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Article history: The incorporation of an alternative technology for the fermentation process, and an improved cogene-
Received 5 September 2017 ration system in the first-generation ethanol production process were evaluated; and a heat integration
Received in revised form analysis was performed as well. The hybrid membrane fermentation, the alternative technology, was
27 April 2018
considered as a non-conventional operation, and its impact on the overall energy consumption of the
Accepted 13 May 2018
Available online 14 May 2018
integrated process was estimated. The improved cogeneration system contemplated a supercritical cycle,
and the increase in surplus electricity was also evaluated assuming a mixture of bagasse and sugarcane
straw as fuel. The heat integration of the process streams was performed applying the Pinch Analysis in
Keywords:
Ethanol
order to determine the targets for minimum external heating and cooling. Furthermore, the integration
Heat integration of the multiple-effect evaporator of sugarcane juice, to the process, was optimised based on the heat
Hybrid fermentation integration analysis results. Moreover, the results showed a possibility of generating a surplus electricity
Sugarcane of 138 MW (275 kWh/t of cane) with the new technologies applied.
© 2018 Elsevier Ltd. All rights reserved.
https://doi.org/10.1016/j.energy.2018.05.092
0360-5442/© 2018 Elsevier Ltd. All rights reserved.
C. Lopez-Castrillon et al. / Energy 156 (2018) 468e480 469
fermentation and separation areas, in the ethanol production pro- production and the produced ethanol as objective functions to be
cess, so that the ethanol is continuously extracted as it is produced maximized in the production process of first- and second-
in the fermentation. This can be achieved by implementing per- generation ethanol from sugarcane. Pina et al. [9] evaluated the
vaporation membrane technology in the conventional fermenta- reduction of the process steam demand and the water usage
tion process, which would result in a positive impact on the energy through heat integration. Regarding alternative technologies in the
consumption in the process. ethanol production process and its integration through Pinch
Taking into account the sugarcane plantations, in recent years, Analysis, the studies of Palacios-Bereche et al. [10], where double-
the sugarcane industry has undergone changes such as a drastic effect distillation is assessed; Palacios-Bereche et al. [11], who
reduction of harvesting burning of sugarcane plantations, and a evaluated the introduction of cooling fermentation and vacuum
proportional increase of mechanised harvesting. Before the mech- extractive fermentation; and Palacios-Bereche et al. [12] who
anisation, the sugarcane straw, comprised of sugarcane tops and evaluated different extraction systems for sugarcane juice, are
dried leaves, was burnt in the field to facilitate the cultivation worth mentioning.
practices of rattoons, however, with the mechanised harvesting Furthermore, the literature presents several studies that, even
increase; these residues remain on the soil surface. Some studies though not related to the ethanol production from sugarcane, are
and management technologies indicate that part of the straw related to the process integration problem assessed in this study.
should be left in the cane fields with the objective of assisting in soil Regarding the study of heat integration of multiple-effect
conservation and water retention. The amount of straw left will evaporators and heat pumps, the study of Sharan and Bandyo-
depend on the type of soil. Currently, with the research advances padhyay [16] presented a methodology to minimise the overall
and the interest in its energy potential, a part of the straw is energy consumption of a system, by thermally integrating a
recovered from the field and mixed with the bagasse to be used as multiple-effect evaporator, thermo-vapour compressors, into the
fuel in the industry. background process. The method focused on the optimal location of
Since the bioelectricity became another important product of the thermo-vapour compressor (TVC) suction position. The authors
the mill, the evolution of cogeneration systems became a necessity evaluated two cases; the first one being a corn glucose concentra-
as well, in order to increase the efficiency of electricity generation. tion system, while the second one presented a desalination system.
In this scenario, the normal way of improving cogeneration systems In the same research topic, Oluleye and Smith [18] carried out a
consists in reducing the steam consumption of the processes by study where different technologies of heat upgrading, such as
means of adopting more efficient technologies and heat integra- mechanical heat pumps, absorption heat pumps, and absorption
tion; besides raising the pressures and temperatures in the steam heat transformers, are integrated to an existing process through a
generation process, and in the use of condensing-extraction steam Mixed Integer Linear Program (MILP). This procedure takes into
turbines, as in the case of the supercritical cycle, which represents account the interactions of the aforementioned technologies with
the most efficient systems for electricity generation based on the the associated cogeneration system, temperature of process
Rankine Cycle. Nowadays, the cogeneration plant Avedøre II located streams, and quantity of heat sources, as well as process economics
in Denmark, which is already in use, works with a supercritical and the potential to reduce carbon dioxide emissions.
steam cycle using different fuels, including biomass. This fact shows Furthermore, in the field of Combined Heat and Power, Total Site
the possibility of improvement and optimisation of the cogenera- Integration is presented as a method for the targeting and inte-
tion systems in sugar-ethanol plants with the inclusion of super- gration of individual processes with heating and cooling re-
critical steam cycles [3]. quirements linked by the same utility system. Several studies have
The heat integration of the process, on the other side, allows the been developed in this area, for instance, Ren et al. [14] presented a
improvement of the energy utilisation of the process streams. This method for targeting the cogeneration potential of Total Site utility
analysis can minimise the process steam consumption and, at the systems from the pressure values and heat loads of the steam
same time, minimise the need for cooling water. It is important to mains, using the commercial software Aspen Plus. The simulator
note that the use of process integration techniques, even in similar supplies temperature values, flow rates, and shaft powers of steam
processes, may require different designs to meet the maximum turbines; furthermore, this study presents a procedure to estimate
energy recovery (MER). Each process should be studied separately, capital cost, GHG emissions, and the water footprint. In another
considering local operating costs, as well as operating conditions. study, Ong et al. [15] developed a method to visualise and solve
At present, there are different studies related to the reduction in Total Site Mass, Heat, and Power Integration, using process inte-
energy consumption in the ethanol and sugar production process, gration and process graph techniques (P-graph), which is an
such as Moncada et al. [4], where the authors studied different approach to visualise multi-dimensional network problems using
conversion paths from the distribution of raw materials in the Mathematical Programming Optimisation. These authors applied
sugarcane mill, analysing the variation in the production of surplus the method to evaluate the incorporation of alternative processes,
electricity and by-products. On the other hand, Ensinas et al. [5] such as gasification of black liquor, hydrothermal liquefaction,
analysed the reduction in steam demand, in a sugarcane plant, simultaneous scarification and co-fermentation of biomass, into an
applying heat integration; and evaluated different configurations of existing Kraft Pulp Mill in New Zealand, together with a combined
cogeneration systems including a BIGCC (Biomass Integrated heat and power system on-site. In the same field, Tarighaleslami
Gasification Combined Cycle). et al. [17] presented an alternative method for utility selection and
Regarding process integration research and multi-objective optimisation of Total Site Heat Integration, using cost and exergy
optimisation, several studies can be found in the literature. For derivative analysis. This method can optimise both non-isothermal
instance, Ensinas et al. [6] performed a thermoeconomic optimi- and isothermal utilities in the same procedure, being the main
sation in the sugarcane juice evaporation system and heater target the minimisation of the total annualised cost. Finally,
network in the plant. Morandin et al. [7] applied optimisation Walmsley [13] presented a new approach for a Total Site Heat
techniques to evaluate the potential for energy savings in the Integration method for the design of integrated evaporation sys-
sugarcane conversion process and in the on-site electricity pro- tems including vapour-recompression based on a hybrid Total Site
duction, assuming bagasse as fuel in the cogeneration system. In Profile, which can be applied to optimise industrial case studies,
addition, Ensinas et al. [8] applied a multi-objective optimisation minimising the energy use and costs.
technique using evolutionary algorithms, setting the electricity The present work aims at evaluating the incorporation of hybrid
470 C. Lopez-Castrillon et al. / Energy 156 (2018) 468e480
fermentation with pervaporation membranes, as well as its heat effect on the cell growth of yeast. For this reason, it is not possible to
integration through Pinch Analysis, into the ethanol production feed the fermentation process with a substrate that is too
process, in combination with improvements in the cogeneration concentrated in sugars. Most of the Brazilian plants use the fed-
system; which include the use of sugarcane straw recovered from batch fermentation with cell recycle, or Meille-Boinot process;
the field, and a supercritical steam power cycle using steam re- however, there are few plants using the continuous fermentation
heating and regenerative heat exchangers, in order to evaluate process. In the conventional process, the wine obtained in the
the surplus electricity. fermentation process has an ethanol content of around 6% wt.
The novelty of this work resides in the study of the introduction Following that, the wine is sent to a distillation step where hy-
of pervaporative fermentation, and its heat integration through drated ethanol is produced with an ethanol content of around
Pinch Analysis, into the overall ethanol production process; eval- 93.5% wt. Optionally, anhydrous ethanol with an ethanol content of
uating the utility consumption and impacts on the cogeneration 99.4% can be produced in a dehydration step.
system. The literature has already presented some studies related This work assumed an ethanol production plant coupled with
to pervaporative fermentation, though, neither of them analyses two new technologies: (i) pervaporation in the fermentation stage,
this technology in an integrated way with the rest of the process. and (ii) supercritical cycle in the cogeneration stage. These tech-
Moreover, although the state of the art already presents studies nologies are presented in the following items.
evaluating supercritical cycles in cogeneration, together with the
ethanol production process, none of them have evaluated the use of 2.2. Pervaporation coupled to the fermentation process
sugarcane straw in these systems, becoming this use of sugarcane
straw another novelty of this work. In the distillation step, the energy consumption depends
explicitly on the ethanol concentration in the feed wine. Conse-
quently, the interconnection between fermentation and distillation
2. Theory: technological aspects affects the energy consumption in these two stages of the process.
Since the yeast suffers inhibition by the ethanol produced in the
2.1. Ethanol production process fermentative medium, one possible solution would be the extrac-
tion of this ethanol as it is formed. This allows the fermentation
Fig. 1 shows a flow sheet of the conventional ethanol production medium to keep a relatively low ethanol concentration, and, as a
process [19]. The process begins with the cleaning of sugarcane, result, an operation with a must with higher sugar concentration
followed by the preparation and juice extraction system, the latter (approximately 25 Brix) can be achieved.
assumed to be performed by mills. The bagasse, fibrous residue of The aforementioned solution could be achieved by imple-
the sugarcane, is sent to the cogeneration system, while the raw menting the pervaporation membrane technology in the
juice extracted is sent to the treatment stage. After that, the juice conventional fermentation process [20]. Pervaporation
concentration takes place in an evaporation system. The final su- (permeation þ evaporation) is a type of membrane operation
crose content in the concentrated juice should be appropriate for applied to the separation of mixtures in liquid phase It is considered
the fermentation process, and it is usually around 17%e19% (19e21 as a technology that could be appropriate to be used in the
Brix). During the fermentation step, ethanol is produced in a bio- fermentation stage, increasing the performance of the fermenta-
logical process lead by Saccharomyces cerevisiae yeast. The alcoholic tion, consequently reducing the steam consumption in the distil-
fermentation is affected by several factors, such as the ethanol lation stage. During the pervaporation process, the substance
produced in the fermentative medium, which has an inhibitory transferred through the membrane (permeate) changes from liquid
to vapour phase. In the case of extractive fermentation, one part of
ethanol and water (ethanol-rich portion) is removed from the so-
lution, while the other portion remains in the fermenter (reten-
tate). After the separation, the permeate is condensed for recovery
[20]. Fig. 2 shows the pervaporation scheme adopted.
According to [22], the mass transfer through the membrane is
governed by the chemical potential gradient in the two phases. In
the case of pervaporation, the chemical potential gradient is
influenced by the partial pressures of the substances in each phase.
The mass flow of the chemical species and the separation factor
Fig. 2. General diagram for hybrid fed-batch membrane fermentation H-FBMF arrange-
Fig. 1. General diagram of an ethanol production plant from sugarcane [19]. ment [21].
C. Lopez-Castrillon et al. / Energy 156 (2018) 468e480 471
depend also on the affinity (solubility) of the chemical species for previous treatments that are of great importance. For this reason,
the membrane material (PDMS1). techniques need to be used in order to remove impurities, mainly
A membrane adapted to the fermenter removes the ethanol that soil that is carried with the cane and straw; and, in some cases, the
is generated in the reaction, shifting the biochemical equilibrium reduction of the ash content and the control of the moisture con-
(inhibition conditions) towards the fermentation products [23]. The tent are also necessary. Different authors affirm that straw burning,
improvement of the fermentation performance has two direct without an appropriate treatment, represents several problems for
consequences on the energy efficiency of the process: (i) the boilers, such as corrosion, abrasion, and deposits of molten ash.
fermenter will need less cooling water per kg of ethanol produced; Two of the most studied problems in the burning of straw in
and (ii) the liquid product of the fermenter will be a wine (distil- cogeneration are corrosion and incrustations; however, different
lation feed) with a higher ethanol content. This phenomenon is authors affirm that cleaning treatments before the burning, such as
directly linked to the energy consumption in distillation. In such a separation and cleaning operations, can mitigate these problems
way, the distillation feed is considered as an ethanol-water solution [26].
with an ethanol concentration higher than the one in the conven- The aforementioned treatments are exposed in Fig. 3a and b:
tional process. This condition in the incoming stream promotes a
decrease in the energy requirements in the distillation columns’
3. Methods
reboilers. Besides, a significant reduction in energy consumption in
the distillation was demonstrated by applying membranes in
3.1. Modelling and simulation of the conventional ethanol
fermentation, in comparison with the traditional process [20].
production process
Regarding the operation, the permeate is constantly removed
and it by-passes the first set of distillation columns (A, A1 and D),
Mass and energy balances in each stage of the conventional
directly feeding the B-B1 column. The retentate is then recycled to
ethanol production process were accomplished using the Aspen
the fermentation vat. The liquid phase is discharged from the
Plus software. A cane rate of 500 t/h for anhydrous ethanol pro-
fermentation vat at the end of the fermentation time and is nor-
duction was assumed. Regarding the distillation process, a con-
mally fed at the first set of columns (column A1).
ventional configuration with two sets of columns was assumed. The
Owing to the fermentation process being operated in batch
first set considered the columns A, A1, and D for wine stripping,
mode, several fermenter vats are used in parallel, though, in lagged
while the columns B-B1 for phlegm stripping were considered in
operation. In addition, the wine from all fermentation vats is dis-
the second set. This configuration can be observed in Fig. 7a.
charged to a standardisation holding tank, before being sent to the
Further information regarding process specifications and results is
distillation sector.
available in Ref. [9].
The use of the straw as fuel in cogeneration systems requires Fig. 3a. System flow chart for cleaning and grinding of straw.
472 C. Lopez-Castrillon et al. / Energy 156 (2018) 468e480
Fig. 3b. Theoretical flow chart of the system for cleaning and grinding of straw.
Fig. 7(a). Distillation scheme for the production of hydrated ethanol. Case study FBF-
200.
This study assumed that 50% of the produced straw (total po-
tential) is used as fuel in the cogeneration system, while the other
Fig. 7(b). Distillation with a permeate feed recovered from the hybrid fermentation
with membranes. Case study H-FBMF-240. 50% is left in the field. It was also assumed that the straw has
different treatments before the combustion and mixing with
bagasse.
identification of the appropriate temperature level of utilities to be It was assumed, in this work, that the cane preparation devices
used, minimising the irreversibilities of the heat exchange process and the mills of the juice extraction system are driven by electric
and allowing the evaluation of the use of lower cost utilities [24]. motors, instead of the direct drive steam turbines commonly used
Furthermore, this tool is useful for the next step, which is the in old mills. Steam cycle options, with different pressure and
appropriate placement of the multiple-effect evaporation system. temperature levels, together with the use of back-pressure and
This analysis was performed by means of the EXCEL software. condensing-extraction steam turbines, were evaluated. The sys-
The value of DTmin was assumed to be 10 C for process streams, tems were simulated on the condition that the demand of steam
and 4 C for evaporation system streams. and electricity of the process is covered by the cogeneration system
Optimisation of the juice evaporation process using heat that consumes a mixture of bagasse and straw as fuel for the gen-
integration: eration of steam.
The separation process to obtain the concentrated juice, or
syrup, occurs in a multiple-effect evaporation system that uses 3.4.1. Steam cycle with condensing-extraction steam turbines e
exhaust steam from the cogeneration system as a heat source in the configuration A
first effect (see Fig. 4). The vapour generated in the separation This configuration is characterised by the fact that all the
process, called vegetal vapour, is used as heat source for the sub- available bagasse (discounting a part for reserve and the bagasse for
sequent effects, providing a saving of steam, when compared to filters) is burnt. The straw was assume to be used, in mixture with
simple evaporation in single stage [24]. bagasse, as additional fuel in the cogeneration system, as it would
The operating conditions of the juice evaporation process were allow a greater production of steam in the boiler and, consequently,
extracted from Ref. [9], being the main parameters the mass flow of a greater amount of surplus electrical energy that could be com-
the clarified juice (141.5 kg/s), the initial temperature (98 C), and mercialised in the network.
the initial Brix (Brix ¼ 15). The final Brix was assumed at 21 for the The scheme of this cogeneration system configuration is shown
Base case, and at 25.7 for the H-FBMF case (A purity of 86% was in Fig. 5. This configuration comprises a biomass boiler, steam
assumed in all cases). turbines, an electric generator coupled to a steam turbine, a
In this analysis, the pre-heating of the clarified juice, prior to its deaerator, electric pumps of boiler feed and condensate return, and
entry into the evaporation system, was included. This way, the a desuperheater to control the temperature reduction of the
clarified juice temperature is raised to the saturation point of the exhaust steam used in the process.
first effect. The simulation of the juice concentration was per-
formed using the calculations implemented in the EES® software, 3.4.2. Supercritical steam cycles. Configuration B
and employing mass and energy balances based on real data ob- Fig. 6 shows the configuration of the supercritical steam cycle
tained from the literature. assumed in this study. It was adopted so as to use a mixture of straw
Mass balance for the first effect: and bagasse as fuel, including the use of steam reheating and
regenerative heat exchangers for heating the returning condensate.
: : :
mc1 mv mc2 ¼ 0 (1) This type of configuration does not yet exist in the sugar-alcohol
Brazilian industry, though; it represents the most efficient system
: : for electricity generation based on the Rankine Cycle [25].
mc1 , Brix1 ¼ mc2 , Brix2 (2)
Since a supercritical cycle operates at pressures and tempera-
Energy Balance for the first effect: Hypotheses DEc ¼ 0 and tures above the critical point, a reheating of the steam leaving the
DEp ¼ 0 high-pressure turbine (TAAP in Fig. 6) is required to increase the
: : : cycle efficiency and decrease the percentage of moisture in the last
mc1 , hc1 mv , hv þ mc2 ,hc2 ¼ Q1 (3) stage of the turbine. This cycle also requires a series of regenerators
to increase the temperature of the water before entering the boiler;
: : increasing, consequently, the system efficiency [25]. The scheme of
m1 , hve m2 , hcve ¼ Q1 (4)
the cogeneration system shown in Fig. 6 has condensing-extraction
Owing to the existence of a multiple-effect evaporation system, steam turbines to take advantage of all the available fuel (bagasse
the heat integration procedure was carried out by steps. The first and straw), representing the straw 23% (wet basis) of the total
step adopted was the heat integration of process streams excluding amount of fuel. Considering the highest values practiced, the
474 C. Lopez-Castrillon et al. / Energy 156 (2018) 468e480
efficiency of the boiler is set at 86% (PCI base) while the steam is presents the final streams for heat integration for cases FBF-200
generated at 300 bar and 600 C, being reheated to 600 C after the and H-FBMF-240.
expansion up to 62 bar that takes place in the TAAP turbine, [25]. Since the fermentation is operated in batch mode, the heat
released in the fermentation, as well as the heat from the heater H1
3.4.3. Study of the pressure and the temperature increase of the and the cooler C1 from the pervaporative process (Fig. 3), were not
steam generated in the boiler taken into account. In addition, since heat is released from the
The influence of the steam parameters at boiler outlet on the fermentation at low temperature (approximately 35 C), the op-
cogeneration system efficiency (steam power cycle efficiency) was portunities of heat integration at this temperature level are scarce.
also studied. Thus, the increase of the pressure and temperature of In such a way, this analysis focuses mainly on the effects of the
generated steam was evaluated for three conditions. The first hybrid fermentation on the distillation step, and on the potential of
condition (C1) was established as the steam generation parameters surplus electricity; taking into account the overall process.
traditionally used by the sugar-alcohol industry in Brazil, with
boilers that use only bagasse as fuel. The second condition (C2) 4.1. Cogeneration system
corresponds to the pressure and temperature used in most of the
new projects of cogeneration systems that have been introduced in For the cogeneration system, the following parameters were
the sector. Such new projects present more efficient boilers and assumed (Table 3):
energy recovery systems from the exhaust gases, such as air pre- Sugarcane straw is understood as green leaves and straw that
heaters and economisers. Different sugar and alcohol production currently remain on the land after harvesting. When staying in the
plants already possess this type of technology. The third condition field, its function is to serve as protection for the soil in the process
(C3) refers to a more advanced system, which works with steam of nutrient replenishment and in pest control. However, it would be
and reaches supercritical conditions. It is not yet used in the sugar- possible to use some of this material as fuel in the boilers, without
alcohol sector; however, it may provide an increase in the future impairing its function in soil recovery [26]. In this work, it is
electricity generation potential, as well as an increase in efficiency. considered that 50% of the total straw produced is left in the field,
These three conditions can be observed in Table 1. while the remaining 50% is used in the cogeneration, which rep-
resents 23% in the bagasse-straw mixture used as fuel. At present,
4. Case study introduction there are plants that use this percentage of straw as fuel in mixture
with bagasse.
Two cases of study were evaluated in this work. The first one According to Figs. 5 and 6, the mass and energy balance simu-
assumed a conventional ethanol production process with a fed- lations for the cogeneration system were performed with the EES®
batch fermentation process (FBF-200), while the second one software, to calculate the surplus electricity for each case study
assumed the incorporation of hybrid fed-batch membrane proposed in Table 4.
fermentation (H-FBMF-240). In the FBF-200 case, the substrate For all proposed case studies, the flowchart exposed in Fig. 3a,
concentration at feed (sugar concentration in the must for representing the cleaning and grinding system of straw prior to the
fermentation) was 200 kg/m3 (21.7 Brix); and in the H-FBMF case, mixing with bagasse, was assumed.
the substrate concentration at feed was 240 kg/m3 (25.7 Brix).
Both cases assumed a mill capacity of 2,000,000 t of cane/y; a 5. Results
crushing rate of 500 t of cane/h; season operating hours of 4000 h/
y; and a bagasse production of 277 kg/t of cane [9]. Additional data The Grand Composite Curve (GCC) was constructed for each case
regarding the main streams are presented in Table A1 of Annex. study. Fig. 8 shows the GCC without considering the streams of the
Leon et al. [17] carried out a study to evaluate the variation of evaporation system.
steam consumption, in the distillation stage, by implementing the According to [28], one of the main advantages of the GCC is the
pervaporation in the fermentation process. According to the identification of the appropriate temperature level of utilities to be
distillation process studied by these authors, Fig. 7a shows the used for each case study; minimising the irreversibilities of the heat
conventional distillation process, and Fig. 7b shows the distillation exchange process, and allowing the evaluation of the use of lower
process coupled to the hybrid fermentation with a permeate feed in cost utilities.
the B-B1 column.
From the aforementioned previous studies, [9] for conventional 5.1. Heat integration with the evaporation process
process and [21] for hybrid fermentation; streams available for heat
integration were extracted and are shown in Table 2. In order to According to [28], the integration of evaporation systems should
simplify the analysis of the heat integration, process streams with a be performed taking into account the overall process, with the help
heat load below 1000 kW were not included. of the GCC. In order to accomplish an appropriate placement of the
After the calculation of the evaporation system, the table of multiple-effect evaporation system, from the results of the evapo-
streams for heat integration is updated with the streams of juice ration system simulation, each effect of the evaporation system is
pre-heating (before the first effect of the evaporation system), represented in the GCC as a horizontal bar [28]. The length of the
vapour condensates, juice for sterilisation, and the streams of the bars represents the heat exchanged in each effect, while its place-
evaporation system (juice and vapours). Table A2 in the Annex ment in the vertical axis is determined by the operation tempera-
ture, which is a function of its operating pressure.
After performing the simulation, the results showed that only
Table 1
two effects of evaporation are necessary in case FBF-200, while case
Operating conditions depending on the pressure and temperature of the steam
generated.
H-FBMF-240 needed three effects. Fig. 9 shows the GCC together
with the evaporation system for cases FBF-200 and H-FBMF-240.
Steam conditions at boiler outlet Pressure [bar] Temperature [ C]
In Fig. 9a (case FBF-200), it can be observed that the bar rep-
C1 65 480 resenting the first effect is larger than the one that represents the
C2 120 520 second. The upper side of the bar represents the heat supplied to
C3 300 600
the effect (heat sink), while the bottom side (heat source)
C. Lopez-Castrillon et al. / Energy 156 (2018) 468e480 475
Table 2
Streams used in the heat integration analysis for each case study.
Stream Name Supply Temperature Target Temperature Base Case FBF-200 H-FBMF-240
DH
Ti [ C] Tf [ C] MW MW
Table 3
Parameters for the simulations [29].
Parameter Value
Table 4
Case studies.
Configuration of the cogeneration system Steam conditions at boiler outlet - Type of Fermentation
Table 5
Results of the GCC analysis.
Fig. 10. Final GCC including the streams of the evaporation systems for the cases FBF-
200 and H-FBMF-240. Fig. 11. Surplus electricity for each case study.
C. Lopez-Castrillon et al. / Energy 156 (2018) 468e480 477
Table 6
Results of the supercritical cogeneration system for each case study.
Steam generated at boiler [t/h] 446.4 446.4 440.6 440.6 486.3 486.3
Pressure of live steam [bar] 65 65 120 120 300 300
Temperature of live steam [ C] 480 480 520 520 600 600
Steam consumption [t/h] 131.4 118.4 131.2 118.4 131.2 118.4
Wsurplus EE [MW] 87.3 86.2 96.2 95.2 137.7 136.3
Specific Wsurplus EE (per tonne of cane) 175 172 192 190 275 273
[kWh/t of cane]
478 C. Lopez-Castrillon et al. / Energy 156 (2018) 468e480
Table A2
Streams for heat integration including evaporation system streams.
DH DH
Ti [ C] Tf [ C] MW MW
Table A3
Electricity balance for evaluated cases.