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Electo Eduardo Silva Lora, Mateus Henrique Rocha, Jos Carlos Escobar Palacio, Osvaldo Jos Venturini, Maria Luiza Grillo Ren and Oscar Almazn del Olmo

The sugar and alcohol industry in the biofuels and cogeneration era: a paradigm change (part II)*
Die Zucker- und Alkoholindustrie im Zeitalter der Biokraftstoffe und Kraft-Wrme-Kopplung: ein Paradigmenwechsel (Teil II)

10

Animal feed production

Another way to use vinasse is the production, by means of biotechnology, of a protein concentrate, which can be used as fodder. This approach provides a great opportunity to solve the dilemma of food versus biofuels. Vinasse contains carbon compounds and nitrogen assimilable by the microorganisms and therefore could be used for production of microbial biomass. This biomass could be used as a protein supplement, called Single Cell Protein (SCP) for animal feed. Vinasse oers the added advantage that it is relatively free of toxins and fermentation inhibitors. SCP is normally considered to be a valuable source of protein but it also contains nucleic acids, carbohydrates, cell wall material, lipids, minerals and vitamins (Silva et al., 2011). First laboratory studies about the utilisation of vinasse for the propagation of microbial biomass can be traced back to the late 1960s. The reduction of organic load and at the same time the production of valuable protein is the best feature of this process. Vinasse being an environmental threat could become a precious advantage, when to be a source of energy and carbon for the biosynthesis of microbial biomass by the aerobic propagation of yeast cells (Otero et al., 2007). Optimal conditions for SCP production and COD reduction of vinasse have been specied for dierent species of microorganisms in continuous cultures. Under these conditions the COD reduction levels ranges from 40 to 70% (Silva et al., 2011; Shojaosadati et al., 1999; Nudel et al., 1987). Although the use of vinasse as culture media not only increases the production of a rich protein biomass and also reduce the COD of the wastes, its application will always depends on the evaluation of its economic feasibility. So, the most appropriate way will be to combine the alternative of protein biosynthesis with fertirrigation. Biogas from vinasse biodigestion could be used for yeast drying. To give an idea of the numbers involved, an ethanol distillery with a capacity of 200,000 L/d will give enough vinasse for the operation of a protein synthesis installation of 50 t/d of a pro-

tein concentrate of 92% dry matter, 45% crude protein. In an average distillery, 4.06.0 kg of yeast per each 100 L of ethanol (100%) can be recuperated (de Souza et al., 2012). Vinasse yeast has a protein content of 45% and cattle feeding grass have a protein content of 610%. The yeast SCP can partially substitute a fraction of the grass in the feed of cattle grazing on pasture and thereby potentially release land (land substitution) for increased sugarcane production, with minimal land use change eects. It is possible to state that a positive land release is the resulting advantage of the use of the vinasse for SCP production. The production of SCP for animal feeding, from the waste vinasses, in a factory of a capacity of 22 t/d, it is equivalent to 1800 ha of land devoted to pasture; if this area is devoted to sugarcane cultivation it will give 144,000 t of sugarcane per year, considering the mean yield of crop in Brazil of 80 t of cane/ha. A conservative approach indicates that the land for cattle grazing in Brazil could be reduced by 50% by SCP production in the alcohol distillers (de Souza et al., 2012).

11

Process integration

The production of co-products should be combined, when possible, with the sugar production through integrated technological schemes, linked together from the technological point of view, energy and services/utilities (Escobar et al., 2011). Escobar (2010) conducted an integrated assessment of a cogeneration plant and a distillery in an autonomous distillery using Aspen Plus and Gate-Cycle softwares. The study involved the simultaneous evaluation of the inuence of various steam parameters of the cogeneration plant, dierent types of mill drives and changes in the ethanol production technology over the plant performance measured through overall eciency indicator. Figures 9(a) and 9(b) show the processes integra-

* Continued from Sugar Industry 139 (2014), pp. 2836

Paper presented at the XXVIII Congress of the International Society of Sugar Cane Technologists, Sao Paulo, Brazil, 2427 June 2013 and published here with the agreement of the Society.
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Technology/Technologie tion schemes in an alcohol distillery and Tables 3 and 4 summarise the evaluated scenarios. A few alternatives were evaluated for each scenario. For example C6: DF-MST-AD means 4.2 MPa and 300 C as steam parameters, an extraction with diusers (DF), multiple stage steam turbines (MST) and atmospheric ethanol distillation (AD). The income from the sale of surplus electricity for steam parameters of 4.2 MPa and 420 C and dierent technologies used in the ethanol production was determined. Assuming USD68.00/ MWh as sales price for the surplus electricity the income generated from the sale of ethanol at a price of USD0.30/L is USD30.95/t cane on average (Fig. 10). Atmospheric ethanol distillation (AD) and multi-pressure distillation processes (MD) are considered as two different scenarios referred to the reduction of the steam consumption in the plant. Figure 11 shows the overall exergetic eciency for the dierent evaluated scenarios of the distillery. It is possible to note that the use of systems based on MST combined with a MD system (scenario C8) gives increments of 2% in the overall eciency of the plant in relation to the base case. Implementation of mills driven by a commercial available electric motors (EM) equipped with an AD and MD systems allows increases in the overall eciency of 0.3 and 1.4%, respectively. When technological alternatives such as DF-MST-AD and DF-EM-AD are considered the increase in the eciency is 1%. The overall eciency could be increased by 3% through the use of the DF-MSTMD and DF-EM-MD systems of the scenario C8 in relation to the base case. It is possible to note that the use of systems based on MST-MD (scenario C9) gives increments of 2% in the overall eciency of the plant in relation to the base case. When the technological alternative EM-AD is used the increase in the overall eciency is 0.3%. The overall eciency could be increased by 2% through the use of the EM-MD system, 1.5% for the use of the technological alternative DF-MST-AD, 3% for DFMST-MD technological alternative, 2% for DF-EM-AD and 3% for DF-EM-MD technological alternative system of the scenario C9 in relation to the base case. In relation to the technological alterna-

Fig. 9a: Process integration scheme in an alcohol distillery cogeneration plant

Fig. 9b: Process integration scheme in an alcohol distillery distillery

Fig. 10: Specic income of technological alternatives considered in scenery C6

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Table 3: Analysed scenarios C1C5 (Escobar, 2010) Equipment and parameters C1* C2 C3 Boiler 2.0 MPa, 300 C 4.2 MPa, 420 C 6.0 MPa, 490 C 8.0 MPa, 510 C 12.0 MPa, 520 C Electric generators Backpressure turbines Condensing-extraction steam turbines (CEST) Mills Single stage turbine (SST) Multistage turbines (MST) Evaporation Multiple eects evaporator (MEE) Distillation Atmospheric distillation (AD) * Base case

99

C4

C5

Table 4: Analysed scenarios C6C9 (Escobar, 2010) Equipment and parameters C6 C7 Boiler 4.2 MPa, 300 C CEST 6.5 MPa, 490 C CEST 8.0 MPa, 510 C CEST 12.0 MPa, 520 C CEST Electric generators Backpressure turbines Condensing-extraction steam turbines (CEST) Mills Multistage turbines (MST) a Electric motor (EM) Diuser multistage turbines (DF-MST) Diuser electric motors (DF-EM) Evaporation Multiple eect evaporator (MEE) Distillation Atmospheric distillation (AD) Multi-pressure distillation (MD) a It is not economically feasible (Pistore and Lora, 2006).

C8

C9

tive MST-AD in scenario C6, the incorporation of technological alternatives DF-MST-AD, MST-MD and DF-MST-MD increases the specic income through the sale of surplus electricity of the plant by 12%, 11% and 22%, respectively. For scenarios C7, C8 and C9 the best specic incomes are obtained when the technological alternative utilised is DF-EM-MD. In these scenarios the incomes are 26%, 23% and 22% higher in comparison to the scenario MST-AD. Another factor that contributes to the reduction in process steam consumption and to the reduction in the volume of vinasse produced is the alcohol content in the fermented wine. For an AD system, increases in alcohol content of wine from 7% to 9% enable a decrease of approximately 18% in the specic consumption of steam in the system (kg/L of hydrated ethanol). For a MD system, it is possible to obtain a decrease of approximately 3% in the specic steam consumption of the system for every 0.5% of increase in alcohol content of wine. It can be seen in Figure 12 that the vinasse production per litre of the Hydrated Ethylic Alcohol (HEA) produced decreases by approximately 6% for every 0.5% increase in alcohol content of wine.

12

Bioreneries: The materialisation of the process integration

The biorenery concept is analogous to the oil renery one: a facility that produces multiple fuels and products from petroleum. However, unlike the oil renery, a biorenery uses renewable resources and its wastes in an integral and diversied way. Based on the thermochemical, biochemical platforms or a mixture of both, the biorefineries can produce a wide range of products (chemicals, fuels, fertilisers, plastics, etc.) and energy with a minimum waste generation and very low pollutant emission. Figure 13 shows the main possible routes to be implemented in a sugarcane based biorenery. Among the main advantages of implementing this type of system in the sugar and alcohol industry, are the energy eciency increase, the production of alternative fuels (e.g. methanol),

Fig. 11: Comparison of exergetic efciency of ethanol plants with different technologies. Left: Comparison of the overall plant efciency for scenario C4 and base case scenario considering different technological alternatives in milling and destillation stages. Right: C9 and base case.
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Technology/Technologie of the circles. All the analysed cases showed the feasibility of the productive integration in the structural framework of the sugar and alcohol factories. It is noteworthy that the exergy analysis showed that the sugarcane energy use eciency is increased due to the complementation and diversication of products within the bioreneries.

13

Industrial ecology

Fig. 12: Specic vinasse production in the plant related to the alcohol content in the distillation of fermented wine

and the lower emission levels, all at reduced costs. In Brazil, the program PAISS (Technological Innovation for the Energy and Biochemical Production from Sugarcane) of BNDES (Brazilian Development Bank) and FINEP (Studies and Projects Funding) provided the funds for the construction of 12 pilot plants and 7 industrial plants. Figures 14 and 15 present the results of the mass and energy balances of a sugarcane biorefinery model, based on the thermochemical platform (gasication), which produces biomethanol, bioethanol and electricity for the grid, consisting of an autonomous distillery, cogeneration plant and annexed methanol plant (Case 2). Figure 15 includes a BIG/GT system (Case4). In this analysis, the exergy of energy and product mass ows, a measure of their intrinsic quality, is used to dene a refined efficiency criteria. Figure 16 shows the results of the overall exergetic eciency of processing sugarcane under bioreneries systems (Ren, 2011) for the following four cases: Autonomous distillery, cogeneration plant and autonomous methanol plant (Case 1). Autonomous distillery, cogeneration plant and annexed methanol plant (Case 2). Sugar and alcohol factory, cogeneration plant and annexed methanol plant (Case 3). Sugar and alcohol factory, cogeneration plant, annexed methanol plant and BIG/GT (Case 4). Figure 16 shows the total available exergy calculated as the sum of the product mass exergy (methanol, ethanol and electricity) pointed out in the shaded area of the circle for each of the analyzed cases and the overall exergy destruction (unavailable exergy that is Fig. 13: Main possible routes in a sugarcane based biorenery. Adapted and complemented from the sum of the destroyed and the lost Ambrsio (2011) exergies) pointed out in the white area

The return of nutrients to the soil through vinasse fertirrigation (Fig.17), or use of the anaerobic digestion sludge and/ or the ash from vinasse incineration are ways of integrating the sugar and alcohol industry to the terrestrial geochemical cycles and a true contribution to the mitigation of the soil degradation. On the other hand the production of protein concentrates for animal feed is the best way to a more rational utilisation of the available land in cattle raising. The fertirrigation system allows the irrigation according to the needs of the crop and drastically increases land productivity and sugarcane production. These practices have demonstrated their eectiveness in substituting chemical fertilizers.

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Fig. 14: Mass and energy balances in an autonomous distillery with an annexed conventional cogeneration and methanol plant (Case 2)

Fig. 15: Mass and energy balances in a sugar and alcohol factory with an annexed BIG/GT cogeneration and methanol plant (Case 4)

14

Sustainability evaluation: LCA

In the sugar and alcohol industry, as in any other human activity, the sustainability evaluation is presently mandatory. LCA is considered the standard tool for sustainability studies despite its inconsistencies (Lora et al., 2011). The real possibility of the implementation of environmentally based trade barriers and certication systems forced the funding of projects and research to solve the bottlenecks of sustainability evaluation methodologies. Two main indicators are used: the Output/Input Index also know as Energy Ratio (Renewable Energy/Fossil Energy Relation) and the reduction in Greenhouse Gases (GHG) emissions of a biofuel when compared with the substituted fossil fuel (for example ethanol and gasoline). The best sugar and
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Fig. 16: Exergetic overall efciency of the sugarcane energy utilisation in different thermochemical platforms biorenery schemes

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Fig. 17: Integration of the sugarcane agro-industry to geochemical cycles through fertirrigation (Rocha et al., 2010)

alcohol factories in Brazil and other countries show excellent values in both indexes; otherwise it is necessary to carry out these studies for dierent geographical and technological scenarios for process improvements or alternatives selection. The energy ratio and the reduction in life cycle GHG emissions of the ethanol production resulted from dierent studies are shown in Table 5.

15 Conclusions
The sugarcane agro-industry is the base and the indispensable support for the implementation of large scale energy cogeneration systems and biofuel production. Also, any strategy must keep in mind that sugar is more than a sweetener; it is the simplest, purest, safest and cheapest source of energy that human beings have. For that reason the cogeneration and biofuels goals in an economic and ecological coherent development will be based on the lignocellulosic residues, forcing parametric and technological changes which, in a few years, can lead to a completely dierent sugarcane, sugar and fuel industry. The changes shall be so radical as to present a novel prole, forcing a new paradigm for the increase of the sugarcane energy, food and safe world contribution. Technological development will allow the advancement from the current option, limited to bioethanol (1st generation biofuels), to cellulosic bioethanol, methanol, DME, biobutanol, biodiesel (jet fuel) and diesel/gasoline (Fischer-Tropsch synthesis) all obtained from biochemical and thermochemical conversion platforms of lignocellulosic residues (2nd generation biofuels). This will allow the use of huge amounts of raw material (sugarcane trash) and the reduction of the impact on food production. More investments in RD&I programs are necessary so that the technologies for the production of 2nd generation biofuels can reach a commercial stage.

Table 5: Energy ratio and GHG emissions of ethanol production Reference GHG emissi- GHG reduction Energy ratio ons in kg CO2/ in % kg ethanol Brazilian studies Cavalett et al. (2013) 0.672 76.0 Seabra et al. (2011) 0.597 78.7 9.0 Walter et al. (2011) 1.035 63.1 Luo et al. (2009) 0.378 86.5 Macedo et al. (2008) 0.553* 80.3 9.3* 0.438** 84.4 11.6** Other countries Argentina (Acreche and Valeiro, 2013) 1.420 49.3 3.4 Mexico (Garca et al., 2011) 2.582 7.8 2.1 Thailand (Silalertruksa and Gheewala, 2009) 0.869 68.9 3.0 Petroleum gasoline (Wang et al., 2011)*** 2.80 * 2005 scenario. ** 2020 scenario. *** The European value of petroleum gasoline life cycle GHG emissions is 83.8 kg CO2-eq/GJ and the USA value ranges between 90 and 110 kg CO2-eq/GJ (Wang et al., 2011).

Acknowledgements
The authors wish to thank the Brazilian National Research and Development Council (CNPq). The Research Support Foundation of the State of Minas Gerais (FAPEMIG) and the Coordinating Body for the Improvement of Postgraduate Studies in Higher Education (CAPES) for the funding of Research and Development projects and for the support through graduate students and reseach productivity grants that allowed the accomplishment of the research projects whose results are included in this paper. Thanks also to ISSCT for the invitation to present this paper as a lecture in the XXVIII ISSCT Congress plenary session.

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Abbreviations
1G 2G AD BIG/CC First Generation Ethanol Distillery Second Generation Ethanol Distillery Atmospheric Distillation process Biomass Integrated Gasification with Combined Cycle BIG/GT Biomass Integrated Gasication with Gas Turbine BNDES Brazilian Development Bank BOD Biochemical Oxygen Demand CAPES Coordinating Body for the Improvement of Postgraduate Studies in Higher Education CEST Condensing-Extraction Steam Turbine CGEE Center for Strategic Studies and Management CNPq Brazilian National Research and Development Council COD Chemical Oxygen Demand CTC Sugarcane Technology Center d.b. Dry Basis DF Diuser DME Dimethyl Ether DRH Dedini Rapid Hydrolysis EM Electric Motor FAPEMIG Research Support Foundation of the State of Minas Gerais FDCA Furan Dicarboxylic Acid FINEP Studies and Projects Funding Agency GHG Greenhouse Gases HEA Hydrated Ethylic Alcohol HMF Hydroxymethylfurfural ICIDCA Cuban Research Institute of Sugarcane Co-products ICSB International Consortium for Sugarcane Biotechnology ISBUC International Sugarcane Biomass Utilization Consortium ISSCT International Society of Sugar Cane Technologists LCA Life Cycle Assessment LLDPE Linear Low Density Polyethylene MD Multi-pressure Distillation process MEE Multiple Eects Evaporator MST Multiple Stage Steam Turbine NEST Excellence Group in Thermal Power and Distributed Generation PAISS Technological Innovation for the Energy and Biochemical Production from Sugarcane PE Polyethylene PLA Polylactic Acid PP Polypropylene RD&I Research, Development and Innovation SCP Single Cell Protein SOFC Solid Oxide Fuel Cell SSCF Simultaneous Saccharication and Co-Fermentation Processes SSF Simultaneous Saccharication and Fermentation SST Single Stage Steam Turbine UNICA Brazilian Sugarcane Industry Association

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Authors addresses: Electo Eduardo Silva Lora (corresponding author), Mateus Henrique Rocha, Jos Carlos Escobar Palacio, Osvaldo Jos Venturini, Maria Luiza Grillo Ren, NEST Excellence Group in Thermal Power and Distributed Generation, Federal University of Itajub, Mechanical Engineering Institute (IEM), Av. BPS 1303, Postal Box 50, Itajub/MG, Brazil; Oscar Almazn del Olmo, ICIDCA Cuban Research Institute of Sugarcane Co-products, Via Blanca y Carretera Central 804, San Miguel del Padrn, A.P. 4036, La Habana, Cuba; e-mail: electo@unifei.edu.br

Sugar Industry 139 (2014) No. 2 | 97104