BIOFOM THE ZERO SUGARCANE MILL:

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2 International Society of Sugar Cane Technologists 27 th ISSCT CONGRESS INTEGRATED PRODUCTION OF ORGANOMINERAL BIOFERTILIZER USING BYPRODUCTS FROM SUGAR AND ETHANOL AGROINDUSTRY, OR... BIOFOM THE ZERO SUGARCANE MILL: ZERO RESIDUES, ZERO EFFLUENTS, ZERO INTAKE WATER, ZERO ODOR!!! VERA CRUZ, MEXICO, 11 th MARCH, 2010 JOSÉ LUIZ OLIVÉRIO SENIOR TECHNOLOGY AND DEVELOPMENT VICE PRESIDENT FERNANDO C. BOSCARIOL SUGAR & ETHANOL DEVELOPMENT ENGINEER MANAGER PAULO E. MANTELATO, ANTÔNIO R. P. CÉSAR, JOÃO R. P. CIAMBELLI, MARCÍLIO N. A. GURGEL, RENATA T. G. SOUZA DEVELOPMENT ENGINEER RESEARCHERS TEAM 2

3 BIOFOM - THE ZERO SUGARCANE MILL WHAT IS BIOFOM HOW TO PRODUCE BIOFOM BIOFOM: FERTILIZATION RESULTS BIOFOM: CASE STUDY BIOFOM: CONCLUSIONS 3

4 BIOFOM - THE ZERO SUGARCANE MILL WHAT IS BIOFOM HOW TO PRODUCE BIOFOM BIOFOM: FERTILIZATION RESULTS BIOFOM: CASE STUDY BIOFOM: CONCLUSIONS 4

5 WHAT IS BIOFOM FOCUS: ZERO WATER CONSUMPTION + ZERO RESIDUES/EFFLUENTS New Factory Design The Water + Biofom Mill LOSSES Evaporation: 1052,00 Bagasse: 130,21 Drain Cane Wash: 694,52 Others: 42, ,57 CANE: 700 SUGAR: 0, Sugar and Bioethanol Mill ETHANOL: 0,26 STILLAGE: 540,14 610,43 INTAKE: KG/L ETH Typical Brazilian Mill CAKE: 40,00 Water Balance when processing 1 ton of cane kg H 2 O/tc 5

6 WHAT IS BIOFOM FOCUS: ZERO WATER CONSUMPTION + ZERO RESIDUES/EFFLUENTS Recovering steam losses, condensating and reutilizing the water Changing wet for dry processes Dry and recover water from stillage CANE: 700 WATER EXPORT: 290, ,7 KG/L ETH. INTAKE: KG/L ETH New Factory Design The Water + Biofom Mill LOSSES Sugar and Bioethanol Mill Sugar and BIOFOM Bioethanol TM + Mill BIOWATER TM Typical Brazilian Dedini Mill Water + Biofom Mill Evaporation: 1052,00 Bagasse: 130,21 Drain Cane Wash: 694,52 Others: 42,84 SUGAR: 0,03 ETHANOL: 0,26 STILLAGE: 540,14 CAKE: 40,00 ASHES + SOOT 1919,57 610,43 BIOFOM 4,66 COMPLEMENTARY NUTRIENTS Water Balance when processing 1 ton of cane kg H 2 O/tc 6

7 WHAT IS BIOFOM BIOFOM composition Soot + Ash Concentrated Vinasse Filter Cake COMPLEMENTARY NUTRIENTS BIOFOM is customized, that means, formulated according to the soil and sugarcane specific needs 7

8 BIOFOM - THE ZERO SUGARCANE MILL WHAT IS BIOFOM HOW TO PRODUCE BIOFOM BIOFOM: FERTILIZATION RESULTS BIOFOM: CASE STUDY BIOFOM: CONCLUSIONS 8

9 BIOFOM Flow Sheet Sugar Cane Filter Cake SUGAR MILL Ash/Soot MIXING/DRYING Dried Mixture sample From Boiler/ BIOFOM Furnace V1 Bleed / Alchoholic Vapours Vinasse Evaporation Concentrated Vinasse sample condensate Hot Gas Ash/Soot Biomass Furnace Bagasse and/or Straw Sample Analysis Hot Gas UREA ( N ) SSP ( P 2 O 5 ) KCl (K 2 O) Formulation composition data Vinasse Composite Granulation and Drying Dried and Granulated BIOFOM 9

10 BOILER BAGASSE Falling Film ASHES + SOOT CONCENTRATED VINASSE CONCENT. VINASSE UREA KCL SSP (P 2 05) FILTER CAKE AUTOMATION COMPOSITE VINASSE FILTER CAKE ASHES + SOOT CONCENTRATED VINASSE STRAW TASTE LABORATORY BIOFOM (N, P, K) SILO GRANULATION/ DRYING HOT GAS BIOMASS FURNACE BAGASSE/ STRAW TO FIELD 10

11 BIOFOM - AUTOMATION INTEGRATED AND OPTIMIZED AUTOMATION TO BIOFOM PRODUCTION AND CUSTOMIZED FORMULATION DEDINI TOTAL MILL AUTOMATION CONTROL INTEGRATED TO BIOFOM PLANT (M E S LEVEL) 11

12 BIOFOM 12

13 BIOFOM - THE ZERO SUGARCANE MILL WHAT IS BIOFOM HOW TO PRODUCE BIOFOM BIOFOM: FERTILIZATION RESULTS BIOFOM: CASE STUDY BIOFOM: CONCLUSIONS 13

14 BIOFOM Official Evaluation Control BIOFOM Planting 23/Oct Harvest 11/Dec Planting 23/Oct Harvest 11/Dec AGRONOMIC EVALUATION OF BIOFOM, MADE BY ESALQ ESCOLA SUPERIOR DE AGRICULTURA LUIZ DE QUEIROZ FROM UNIVERSIDADE DE SÃO PAULO PLANT TEST: MAIZE - INTERNATIONAL CRITERIA AND METHODOLOGY UTILIZED 14

15 Fans for damp air circulation Padhouse system Greenhouse at ESALQ-USP, utilized in the experiment 15

16 Experiment treatments 16

17 Experiment treatments 30/45% DM 30/45% DM Mixed 30/45% DM Ethanol Molasses Mixed 17

18 Pot with plastic bag to avoid water and nutrients losses by lixiviation. Volume 2,5 l=2 kg soil BIOFOM granules being homogenized in the soil (upper half of the pot) 18

19 2 corn seeds per pot DOW 2B710 19

20 Pots divided into random groups. Corn plants growing: 5 th day 20

21 Corn plants 8 th day 1 seed/pot 21

22 Corn plants harvesting at 50 th day 22

23 BIOFOM Results Control Sample BIOFOM Mineral 23

24 Results Analysis Leaf Area Scanner 24

25 Corn root with BIOFOM 25

26 Results Mineral Fertilizer NITROGÊNIO N NITROGÊNIO N CÁLCIO Ca BORO B FÓSFORO P FÓSFORO P MAGNÉSIO Mg ZINCO Zn MANGANÊS Mn POTÁSSIO K POTÁSSIO K ENXOFRE S COBRE Cu FERRO Fe + ORGANIC MATTER 26

27 Greenhouse tests of BIOFOM - Summary Parameter Part analysed Control sample BIOFOM (complemented to 100% of formula of cane plantation) Mineral fertilizer J M MJ Leaf area (cm2) Dry substance (g) Nitrogen (mg/dm3) Phosphorus (mg/dm3) Potassium (mg/dm3) Aerial part Root Aerial part Root Soil nd nd nd nd nd Aerial part Root Soil Aerial part Root Soil Granules remaining (%) after harvest plantation) (50 days after Dry Subst nd N nd P nd K nd Note: MJ : vinasse from molasse and juice, M: vinasse from molasses, J: vinasse from juice, nd: not detected 27

28 BIOFOM - THE ZERO SUGARCANE MILL WHAT IS BIOFOM HOW TO PRODUCE BIOFOM BIOFOM: FERTILIZATION RESULTS BIOFOM: CASE STUDY BIOFOM: CONCLUSIONS 28

29 BIOFOM Production & Savings Integrated Biofom Production in Sugar & Ethanol Mill Cane Crushing ton/crop Harvested Area ha Planted Area ha Concentrated Vinasse (60% DS) ton/crop In Natura Filter Cake (40% DS) ton/crop Ash and Soot ton/crop BIOFOM Production (85% DS) ton/crop Relative Production kg BIOFOM/TC 50 Nutrients Chemical fertilizer saved by Biofom (t/crop) Fertilizer needs Fertilizer recycled/ available in BIOFOM Chemical Fertilizer Complement UREA (45% N) ,1% SSP (21% P 2 O5) ,1% Potassium chloride (60% K 2 O) ,1% 196 Total ,6% Other Nutrients - Ca Mg S B Zn Cu Zn Mn Fe Organic Matter - + than 40% DS: Dry Substance 29

30 Vinasse irrigation with reel

31 Current filter cake application

32 Current boiler ash and soot application

33 Mineral Fertilizer application 33

34 BIOFOM Application Investments in trucks, agricultural equipment and distribution system reduced 67% (worst case: ethanol mill very close to the plantation) Expenses reduced 70% comparing traditional mineral fertilization and BIOFOM + complementary fertilization 34

35 BIOFOM: case study Economic Evaluation Investment /Costs to produce/use Biofom in industrial and agricultural operations Savings by using BIOFOM in agricultural operations Additional Investments (BIOFOM Plant/ BIOFOM application to the Field) Additional fixed and variable costs (extra man power/ steam, electricity, bagasse consumption/ BIOFOM application to the field) Reduction in the investment Reduction in the cost of mineral fertilizers acquisition Reduction in operational costs Discounted pay back time (capital cost 12% per year): 2 to 3,5 years, depending on the distance between the ethanol mill and the sugarcane plantation 35

36 BIOFOM - THE ZERO SUGARCANE MILL WHAT IS BIOFOM HOW TO PRODUCE BIOFOM BIOFOM: FERTILIZATION RESULTS BIOFOM: CASE STUDY BIOFOM: CONCLUSIONS 36

37 BIOFOM Benefits Agronomical Effects by using BIOFOM: Enables recycling near 70% of the fertilizer required in sugarcane plantations BIOFOM can be formulated according to the specific needs of the soil and sugarcane Improves the soil physical-chemical properties: increases the CEC (Cationic Exchange Capacity) due to the organic matter, the porosity and the water retention capacity facilitates the absorption of nutrients; reduces the losses caused by leaching; reduces erosion; Reduces the infrastructure required to distribute chemical fertilizer, vinasse, filter cake, ashes and soot To evaluate BIOFOM overall influence in sugarcane production, real conditions field tests need to be made, to confirm other benefits that can be obtained by using organic replacing chemical fertilizer 37

38 BIOFOM Benefits Sustainability Effects by using BIOFOM: Economic Sustainability: reduces agricultural investments and operational costs; presents adequate return on investment pay back time; Social Sustainability: eliminates the risk of water contamination by vinasse and other residues/effluents; provides better comfort, hygiene, safety and good health conditions Environmental Sustainability: eliminates the need for intake water to the mill by using the water contained in sugarcane; make it possible to export water by the mill that can be reused in the industry and/or in the field; eliminates residues, liquid effluents and odors; contributes to GHG (Greenhouse Gases) emissions reduction replacing fossil fuels chemical fertilizers 38

39 39

40 Zero residues Zero liquid effluents Zero odor Zero intake water Minimum emissions 40

41 Conclusion is a sustainable fertilizer economic social environmental 41

42 International Society of Sugar Cane Technologists THANK YOU FOR YOUR ATTENTION DEDINI S/A INDÚSTRIAS DE BASE Rodovia Rio Claro-Piracicaba, km 26,3 Caixa Postal CEP Piracicaba - SP Brasil Fax: +55 (19) Tel.: +55 (19) dedini@dedini.com.br site: 42