Presentation Isaf2010
- 1. Sugar cane as an energy crop: current status and future trends in BrazilAndré Martins de MartiniPromon EngenhariaBrazilWednesday, 10th of March, 2010
- 3. Overview of sugar cane and ethanol production in Brazil
- 4. Energy outlook and cogeneration
- 5. Case Study – the “energetic” plant
- 7. ConclusionObjective and introductionObjectiveThe main objective of this presentation is to show an overview of utilization of sugar cane as an energy crop in Brazil, presenting some of the characteristics of the Brazilian production, the rationale behind cogeneration and the future developments in this area.IntroductionSugar cane production was introduced in Brazil right after colonizationThe biggest technological advances, however, not only in the agricultural side but also in ethanol production, happened after the “Pró-álcool” ProgramPró-álcool” Program was a governmental program of substitution of gasoline to alcohol in order to mitigate the effects of the oil crisis during the 70´s.
- 8. Overview of sugar cane and ethanol production in BrazilEvolution of sugar cane production from 1975 to 2008 After negligible increase during the 90´s, Brazilian total production has been raising for the last 5 years in an average rate of 15% per year.Source: Brasil. Ministério da Agricultura, Pecuária e Abastecimento. Anuário estatístico da agroenergia / Ministério da Agricultura, Pecuária e Abastecimento. – Brasília : Mapa/ACS, 2009. 160 p.
- 9. Overview of sugar cane and ethanol production in Brazil Evolution of world sugar cane production from 1990 to 2007Brazil is the biggest sugar cane producer, with a production 45% larger than the second biggest producerSource: Brasil. Ministério da Agricultura, Pecuária e Abastecimento. Anuário estatístico da agroenergia / Ministério da Agricultura, Pecuária e Abastecimento. – Brasília : Mapa/ACS, 2009. 160 p.
- 10. Overview of sugar cane and ethanol production in Brazil Comparison between Brazilian and American ethanol productionBrazil was the biggest ethanol producer until 2006, when USA took the first place after a continuous period of intensive increase in production via stimulus of corn ethanolSource: Brasil. Ministério da Agricultura, Pecuária e Abastecimento. Anuário estatístico da agroenergia / Ministério da Agricultura, Pecuária e Abastecimento. – Brasília : Mapa/ACS, 2009. 160 p. ; RenewableFuelsAssociation,: http://www.ethanolrfa.org/industry/statistics/#E
- 11. Overview of sugar cane and ethanol production in Brazil Sugarcane national agro-ecological zoning The already impressive figures of Brazilian production does not show the real potential for ethanol production.This map shows the agro-ecological zoning of Brazil, which defines the areas where production can be extended to.This figure clearly shows that an increase in production and planted area does not mean degradation of protected biomes like Amazon and Pantanal.Source: http://blog.planalto.gov.br/wp-content/uploads/2009/09/mapabrasil.jpg. Acessed in February/2010
- 12. Overview of sugar cane and ethanol production in Brazil Energy balance of sugarcane bioethanol production in Brazil (MJ/tc) The most exciting characteristic of sugar cane production in Brazil is its energy ratio.This outstanding result is partially obtained by the use of bagasse as source of energy for processing sugar cane and more recently for generating electricity connected to the grid in cogeneration plants* Source: Sugarcane-based bioethanol : energy for sustainable development / coordination BNDES and CGEE – Rio de Janeiro :BNDES, 2008.
- 13. Energy OutlookTotal Primary Energy ProductionBRAZILWORLDRenewables: 12,7%Renewables: 46,0%Source: “BrazilianEnergy Balance 2009 ; IEA
- 14. Energy OutlookElectricity generation by source+300%The planned increase in oil fired thermal power plants stems from the necessity of higher stability and supply security, due to the dependence of reservoirs levels and rain regime.Source: ONS; IEA
- 15. Energy outlookBiomass cogeneration can be an alternative to this situation…The graph shows the anti-cyclical pattern of bagasse cogeneration in Brazil. The peak of production occurs during the harvest, exactly during the dry season when the reservoirs reach the lowest level.Source:Castro, N.; Brandão; Dantas, G. A.; Timponi, R.R.; Oportunidades de Comercialização de Bioeletricidade no Sistema Elétrico Brasileiro. 2009
- 16. Energy outlook… with possibility to generate energy equivalent to Itaipu in less than 10 years10.1581 “Itaipu-equivalent”Studies of UNICA* shows that the increase of production and the use of straw can provide in 2017/2018 “another Itaipu” (around 10.200 MW av.) in biomass cogenerationSource: JANK, M.S.Bioeletricidade de cana-de-açúcar - Integração na matriz elétrica e oportunidade de Oferta e cenários para 2010 e 2011* UNICA = BrazilianSugarcaneIndustryAssociation
- 17. Energy outlookReasons to stimulate cogeneration projectsGeneration profile from sugar cane plants is supplementary to the hydrologic regime
- 18. Inflexibility and predictability of generation contribute to maintenance of reservoir levels during dry stations of the year
- 19. Each 1.000 MWav. added in a given period saves up to 4% of reservoir levels (*)
- 20. Construction time of new projects is much smaller when compared to big sized hydro power plants
- 21. Location of sugar cane production (and thus the biomass generation) is close to the main load ( southeast region of Brazil)
- 22. Increase in biomass minimize the use of emergency oil fired plants in peaks of demand
- 23. Each 1.000 MWav. added in a given period avoids R$ 25 million to the Brazilian interconnected system (*)* Source:Silvestrin, C. A. A Bioeletricidade na Expansão da Oferta de Energia Elétrica; Fórum APINE – CanalEnergia Abastecimento Energético 2008 - 2009
- 24. Case StudyState-of-the-art cogeneration and ethanol production unitETHANOL AND ENERGY PLANTJATAÍ – GOLocated in Jataí, State of Goiás(950km from São Paulo and Rio de Janeiro)
- 25. Owner: Cosan
- 26. Total crushing capacity: 4 MTPY
- 27. Total Electricity Generation: 100MW
- 28. Ethanol production: 400 million liters / yearCase StudyState-of-the-art cogeneration and ethanol production unitDISTILLERY2 x 900 m3/d of Hydrated EthanolFERMENTATION7 Vessels of 1600 m3JUICE TREATMENT(Fast Decanter, Evaporators, Multi-Reboiler/Roberts, etc.)1000 m3/h de juiceUTILITIES(Water treatment, Demineralized Water, Chemicals, Fire Fighting, etc.)1000 m3/h of raw water450 m3/h of treated water100 m3/h of demi waterTURBINES(Backpressure and Condensation)72,5 MW (export)PREPARATION AND EXTRACTION (DIFFUSER)21.000 TPDBOILERS(HIGH PRESSURE)2 x 225 t/h of steam @ 100 bar and 520 ºCVIGNASSE840 m3/hRECEPTION AND OFF-LOADING21.000 TPD
- 29. Case StudyState-of-the-art cogeneration and ethanol production unitMar/2008
- 30. Case StudyState-of-the-art cogeneration and ethanol production unitJUL/2008
- 31. Case StudyState-of-the-art cogeneration and ethanol production unitMar/2009
- 32. Case StudyState-of-the-art cogeneration and ethanol production unit
- 33. Case StudyState-of-the-art cogeneration and ethanol production unit
- 34. Case StudyState-of-the-art cogeneration and ethanol production unit
- 35. Case StudyState-of-the-art cogeneration and ethanol production unit
- 36. Case StudyState-of-the-art cogeneration and ethanol production unit
- 37. ETHANOL AND ENERGY PLANTJATAÍ – GOPROJECT DATATotal duration: 24 months
- 38. Peak of manpower: 2700 peopleEngineering documents: 1700
- 40. Volume of concrete: 25.000 m³
- 41. Piles: 41,000 m
- 42. Built area (buildings): 12.500 m²
- 43. Equipments: 310
- 46. Steel structure: 1.900 tons
- 48. Instruments: 2.000Case StudyState-of-the-art cogeneration and ethanol production unit
- 49. ProspectsRecent DevelopmentsUtilization of Straw as supplementary fuel
- 51. Gasification technologiesProspectsRecent DevelopmentsUtilization of Straw as supplementary fuel
- 52. Mechanization of the harvest provides straw as a by-product
- 53. Straw is lighter and dryer and has a higher Heat of Combustion than bagasse -> ΔHstraw = 1.7 ΔHbagasse
- 54. Mixtures of 10% to 20% of straw in mass with bagasse can be used in current boilers without affecting the performance nor the lifespan of the equipment -> this can provide 30% more energy using the same installation (i.e., bagasse can be stored for inter-harvest periods)
- 55. The challenges for straw utilization in larger scale are:
- 56. Development of appropriate separation systems
- 57. Development of specific transport and mixing systems:
- 58. Development of new materials for boilersProspectsRecent DevelopmentsVignasseMethanization
- 59. Vignasse is the biggest effluent of an ethanol facility.
- 60. Even when it can be used for fertirrigation, concentration of salts in the long run depletes the quality of the soil
- 61. Laws and regulations tend to be more severeDediniMethax Plant at SãoJoão MillSãoJoãoda Boa Vista – Brazil (*)It has high DOB and COD; It is highly corrosive and can easily contaminate watersheds and rivers.
- 62. Methanization in anaerobic biodigesters seems to be one of the most promising treatment technologies:
- 63. Produces biogas and solid material that can be used as organic fertilizer
- 64. Biogas produced can be used as supplementary source of energy
- 65. The challenges for methanization development are decrease of cost of drying and higher productivity of bioreactors.* Source: Olivério, J.L. Upgrading and modernizing onsite generarion facilities. Cogeneration Brazil 2009. Dedini
- 67. Bagasse and straw gasification can be a breakthrough in terms of improvement on electricity generation and overall efficiency
- 68. Researches show that a gasification unit integrated with a gas turbine and a heat recovery steam generator (HRSG) can produce two times more energy than conventional steam cycle with bagasse fired boilers and condensing turbogeneratorsBiomass integrated gasification unit – combined cycle * The challenges for further development in gasification technology are:
- 69. operation of high capacity pressurized gasifiers
- 70. gas cleaning and separation of alkali and particulates from the gas produced
- 71. modification of gas turbines for using gas with low caloric power obtaining a performance comparable to turbines that burn natural gas
- 72. significant reduction of capital costs through the learning effect* Source: Chang, K. K. W., Wing, A. L. A., Hoi, L. W. S.. Bagasse gasification technologies for electricity production in the sugar industry. Mauritius Sugar Industry Research Institute, Réduit, Mauritius
- 73. Case StudyTechnological change can improve efficiency and generate more powerBASE CASE “ENERGY PLANT” - 4 MTPY OF CRUSHING CAPACTITYCurrenT statusTotal output: 100mwAssumptions
- 74. Biogas produced is burned and bagasse is saved for inter-harvest
- 75. Surplus of bagasse can generate 6MWav. In condensation turbine during inter-harvestSTEP 1VignasseMethanizationAFTER STEP 1Total output: 106mwAssumptions
- 76. ΔHstraw = 1.7 ΔHbagasse
- 77. Mixture of 20% in mass of straw and bagasse
- 78. Efficiency of the boiler is not affectedSTEP 2Straw burning(20% in mass)AFTER STEP 2Total output: 127mwAssumptions
- 79. Operation of gasification is stable
- 80. Efficiency of gas turbine is comparable to current gas turbinesSTEP 3GasificationAFTER STEP 3Total output: 161mw
- 81. André Martins de Martiniandre.martini@promon.com.brwww.promon.com.brSão PauloBRRio de JaneiroBRAv. Pres. Juscelino Kubitschek, 183004543-900 São Paulo - SPPraia do Flamengo, 15422210-906 Rio de Janeiro - RJCONFIDENTIAL– This document contains confidential information with restricted access and ownership or possession of Promon SA, or any of its subsidiaries or affiliates, and are protected by applicable law against disclosure. The possession, display, disclosure, distribution or unauthorized use of of this document is strictly prohibited.