Research Project Information

Research Project Summary Information

Commercialization of the Collision Mill Technology in New York(ST8501-1)

Mesa Reduction Engineering and Processin


As part of the Salix Consortium, NYSERDA has long had a relationship with the NRG Power, LLC facility in Dunkirk that was retrofitted to burn 10 MW wood along with 600 MW of coal. NRG Energy, Inc. and subcontractor Antares Group, Inc. developed specialized skills while involved in the previous effort.

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Project Description

Stage One used data generated by an existing prototype to help improve the ability to predict the performance of full-scale equipment. Stage Two will construct the first commercial-scale mill.


Currently, a utility power plant that uses pulverized coal can add only 5% biomass if it is introduced through the coal pulverizers. This technology can increase, to 20%, the amount of biomass that this type of coal plant can use. By manufacturing a product that can be introduced through a coal pulverizer, the need for a separate feed system and port into the boiler is avoided. In fact, the pulverizer itself is not needed.

Project Results

Specific objectives achieved by the end of Stage One work included construction of a model of a Collision Mill that: 1) costs about $250,000 to fabricate (a typical pulverizer costs about $400,000 to $600,000); 2) mills coal, wood, and other biomass, either alone or co-mingled; 3) creates a particle size of 1/8 inch or smaller; 4) processes input feedstock for a processing cost of $1.50 to $2.00 per ton; 5) uses baffling to solve turbulence issues identified in the existing prototype Collision Mills; and, 6) can be used to create blueprints for a commercial-scale Collision Mill. Dust was a serious safety concern during testing at Schutte Hammermill, Inc. in Buffalo. Further testing was performed on location at AES Corporation’s Greenidge power station, which has adequate dust controls. Some of this testing was originally planned for Stage Two. For this reason, the computer model simulation that was originally planned was scrapped so the resources could be used for the testing. The project was selected for Stage Two funding under NYSERDA PON 1118, and the contractor has been selected for NYSERDA business assistance from Navigant Consulting.


Mesa Reduction Engineering and Processin
6030 E Lake Rd
Auburn, NY 13021

Principle Investigator

Matt McArdle

Universities Involved


Project Type:

Indigenous/Renewable Energy Resources

Technologies Types:

NYSERDA Contact Information

Judy Jarnefeld


R&D - Environment & Energy Res

Contract Details

Start Date: 1/11/2010
Project Status: Active
Contract Number: ST8501-1

Last Updated: 10/28/2011