Industrial Processing Integration of alcohol and sugar production, Cogeneration of electricity Brazil’s Ethanol Experience and its Transferability World Bank – April José Felix Silva Junior

What it will be tried to show 1.Productions of sugarcane, sugar and ethanol 2.Operations flowsheet and productions alternatives 3.Fermentation and distillation – basic figures 4.Sugarcane quality – Calculated yields 5.Main characteristics of the integration process 6.Energy generated by sugar cane 7.Expansion of the sugar and ethanol industry 8.Scenario for ethanol demand 9.Improvements and innovation

Sugarcane – Source of Green Energy JUICE BAGASSE LEAVES & TOPS SUGAR CO-GENERATION OF ELECTRICITY Ethanol

Brazilian Production of Sugarcane, Sugar and Ethanol Crop Season 05/06 partial results

Brazilian Production of Anhydrous and Hydrated Ethanol Crop Season 05/06 partial results

Flowsheet of Sugar and Ethanol Production Juice

Fermentation Process Basic information –Final ethanol content: 9 %vol –Final yeast concentration:13% –Fermentation time:6-11h –Average production rate :450 m 3 /day –Total fermenter capacity:3000 m 3 –Yield (stoichiometric):up to 91% –Temperature:34-36ºC

Evolution of Ethanol Yield %

Evolution of Fermentation Time (h)

Distillation Flow Diagram

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 : L / L ethanol (hydrated 93% by weight ) L / L (anhydrous 99.4% by weight) Dehydration: Azeotropic (cyclohexane) Extractive (monoethyleneglycol) Molecular sieves

Quality of Sugarcane – Pol%cane

Ethanol from Molasses and Juice MASH JUICE FOR SUGAR FACTORY SUGAR ETHANO L FROM SUGARS SUGARCANE MILLING FERMENTATION DISTILLATION MOLASSES JUICE FOR ETHANOL ETHANOL FROM MOLASSES ETHANOL DISTILLERY Sugars = Suc + Glu + Fru

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

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

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 kg of stalk fiber (bagasse, dry basis) kg of leaves fiber (trash, dry basis) Total (0.17 toe) 1 ha82 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.

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 millions of m3

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

Sugar and Ethanol Calculated