STATE OF THE ART SUGARCANE MILL, OR... DEDINI'S LATEST GENERATION TECHNOLOGIES!!! PIRACICABA, 13 th APRIL, 2012 JOSÉ LUIZ OLIVÉRIO SENIOR TECHNOLOGY AND DEVELOPMENT VICE PRESIDENT 2
DEDINI'S LATEST GENERATION TECHNOLOGIES!!! INTRODUCTION DEDINI S/A INDÚSTRIAS DE BASE DEDINI IN BIOENERGY 3
DEDINI'S LATEST GENERATION TECHNOLOGIES!!! INTRODUCTION DEDINI S/A INDÚSTRIAS DE BASE DEDINI IN BIOENERGY 4
INTRODUCTION TO DEDINI S/A INDÚSTRIAS DE BASE FOUNDED IN 1920, DEDINI HAS TODAY 3.500 DIRECT EMPLOYEES DEDINI IS A CUSTOM MADE CAPITAL GOODS SUPPLIER INDUSTRY WITH EMPHASIS ON THE SUGAR, ETHANOL AND BIOENERGY SECTOR, OFFERING COMPLETE TECHNOLOGY WITH A BROAD LINE OF PRODUCTS, AND PIONEERISM AND INNOVATION TRADITION. SCOPE OF SUPPLY: FEASIBILITY STUDIES, CONCEPTUAL/ PROCESSUAL/ BASIC ENGINEERING, PARTS, COMPONENTS, EQUIPMENT, COMPLETE TURNKEY PLANTS, SERVICES DEDINI S/A INDÚSTRIAS DE BASE IS A 100% BRAZILIAN COMPANY RESULTING FROM THE MERGER OF DEDINI, ZANINI, BADONI AND CODISTIL. HISTORICAL MARKET SHARE IN BRAZIL: ABOVE 80%. MORE THAN 80% OF TOTAL ETHANOL PRODUCED IN BRAZIL USES DEDINI DISTILLERIES AND EQUIPMENT (25% OF WORLD ETHANOL) 5
INTRODUCTION TO DEDINI S/A INDÚSTRIAS DE BASE OWN TECHNOLOGIES - Sugar and Ethanol Plants; - Sugar Refineries, Liquid Sugar and Syrup plants; - Sugarcane Brandy (Cachaça); - ThermoPower/Cogeneration plants & boilers (biomass/bagasse/compact); - Storage of concentrated/ NFC juice and beverages; - CCT Cilindrical Conical Tanks/ Breweries; - Fertilizer industry equipment; - Special Castings. - Automation and Process Control CLIENT TECHNOLOGIES TECHNOLOGIES LICENCED TECHNOLOGIES - Biodiesel Plants; - Breweries/ Brewhouse; - Wastewater treatment plants; - Liquid Filtration/ Breweries & others; - Modular Chainless Diffuser; - Ethanol membrane dehydration; - Stillage Concentration; - Compact Hydro Power Plants. - Chemical & Petrochemical; - Automotive; - Steel & Metals; - Hydromechanics; - Pulp & Paper; - Cement & Mining; - Castings; - Thermo energy; - Dished Ends; - Pharmaceutical. 6
INTRODUCTION TO DEDINI S/A INDÚSTRIAS DE BASE TECHNOLOGICAL PARTNERSHIPS 7
DEDINI S/A INDÚSTRIAS DE BASE INTRODUCTION TO DEDINI S/A INDÚSTRIAS DE BASE BRAZILIAN LEADERSHIP - MAIN MARKETS INDUSTRY/ SEGMENT MARKET SHARE (1) SUGAR & ETHANOL & BIOELECTRICITY (SINCE 1920) (*) MORE THAN 50% BREWERIES (SINCE 1990) MORE THAN 60% WASTE WATER TREATMENT (SINCE 1986) MORE THAN 80% JUICE STORAGE/ TANK FARMS (SINCE 1986) MORE THAN 90% BIODIESEL (SINCE 2004) MORE THAN 60% MEDIUM AND BIG PLANTS (1) REF.: 3 TO 5 YEARS, JUNE/2010 (*) WORLD LEADERSHIP 8
6 big Industrial Plants strategically located in Brazil RECIFE Plate shop MACEIÓ Machinery Plate shop Heavy Machinery Plate shop/boilers Heavy Equipment SERTÃOZINHO PIRACICABA Headquarter Stainless Plate shop Dished Ends Foundry Heavy Machinery Heavy Machinery 9
INTRODUCTION TO DEDINI S/A INDÚSTRIAS DE BASE GROSS REVENUES 2000 to 2010 2.500 2.195 2.000 MM (R$/US$) 1.500 1.000 500 0 657 424 304 328 270 178 120 145 65 76 104 107 7 11 16 26 51 52 1.552 1.033 804 474 99 111 1.456 1.221 1.023 717 538 185 133 72 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Gross Revenues - R$ Gross Revenues - US$ Export - R$ 2000 to 2006: R$ US$ = AVG EACH YEAR - 2007 to 2010: R$ US$ = AVG EACH MONTH 10
DEDINI'S LATEST GENERATION TECHNOLOGIES!!! APRESENTAÇÃO: THE DEDINI TRADITIONAL S/A INDÚSTRIAS MILL DE BASE DEDINI'S LATEST GENERATION TECHNOLOGIES DEDINI IN BIOENERGY DSM DEDINI SUSTAINABLE MILL: THE 6 BIOS REVOLUTION 11
DEDINI IN BIOENERGY THE TRADITIONAL MILL DEDINI'S LATEST GENERATION TECHNOLOGIES DSM DEDINI SUSTAINABLE MILL: THE 6 BIOS REVOLUTION 12
TRADITIONAL TECHNOLOGY AND PRODUCTION PROCESS: SUGAR AND SURPLUS ENERGY PRODUCTION FLOWCHART SUGAR AND SURPLUS BAGASSE CANE RECEPTION/ CLEANING/ PREPARATION EXTRACTION JUICE SUGAR PROCESS SUGAR MOLASSES B A G A S S E STEAM GENERATION (BOILER) SURPLUS BAGASSE PRODUCT FLOW ELECTRICITY GENERATION (TURBOGENERATOR) HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE) 13
TRADITIONAL TECHNOLOGY AND PRODUCTION PROCESS: SUGAR, SUGAR BIOETHANOL AND SURPLUS AND SURPLUS ENERGY ENERGY PRODUCTION PRODUCTION FLOWCHART FLOWCHART SUGAR, SUGAR BIOETHANOL AND SURPLUS AND SURPLUS BAGASSE BAGASSE CANE RECEPTION/ CLEANING/ PREPARATION EXTRACTION B A G A S S E JUICE J U I C E SUGAR PROCESS MOLASSES BIOETHANOL PROCESS SUGAR BIOETHANOL STILLAGE STEAM GENERATION (BOILER) SURPLUS BAGASSE BAGASSE PRODUCT FLOW ELECTRICITY GENERATION (TURBOGENERATOR) HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE) 14
TRADITIONAL TECHNOLOGY AND PRODUCTION PROCESS: SUGAR, BIOETHANOL AND AND SURPLUS SURPLUS ENERGY ENERGY PRODUCTION FLOWCHART SUGAR, BIOETHANOL AND SURPLUS BAGASSE ELECTRICITY CANE RECEPTION/ CLEANING/ PREPARATION EXTRACTION B A G A S S E JUICE J U I C E SUGAR PROCESS MOLASSES BIOETHANOL PROCESS SUGAR BIOETHANOL STILLAGE STEAM GENERATION (BOILER) SURPLUS BAGASSE BAGASSE PRODUCT FLOW ELECTRICITY GENERATION (TURBOGENERATOR) HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE) 15
TRADITIONAL TECHNOLOGY AND PRODUCTION PROCESS: SUGAR, BIOETHANOL AND SURPLUS ENERGY PRODUCTION FLOWCHART SUGAR, BIOETHANOL AND SURPLUS BIOELECTRICITY CANE RECEPTION/ CLEANING/ PREPARATION EXTRACTION B A G A S S E JUICE J U I C E SUGAR PROCESS BIOETHANOL PROCESS MOLASSES SUGAR BIOETHANOL STILLAGE STEAM GENERATION (BOILER) SURPLUS BAGASSE PRODUCT FLOW ELECTRICITY GENERATION (TURBOGENERATION) BIOELECTRICITY HIGH PRESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE) 16
DEDINI IN BIOENERGY THE TRADITIONAL MILL DEDINI'S LATEST GENERATION TECHNOLOGIES DSM DEDINI SUSTAINABLE MILL: THE 6 BIOS REVOLUTION 17
Sugar & Bioethanol & Bioelectricity Since 1920 18
TECHNOLOGIES FOR MAXIMUM BIOSUGAR AND BIOETHANOL PRODUCTION LATEST GENERATION TECHNOLOGIES CANE RECEPTION/ CLEANING/ SEPARATION PREPARAT. EXTRACTION B A G A S S E JUICE J U I C E SUGAR PROCESS BIOETHANOL PROCESS MOLASSES SUGAR BIOETHANOL STILLAGE STEAM GENERATION (BOILER) SURPLUS BAGASSE PRODUCT FLOW ELECTRICITY GENERATION (TURBOGENERATOR) HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE) 19
Technologies for Maximum Biosugar and Bioethanol Production Dedini s Latest Generation Technologies 1. Dry cleaning replacing cane wash 2. High performance MCD Dedini milling tandem or Dedini-Bosch Modular Diffuser 3. To eliminate sugar entrainment and degradation in evaporators 4. Ecoferm Dedini-Fermentec Fermentation System with higher ethanol content and with Ecochill (absorption chiller) 5. Destiltech Distillation system with minimum ethanol losses in stillage 6. DRD Dedini Refinado Direto (Dedini Direct Refined) 7. DAP Dedini Automação de Processos Automation using intelligent software up to MES Level Manufacturing Execution System 8. Process sweet sorghum at the sugarcane mill Technological Partner Patent Application Dedini Patent Application 20
MAXIMUM SUGAR/BIOETHANOL PRODUCTION OPTIMIZED TRADITIONAL PROCESS JUICE EXTRACTION MAXIMUM EXTRACTION YIELD 23 SEPT, 2005 DEDINI MCD-01 1 st MILLING UNIT 56 x100 (1.422 x 2.540 mm) ASSEMBLED 6 MILLING TANDEM 56 x100 AT U.S. SUGAR ELECTRO-HYDRAULIC DRIVE 2006 U.S.SUGAR - BIGGEST CRUSHING CAPACITY IN THE WORLD IN A SINGLE MILLING TANDEM: 28.000 TCD 97% EXTRACTION - HIGH PERFORMANCE 21
MAXIMUM SUGAR/BIOETHANOL PRODUCTION OPTIMIZED TRADITIONAL PROCESS JUICE EXTRACTION MAXIMIZE EXTRACTION YIELD DEDINI-BOSCH MODULAR CHAINLESS DIFFUSER EXPANDABLE NO CHAINS LOWER MAINTENANCE LIGHTER SOLUTION 98% EXTRACTION HIGH PERFORMANCE THE 1 st IN OPERATION IN BRAZIL AND THE 1 st COMMERCIAL IN THE WORLD SEPTEMBER/08 NOROESTE MILL 12.000 TCD ( 15.000 TCD) 22
MAXIMUM SUGAR/BIOETHANOL PRODUCTION OPTIMIZED TRADITIONAL PROCESS JUICE EVAPORATION MINIMUM SUGAR LOSSES BY ENTRAINMENT AND DEGRADATION DEDINI FALLING FILM EVAPORATOR SYSTEM WITH ENTRAINER TRAP 23
MAXIMUM BIOETHANOL PRODUCTION OPTIMIZED TRADITIONAL PROCESS FERMENTATION MAXIMUM FERMENTATION YIELD ECOFERM DEDINI-FERMENTEC FERMENTATION SYSTEM WITH HIGHER ETHANOL CONTENT BATCH / CONTINUOUS - BIOREACTORS CONCEPT + COLD WATER FLOW UTILIZATION AT THE MILL INTEGRATING THERMAX CHILLER AND TEMPERATURE CONTROL AT FERMENTATION HIGHER YIELD, LOWER STILLAGE VOLUME, LOWER CONSUMPTION AND ENERGY OPTIMIZATION 24 LIGHT SYRUP MASH 30ºC 15,5ºGL - 4,8 L STILLAGE/L BIOETH. (USING REBOILER)
MAXIMUM SUGAR PRODUCTION OPTIMIZED TRADITIONAL PROCESS REFINED SUGAR PROCESS MINIMUM SUGAR LOSSES TRADITIONAL PROCESS CANE DRD PROCESS CANE REFINERY SUGAR MILL RECEPTION, PREPARATION, EXTRACTION SULFITATION LIMING HEATING CLARIFYING SCREENING/ FILTRATION EVAPORATION FLOTATION BOILING CRYSTALLIZATION CENTRIFUGATION DRYING/ SACKING DISSOLUTION FLOTATION FILTERING DECOLORATION BY ION EXCHANGE BOILING/ CRYSTALLIZ./ CENTRIFUG. DRYING/ PACKING/ SACKING DIRECT REFINED AT SUGAR MILL RECEPTION, PREPARATION, EXTRACTION SULFITATION DOSING OF SACHARATE HEATING CLARIFYING FILTRATION OF CLARIFIED JUICE EVAPORATION FLOTATION SYRUP FILTERING DECOLORATION BY ION EXCHANGE BOILING/ CRYSTALLIZ./ CENTRIFUG. DRYING/ PACKING/ SACKING DEDINI IMPROVEMENTS/ NEW PROCESSES REFINED (LOSSES 3 TO 5%) DIRECT REFINED (COLOR < 45 ICUMSA) (LOSSES 1 TO 2%) DRD PROCESS MINIMUM INVESTIMENT/ COST HIGHER VALUE ADDED ENERGY CONSUMPTION: 37% LESS ELECTRICITY, 50% LESS STEAM 25
Processing Sweet Sorghum at the Sugarcane Mill will increase the crop duration and bioethanol/bioelectricity production Center-South Nov Dec Jan Feb Sweet Sorghum harvesting Oct Mar 70 s crop duration: 6 months Sep Apr Today: 9 months Extended Crop with sorghum: 11 months Aug Jul Jun May 26
BIOSUGAR, BIOETHANOL AND BIOELECTRICITY MILL TECHNOLOGIES FOR MAXIMUM SURPLUS BIOELECTRICITY PRODUCTION LATEST GENERATION TECHNOLOGIES CANE RECEPTION/ CLEANING PREPARAT. EXTRACTION B A G A S S E JUICE J U I C E SUGAR PROCESS MOLASSES BIOETHANOL PROCESS SUGAR BIOETHANOL STILLAGE STEAM GENERATION (BOILER) SURPLUS BAGASSE PRODUCT FLOW ELECTRICITY GENERATION (TURBOGENERATION) BIOELECTRICITY HIGH PRESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE) 27
BIOSUGAR, BIOETHANOL AND BIOELECTRICITY MILL TECHNOLOGIES FOR MAXIMUM SURPLUS BIOELECTRICITY PRODUCTION LATEST GENERATION TECHNOLOGIES CANE STRAW STRAW RECEPTION/ CLEANING SEPARATION STRAW PROCESS PREPARAT. EXTRACTION B A G A S S E JUICE J U I C E SUGAR PROCESS MOLASSES BIOETHANOL PROCESS SUGAR BIOETHANOL STILLAGE ANAEROBIC BIODIGESTION BIODIGESTED STILLAGE STEAM GENERATION (BOILER) BIOGAS PRODUCT FLOW ELECTRICITY GENERATION (TURBOGENERATION) SURPLUS BIOELECTRICITY BIOELECTRICITY HIGH PRESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE) 28
1. Electric Drive to Knives/Shredder 2. Electric-Hydraulic Drive / Electro-Mechanical Drive via planetary gearbox to milling units or Dedini-Bosch Modular Diffuser 3. Multi-effect Falling Film Evaporation System 4. Regenerative Heat Exchangers Technologies for Maximum Surplus Energy Production Dedini s Latest Generation Technologies 5. Ecoferm Dedini-Fermentec Fermentation System with higher ethanol content and with Ecochill (absorption chiller) 6. Dedini-Siemens Split Feed Distillation 7. Dedini-Vaperma Membrane Dehydration System 8. Dedini-Bosch Continuous Vacuum Pan 9. DRD Dedini Refinado Direto (Dedini Direct Refined) 10. DCV Dedini Stillage Concentration System, Dedini-Benchmark partnership 11. Maximum surplus bagasse utilization as boiler fuel (except re-start) 12. System and equipment for straw utilization as boiler fuel 13. Methax Stillage Anaerobic Biodigestion System producing biogas/biomethane 14. Dedini AT Single Drum Multifuel Boilers high: pressure/ temperature/ energy efficiency 15. Condensation turbine with multi-stage extraction control 16. Process sweet sorghum at sugarcane mill 17. DAP Dedini Automação de Processos Automation using intelligent software up to MES Level Manufacturing Execution System Maximum available energy utilization Technological Partner Patent Application Minimum energy consumption Dedini Patent Application 29
MAXIMUM SURPLUS ENERGY PRODUCTION SUGAR PROCESS MINIMUM ENERGY CONSUMPTION JUICE TREATMENT AND CONCENTRATION MULTIPLE EFFECT FALLING FILM EVAPORATION SYSTEM DEDINI-BOSCH CONTINUOUS VACUUM PAN REGENERATIVE HEAT EXCHANGER DEDINI FALLING FILM EVAPORATOR 30
MAXIMUM SURPLUS ENERGY PRODUCTION BIOETHANOL PROCESS MINIMUM ENERGY CONSUMPTION DEDINI JUICE TREATMENT AND CONCENTRATION MULTIPLE EFFECT FALLING FILM EVAPORATION SYSTEM ECOFERM DEDINI-FERMENTEC FERMENTATION SYSTEM REGENERATIVE HEAT EXCHANGER DEDINI OPTIMIZED FERMENTATION & DISTILLATION 31
MAXIMUM SURPLUS ENERGY PRODUCTION STILLAGE CONCENTRATION MINIMUM ENERGY CONSUMPTION RAÍZEN COSTA PINTO MILL 1 ST BRAZILIAN STILLAGE CONCENTRATION PLANT WITH ENERGY INTEGRATION TO DISTILLERY UP TO 25 BRIX: EVAPORATION INTEGRATED TO THE MILL/DISTILLATION WITH NO ADDITIONAL STEAM CONSUMPTION UP TO 65 BRIX: EVAPORATION PARTIALLY INTEGRATED WITH MINIMUM STEAM CONSUMPTION ECOFERM + DCV UP TO 65 BRIX WITHOUT ADDITIONAL STEAM CONSUMPTION DCV DEDINI CONCENTRAÇÃO DE VINHAÇA (DEDINI STILLAGE CONCENTRATION SYSTEM), DEDINI-BENCHMARK PARTNERSHIP 32
MAXIMUM SURPLUS ENERGY PRODUCTION MAXIMUM AVAILABLE ENERGY UTILIZATION: BAGASSE, BIOGAS, STRAW OPTIMIZE THE MILL TO MAXIMUM SURPLUS BAGASSE AND 100% (EXCEPT RE-START) BAGASSE UTILIZATION AS A BOILER FUEL BIOGAS/BIOMETHANE UTILIZATION AS A BOILER FUEL STRAW UTILIZATION AS A BOILER FUEL DEDINI TECHNOLOGIES TO ENERGY OPTIMIZATION 33
MAXIMUM SURPLUS ENERGY PRODUCTION MAXIMUM AVAILABLE ENERGY UTILIZATION STRAW PROCESS Integral (billets + straw) Cane Harvesting Integral Cane Unloading in a Cane Feed Table Straw Separation and Dry Cleaning System Dedini s Rotary Screen with Discharge Bin completing Cleaning Dedini Boiler Straw Chopping Straw Conveyor TRADITIONAL SYSTEM AND EQUIPMENT FOR STRAW UTILIZATION AS A FUEL, SUCH AS: INTEGRAL SUGARCANE CLEANING SYSTEM AND STRAW SEPARATION, HANDLING SYSTEM, STRAW CLEANING AND SAND SEPARATION, CHOPPING AND BOILER FEEDING. STRAW PROCESS 34
MAXIMUM SURPLUS ENERGY PRODUCTION MAXIMUM AVAILABLE ENERGY UTILIZATION STEAM PRODUCTION DEDINI MULTIFUEL BOILER BAGASSE, STRAW AND BIOGAS UTILIZATION AS FUELS UP TO 400 TS/H 120 BAR 540 C 89% POWER EFFICIENCY (LHV) DEDINI AT TM SINGLE DRUM BOILER 2X320 TS/H 100 BAR - 530 C RAÍZEN BARRA MILL 35
DEDINI S CONTRIBUTION TO SUGARCANE INDUSTRY RESULTS OF INDUSTRIAL TECHNOLOGICAL EVOLUTION IN THE SUGAR & BIOETHANOL SECTOR 2011 Beginning PROALCOHOL Today State of the Art Crushing Capacity (Tcd) - 6x78 Vert. Shredder/ Milling Tandem 5.500 15.000 Fermentation Time (H) Batch/Cont. Ferm. 24 6-8 Beer Ethanol Content ( O GL) Ecoferm 6,5 Up to 16 Extraction Yield (%Sugar) - 6 Mill Units Milling Tandem/ Modular Diffuser 93 97/ 98 Fermentation Yield (%) Ecoferm 80 92 Distillation Yield (%) Destiltech 98 99.5 Total Yield (Liter Hydr. Bioeth./Ton Cane) DEDINI Technology 66 87 Total Steam Consump. (Kg Steam/T Cane) DEDINI Technology 600 320 Steam Consump. - Anhydr. (Kg S/Liter) Split Feed+ Membrane/Mol. Sieve 4,5 2,0 Boiler Efficiency (% LHV) Pressure (Bar) / Temperature (ºC) DEDINI PRODUCTS AZ/ AT/ Single Drum/ Fluidized Bed 66 89 21 / 300 120/ 540 Surplus Bagasse (%) - Bioethanol Mill DEDINI Technology Up to 8 Up to 78 Surplus Bioelectricity to the Grid, Bioethanol Mill, 12.000 TCD (MW) DEDINI Technology - Biomethane from Stillage (Nm 3 /L Bioethanol) Methax - 0.1 Stillage Production (L Stillage/L Bioethanol) Ecoferm/ DCV 13 5.0/ 0,8 Intake Water Consumption (L Water/L Bioeth.) Water Mill 262,5 (-) 3,7 50,7 36
DEDINI S CONTRIBUTION TO THE SUGARCANE INDUSTRY DEDINI S NUMBERS SUGAR AND ETHANOL BIOETHANOL SUPPLIES - BIOETHANOL DISTILLERIES 869 - COMPLETE BIOETHANOL MILLS (TURN KEY) - BRAZIL 108 ETHANOL/SUGAR PLANTS ABROAD: VENEZUELA/ECUADOR/URUGUAY/MEXICO/HAITI/PAKISTAN/ETHIOPIA/GUATEMALA ARGENTINA/PERU/COSTA RICA/PARAGUAY/VIRGIN ISLAND/BOLIVIA/JAMAICA/SUDAN 29 CRUSHING MILLS BOILERS COGENERATION PLANTS (TK) 2 618 1 255 114 DECEMBER/11 WORLD S GREATEST SALES VOLUME DEC/2007 37
DEDINI IN BIOENERGY THE TRADITIONAL MILL DEDINI'S LATEST GENERATION TECHNOLOGIES DSM DEDINI SUSTAINABLE MILL: THE 6 BIOS REVOLUTION 38
1 T CLEAN SUGARCANE 1,2 T INTEGRAL SUGARCANE SUGARCANE THE AGRIENERGY VIEW SUGARCANE ENERGY FOCUSED VISION ~ = 1,2 OIL BARRELS 1 T-FIELD 1718 x 10 3 KCAL JUICE TOTAL SUGAR 153 KG BAGASSE (50% MOISTURE) 276 KG STRAW (*) (15% MOISTURE) 165 KG 608 x 10 3 KCAL 598 x 10 3 KCAL 512 x 10 3 KCAL 1718 x 10 3 KCAL 1 OIL BARREL 1386 x 10 3 KCAL SEASON 2010/11 SUGAR CANE IS PURE ENERGY 1/3 FROM SUGAR JUICE 1/3 FROM BAGASSE 1/3 FROM STRAW (*) CANE TRASH, i.e., STRAW = TOPS, LEAVES, STRAW SUGAR: THE CHEAPEST FOOD (IN KCAL) IN THE WORLD BIOETHANOL: CLEAN AND RENEWABLE ENERGY CLEAN AND RENEWABLE ENERGY CLEAN AND RENEWABLE ENERGY TOTAL 722.000 b/d 722.000 b/d 722.000 b/d 2.166.000 b/d ENERGY EQUIVALENCE 39
SUGARCANE THE AGRIENERGY VIEW CRUDE OIL PRODUCED IN BRAZIL ENERGY DAILY AVERAGE BRAZILIAN SUGARCANE ENERGY DAILY AVERAGE OIL BARREL EQUIVALENT 2000 1.000 energy equivalent oil barrels/day 1792 1670 2003 2166 1600 1493 1335 1311 1200 800 400 0 SOURCE: ANP, DATAGRO 995 2001 2004 2007 2010 (*) DEDINI FORECAST CRUDE OIL 3.000.000 oil barrels/day 6,4 x 10 15 CANE kj/d 2016/17 * SEASON/YEAR 40
SUGARCANE THE AGRIENERGY VIEW BRAZILIAN SUGARCANE - TOTAL ENERGY CONTENT SUGARCANE ENERGY VIEW COMPARATIVE - 2010 4,00 1.000 energy equivalent oil barrels/day 3,50 3,00 2,50 2,00 2,65 82% 1,80 120% 2,17 110% 1,98 1,50 1,00 0,50 0,00 GERMANY UNITED KINGDOM BRAZIL FRANCE SOURCE: Dedini s Projections from EIA SUGARCANE TOTAL CRUDE OIL/DERIVATIVES CONSUMPTION 41
DEDINI S NEW VISION ON SUGARCANE INDUSTRY TECHNOLOGICAL EVOLUTION WILL BE FOCUSED ON MAXIMUM UTILIZATION OF SUGARCANE HIGH IMPACT UPCOMING TECHNOLOGIES DERIVED FROM AN ENERGY FOCUSED VISION SEVERAL NEW DEVELOPMENTS ARE ON TRACK 3 OUTSTANDING UPCOMING TECHNOLOGIES ARE SELECTED DUE TO THE REVOLUTIONARY IMPACT FOR THE SECTOR BIOELECTRICITY PRODUCTION WITH MAXIMUM ENERGY UTILIZATION OF SUGAR CANE: - BAGASSE - STRAW (1) - CO-PRODUCTS (STILLAGE) 1 st Generation 50,7 Mw (2) Bagasse estado State of da the arte Art 2 nd Generation 112,1 Mw (2) Bagasse + 100% Straw (3) 3 rd Generation 150 Mw (2) Gasific./ Comb. Cycle 1 st Generation 7 184 (4) l eth./ha from the juice BIOETHANOL PRODUCTION FROM BAGASSE AND STRAW 2 nd Generation 12 824 (5) l eth./ha Juice(+) Bagasse/ Straw Hydrolysis 3 rd Generation >12 824 (6) Juice (+) Thermo- Chemical Technol. -BTL- BIODIESEL/ BIOPRODUCTS PRODUCTION INTEGRATED IN A SUGAR AND BIOETHANOL MILL Biodiesel RM (7) : Vegetable Oil/ Animal fat Biodiesel/ Bioproducts RM (7) : Juice/ Bagasse/ Straw (1) STRAW = TOPS, LEAVES, STRAW 1/3 OF SUGARCANE S ENERGY (3) BAGASSE + 50% STRAW = 83,9 MW (4) 80 TC/HA x 89,8 L ETH/TC (5) 80 TC/HA x (89,8 L ETH/TC + 70,5 L ETH. HYDROL. /TC) (6) 80 TC/HA x (89,8 L ETH/TC + > 70,5 L BIOSYNFUELS /TC) (2) ETHANOL MILL = 500 T CANE/HOUR = 12.000 T C/DAY 2 MM T C/CROP (7) RM: RAW MATERIAL 42
43 43 State of the Art Bioethanol, Bioelectricity, Biodiesel Dedini s 3 BIOs Mill
The Complete 3 Bios Mill is also a Dedini product 44
Dedini s State of the Art Mill is a product in continuous development 45
BIOETHANOL + BIOELECTRICITY BIODIESEL INTEGRATION FIRST GENERATION 4 BIOS MILL Barralcool Mill Biodiesel Plant integrated to Barralcool Mill BIOETHANOL BIOENERGY Sugarcane Farm/ Refurbished Area BIODIESEL - USED AT THE FARM BIODIESEL SOLD TO THE MARKET SOYA OIL DEDINI: INTRODUCTION OF THE CONCEPT TO THE WORLD MARKET AND FIRST WORLD SUPPLY/ 1 st WORLD CONTINUOUS ETHYLIC PROCESS PLANT BARRALCOOL MILL: 1 st MILL IN THE WORLD PRODUCING THE 3 BIOs: BIOETHANOL, BIOELECTRICITY AND BIODIESEL, PLUS BIOSUGAR = 4 BIOs MILL 46
INAUGURATION: 21/NOV/ 2006 BRAZILIAN PRESIDENT LULA MATO GROSSO GOVERNOR MAGGI BARRALCOL PRESIDENT J. PETRONI 47
FACTORY DESIGN CUSTOMIZED ACCORDING TO THE INVESTOR OBJECTIVE DEDINI S SUGARCANE MILL IS A BIG MACHINE THAT TRANSFORMS SUGARCANE INTO THE DESIRED PRODUCTS MAXIMUM BIOETHANOL PRODUCTION MILL MAXIMUM SUGAR PRODUCTION MILL FLEXIBLE MAXIMUM SUGAR/ BIOETHANOL MILL MAXIMUM ENERGY PRODUCTION MILL 3 BIOS MILL DSM DEDINI SUSTAINABLE MILL MILL ACCORDING TO CLIENT DECISION 48
DSM - DEDINI SUSTAINABLE MILL ECONOMIC DSM is competitive in a free market, without subsidies ENVIRONMENTAL DSM solutions includes not to waste (also minimizing consumption), not to commit, not to pollute the environment and the natural resources, mainly air, water, energy, materials/raw materials, biodiversity, and generates minimum or zero emissions, effluents, residues, and odors. DSM attends the standards and regulations, reducing/ eliminating environmental impacts, and contributes to agricultural sustainability DSM contributes and makes it easier the management system ISO 14000 SOCIAL In DSM, the equipment, processes, materials, installations need to be located, to move, to operate, attending the standards and regulations, promoting and providing comfort, hygiene, safety and good health conditions The operator applies minimum physical effort considering ergonomic concepts providing a correct man-machine interaction DSM uses automation through integrated and intelligent software, MES level, linked and integrated to ERP System DSM contributes and makes it easier the management system SA-8000 49
DSM Dedini Sustainable Mill The Future available today Optimization Concept Maximum Biosugar Maximum Bioethanol Maximum Bielectricity Integrated Biodiesel Zero Concept Zero residues Zero liquid effluents Zero odors Zero intake water Minimal emissions GHG (1) EMISSIONS Kg CO 2 /L GHG REDUCTION (2) ETH. EQUIV. (3) MITIG. (4) TRADITIONAL MILL 2,02 89% DSM STATE OF THE ART 2,56 112% DSM NEAR FUTURE (5) 3,02 132% DSM POTENTIAL >5,00 219% (1) GHG - Greenhouse gases (2) Life cycle analysis (3) CO2 emissions avoided using ethanol (4) MITIG. - Mitigation = % CO2 avoided emissions by using ethanol replacing gasoline in vehicles (5) 50% straw utilization to produce bioelectricity 50
Technologies for Maximum Biosugar and Bioethanol Production Dedini s Latest Generation Technologies = for GHG reduction 1. Dry cleaning replacing cane wash 2. High performance MCD Dedini milling tandem or Dedini-Bosch Modular Diffuser 3. To eliminate sugar entrainment and degradation in evaporators 4. Ecoferm Dedini-Fermentec Fermentation System with higher ethanol content and with Ecochill (absorption chiller) 5. Destiltech Distillation system with minimum ethanol losses in stillage 6. DRD Dedini Refinado Direto (Dedini Direct Refined) 7. DAP Dedini Automação de Processos Automation using intelligent software up to MES Level Manufacturing Execution System 8. Process sweet sorghum at the sugarcane mill Technological Partner Patent Application Dedini Patent Application 51
Technologies for Maximum Surplus Energy Production Dedini s Latest Generation Technologies = for GHG reduction 1. Electric Drive to Knives/Shredder 2. Electric-Hydraulic Drive / Electro-Mechanical Drive via planetary gearbox to milling units or Dedini-Bosch Modular Diffuser 3. Multi-effect Falling Film Evaporation System 4. Regenerative Heat Exchangers 5. Ecoferm Dedini-Fermentec Fermentation System with higher ethanol content and with Ecochill (absorption chiller) 6. Dedini-Siemens Split Feed Distillation 7. Dedini-Vaperma Membrane Dehydration System 8. Dedini-Bosch Continuous Vacuum Pan 9. DRD Dedini Refinado Direto (Dedini Direct Refined) 10. DCV Dedini Stillage Concentration System, Dedini-Benchmark partnership 11. Maximum surplus bagasse utilization as boiler fuel (except re-start) 12. System and equipment for straw utilization as boiler fuel 13. Methax Stillage Anaerobic Biodigestion System producing biogas/biomethane 14. Dedini AT Single Drum Multifuel Boilers high: pressure/ temperature/ energy efficiency 15. Condensation turbine with multi-stage extraction control 16. Process sweet sorghum at sugarcane mill 17. DAP Dedini Automação de Processos Automation using intelligent software up to MES Level Manufacturing Execution System Maximum available energy utilization Technological Partner Patent Application Minimum energy consumption Dedini Patent Application 52
Complementary Industrial Technologies for GHG reduction in agricultural activities 1. Biodiesel production integrated to the Sugarcane Mill 2. Water Producing Mill 3. BIOFOM Organomineral Biofertilizer 4. Straw utilization avoiding cane burning before harvesting Technological Partner Patent Application Dedini Patent Application 53
HIGHER ENVIRONMENTAL SUSTAINABILITY INFLUENCE IN SUGARCANE MILLS DESIGN FOCUS: WATER CONSUMPTION NEW FACTORY DESIGN THE WATER SELF SUFFICIENT MILL a Recover steam losses, condensate and reutilize the water b Change wet for dry processes c Use concentrated instead of diluted flows (high gravity processes)-ecoferm LOSSES Evaporation: 1052,00 Bagasse: 130,21 Drain Cane Wash: 694,52 Others: 42,84 1919,57 b a CANE: 700 2.530 INTAKE: 1.830 23 KG/L ETH Sugar and Sugar and Bioethanol Bioethanol Mill Mill Zero Typical Intake Brazilian Water Mill Mill TM SUGAR: 0,03 ETHANOL: 0,26 STILLAGE: 540,14 CAKE: 40,00 610,43 c Water Balance when processing 1 ton of cane kg H 2 O/tc 54
HIGHER ENVIRONMENTAL SUSTAINABILITY INFLUENCE IN SUGARCANE MILLS DESIGN FOCUS: WATER CONSUMPTION OPTIMAL SUGARCANE MILL DESIGN THE BIOWATER MILL TM THE WATER EXPORTER MILL AND ORGANO-MINERAL BIOFERTILIZER (BIOFOM TM ) PRODUCER MILL d EXPORT: 290,71 3,7 KG/L ETH. Concentrate and recover water from stillage DCv / Ecoferm+DCv CANE: 700 700 LOSSES Sugar and Bioethanol Mill Sugar and Bioethanol BIOFOM TM Mill + BIOWATER TM Zero Intake Water Mill TM Biowater Mill TM Evaporation 136,00 Bagasse 130,21 Drain Cane Wash: 0 Others 102,50 368,71 SUGAR: 0,03 ETHANOL: 0,26 STILLAGE: 291,00 CAKE: 40,00 ASH+SOOT d 4,66 331,29 COMPLEMENTARY NUTRIENTS Water Balance when processing 1 ton of cane kg H 2 O/tc BIOFOM Organo-Mineral Biofertilizer (Concentrated Stillage, Filter Cake, Boiler Ashes/Soot + Complementary Nutrients if necessary) 55
BIOFOM ORGANO MINERAL BIOFERTILIZER BIOFOM composition Soot + Ash Concentrated Stillage Filter Cake COMPLEMENTARY NUTRIENTS BIOFOM is customized, that means, formulated according to the soil and sugarcane specific needs 56
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 57
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DEDINI S/A INDÚSTRIAS 2010 ACHIEVEMENTS DE BASE ISSCT CONGRESS MEXICO MARCH / 2010 DSM during Plenary Section Presentation For the first time an equipment manufacturer was invited to deliver a presentation at Plenary Section 62
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To download this presentation use the link www.dedini.com.br/dedinitechnology.zip 66