Biomass conversion in thermo‐catalytic reforming reactor: process modeling and kinetic insights for integrated intermediate pyrolysis

Abstract A sustainable energy transition in the 21st century necessitates efficient biomass‐to‐energy conversion technologies, with pyrolysis playing a crucial role. Thermo‐catalytic reforming (TCR) combines intermediate pyrolysis with a catalytic post‐reforming stage, producing higher‐quality bio‐oil, char, and syngas than conventional pyrolysis. However, process models capable of predicting TCR performance across different feedstocks remain limited. This work presents an Aspen Plus‐based kinetic process model that couples both TCR reaction stages, primary pyrolysis, and catalytic post‐reforming, within a single framework. The model integrates the CRECK kinetic mechanism with a detailed char decomposition model, predicting product yields and gas composition directly from feedstock elemental analysis. It is validated against experimental data from five compositionally distinct feedstocks: digestate, municipal solid waste, eucalyptus, bagasse, and straw pellets. These span both conventional lignocellulosic biomass and heterogeneous waste streams. The model achieves strong agreement for char yield predictions across all five feedstocks, within approximately 1–2% deviation, while bio‐oil prediction accuracy varies by feedstock composition. Sensitivity analysis of post‐reformer temperature (800–900 °C) shows a consistent increase in H 2 (by approximately 8–12%) and decrease in CH 4 (by approximately 23–46%) across all feedstocks. This trend is driven by steam methane reforming and water–gas shift conversion, identifying higher post‐reformer temperature as a generalizable route to improved syngas quality. The model requires only standard elemental feedstock analysis as input, linking feedstock composition directly to predicted product distribution and enabling identification of favorable operating conditions ahead of physical trials.