Bio-Solid Fuel from Wheat Straw via Microwave Torrefaction: Process Optimization and Environmental Assessment

There is a need to address the limitations of wheat straw (WS) as a raw biomass fuel, promote its valorisation into a high-quality renewable solid fuel, and enable this fuel to replace fossil fuels in applications such as power plants and industrial boilers. This study focused on optimizing microwave torrefaction parameters to enhance key fuel properties. Optimal conditions were determined via the Box–Behnken design (BBD) within Response Surface Methodology (RSM) as 422.32 W of microwave power, 14.95 min of irradiation time, and a 15 g microwave absorber, resulting in a 69.12% mass yield, an 18.44 MJ/kg higher heating value (HHV) surpassing lignite at 16.76 MJ/kg, and a 25.50% Energy-Mass Co-efficiency Index (EMCI). Fourier transform infrared spectroscopy (FTIR) and thermogravimetric analysis/derivative thermogravimetric analysis (TG/DTG) were conducted to gain insights about chemical composition and thermal stability variations due to torrefaction. LCA showed that electricity produced from 1 ton of torrefied WS reduces CO2 emissions by 259.26 kg CO2eq compared to electricity generated from bituminous coal. From an economic perspective, the usage of torrefied WS for power generation lead to a net profit of CNY 435.19/ton. This scalable technology, by valorising agricultural waste for fuel production, delivers dual environmental and economic benefits, laying the groundwork for industrial deployment.