Impact of Water Vapor on the Predictive Modeling of Full-Scale Indirectly Heated Biomass Torrefaction System Throughput Capacity

Biomass torrefaction must be self-sustaining and continuous to be commercially viable, eliminating dependence on additional fuels while achieving industrial-scale production. This study presents a predictive model of a full-scale continuous biomass torrefaction process that explicitly incorporates the radiation absorption properties of torrefaction gas, with a focus on water vapor. Previous research, primarily based on lab-scale batch processes, has not adequately addressed scale-up challenges or the dynamic evolution of torrefaction gas. Industrial insights from Perpetual Next confirm that water vapor significantly impacts reactor performance by absorbing heat and reducing radiative flux to the biomass. Simulations show that neglecting water vapor absorption in reactor design can lead to throughput deviations of 10–20%, affecting process stability and efficiency. Industrial-scale validation demonstrates that the model accurately predicts this effect, ensuring realistic energy demand and throughput expectations. By explicitly incorporating water vapor absorption into the radiation balance, the model provides a validated framework for optimizing reactor design and process scale-up. It demonstrates that failing to consider this effect can lead to operational instability and deviations from the intended torrefaction severity, ultimately affecting industrial-scale performance and self-sustaining operation.