1. 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 jfsilva@copersucar.com.br

2. 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

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

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

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

7. Flowsheet of Sugar and Ethanol Production Juice

8. 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

9. Evolution of Ethanol Yield %

10. Evolution of Fermentation Time (h)

11. Distillation Flow Diagram

12. 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

13. Quality of Sugarcane – Pol%cane

14. 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

15. 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

16. 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

17. Milling Diagram

18. 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

19. 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 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.

20. 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

21. Expansion of the Sugar and Ethanol Industry New projects

22. Copersucar’s Scenario for Ethanol Demand millions of m3

23. 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

24. 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

25. Thank you José Felix Silva Junior jfsilva@copersucar.com.br

26. Sugar and Ethanol Calculated