Industrial Processing
Integration of alcohol and sugar production,
Cogeneration of electricity
Brazil’s Ethanol Experience and its
Transferability
World Bank – April 25 2006
José Felix Silva Junior
[email protected]
What it will be tried to show
1.
2.
3.
4.
5.
6.
7.
8.
9.
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
Sugarcane – Source of Green Energy
JUICE
BAGASSE
LEAVES & TOPS
SUGAR
Ethanol
CO-GENERATION
OF ELECTRICITY
450.000
30.000
400.000
Sugarcane (1000t)
25.000
350.000
300.000
20.000
250.000
15.000
200.000
150.000
10.000
100.000
5.000
50.000
Crop Season
Sugarcane
Crop Season 05/06 partial results
Sugar
Total Ethanol
04/05
02/03
00/01
98/99
96/97
94/95
92/93
90/91
88/89
86/87
84/85
82/83
80/81
78/79
76/77
74/75
72/73
0
70/71
0
Sugar (1000t ) and Ethanol (1000m3)
Brazilian Production of Sugarcane,
Sugar and Ethanol
Brazilian Production of Anhydrous
and Hydrated Ethanol
12.000
Ethanol (1000m3)
10.000
8.000
6.000
4.000
2.000
Crop Season
Anhydrous
Crop Season 05/06 partial results
Hydrated
04/05
02/03
00/01
98/99
96/97
94/95
92/93
90/91
88/89
86/87
84/85
82/83
80/81
78/79
76/77
74/75
72/73
70/71
0
Juice
Flowsheet of Sugar and Ethanol Production
Fermentation Process
Basic information
– Final ethanol content: 9 %vol
– Final yeast concentration:13%
– Fermentation time:
6-11h
– Average production rate : 450 m3/day
– Total fermenter capacity:
3000 m3
– Yield (stoichiometric): up to 91%
– Temperature:
34-36ºC
Evolution of Ethanol Yield %
92
91
90
89
(%)
88
87
86
85
84
83
82
1975
1980
1985
1990
Year
1995
2000
2005
Evolution of Fermentation Time (h)
16
15
14
13
(h)
12
11
10
9
8
7
6
1975
1980
1985
1990
Year
1995
2000
2005
Distillation Flow Diagram
Água
Quente
Água
Quente
Água
Fria
Água
Quente
Água
Fria
H
H
H
E
E
E
Água
Fria
H
H
H
E
E
E
Água
Quente
H
Vinhaça
Saída
A
B
,Ciclohexano
A
B
I1
A
B
C
Aparelho - 02
Água
Fria
Setor de Destilação
Água
Quente
Vinhaça
Entrada
Vapor de
escape
Aparelho - 03
Condensado
Água
Fria
01
02
H
Ciclohexano
Água
Fria
I
,
I1
Armazenagem
de álcool
C
I2
I2
P
P
Água
Quente
Condensado
,
I1
K
Vinhaça
Entrada
Água
Fria
Ciclohexano
I
Vinhaça
Saída
H
H
Água
Fria
P
Água
Quente
Aparelho - 01
Água
Quente
I
K
Condensado
Água
Quente
E
,
C
P
K
Vapor de
escape
E
Ciclohexano
I
I
Vinhaça
Entrada
E
H
Água
Fria
I1
Vinhaça
Saída
C
H
H1
H
I
H
Água
Quente
H
Água
Fria
Tanques medidores
H
Água
Quente
Vapor de
escape
Aparelho - 04
Álcool
Distillation
– Steam consumption: 3-5 kg / L ethanol
– Yield:
> 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
Quality of Sugarcane – Pol%cane
Pol%cane - Average of 5 Crop Seasons
17,00
16,00
16,22
15,00
14,00
14,30
13,00
12,24
2º Nov.
1º Nov
2º Oct
1º Oct
2º Sept
1º Sept
2º Aug
1º Aug
2º July
1º July
2º June
1º June
2 May
1º May
2º April
1º April
12,00
Ethanol from Molasses and Juice
SUGARCANE
Sugars = Suc + Glu + Fru
MILLING
JUICE FOR SUGAR
JUICE FOR ETHANOL
FACTORY
DISTILLERY
MASH
FERMENTATION
DISTILLATION
MOLASSES
ETHANOL
FROM
MOLASSES
SUGAR
ETHANO
L
FROM
SUGARS
ETHANOL
Production Alternatives for Sugar and Ethanol
(Calculated for 1 t of cane)
Loss of 9.5% of pol%pol in cane
Fermentation yield 88%
Sugar Division - 50% for sugar and 50% for ethanol
TRS - Total Recoverable Sugar
Sugar - Polarization 99.7º Z
Ethanol Anhydrous - 99.3% by weight
Sugar & Ethanol from Final Molasses
Crop
Pol%cane
Season
TRS
kg/tc
Sugar 50% sucrose
Start
Peak
End
12.24
16.22
14.3
122.87
159.11
141.24
Ethanol 50% sucrose+
RS from cane + sugars
from molasses
All Sugars to Ethanol
Sugar
kg/tc
Ethanol
L/tc
94.30
133.30
115.39
13.53
10.90
11.44
Sugar
kg/tc
Ethanol
L/tc
47.15
66.65
57.69
41.65
50.52
45.74
Ethanol
L/tc
69.69
90.15
80.04
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
Milling Diagram
Água de lavagem de cana
Espalhador
Eletro-Imã
Bagaço para as
caldeiras
Água de
embebição
Bagaço da peneira
Mesa 18 ° - cana inteira
Cana
Desfribador
Rolo alimentador
Picador 02
Esteira de cana picada
Picador 01
Peneira
Rotativa
Tanque Pulmão
Tanque de
Ácido
Fosfórico
Vinhaça
(Entrada)
Trocador de calor
regenerativo
Bagacilho para lodo
dos decantadores
Caldo clarificado para
destilaria
Circuito açúcar
Circuito álcool
Vinhaça
(Saída)
Caldo clarificado do
decantador de álcool
Caldo do circuito açúcar
para a sulfitação
Caldo do circuito álcool
para os trocadores de calor
Legenda
Usina Santo Antonio S. A. - Fluxograma de Processo - Setor de moendas
Caldo de cana
Águas industriais
Bagaço
Produtos químicos
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
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
1 ha
82 t cana
300 million tons of cane
7 500(0.17 toe)
600 GJ (13 toe)
50 million toe/year
Note: Primary energy consumption in Brazil is 235 million toe/year.
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 > 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
Expansion of the Sugar and Ethanol Industry
New
projects
Copersucar’s Scenario for Ethanol Demand
27,3
30,0
24,8
22,6
millions of m3
25,0
20,6
18,6
20,0
15,0
3,5
0,9
2,9
0,9
2,2
0,8
4,6
4,0
16,8
10,0
13,8
14,8
16,2
2005/06
2006/07
2007/08
5,2
1,0
0,9
0,9
17,7
19,3
21,1
5,0
0,0
Fuel
Industrial
2008/0
9
Exports
2009/10
2010/11
Improvement and Innovation (R&D)
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
Improvement and Innovation (R&D)
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
Thank you
José Felix Silva Junior
[email protected]
Sugar and Ethanol Calculated
ENTRADA DE DADOS
Pol % cana
16,2200
Pureza do caldo
88,39
Fibra % cana
12,46
Rend. obtido açúcar
Rend. obtido álcool
%
%
%
kg/t cana
L/t cana
10*POL= 162,20
Perdas de açúcares
Parcela da sacarose
para fabric. açúcar
9,5%
146,79
10*AR= 5,100
Perdas
15,41
0,00
9,5%
4,62
1- SJM
0,00
154,52
0,5100 %
0,0%
159,13 kg/t cana
175,84 kg/t cana
CONSIDERANDO-SE:
Perdas fase comum
Eficiência global dest.
9,50%
0,5665
Eficiência destilaria
Fermentação
Destilação
Global
Sacarose
desviada
146,79
0,00
SJM=
VALORES CALCULADOS
Açúc. redutores % cana
Sacarose para açúcar (PCTS)
ATR
ART % cana
ATR Produtos
4,62
Relação com PCTS
90,54%
Total
159,13
kg de ART no melaço
Eficiência destilaria = 0,5665 litros/kg ART
Rend. em açúcar:
Rend. em álcool anidro:
RS=
0,00
kg/t cana
RE= 90,15 L/t cana
Dif prod.
0,00
90,15
ATR Prod. 0,00
159,13
ATR Prod. Total
159,13
88,0
99,0
87,1