A Review of Biomass Pyrolysis for Production of Fuels: Chemistry, Processing, and Techno-Economic Analysis

Biomass pyrolysis is a thermochemical process that breaks down organic matter in the absence of oxygen, offering a sustainable route for converting biomass into bio-oil, biochar, and syngas. This review provides a comprehensive overview of pyrolysis, focusing on its fundamental principles, modes, and its applications across different industries. It covers major pyrolysis types and explores the reactors used in these processes and how key parameters, such as temperature, heating rate, and residence time, impact the distribution and quality of pyrolysis products. Special attention is given to bio-oil upgrading methods, including catalytic and non-catalytic processes, and how they affect fuel quality. The study also presents techno-economic assessments of various pathways, identifying cost-effective configurations like pyrolysis combined with hydrotreatment and heat integration. Despite encouraging advancements, scaling up bio-oil technologies continues to face significant challenges, primarily due to cost competitiveness and variability in feedstock supply. This review emphasizes the critical need for continued innovation in reactor design, catalyst efficiency, and integrated process optimization, alongside supportive policy frameworks and strategic investments to accelerate commercial deployment. Finally, this review aims to help researchers, engineers, and policymakers work together to advance pyrolysis technology as a practical solution for producing low-carbon fuels and chemicals.