Process Optimization of Pellet Manufacturing from Mixed Materials in Ultrasonic Vibration-Assisted Pelleting

Abstract

Achieving carbon neutrality and alleviating the rural energy predicament are crucial aspects in rural areas, particularly in the severe cold regions of northeast China. Pellets serve as clean, renewable energy sources and are ideal alternative fuels. This study investigated the influencing factors and effects of mixed raw materials in ultrasonic vibration-assisted pelleting (UV-A pelleting). Rice straw and corn stover were mixed to produce pellets, and a central composite rotatable design (CCRD) was conducted to analyze the variables and their interactions on pellet density and durability. Mathematical regression models for pellet density and durability were established and then validated through ANOVA analysis. The results showed that all variables significantly affected the density and durability of pellets. The mixing ratio had a greater impact on pellet durability compared to density due to differences in ingredients. The optimal combination of process parameters included a mixing ratio of 25%, molding pressure of 4 MPa, pelleting time of 37 s, and ultrasonic power output at 200 W, resulting in a pellet density of 1301.18 kg/m3 with a durability reaching 94.26%. The desirability value (0.997) under these optimal conditions confirmed the validity of the models; further experiments also verified their effectiveness. The combustion of the optimized pellet was analyzed using thermogravimetric (TG) and derivative thermogravimetric (DTG) analysis in an air atmosphere. Four combustion stages and ignition temperature were provided.