Production of Bio-Methane from Sugar Cane Vinasse. German-Brazilian Project proposal CLIB2021/IFG/UFG

Transcription

1 Production of Bio-Methane from Sugar Cane Vinasse German-Brazilian Project proposal CLIB2021/IFG/UFG

2 Project Proposal Production of Bio-Methane from Sugar Cane Vinasse Speaker: Prof. Dr. Joachim W. Zang IFG - Federal Institute for Education, Science and Technology in Goiás, Campus Goiânia Contact: zang@ifg.edu.br Adress: IFG - Coord. de Pesquisa e Inovação do Campus Goiânia, Rua 75, no. 46, Centro, CEP: , Goiânia, Goiás, Brazil

3 Sumário/Summary 1. Geography 2. German-Brazilian work-group. CLIB2021- IFG,UFG 3. Ethanol- and electricity production based on sugar cane in Goiás residues: vinasse, straw, filter cake 4. Biogas production from vinasse. 5. Possible impacts of the project on the brazilian energy matrix. 3

4 The state of Goiás is located within the Brazilian Highlands in the center of Brazil. Goiás occupies a large plateau, the vast surface level is between 750 and 900 m above sea level. The seventh biggest state of the 26 Brazilian states occupies about km 2, about the size of Germany ( km 2 ) 2012 Prof. Dr. Joachim W. Zang, IFG, Brazil

5 Brazilian Midwest Goiás: Population (IBGE, 2010) Area: km² Population density: 17.6/km² Germany Population: (Stat. Ämter, 2011) Area: km² Population density: 229/km 2

6 The state of Goiás The state is covered with a woodland savanna known in Brazil as Cerrado, although there are still tropical forests along the rivers. Tropical Climate: Mean monthly temperatures vary between 22 C=71.6 F and 26 C=78.8 F. The year is divided in a drought season from von April September 2010 Prof. Dr. Joachim W. Zang, IFG, Brazil

7 Goiás: and a rainy season from October to March. The total yearly precipitation is about 1700 mm (Germany 580 mm) 2011 Prof. Dr. Joachim W. Zang, IFG, Brazil

8 Gross Domestic Product of the State of Goiás - Sustainable growth Sugar cane production growth +34% 2011 Prof. Dr. Joachim W. Zang, IFG, Brazil

9 1. Work group Project participants of CLIB2021: DURAG, EVONIK-Degussa, Fraunhofer Institut, Schaumann Group, University of Bielefeld. 9

10 1. Work group University of Applied Sciences of Trier Prof. Dr. Ulrich Bröckel, Director IMIP Institut für Mikroverfahrenstechnik und Partikeltechnologie 10

11 1. Work group Federal Institute of Goiás IFG Chemical Technology: Prof. Dr. Joachim W. Zang, Prof. Dr. Warde Antonieta da Fonseca-Zang, Prof. Dr. Sérgio Botelho de Oliveira. Mechanical Engineering: Prof. Jaír Dinoah. Electrical Engineering: Prof. Dr. Elder Geraldo Domingues Network Technologies: Prof. Dr. José Luis Domingos. Prof. MS. Wagner Bento 11

12 1. Work group Federal University of Goiás UFG Agronomy Department: Prof. Dr. Wilson Mozena Leandro Prof. Dr. Alfredo Borges de Campos

13 1. Work Group Collaborator: Laboratório Nacional do Ministério de Agricultura, Pecuária e Abastecimento em Goiás [LANAGRO/MAPA]/National Laboratory of the Ministry of Agriculture, Livestock and Supply Quím. Luis Sávio Teixeira, Chefe do Laboratório Nacional de Fertilizantes e Condicionadores de Solo/ Head of the National Laboratory for Fertilizers and Soil Conditioners. 13

14 1. Work Group Collaborator: SIFAEG/Trade Unions of the sugar and ethanol industry in the State of Goiás. President: André Luiz Baptista Lins Rocha 14

15 1. Work Group Collaborator: State secretary of Science and Technology Goiás - SECTEC Secretary: Mauro Netto Faiad State secretary of Industry and Trade Goiás SIC Secretary: Alexandre Baldy 15

16 1. Work Group CentroAlcool Inhumas 22/09/

17 2. Ethanol Production from Sugar Cane Bioethanol is produced in Brazil leaving 10 to 18 liters of vinasse for every liter of ethanol. ethanol vinasse For the project is planned the use of vinasse to produce bio-methane and fertilizer. 17

18 Sugar Cane, bioelectricity and vinasse. Sugar-Cane: Worldwide about hectar of agricultural areas are used to produce sugar cane. Actually about 42% of sugarcane is produced in Brazil on an area of about hectar. 18

19 Distribution of the 350 sugar-cane processing industries in Brazil (BNDS & CGEE, 2008). State of Goiás 19

20 Ethanol in Goiás Sugar Cane Saccharum (37 species) 20

21 Sugar cane cultivation The ideal climate for cultivation of sugar-cane is given by a hot and humid season that provides germination and vegetative development, Followed by a cold and dry season to guarantee the maturation and the accumulation of sucrose in the stems. 21

22 Sugar-cane cultivation The demand for fertilizers for the cultivation of sugar cane is reduced in large part because of industrial waste (vinasse) that is returned to the fields, e.g. all the potassium is supplied by fertigation with vinasse. 22

23 Harvesting periods Vary with the rainfall to allow the cutting and transportation and work to achieve the best point of maturation and accumulation of sugars. In the South-Central region of Brazil, the harvest is held from April to December, While in the Northeast sugar cane is harvested between August and April. 23

24 Bioethanol Production The sugar cane can t be stored more than a few days. Once in the production plant, the sugar cane is washed a goes on to the extraction system in four to seven mills in a sequence. 24

25 Bioethanol Production Simplified flow chart of Ethanol Production Process in Brazil 25

26 Industrial Process During the milling the juice containing the saccarose is separated from the fibers (bagasse), which is used as fuel for destillation and co-generation of electrical energy. 26

27 Industrial Process The extracted juice is used to produce sugar or bio-ethanol. the first steps of the processes of sugar and ethanol production are similar. 27

28 Industrial Process for Bio-Ethanol The juice is fermented during a 8 to 12 hours period, producing a wine with 7 to 10% ethanol content. 28

29 Industrial Process During the following destillation process hidrated bioethanol is produced inicially with 96 GL leaving 10 to 18 liters of vinasse per liter of bioethanol. 29

30 Residues of the industrial process 1- Vinasse: Between 800 and liters per ton of processed sugar cane or 10 to 18 L per liter of bioethanol, 2- Filter cake: About 40 kg of humid filter cake per ton of processed sugar cane. 3- Burning ashes: About 17 kg per ton of burned bagasse (ELIA NETO, 2007). 30

31 In Brazil these residuals are valorized as byproducts used as fertilizers and for irrigation; Reducing the need for mineral fertilizers and reducing the necessity for irrigation during the dry season. 31

32 Bagasse as fuel to produce heat and electric energy in bio-ethanol plants Demand: about 12 kwh per ton of processed sugar cane. The use of bagasse (straw) in energy cogeneration can produce enough energy for the process and makes it auto sufficient. 32

33 Bioelectricity Tendency: The plants are transformed from ethanol and sugar production also to bio-electricity plants, producing more than 100 kwh of electric energy per ton of sugar cane. 33

34 Productivity of bio-ethanol and sugar In case of exclusive production of bio-ethanol, from one ton of sugar cane can be produced 86 liters of hydrated bio-ethanol. When the objective is to produce sugar, beside the 100 kg of sugar 23 liters of bioethanol can be produced (CTC, 2005). 1 ton 86 L or 100 kg 23 L + 34

35 Production in the State of Goiás harvesting period t of sugar cane 32 active production sites t of sugar liters of ethanol -> Leaving about liters of vinasse. Source: 35

36 Vinasse 37 billion liters in 2011 Vinasse Foto author, Vinasse irrigation channel Source: Rosetta, 2007 Pipelines for vinasse conduction Source: Rosetta, 2007 Irrigation with hidraulic cannon: Rosetta,

37 4. Project Proposal CLIB 2021-IFG Bio-methane from Sugar Cane Vinasse

38 Term: Biogas Biogas typically refers to a mixture of gases produced by the biological breakdown of organic matter in the absence of oxygen. Organic waste such as dead plant and animal material, animal dung, and kitchen waste can be converted into a gaseous fuel called biogas. Biogas is a type of biofuel. (Wikipedia, 2012). The gas methane CH 4 is the principal component of biogas. 38

39 Term: Biogas The composition of biogas varies depending upon the origin of the anaerobic digestion process: Methane (CH 4 ): 40 70% Vol. of the produced biogas Carbon dioxide (CO 2 ): 30 60% Vol. of the produced biogas Hydrogen (H 2 ): 0 1% Vol. Hydrogen sulfide (H 2 S): 0 3% Vol. Water (H 2 O): 0 10% Vol. Oxygen (O 2 ): 0 2% Vol. Traces of ammonia (NH 3 ): 0 2,5 mg/m 3 39

40 Possible use of biogas in Goiás Co-generation of Electric and calorific Energy. Heating in industrial processes, for food, ceramics, mining, etc. Purification to bio-methane for use in combustion engines (Otto motors, car fuel) To use as raw material in the chemical industry (green chemistry). 40

41 Production of Bio-Methane from Sugar Cane Vinasse Project proposal CLIB2021/IFG/UFG More than 37 million tonnes of vinasse incur annually in Goiás without a really strong economical and ecological outlet. This project proposes the production of pure bio-methane from vinasse for the use as motor-fuel. 41

42 Production of Bio-Methane from Sugar Cane Vinasse If agricultural machines are equipped with methane-motors this fuel can be used close to the production site of a plant. In the State of Goiás exists only one gasstation for GLP-car-gas due to the big distance to the petrol-industry-centers of more than 1000 km. Project proposal CLIB2021/IFG/UFG 42

43 Production of Bio-Methane from Sugar Cane Vinasse Bio-methane might find another high-volume market in the European Union because the target of reducing CO 2 -emission by 80% till 2050 (compared to 1990) puts an enormous pressure on the European fuel industry to provide sustainable energy. Project proposal CLIB2021/IFG/UFG 43

44 Production of Bio-Methane from The process includes Sugar Cane Vinasse 1) the transformation of vinasse to biogas, 2) the purification of biogas to bio-methane and 3) storage of bio-methane. Project proposal CLIB2021/IFG/UFG 44

45 Production of Bio-Methane from R&D Topics Sugar Cane Vinasse Technical and economical feasibility study State of the art of producing biogas from vinasse Options for technical and economical improvement Bio-methane markets Project proposal CLIB2021/IFG/UFG 45

46 Production of Bio-Methane from R&D Topics Sugar Cane Vinasse Biogas fermentation Batch- of continuous processes Microbial population Vinasse composition / Additives Process parameters Productivity and yield of a standardized biogas quality Biogas reactor types Project proposal CLIB2021/IFG/UFG 46

47 Production of Bio-Methane from R&D Topics Sugar Cane Vinasse Bio-methane purification Bio-methane storage and logistics Bio-methane marketing and distribution Project proposal CLIB2021/IFG/UFG 47

48 Production of Bio-Methane from R&D Topics Sugar Cane Vinasse Usage of residual biomass form biogasfermentation Usage of biogas in motors Specification of biogas Modification of motors Project proposal CLIB2021/IFG/UFG 48

49 5. Impact on the Brazilian Energy Sector

50 5. Possible Impacts on the Brazilian Energy Sector 70% of the electric energy in Brazil is produced in 140 hydroeletric power plants Energy production in the state of Goiás: MWh (2010). About two thirds of this energy is transferred to other brazilian states. Hydroelectric Power Plant Serra da Mesa Source: < _BEN_-_Ano_Base/1_-_BEN_Portugues_-_Inglxs_-_Completo.pdf> Hydroelectric Power Plant of Corumbá 50

51 State of Goiás Hidroelectric power plants Artificial Lake Serra da Mesa, northern region of Goiás. Volume: 43,25 km 3 Superfície: km² Power output: MW Source: Google Earth, Prof. Dr. Joachim W. Zang, IFG, Brazil 51

52 Ethanol production in Goiás Burning of the bagasse 52

53 Produção de Etanol em Goiás. Projeto: Biogás da vinhaça/ Biogas from vinasse Vinasse Foto author, Pilot Plant installed in Germany. 750 KW. SCHAUMANN,

54 Sugar- and Ethanol-Industry in Goiás Sample Calculation 37 billion of liters of vinasse = m 3 in Goiás per year. One cubic meter of vinasse might produce up to 11,5 m 3 of biogas, from which it is possible to produce up to 169 kwh electric power (Lamonica, 2006) without reducing its fertilizing potential. 54

55 Sugar- and Ethanol-Industry in Goiás Sample Calculation m 3 vinasse x 11,5 m 3 biogas /m 3 vinasse = m 3 biogas or m 3 vinasse x 169 kwh/m 3 vinasse = 6253 GWh Actual annual production of energy in Goiás: GWh Prof. Dr. Joachim W. Zang, IFG, Brazil 55

56 CLIB/IFG/UFG Thank you for your attention. Prof. Dr. Joachim Werner Zang 56