and buffer location and size in the biomass pre-processing system. This method,referred to as the hybrid process control (HPC), aims to maximize throughputover time. We compare HPC with a baseline feed forward process control. Ourcase study based on switchgrass finds that HPC reduces the variation of areactor's feeding rate by 100\% without increasing the operating cost of thebiomass pre-processing system for biomass with moisture ranging from 10 to25\%. A biorefinery can adapt HPC to achieve its design capacity.

Optimal Control to Handle Variations in Biomass Feedstock Characteristics and Reactor In-Feed Rate