Industrial Processing Integration of alcohol and sugar production, Cogeneration of electricity

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Industrial Processing Integration of alcohol and
sugar production, Cogeneration of electricity

• Brazils Ethanol Experience and its
  Transferability
• World Bank April 25 2006

José Felix Silva Junior jfsilva_at_copersucar.com.br
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What it will be tried to show

• Productions of sugarcane, sugar and ethanol
• Operations flowsheet and productions alternatives
• Fermentation and distillation basic figures
• Sugarcane quality Calculated yields
• Main characteristics of the integration process
• Energy generated by sugar cane
• Expansion of the sugar and ethanol industry
• Scenario for ethanol demand
• Improvements and innovation

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Sugarcane Source of Green Energy
SUGAR
JUICE
Ethanol
BAGASSE
CO-GENERATION OF ELECTRICITY
LEAVES TOPS
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Brazilian Production of Sugarcane, Sugar and
Ethanol
Crop Season 05/06 partial results
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Brazilian Production of Anhydrousand Hydrated
Ethanol
Crop Season 05/06 partial results
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(No Transcript)
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Flowsheet of Sugar and Ethanol Production
Juice
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Fermentation Process

• Basic information
• Final ethanol content 9 vol
• Final yeast concentration13
• Fermentation time 6-11h
• Average production rate 450 m3/day
• Total fermenter capacity 3000 m3
• Yield (stoichiometric) up to 91
• Temperature 34-36ºC

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Evolution of Ethanol Yield
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Evolution of Fermentation Time (h)
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Distillation Flow Diagram
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Distillation

• Steam consumption 3-5 kg / L ethanol
• Yield gt 99
• Residues
• Vinasse (12-15 L/L) recycled as ferti-irrigation
  at the cane fields
• Water consumption
• 100-120 L / L ethanol (hydrated 93 by weight )
• 140-170 L / L (anhydrous 99.4 by weight)
• Dehydration Azeotropic (cyclohexane)
• Extractive (monoethyleneglycol)
• Molecular sieves

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Quality of Sugarcane Polcane
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Ethanol from Molasses and Juice
SUGARCANE
Sugars Suc Glu Fru
MILLING
JUICE FOR SUGAR
JUICE FOR ETHANOL
MASH
FACTORY
DISTILLERY
FERMENTATION DISTILLATION
MOLASSES
ETHANOL FROM SUGARS
ETHANOL FROM MOLASSES
SUGAR
ETHANOL
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Production Alternatives for Sugar and Ethanol
(Calculated for 1 t of cane)
Sugar Ethanol from Final Molasses
Sugar 50 sucrose Ethanol 50 sucrose RS from
cane sugars from molasses
All Sugars to Ethanol
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Integration Production of Sugar and Ethanol

• Main Characteristics
• Extended crop season beginning and end with
  ethanol production
• Cane of low content of sugar and purity goes to
  ethanol production
• Use of juices from different steps of the process
  low purity juice from milling, etc.
• No hard work to recover sugar in final molasses
• No loss in final molasses

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Milling Diagram
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Integration Production of sugar and Ethanol

• Main Characteristics
• Sugar of better quality no need to recycle
  molasses of low purity
• Higher purity in the mash (treated juice
  molasses) for high fermentation yield
• Energetic optimization bleeding of steam for
  the distillery
• Variation on the ratio of sugar and ethanol
  produced according to the market

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Energy Generated by Sugarcane
1 t of Cane Stalks (Clean)
Energy (MJ) 145 kg of sugars 2
300 140 kg of stalk fiber (bagasse, dry basis)
2 600 140 kg of leaves fiber (trash, dry basis)
2 600 Total 7
500(0.17 toe) 1 ha 82 t cana
600 GJ (13 toe) 300 million tons of cane
50 million toe/year Note
Primary energy consumption in Brazil is 235
million toe/year.
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Electric Power Generation Potential

• Sugar mill is self sufficient in energy, using
  bagasse as fuel during the crop season
• Some mills produce surplus energy to sell
• Installed capacity 2,800 MW (100 )
• Self-consumption 2,200 MW (78 )
• Contracted 600 MW (22 ) (Sao Paulo 500 MW gt
  46 plants)
• Short-term potential today technology 6,000
  to 8,000 MW
• Long-term potential new technologies and
  increase in sugarcane 15,000 to 22,000 MW

Source ANEEL (National Electric Power Agency /
UNICA
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Expansion of the Sugar and Ethanol Industry
New projects
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Copersucars Scenario for Ethanol Demand
millions of m3
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Improvement and Innovation (RD)

• Work has to be done to
• Automatic process control
• Treatment of the mash
• High ethanol yeast
• Immobilized yeast / Flocculant yeast
• Reducing of the vinasse produced
• Specific Membranes for dehydration
• Vacuum distillation

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Improvement and Innovation (RD)

• Energy
• Reduction of steam consumption
• 500 350 280 kg/tc (needs investment)
• Use of trash (leaves and tops) as fuel
• High pressure and more efficient boilers and
  turbine generators
• Gasification of bagasse

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Thank you

• José Felix Silva Junior
• jfsilva_at_copersucar.com.br

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Sugar and Ethanol Calculated