Applied Bioethanol Technology in Brazil

Transcription

1 Applied Bioethanol Technology in Brazil Josef Dörfler Partner of Fermentec Ltda - Brazil Austria - Europe Detmold, on April 24 th, 2007

2 Presentation Outline 1. Sugar Cane Growing 2. The Brazilian Alcohol Industry History and Development 3. International Trends in the Bioethanol Sector Key Notes 4. Brazil/ Technology for Bioethanol Production 1. Sugar Cane Management 2. Sugar Cane Processing 3. Applied Fermentation Concepts 4. Destillation and Purification 5. Usage of Bioethanol as a Biofuel 6. Summary 2

3 1. Sugar Cane Growing Areas - Worldwide 3

4 1. Sugar Cane Growing Areas Brazil at the Present The main area for sugar cane cultivation is located in Sao Paulo State. Year 2006: litres Bioethanol (= 17.6 billion litres) were produced in Brazil. Source: CTC/ Copersucar 4

5 2. The Brazilian Alcohol Industry History and Development Past 1975: Start of the nationale development program Proalcool. 1979: Ramp up of the production capacity for serving the national fuel energy sector. 85% of the private cars in Brazil were using bioethanol. (market price in 1980: approx. 700 USD/m³) Phase of cheap Energy up to 1999: Market consilidation within the alcohol industry sector (market price in 1999: <= 200 USD/m³) Source: UNICA (2004) 5

6 2. The Brazilian Alcohol Industry History and Development Present and Future Since 2000: Ongoing increase of production capacities and improvement of the related technologies. > 320 processing factories (combination: sugar & ethanol) are in operation now to 2012: Continous increase of processing volume from 17.6 billion up to 28 billion litres/ year (forecast statement). 77 new plants will be established. Source: UNICA (2004) and Amorim (2007) 6

7 3. International Trends in the Bioethanol Sector Key Notes NOW: Worldwide gasoline consumption of approx billion litres/ year. Only 2,5% of that amount is from bioethanol source. FORECAST: Bioethanol growth rates of more than 25% per year are expected for the next years. All countries in the world are/ will strongly invest into bioethanol facilities. The further improvement of bioethanol technology is driven by national and international R&D-programs. 7

8 3. International Trends and Competition in the Bioethanol Sector Worldwide Installed Production Capacities Region of Production Year 2004 Year 2005 Year 2007 *) (billion litres) (billion litres) (billion litres) Brazil USA European Union Asia China India Africa Total World Hot Spots of fast growing markets for ethanol plants Source: EC-Commission Paper EU-Strategy for Biofuels (2006) *) forecasted quantities by the national governments (2007) 8

9 4.1. Brazilian Bioethanol/ Sugar Cane Management - Productivity The sugar content (succrose) of sugar cane is in the range 13% to 17%. Year of seeding: no harvest 1 st harvest year: 120 tons/ ha 2 nd harvest year: 100 tons/ ha 3 rd harvest year: 90 tons/ ha 4 th harvest year: 80 tons/ ha 5 th harvest year: 70 tons/ ha 9

10 4.1. Brazilian Bioethanol/ Sugar Cane Management - Harvesting Burning of the field Harvest period in the Sao Paulo State region: March to September (8 months) 10

11 4.1. Brazilian Bioethanol/ Sugar Cane Management Economic Values Prices and Yields: market price: approx. 17 USD/ ton (13 / ton) of sugar cane (end of 2006) sugar content: alcohol yield: % (w/w) in sugar cane approx. 85 litres/ ton sugar cane 11

12 4.2. Brazilian Bioethanol/ Sugar Cane Processing - Extraction The sugar cane is containing directly fermentable sugars no thermal and enzymatic conversion is required. The sugar is extracted by water. The pictures below are from sugar cane processing. 12

13 4.2. Brazilian Bioethanol/ Sugar Cane Processing Energy Generation The remaining biomass bagasse is used as an energy source for cogeneration of steam and electricity. The Brazilian sugar factories are energy selfserving. The surplus of electric power is sold to the country`s energy market. 13

14 4.3. Brazilian Bioethanol/ Applied Fermentation Concepts The Scientific Base The carbon- and energy balance of the alcoholic fermentation process by yeast. = 64,6 ml EtOH Source: Fermentec/ Brazil (2006) 14

15 4.3. Brazilian Bioethanol/ Applied Fermentation Concepts Yeast Recycling is the Key for High Productivity The yeast recycling process is successfully applied and improved in the Brazilian ethanol industry since The requirement for application that concept is a nutrient solution with low insoluble solids. Through yeast recycling a highly efficient conversion rate from sugar to ethanol can be realized. Picture: The biggest Brazilian plants are applying yeast recycling and are getting technological consulting from Fermentec. 15

16 4.3. Brazilian Bioethanol/ Applied Fermentation Concepts Batch Process 16

17 4.3. Brazilian Bioethanol/ Applied Fermentation Concepts Continues Process 17

18 4.3. Brazilian Bioethanol/ Applied Fermentation Concepts Some Process Characteristics in Large Scale >75% of production is done as batch process. Typical size of fermentation vessels is 500 m³ up to 1500 m³. Typical time of a batch is up to 10 hours. Therefore 2 batches per day can be performed one vessel. Conversion yields up to 92% (sugar -> ethanol) are realized. Picture: Headquarter of Fermentec Ltda. in Piracicaba/ Sao Paulo State Brazil 18

19 4.3. Brazilian Bioethanol/ Applied Fermentation Concepts Vessel Design 7 Batch fermenters, each 1500 m³ The state of art design of the vessels at the bottom (recycling pump and heat exchanger) 19

20 4.3. Brazilian Bioethanol/ Applied Fermentation Concepts Yeast Separation and Treatment The continous centrifugation process The separated yeast is treated and reused for the next batch 20

21 4.3. Brazilian Bioethanol/ Applied Fermentation Concepts Different Steps of the Alcohol Process sugar solution yeast cream wine beer wine without yeast destilled alcohol 21

22 4.4. Brazilian Bioethanol/ Destillation and Purification Columns for ethanol destillation and purification different qualities are produced: Hydrated Alcohol (with 96% Ethanol) Anhydrous Alcohol (with 99,5% 99,8% Ethanol) 22

23 4.4. Brazilian Bioethanol/ Destillation and Purification A huge tank farm with a capacity of m³ ethanol A smaller tank farm In front the cooling towers for the fermentation unit 23

24 5. Usage of Bioethanol as a Biofuel (1) Fuel prices in Brazil (from October 2006) 1 Euro = 2,7 Real Diesel 66 Cent/ L Gasoline 89 Cent/ L Alcohol 46 Cent/ L 24

25 5. Usage of Bioethanol as a Biofuel (2) At each gasoline station in Brazil bioethanol is available for running the flex fuel cars. Hydrated alcohol (96%) can be used for those cars. 25

26 6. Summary (1) 428 million tons of sugar cane were processed in 320 factories during further factories are under planning and construction now. Brazil and US are competing for the leading position in ethanol production. Actual values for 2006: USA: 18.9 billion litres Brazil: 17.6 billion litres Source: Amorim (2007), International Sugar Journal (March 2007) 26

27 6. Summary (2) 40% of the Brazilian gasoline consumption in the private car sector is from the renewable source ethanol Since the year 2005 the share for flex fuel vehicles is reported more than 70% of the sold cars on the Brazilian market. 27

28 Thank you for your attention! Contact: Dr. Josef Dörfler, MBA Zivilingenieur für Lebensmittel- & Gärungstechnologie 3281 Oberndorf Austria - Europe josef.doerfler@utanet.at Phone.: Further details: 28