Biomass Processing System - ToronBPS™ 100
Biomass Processing System for Biomethane and Alternative Fuels
The Biomass Processing System reduces bulky agricultural residue such as straw, corn stalks, and sugarcane leaves into fine particles sized for biomethane and alternative fuel feedstock. Biogas plant operators, biomethane facilities, and alternative fuel producers use it to convert baled or bulk biomass into a consistent particle size without manual pre-sorting between stages. Torontech built the system around a dual shaft shredder, a two-stage fine crushing line, and a fully enclosed dust collection system that runs with only one to two operators.
Material enters through the metal chain conveyor and passes through the dual shaft shredder for primary size reduction. A material distribution bin evens out the flow before the biomass moves into the primary fine crushing stage and then the secondary fine crushing stage, reducing particle size progressively rather than in a single pass. After the two-stage crushing sequence, particles reach 30 to 50 mm; a third crushing stage brings the output down to 1 to 5 mm for feedstock applications that need finer material.
The system runs fully enclosed, with a cyclone separator and dust collector operating under negative pressure to contain dust and debris generated during crushing. This keeps the operating environment cleaner and supports consistent output quality across continuous operation.
Biomass Processing System - ToronBPS™ 100 Applications
The Biomass Processing System serves operations that need to reduce agricultural residue to a consistent particle size before it enters a biogas digester or alternative fuel process.
- Biogas and Biomethane Production: reduces straw and stalks to a fine particle size that improves feedstock digestibility and biogas yield in anaerobic digesters
- Agricultural Residue Recycling: processes corn straw, wheat stalk, rice straw, and sugarcane leaves collected from crop harvesting
- Alternative Fuel and Biomass Power Generation: prepares biomass feedstock for co-firing and biomass power plant applications
- Livestock Bedding and Feed Preparation: reduces bulky straw into a manageable, consistent particle size for animal husbandry use
- Composting and Organic Waste Processing: size-reduces fibrous agricultural residue ahead of composting to speed decomposition
Biomass Processing System - ToronBPS™ 100 Key Features
The Biomass Processing System combines shredding, staged fine crushing, and dust containment into a fully enclosed line that runs with minimal operator involvement.
- Extra High Torque: the dual shaft shredder handles dense, bundled biomass such as baled straw without stalling or jamming
- Ultrafine Shredding: a three-stage crushing sequence reduces particle size to 1 to 5 mm for feedstock applications that need finer material
- Dust and Debris Removal: a negative pressure cyclone separator and dust collector contain airborne particulate for a cleaner operating environment
- Material Distribution Bin: evens out material flow between shredding and crushing stages, supporting consistent throughput
- Two-Stage Fine Crushing: primary and secondary crushing stages progressively reduce particle size for more uniform output
- Low Operator Requirement: the fully enclosed, automated design runs with only one to two operators
Theory and Method
The dual shaft shredder performs primary size reduction through a low-speed, high-torque shearing action. Two counter-rotating shafts fitted with interlocking cutting discs pull baled or bulk biomass inward and tear it apart between the shafts. This shearing action handles the fibrous, variable-density structure of straw and stalks without the wrapping and jamming that a high-speed cutter would experience on long fibrous material.
After primary shredding, the fine crushing stages use a grinding action to progressively reduce particle size rather than attempting a single large reduction. The primary fine crusher brings shredded material down to an intermediate size, and the secondary fine crusher further reduces it, so each stage works within a narrower size-reduction range for more consistent output. This staged approach reduces the load on any single crushing stage and produces a more uniform particle size distribution than a one-pass system.
The cyclone separator and dust collector work together under negative pressure to remove airborne dust and fine debris generated during crushing. Air carrying dust particles is drawn into the cyclone separator, where centrifugal force spins out heavier particles for collection, while the dust collector captures the finer remaining particulate before air is released. This keeps dust contained at the source rather than dispersing into the surrounding work area.
Biomass Processing System - ToronBPS™ 100 Technical Specifications
| Component | Description |
|---|---|
| Feeding Method | Metal chain conveyor |
| Primary Reduction | dual shaft shredder |
| Material Handling | Belt conveyor, distribution bin |
| Secondary Reduction | Primary fine crushing stage |
| Tertiary Reduction | Secondary (ultra-fine) fine crushing stage |
| Dust Control | Cyclone separator, negative pressure dust collector |
| Output Particle Size (2-stage crushing) | 30 to 50 mm |
| Output Particle Size (3-stage crushing) | 1 to 5 mm |
| Operator Requirement | 1 to 2 operators |
Tell us what you're processing, testing, or measuring, and our team will help you find the right configuration. Contact the Torontech team for pricing and lead times.