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

SUGARCANE BAGASSE HYDROLYSIS FOR FURTHER

ETHANOL PRODUCTION

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

FOSTERING ELECTRICITY GENERATION FROM

SUGARCANE

PRESENT SITUATION

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

FOSTERING ELECTRICITY GENERATION FROM

SUGARCANE

MEDIUM TERM

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

NEAT ETHANOL & FLEXFUEL VEHICLES

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

Alcohol due advantages. Gasoline due traditionBoth together to demonstrate this technology

CARBON SEQUESTRATION

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

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

ScenB2 & Sugarcane& Sequestration