ISBUC Proposal : Status and Alternatives

ISBUC Proposal: Status and Alternatives

III ISBUC MeetingMauritius, June 29-July 3, 2009

Manoel Regis Lima Verde Leal

CENEA-Ceará

NIPE/UNICAMP

ISBUC MEMBERSHIP

Mauritius Sugar Industry Research Institute Mauritius

SA Canegrowers Association South Africa

CRC Sugar Industry Innovation Through Biotechnology

Australia

Centre D‘Essai de Recherche et de Formation Reunion

Kenana Sugar Company Limited Sudan

CENGICANA Guatemala

ZeaChem Inc. USA

Sugar Research and Innovation, Queensland University of Technology

Australia

Tongaat Hulett Sugar Ltd South Africa

Mitr Phol Sugarcane Research Centre Thailand

Omnicane Milling and Thermal Energy Operations

Mauritius

ISBUC Objectives

To promote research to convert sugarcane biomass into value-added products;

To establish collaboration among research providers;

To use the input of sugar companies and other stakeholders to direct research priority for maximum benefit.

ISBUC Meetings

Preliminary Planning Meeting: South Africa (July 2006)

Regular Meetings Maceió, Brazil (November 2006) Durban, South Africa (August 2007) Products Two proposals for project development: Vinasse: life cycle analysis and cost

assessment of different methods for its disposal

BIG/GT: Design, construction and evaluation of a sugarcane biomass gasification pilot plant with 3 MW

BIG/GT Proposal(1)

Objective To design, construct and extensively test a 3 MWe BIG/GT

bagasse/trash fueled power plant in a sugar mill for the evaluation and improvement of the technological drawbacks of this technology at industrial scale.

Specific Objectives .To evaluate a fluidized bed industrial gasifier (mainly feeding

system, efficiency and gas cleaning). .To evaluate the operation of a gas turbine adapted to low

calorific value gas use. .To establish the BIG/GT system real operating achievable

efficiency and the potential for improvement. .To identify, evaluate and solve the main operational problems of

the system. .To calculate the BIG-GT system economic indicators and

perform technical-economic analysis.

BIG/GT Proposal (2)

Justification The necessity of a first industrial pilot scale test facility

to progress toward commercial implementation of this technology.

The high cost of the first industrial prototype makes international funding and collaboration necessary.

High efficiency electricity generation is extremely important in the actual context of a diversified food and energy producing sugarcane industry,

Among ISBUC members there are research institutions and groups with expertise in bagasse gasification and BIG/GT system modeling.

Feedback to ProposalVinasse

Apparently no interest

It is only important to large scale ethanol producers

Feedback to ProposalsBIG/GT

Why BIG/GT? Hydrolysis, two stage gasification, other.

Why electricity and not biofuels and other products? Why 3 MW? See the GT’s available for low BTU gas

and decide. Some important points need clarification and

justification: why is BIG/GT needed? Why was it chosen? Will it be attractive to mill owners? Business case; Project Plan; high fiber cane; Capital and operating costs; Revenues; Economic analysis; What happened to other demo plants?

Two stage project: Feasibility study and development of detailed design and cost estimates.

Questions to Be Answered

Are 2nd G technologies really better than 1st G What are the alternatives? Which is closest to commercial stage? What is the economy of scale? Why a demo plant? What size and where? What funds will be needed to make it profitable? Where to go for funding? Investment, operating costs and revenues? What is the expected learning curve? Energy cane, what should it look like? Sugarcane trash availability, quality and cost?

New Topics For Consideration

The future of sugarcane industry How much can we get from sugarcane Final products The cane of the future Maximum use of sugarcane biomass

Sugarcane Today

Feedstock for food industry Breeding aiming at increase in sucrose/ha Fiber: bagasse used inefficiently and trash

is wasted Very few countries have focus on energy as

an important product

Brazil: ethanol

Mauritius: electricity

BRAZILIAN AVERAGE DISTILLERY(2005)

Factory conditions . Steam conditions: 22 bar/300 ºC . Process steam consumption: 500 kg/tc (330 kWh/tc) . Mechanical energy consumptions: 16 kWh/tc . Electricity consumption: 12 kWh/tc . Plant overall efficiency: 84% . Surplus power generations: 0 . Surplus bagasse: 8%

Sugar cane characteristics (Macedo, 2004) . Pol % cane: 14.5 . Fibre%cane 13.5 . Reducing sugars%cane 0.56 . Cane productivity 68.7 t/ha/yr (82.4 t/ha harv.)

TRS=158 kg/tc resulting in 86 l ethanol/tc

Primary Energy of Sugarcane (2005)

Component Energy (MJ)

150 kg of sugars 2,500

135 kg of stalk fibres 2,400

140 kg of leaf fibres 2,500

Total 7,400

68.4 tc/ha/yr 510 GJ/ha/yr

(12.1 toe)

Energy Recovery (2005)

1 tonne of clean stalks

Products Energy (MJ)

86 L ethanol 2,000

80 kWh 290

Total 2,290

Recovery efficiency = 30.9%

Driving Forces For ISBUC

The potential to increase energy recovery;

The potential to increase revenues; The future of sugarcane industry: the

energy concept; The importance of reducing GHG

emissions;

Sugarcane Evolution in Brazil

Conventional breeding

1975 – 2000: +33% yield and +8%Pol

2000 - 2020: same annual improvement

Conventional distillery

Steam conditions (bar/0C): 22/300 to 85/520

Process steam (kg/tc): 500 to <340

Process efficiency (%): 84 to 90

The Future

Possible deviations from BAU scenario

GM sugarcane;

Maximum use of sugarcane biomass;

Second generation biofuels from fiber;

Energy cane.

Objectives of the III ISBUC Meeting

To decide the future steps Which technology to pursue; The concept of the joint effort proposal: Objective Structure Responsible group Time schedule What to take to XXVII ISSCT Congress.

Final Comments (1)

Sugarcane is a food feedstock but it is the best biofuel feedstock

Sugarcane to energy cane transition

-Phase 1: adapt present technology and cane varieties to maximize energy products

-Phase 2: breed cane for energy and combine first and second generation technologies for maximum energy recovery and minimum cost

Final Comments (2)

Long term view : two routes -Food industry with energy co-products:

conventional sugarcane breeding and processing

-Energy industry: energy cane with integrated first and second generation technologies; trash and gasification will be key players

Final Comments (3)

KEY ISSUES

Green cane harvesting with trash recovery Energy cane breeding Energy cane harvesting Energy cane processing: new paradigm Plant scale and year round operation

THANK YOU !

Dr. Manoel Regis Lima Verde LealCENEA–Centro de Energias Alternativas e Meio AmbienteNIPE/UNICAMP

E-mail: [email protected]