LAMNET WORKSHOP ROME Lessons Learned from Bioenergy Program Implementation in Brazil JOSE ROBERTO MOREIRA Brazilian National Reference Center on Biomass CENBIO Palazzo dei Congressi, Rome, Italy May 09, 2004
Dec 22, 2015
LAMNET WORKSHOP ROME
Lessons Learned from Bioenergy Program Implementation in Brazil
JOSE ROBERTO MOREIRA
Brazilian National Reference Center on Biomass CENBIO
Palazzo dei Congressi, Rome, Italy
May 09, 2004
MAJOR ACHIEVEMENTS OF SUGARCANE INDUSTRY IN BRAZIL
•SUGARCANE BAGASSE HYDROLYSIS FOR FURTHER ETHANOL PRODUCTION
•FOSTERING ELECTRICITY GENERATION FROM SUGARCANE
A) PRESENT GROWTH
B) FUTURE GROWTH – PROINFA
•FLEXFUEL VEHICLES
•CARBON SEQUESTRATION
ETHANOL
(+)
STILLAGE
INTRODUCTION TO THE HYDROLYSIS PROCESS
THE THREE PROCESSING STAGES TO CONVERT CELLULOSIC MATERIAL IN ALCOHOL
HYDROLYSIS
(SACCHARIFICATION)
FERMENTATION
( + )
DISTILLATION
( + )
HEXOSES
HEXOSES
PENTOSES
WINE
WINE
+CO2
+ CO2
HEXOSES IN WINE
PENTOSES IN WINE
YEAST A
YEAST B
ACCID
BATCH
ACCID
BATCH
CELLULOSE
HEMICELULOSE
WATER
WATER
(+)
(+)
PHYSICAL
PROCESSWINE
SCHEMATIC VIEW OF LIGNOCELLULOSIC MATERIAL FIBER
HOW DHR-DEDINI FAST HYDROLYSIS SOLVES THESE PROBLEMS
• USING A STRONG LIGNIN SOLVENT, AT HIGH TEMPERATURE, IT IS POSSIBLE TO ACCESS CELLULOSE AND HEMICELLULOSE AFTER LIGNIN SOLUTION.
• FAST SPEED SUGAR FORMATION (MINUTES), INCREASES THE YIELD.
• HYDROLYSIS BATCH, ENHANCED BY THE LIGNIN SOLVENT, HAS A VERY SMALL ACID CONCENTRATION. • IMMEDIATE REMOVAL OF SUGAR AND FAST COOLING OF HYDROLYSED PRODUCT INTERRUPTS SUGAR DEGRADATION DUE TEMPERATURE.
• HYDROLYSED NEUTRALIZATION STABILIZES SUGAR PRODUCED.
LIGNIN
CELLULOSE
HEMICELLULOSE
WHAT IS THE DHR-DEDINI FAST HYDROLYSE PROCESS
DHR CONTINUOUS
REACTOR
BAGASSE
HYDRO SOLVENT SOLUTION WITH LOW ACCID CONCENTRATION
LIGNIN SOLVENTS - THERE ARE MANY (ONLY RHODIA HAS 26)
DEDINI TRIED SEVERAL SOLVENTS AND OPTED FOR ETHANOL
CHEMICAL HYDROLISIS WITH VERY DILLUTED ACCID
ORGANOSOLV PROCESSDHR PROCESS = +
HYDROLYSED PRODUCT
HYDROLYSED PRODUCT
HYDROLYSED PRODUCT
FLASH NEUTRALISERWINE
WHAT IS THE DHR-DEDINI FAST HYDROLYSE PROCESS
PRESENTLY: SMALL INDUSTRIAL UNIT IN OPERATION..
VERY SOON: CONCLUSION OF ENGINEERING PERFORMANCE EVALUATION FOR DESIGN OF A INDUSTRIAL PLANT.
SOON: AVAILABILITY OF COMMERCIAL DHR TECHNOLOGY FOR SALE
THE SMALL INDUSTRIAL UNIT - 5,000 L/DAY
THE DEVELOPMENT OF DHR - DEDINI FAST HYDROLYSIS TECHNOLOGY
BAGASSE: INPUT MATERIAL FOR DHR PROCESS AND HYDROLYSIS UNIT HYDROLYSIS REACTOR WITH THE
BAGASSE FEEDING SYSTEM
SOLVENT RECOVERY TOWER (ETHANOL) AND THE SEPARATION OF
HYDROLYSIS PRODUCTS
FERMENTATION AND DISTILLATION: CONVENTIONAL
AVAILABLE FACILITIES ARE USED
THE DEVELOPMENT OF DHR - DEDINI FAST HYDROLYSIS TECHNOLOGY
THE SMALL INDUSTRIAL UNIT - 5,000 L/DAY
POTENTIAL AND IMPACT OF DHR-DEDINI FAST HYDROLYSIS PROCESS
DHR - IMPACT ON PRODUCTION AND PRODUCTIVITY
ALCOHOL DISTILLERY - TRADITIONAL PROCESS
1 HA
WINE6,400 L
HYDRATED ALCOHOL
80 TCLEAN CANE
WITH THE SAME PLANTED AREA IT IS POSSIBLE ALMOST DOUBLE PRODUCTION
ALCOHOL PLANT - TRADITIONAL PROCESS + DHR (EXPECTED RESULTS FOR MAXIMUM POTENTIAL PROCESS PRODUCTIVITY
WITH ENERGY USE OPTIMISATION)
12,050 LHYDRATED ALCOHOL
BAGASSE + SOME
BARBOJO
5,650 LHYDRATED ALCOHOL
96 TINTEGRAL CANE
(INCL. SOME BARBOJO)
6,400 LHYDRATED ALCOHOL
WINE1 HA
L Alc/t bag
R$/L
110
120
130
140
150
160
170
180
100
0,15
0,20
0,25
0,30
0,35
0,45
0,40
Initial Conservative Yield
Acceptable for new emerging technology
Higher productivity due to know-how and technology development
Potential Process Yield
DHR - ECONOMIC IMPACT
ALCOHOL COST REDUCTION WITH DHR TECHNOLOGY EVOLUTION
0,291
0,247
0,402
109
MAY / 021 US$=R$2,50
U$ 26 /BarrelECONOMICALLY FEASIBLE
WITH TRADITIONAL ALCOHOL PRODUCTION PROCESS
POTENTIAL AND IMPACT OF DHR-DEDINI FAST HYDROLYSIS PROCESS
G A S O L I N E A N D N E A T E T H A N O L C A R S A L E S – B R A Z I L 1 9 7 5 - 1 9 9 9
4.92.7 4.210.43.17.4 4.516.8 8.726.110.227.212.149.317.4
52.114.2
58.719.31
66.423.3
80.232110
58.3
190
70
220
90
400
150
700
200
1000
270
1350
0
200
400
600
800
1000
1200
1400
1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
EVOLUTION OF COGENERATION IN SUGAR MILLS - ELECTRICICITY SOLD TO THE GRID - STATE OF SÃO PAULO
MW GWh
Installed Electricity Capacity in the Sugarcane Sector in State of Sao Paulo
Average value in 2001 (5.98 MW and 132 units)
Average Value in 2004 (11.06 MW and 138 units)
Installed Capacity (MW)
Nu
mb
er of U
nits
ELECTRICITY GENERATION FROM BIOMASS SOURCES – OPERATING CAPACITY
FUEL No. OF UNITS
CAPACITY (MW)
(%)
WOOD WASTES 13 80.3 2.98 SUGARCANE 188 1,844.4 68.42 RICE STRAW 3 14.4 0.53 BLACK LIQUOR 12 756.7 28.07 BIOGAS 1 0.03 - TOTAL 217 2,695.9 100.00
POTENTIAL BIOMASS GENERATION IN BRAZIL
OFFICIAL EVALUATION RESULTS
•SUGARCANE SECTOR 4,000MW
•RICE PROCESSING SECTOR 300MW
•PAPER AND CELLULOSIC SECTOR 1,000MW
PROINFA - PROGRAM TO FOSTER USE OF ALTERNATIVE ENERGY SOURCE FOR ELECTRICITY GENERATION
•20 YEARS LONG PPA WITH ELETROBRAS FOR 3,300MW, SIGNED BY THE END OF MAY.
•CAP BY ENERGY SOURCE (1,100MW FOR BIOMASS, 1,100 MW FOR WIND & 1,100 FOR SMALL HYDRO)
•CAP BY REGION (220MW PER STATE PER ENERGY SOURCE)
•UP TO 25% OF THE TOTAL MAY BE INSTALLED BY CONVENTIONAL ELECTRIC UTILITES IF THERE IS NOT EOUGH DEMAND FROM IPP
•SUBSIDIES WILL BE COVERED BY ALL ELECTRICITY USERS.
•IPP WILL BE CLASSIFIED ACCORDING THE DATE OF ISSUE OF INSTALLATION AUTHORISATION.
ELECTRICITY WILL BE ACQUIRED BY ELETROBRAS AT THE FOLLOWING PRICE
R$ / MWh SMALL HYDRO 117.02 WIND OPERATIONAL FACTOR <32.4% 204.35 WIND OPERATIONAL FACTOR >41.9% 180.18 WIND 32.4 < OPERATIONAL FACTOR <41.9% VALUE BETWEEN
204 AND 180 SUGARCANE 93.77 RICE HUSKS 103.20 FIREWOOD 101.35 BIOGAS 169.08
CURRENT POTENTIAL OF ELECTRICITY GENERATION USING GAS TURBINE
•GAS TURBINE AND STEAM TURBINE
•STEAM CONSUMPTION IN SUGARCANE PROCESSING = 280kg/TCANE
•FOR 290 MTONNES OF SUGARCANE:
290,000,000 X 0,250MWh/TCANNE = 72,500 GWh OR 16,111 MW FOR 4,500HRS/YR
SUGARCANE, SUGAR AND ALCOHOL PRODUCTION IN BRAZIL
0
100
200
300
400
SU
GA
RC
AN
E 10
6 TO
NN
ES
0
5000
10000
15000
20000
25000
30000
SU
GA
R (1
03 T
ON
NE)
/ALC
OH
OL
(103
M3)
Sugarcane
Sugar
Alcohol Total
Sales of Brazilian Made Automobiles in the Internal Market 1980-2004
0
200
400
600
800
1000
1200
1400
1600
1800
Year
Th
ou
san
d o
f u
nit
s
All Cars
Gasoline blended
Neat Alcohol /Flexfuel
Source: Azar et al, 2003 and Author
CO2 EMISSIONS FROM VARIOUS PLANT
PLANT “TYPICAL” SIZE C02 EMISSIONS
(KG PER SECOND)
COAL FIRED POWER PLANT 500 –1000 MWe 130 – 260
NATURAL GASS FIRES POWER PLANT
300 MWe 40
PULP MILL (TYPICAL LARGE BIOMASS CONVERSION FACILITY)
1500 – 3000 ton PULP PER DAY
36 – 72
SUGARCANE MILL (TYPICAL LARGE SIZE CONVERSION FACILITY)
25,000 tonne OF SUGARCANE/DAY
200 DAYS OF OPERATION/YR
20 ONLY FROM FERMENTATION 43 FERMENTATION + POWER
GENERATED
DISTRICT HEATING STATION 0 – 100 MWheat 1 - 10
CO2 ENERGY EMISSION IN SCENARIO IPCC B2 WITH AND WITHOUT SUGARCANE
0
2
4
6
8
10
12
14
1990 2000 2010 2020 2030
Year
GtC
/yr Scen B2
ScenB2 & Sugarcane