Biofuel is considered a sustainable substitute for traditional liquid transportation fuels. The wide adoption of biofuel can effectively reduce the greenhouse gas emissions and secure the energy supply of the U.S. One major concern of the wide adoption of biofuel is the energy consumption during biofuel manufacturing processes, which plays a critical role in successful substitution. In this paper, we focused on the investigations of the relationships between the energy consumption and process parameters of the processes on size reduction and ultrasonic vibration-assisted pelleting. The methodology of design of experiments was used to analyze the experimental results of energy consumptions with different process parameter settings of the two processes. Critical parameters that significantly influence the energy consumption were identified. The optimal configurations of the process parameters were recommended.

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