Energy analysis of the ethanol industry considering vinasse concentration and incineration

Nowadays, the ethanol represents the most consolidated biofuel in Brazil. Despite presenting environmental advantages in comparison with non-renewable fuels, the concern for the ethanol process residues is increasing. Among these residues, the vinasse, bottom product of distillation process, is the most important since its characteristics such as BOD, acidic nature and large volume make its disposition difficult and costly. The aim of this study is the integration of a vinasse concentration and incineration system to a conventional sugar, ethanol and electricity production process. For this study, the Aspen Plus® software was used to simulate the production process. Assuming a sugar-ethanol production plant, different scenarios were analysed considering vinasse concentration with a multiple-effect evaporator system, vinasse incineration with salt recuperation, and heat integration. In scenarios that do not assumed heat integration, the main results show that vinasse incineration is necessary to contribute to the steam generation in order to cover the steam demand of the process, including the vinasse concentration. Regarding the heat integration procedure, an appropriate placement of evaporators was achieved through the reduction of the number of effects on both the vinasse and juice evaporation systems; thus promoting a meaningful reduction in the steam consumption of the integrated process1429610

Double-effect Distillation And Thermal Integration Applied To The Ethanol Production Process

A double-effect distillation system allows a significant reduction in energy consumption, since the condensers and reboilers of different columns can be integrated thermally. To achieve this goal, some columns operate under a vacuum, while others operate close to atmospheric pressure. These pressure levels bring about different temperature levels, allowing energy recovery. Thus, the aim of this study is to assess the incorporation of double-effect distillation in ethanol production, and its impact on energy consumption and electricity surplus production in the cogeneration system. Moreover, because double-effect distillation and thermal integration involve an increase in equipment costs, an economic assessment was done. Several cases were evaluated and a thermal integration technique was applied, in order to integrate the overall process. The thermal integration study showed that it is possible to integrate the juice concentration step (multiple effect evaporation system) in the overall process without additional thermal consumption, through the selection of a suitable set of pressures in the evaporation system. The results showed a reduction in steam consumption of between 17% and 54%, in comparison with the Base Case. Regarding the electricity surplus, this increased by up to 22% when extraction-condensing steam turbines were adopted

Mechanical Vapour Recompression Incorporated To The Ethanol Production From Sugarcane And Thermal Integration To The Overall Process Applying Pinch Analysis

Vapour recompression is a means of upgrading energy by the compressing of a lower pressure vapour up to a higher pressure, thus making the energy more available to do useful work. There are two types of vapour recompression: thermo-compression and mechanical recompression. Thermo-compression uses high pressure steam through a nozzle to compress a lower pressure vapour to an intermediate pressure. On the other hand, in mechanical recompression "mechanical" means that the compression task is done through the expenditure of mechanical energy for instance a steam turbine driven a compressor. Other means of driving could be also include an electric motor or an internal combustion engine. In both of cases the main advantage of vapour recompression is that it is not necessary to supply the latent heat of vaporization to the vapour being compressed. The aim of this study is to evaluate the possibilities of the incorporation of mechanical vapour recompression in the ethanol production process from the energy point of view. Thus mechanical vapour recompression is integrated to the juice evaporation system which is composed by a multiple effect evaporator. Simulations in Aspen Plus were accomplished to perform the mass and energy balances. Results showed that the introduction of vapour recompression promoted a reduction in steam consumption of approximately 10 % in evaporation system and 4% in overall process. In order to further reduce the steam consumption of the plant, Pinch Analysis was applied to integrate the vapour recompression process coupled to evaporation system to all available streams in ethanol production process..39Special Issue397402Baloh, T., Sugar of a beet sugar factory in which vapour compression is applied (1984) Sugar Journal, , September, 1984Boggild, K., Andersen, K., Energy reduction by vapour compression - An example from Naskskov sugar factory (1989) Zuckerind, 114, pp. 478-481Dias, M.O.S., Modesto, M., Ensinas, A.V., Nebra, S.A., Maciel, R.F., Rossell, C.E.V., Improving bioethanol production from sugarcane: Evaluation of distillation, thermal integration and cogeneration systems (2011) Energy, 36, pp. 3691-3703(2014) Evaporation Technology Using Mechanical Vapour Recompression, , www.niroinc.com, GEA accessed 26.02.2014Kiss, A.A., Landaeta, S.J.F., Infante, F.C.A., Mastering heat pumps selection for energy efficient distillation (2012) Chemical Engineering Transactions, 29, pp. 397-402Palacios-Bereche, R., Ensinas, A.V., Nebra, S.A., Energy consumption in ethanol production by enzymatic hydrolisis - The integration with the conventional process using Pinch Analysis (2011) Chemical Engineering Transactions, 24, pp. 1189-1194Palacios-Bereche, R., Mosqueira-Salazar, K.J., Modesto, M., Ensinas, A.V., Nebra, S.A., Serra, L.M., Lozano, M.A., Exergetic analysis of the integrated first- and second-generation ethanol production from sugarcane (2013) Energy, 62, pp. 46-61Rein, P., (2007) Cane Sugar Engineering, , Verlag Dr. Albert Bartens K. G Berlin, GermanyVan Der Poel, P.W., Schiweck, H., Schwartz, T., (1998) Sugar Technology, Beet and Cane Sugar Manufacture, , Verlag Dr. Albert Bartens K. G, Berlin, German

Ethanol Production By Enzymatic Hydrolysis From Sugarcane Biomass-the Integration With The Conventional Process

The aim of this study is to make an evaluation of the possibilities of ethanol production increase through the introduction of bagasse hydrolysis process in conventional distilleries, considering the limiting situation of bagasse use: it is the major by-product in sugar and ethanol production and is burnt in boilers to satisfy the steam and power requirements of the process. Simulations in ASPEN PLUS® software were performed, in order to evaluate the mass and energy balances, for the integrated process, considering the pre-treatment of sugarcane bagasse by steam explosion. The cogeneration system was also modelled and integrated with the ethanol production process. It consists of a steam cycle with backpressure steam turbines and parameters of live steam of 67 bar and 480°C. In all the cases studied it was considered that the steam flowused in the system was just that necessary to fulfil the process thermal needs, so, it was assumed that the surplus of bagasse was used to produce ethanol. The use of sugarcane trash was considered in order to accomplish the energetic needs of the overall process as well as lignin cake, which is a hydrolysis process residue. Several cases were evaluated, which include: the conventional ethanol production plant without hydrolysis (Case I), the conventional plant joint with hydrolysis process without thermal integration considering different solid contents in the hydrolysis reactor (Cases II, III and IV), and the conventional plant joint with the hydrolysis process considering thermal integration through Pinch method (Case V). The results shown a modest ethanol production increase of 9.7% for the situation without thermal integration and low solid content in the hydrolysis reactor, on the other hand, the case where thermal integration was applied presented an ethanol production increase of 17.4%.5159172Leite, R.C.C., Fuel bioethanol an opportunity to Brazil (2009), Brasilia: Centro de Gestão e Estudos Estratégicos, In PortugueseRein, P., Cane Sugar Engineering (2007), Berlin: Verlag Dr. Albert Bartens K. GWooley, R.J., Putsche, V., Development of an ASPEN PLUS Physical Property Database for Biofuels Components (1996), www.p2pays.org/ref/22/21210.pdf, National Renewable Energy Laboratory, Available at, accessed 12.11. 2007Palacios-Bereche, R., Modeling and energy integration of the ethanol production process from sugarcane biomass [PhD Thesis] (2011), Campinas, Brazil: University of Campinas, In PortugueseDias, M.O.S., Simulation of ethanol production processes from sugar and sugarcane bagasse, aiming process integration and maximization of energy and bagasse surplus (2008), [dissertation]. Campinas, Brazil: University of Campinas, In PortugueseEijsberg, R., The design and economic analysis of a modern bioethanol factory located in Brazil (2006), [dissertation]. Delft, The Netherlands: University DelftRossell, C.E.V., Sugarcane processing to ethanol for fuel purposes (1988) Chemistry and Processing of Sugarbeet and Sugarcane, , In, edited by Clarke M. A. and Godshall M.A., Elsevier Science Publishers B. V., AmsterdamFinguerut, Fermentation, Hydrolysis and Distillation (2008) Biomass for Energy, pp. 436-474. , In: Cortes et al. editors, Campinas, Brazil: Ed. UnicampDias, M.O.S., Modesto, M., Ensinas, A.V., Nebra, S.A., Maciel Filho, R., Rossell, C.E.V., Improving bioethanol production from sugarcane: evaluation of distillation, thermal integration and cogeneration systems (2010) Energy, 36, pp. 3691-3703Palacios-Bereche, R., Nebra, S.A., Thermodynamic modeling of a cogeneration system for a sugarcane mill using ASPEN PLUS, difficulties and challenges (2009), COBEM 2009: Proceedings of the 20th International Congress of Mechanical Engineering, Nov 15-20, Gramado, BrazilMagnusson, H., Process simulation in Aspen Plus of an integrated ethanol and CHP plant (2005), [dissertation]. Sweden: Umea UniversitySun, Y., Cheng, J., Hydrolysis of lignocellulosic materials for ethanol production: a review (2002) Bioresource Technology, 83, pp. 1-11Efe, C., Technical and economical feasibility of production of ethanol from sugar cane and sugarcane bagasse (2005), [dissertation], Delft, The Netherlands: TU-DelftCarrasco, C., Baudel, H.M., Sendelius, J., Modig, T., Roslander, C., Galbe, M., Hahn-Hägerdal, B., Lidén, G., SO2-catalyzed steam pretreatment and fermentation of enzymatically hydrolyzed sugarcane bagasse (2010) Enzyme and Microbial Technology, 46, pp. 64-73Kling, S.H., Carvalho Neto, C., Ferrara, M.A., Torres, J.C.R., Magalhaes, D.B., Ryu, D.D.Y., Enhancements of enzymatic hydrolysis of sugar cane bagasse by steam explosion pretreatment (1987) Biotechnology and Bioengineering, 29, pp. 1035-1039Sanchez, O.J., Cardona, C.A., Trends in biotechnological production of fuel ethanol from different feedstocks (2008) Bioresource Technology, 99, pp. 5270-5295Jorge, L.M.M., Righetto, A.R., Polli, P.A., Santos, O.A.A., Maciel Filho, R., Simulation and analysis of a sugarcane juice evaporation system (2010) Journal of Food Engineering, 99, pp. 351-359Cardona, C.A., Sanchez, O.J., Energy consumption analysis of integrated flowsheets for production of fuel ethanol from lignocellulosic biomass (2006) Energy, 31 (13), pp. 2447-2559Walter, A., Ensinas, A.V., Combined production of second-generation biofuels and electricity from sugar-cane residues (2010) Energy, 35, pp. 874-879Hassuani, S.J., Leal, M.R.L.V., Macedo, I.C., Biomass power generation: Sugarcane bagasse and trash, Piracicaba (2005), Brazil: Ed. PNUD and CTCMichelazzo, M.B., Sensitivity analysis of six systems for collection of sugarcane trash (Saccharum spp.) (2005), [dissertation]. Campinas, Brazil: University of Campinas, In PortugueseWestphalen, D.L., Wolf Maciel, M.R., Pinch Analysis of evaporation systems (2000) Brazilian Journal of Chemical Engineering, 17, pp. 4-7Pereira, L.T.C., Teixeira, R.S.S.T., Bom, E.P.S., Freitas, S.P., Sugarcane bagasse enzymatic hydrolysis: rheological data as criteria for impeller selection (2010) Journal of Industrial Microbiology & Biotechnology, , DOI 10.1007/s10295-010-0857-8Dias, M.O.S., Ensinas, A.V., Nebra, S.A., Maciel Filho, R., Rossell, C.E.V., Production of bioethanol and other bio-based materials from sugarcane bagasse: Integration to conventiona l bioethanol production process (2009) Chemical Engineering Research and Design, 87, pp. 1206-1216Galbe, M., Zacchi, G., Ethanol production from lignocellulosic materials (2010) Bioethanol from sugarcane: R&D for productivity and sustainability, 12, pp. 697-716. , In: CORTEZ, L.A.B. (Coord.), Sao Paulo: Blucher, Part. 4, ChapCella, N., Trash use as fuel in biomass boilers. Course Boilers, Environment and Renewable Energy (2010) Ribeirao Preto, , 23-24 de juneDias, M.O.S., Cunha, M.P., Maciel Filho, R., Bonomi, A., Jesus, C.D.F., Rossell, C.E.V., Simulation of integrated first and second generation bioethanol production from sugarcane :comparison between different biomass pre-treatment methods (2011) Journal of Industrial Microbiology & Biotechnology, 38, pp. 955-96

New Alternatives For The Fermentation Process In The Ethanol Production From Sugarcane: Extractive And Low Temperature Fermentation

Ethanol is produced in large scale from sugarcane in Brazil by fermentation of sugars and distillation. This is currently considered the most efficient biofuel technology, leading to significant reduction on greenhouse gases emissions. However, some improvements in the process can be introduced in order to reduce the steam consumption. In current distilleries, a significant fraction of the energy consumption occurs in the purification step-distillation and dehydration-since conventional fermentation systems employed in the industry require low substrate concentration, thus producing wine with low ethanol content (around 8.5 °GL), which must be distilled, consequently with high energy consumption. In this study, alternatives to the conventional fermentation processes employed in the industry are assessed, in the context of a large scale sugarcane autonomous distillery, through computer simulation. These new alternatives are: low temperature fermentation and vacuum extractive fermentation. The aim of this study is to assess the incorporation of these alternative fermentation processes, evaluating the impacts in ethanol production, energy consumption and surplus electricity produced in the cogeneration system. Simulations of the complete ethanol production process, including these alternative technologies were carried out using the Aspen Plus software. Several cases were evaluated, taking into account different cooling technologies, which include vapour compression refrigeration systems and absorption refrigeration systems. A thermal integration technique was applied. Results shown that the ethanol production increases between 3.3% and 4.8% and a reduction in steam consumption of up to 36%. About the surplus electricity, the reduction in steam consumption promotes a reduction in surplus electricity when a steam cycle with backpressure steam turbines is adopted, however, a surplus electricity of 85 kWh/t of cane can be achieved when condensing-extracting steam turbines are used.Cortez, L.A.B., Sugarcane Bioethanol-R&D for Productivity and Sustainability (2010), São Paulo, Brazil: Edit. E. BlucherDias, M.O.S., Junqueira, T.L., Jesus, C.D.F., Rossell, C.E.V., Maciel, F.R., Bonomi, A., Improving second generation ethanol production through optimization of first generation production process from sugarcane (2012) Energy, 43, pp. 246-252Dias, M.O.S., Junqueira, T.L., Jesus, C.D.F., Rossell, C.E.V., Maciel, F.R., Bonomi, A., Improving bioethanol production-Comparison between extractive and low temperature fermentation (2012) Applied Energy, 98, pp. 548-555Rein, P., (2010), Cane Sugar Engineering, Berlin, Verlag Dr. Albert Bartens K. GTorija, M.J., Rozès, N., Poblet, M., Guillamon, J.M., Mas, A., Effects of fermentation temperature on the strain population of Sacharomyces cerevisiae (2003) International Journal of Food Microbiology, 80, pp. 47-53Dias, M.O.S., Filho, M.R., Rossell, C.E.V., Efficient cooling of fermentation vats in ethanol production-Part 1 (2007) Proceedings of International Society of Sugar Cane Technologists, 26, pp. 1210-1216Olivério, J.L., Tamassia Barreira, S., Boscariol, F.C., César, A.R.P., Kiyomi Yamakawa, C., Alcoholic fermentation with temperature controlled by ecological absorption chiller-EcoChill (2010) Proceedings of International Society of Sugar Cane Technologists, 27, pp. 1-9Magazoni, F.P., Monteiro, J.B., Cardemil, J.M., Colle, S., Cooling of ethanol fermentation process using absorption chillers (2010) Int. J. of Thermodynamics, 13, pp. 111-118Cardemil, J.M., Colle, S., Monteiro, J.B., Magazoni, F.C., Economic evaluation of refrigeration alternatives for alcoholic fermentation (2009) Proceedings of 22nd International Conference on Efficiency, Cost, Optimisation, Simulation and Environmental Impact of Energy Systems, pp. 1455-1464. , In, ECOS 2009, Foz de Iguaçú, Paraná, Brazil, August 20-September 3Chunnanond, K., Aphornratana, S., An experimental investigation of a steam ejector refrigerator: the analysis of the pressure profile along the ejector (2003), http://www.energy-based.nrct.go.th, National Research Council of Thailand, Available in, in: September 29th, 2010Luong, J.H.T., Kinetics of ethanol inhibition in alcohol fermentation (1985) Biotechnology and Bioengineering, 27 (3), pp. 280-285Atala, D.I.P., Assembly, instrumentation, control and experimental development of an extractive fermentation process for ethanol production (2004), PhD Thesis, Faculty of Food Engineering, University of Campinas, Campinas, SP, Brazil (in Portuguese)Unicamp, M.F., Atala, D.I.P., Fermentative vacum extraction process for the production of ethanol (2005), http://www.patentesonline.com.br/processo-fermentativo-extrativo-a-vacuo-para-producao-deetanol-61210a.html, Patent Int CI7.:, PI0500321-0. January 28th, Available in, in: October 29th, 2010 (in Portuguese)Rivera, E.C., Costa, A.C., Atala, D.I.P., Maugeri, F., Wolf Maciel, M.R., Maciel Filho, R., Evaluation of optimization techniques for parameter estimation: Application to ethanol fermentation considering the effect of temperature (2006) Process Biochemistry, 41, pp. 1682-1687Costa Filho, M.V.A., Monteiro, J.B., Magazoni, F.C., Colle, S., Modelling, simulation and analysis of ethanol fermentation process with control structure in industrial scale (2009) Proceedings of 22nd International Conference on Efficiency, Cost, Optimisation, Simulation and Environmental Impact of Energy Systems-ECOS 2009, pp. 1351-1360. , In, Foz de Iguaçú, Paraná, Brazil, August 20-September 3Costa, A.C., Atala, D.I.P., Maugeri, F., Maciel Filho, R., Factorial design and simulation for the optimization and determination of control structures for an extractive alcoholic fermentation (2001) Process Biochemistry, 37, pp. 125-137Leite, R.C.D.C., (2009), Bioethanol fuel: an opportunity for Brazil, Brasilia, DF, Centro de Gestão e Estudos Estratégicos, in PortuguesDias, M.O.S., Simulation of the ethanol production process from sugar and bagasse aiming the process integration and the maximization of the production of energy and bagasse surplus, 2008 Master thesis, Chemical Engineering Faculty, University of Campinas, Campinas, Brazil (in Portuguese)(2010), Usina Colombo III, São Paulo State, Brazil, Personal Communication, OctoberEnsinas, A.V., Thermal integration and thermoeconomic optimization applied to industrial process for the production of sugar and ethanol from sugarcane, 2008 Doctoral Thesis, Mechanical Engineering Faculty, University of Campinas, Campinas, Brazil (in Portuguese)Elia Neto, A., Handbook of water conservation and reuse in the sugarcane agroindustry (2009), Brasilia: Agência Nacional de Águas (ANA), (in Portuguese)Camargo, C.A., Energy conservation in the sugar industry and alcohol (1990), São Paulo: Instituto de Pesquisas Tecnológicas (IPT), (in Portuguese)Boletim Técnico do Controle Mutuo (2005), CTC-Centro de Tecnologia Canavieira, (in Portuguese)Dias, M.O.S., (2009), Personal communicationViegas, M.C., Optimization of continuous fermentation system using reactors tower type and yeast with flocculants characteristics (2003), Doctoral Thesis, Chemical Engineering Faculty, University of Campinas, Campinas, Brazil (in Portuguese)Ruas, T.C.B.G., Technological control in sugarcane agroindustry (2001), Technical Course in Sugar and Alcohol. Centro Estadual de Educaçao Tecnológica "Paula Souza", Araras, São Paulo, (in Portuguese)Amorim, H.V., Alcoholic Fermentation, science and technology (2005), Piracicaba: Fermentec, Brazil (in Portuguese)Meirelles, A.J.A., Expansion of bioethanol production and technological improvement of alcoholic distillation (2006) Workshop "Production of ethanol." Engineering School of Lorena, , In:, Lorena, Brazil, in PortugueseJunqueira, T.L., Simulation of extractive distillation columns, conventional and azeotropic systems, in the bioethanol production process through the modeling of non-equilibrium and the modeling of equilibrium stages with efficiency (2010), Master thesis, Chemical Engineering Faculty, University of Campinas, Campinas, Brazil (in Portuguese)Brito, R.P., Extractive distillation process: dynamic modelling, simulation and evaluation of a new configuration (1997), Doctoral Thesis, Chemical Engineering Faculty, University of Campinas, Campinas, Brazil (in Portuguese)Sánchez Prieto, M.G., Cogeneration alternatives in the sugar and alcohol industry-Case study (2003), Doctoral Thesis, Mechanical Engineering Faculty, University of Campinas, Campinas, Brazil (in Portuguese)Seabra, J.E.A., Technical-economic evaluation of options for the complete utilization of sugarcane biomass in Brazil (2008), Doctoral Thesis, Mechanical Engineering Faculty, University of Campinas, Campinas, Brazil (in Portuguese)Dias, M.O.S., Cunha, M.P., Maciel Filho, R., Bonomi, A., Jesus, C.D.F., Rossell, C.E.V., Simulation of integrated first and second generation bioethanol production from sugarcane: comparison between different biomass pre-treatment methods (2011) J. Ind. Microbiol. Biotechnol, 38, pp. 955-966Dias, M.O.S., Desenvolvimento e otimização de processos de produção de etanol de primeira e segunda geração e eletricidade a partir da cana-de-açúcar (2011), p. 253. , Tese (Doutorado) -Faculdade de Engenharia Química, Universidade Estadual de Campinas, CampinasJunqueira, T.L., Dias, M.O.S., Maciel Filho, R., Wolf Maciel, M.R., Rossell, C.E.V., Atala, D.I.P., Propositions of alternative configurations of the distillation columns for bioethanol production using vacuum extractive fermentation process (2009) Chemical Engineering Transactions, 17, pp. 1627-1632Cohen, L.M., Modelagem e simulação do processo de fermentação extrativa a vácuo com uma câmara de flash e separação do CO2 utilizando uma coluna de absorção (2011), p. 119. , Dissertação (Mestrado). Faculdade de Engenharia Química. Universidade de Campinas, CampinasCohen, L.M., Quintero, H.I., Ramirez, R., Maciel Filho, R., Atala, D.I.P., Simulation and Optimization of the Vacuum Extractive Fermentation Coupled to an Absorption Column for Bioethanol Production Using a High Biomass Concentration (2011), ICheaP-10-The tenth International Conference on Chemical & Process Engineering, 8-11 May, Florence, ItalyPhillips, B.A., Development of a high-efficiency, Gas-Fired, Absorption Heat Pump for Residential and Small-Commercial Applications (1990), http://www.ornl.gov, Phase I Final Report. Oak Ridge National Laboratory, Available inPalacios-Bereche, R., Modelling and energetic integration of the ethanol production from sugarcane biomass. Doctoral thesis (2011), Mechanical Engineering School, University of Campinas, São Paulo, Brazil, (In Portuguese)Ensinas, A.V., Nebra, S.A., Lozano, M.A., Serra, L.M., Design of evaporation systems and heaters networks in sugar cane factories using a thermoeconomic optimization procedure (2007) International Journal of Thermodynamics, 10 (3), pp. 97-105Ensinas, A.V., Nebra, S.A., Exergy analysis as a tool for sugar and ethanol process (2009) Handbook of exergy, hydrogen energy and hydropower research, Nova Science Publishers Inc, pp. 125-160. , in G. Pélissier, A. Calveted (Eds.), NewYor

Extraction Process In The Ethanol Production From Sugarcane - A Comparison Of Milling And Diffusion

The objective of the extraction process in the ethanol production from sugarcane is to separate the sucrose-containing juice from the remainder of the cane, mainly fibre. The two currents, products of this process, are the juice and the bagasse. The juice is used to produce ethanol and the bagasse is the fuel for the boilers. Two types of devices are employed to perform this operation: mills and diffusers. Each one of them consumes different types of energy: mills consume mechanical energy, diffusers consume basically thermal energy. As both devices utilize an important quantity of energy, their effect in the energy balance of the factory needs to be taken into account. Aiming to discuss and characterize these effects, simulations of the complete ethanol production process, including the cogeneration system, were carried out using the Aspen Plus software, considering both devices. Process integration was also performed targeting to reduce the energy consumption. These results are presented and compared. Considering the integrated ethanol production process, with extraction -condensing steam turbines in cogeneration system, working with mills, it can produce an electricity surplus of 83.4 kWh/t of sugarcane, however, for the same conditions, working with the diffusion extraction process a production of 91.3 kWh/t of cane can be obtained, including also a small increase of 2 % in the ethanol production.39Special Issue15191524Birkett, L., Integrating a cane diffuser into an existing sugar factory (1999) International Sugar Journal, 101 (1201), pp. 99-104Dias, M.O.S., Ensinas, A.V., Nebra, S.A., Maciel-Filho, R., Rossell, C.E.V., Wolf Maciel, M.R., Production of bioethanol and other bio-based materials from sugarcane bagasse: Integration to conventional bioethanol production process (2009) Chem. Eng. Res. des, 87, pp. 1206-1216Elia Neto, A., (2009) Guide for Water Reuse and Conservation in the Sugar Cane Industry, , (in Portuguese) Agência Nacional de Aguas (ANA), Brasilia, BrazilEnsinas, A.V., (2008) Thermal Integration and Thermoeconomic Optimization Applied to Industrial Process of Sugar and Ethanol from Sugarcane (In Portuguese), , Ph.D Thesis University of Campinas, Campinas, BrazilEnsinas, A.V., Modesto, M., Nebra, S.A., (2007) Analysis of Different Cane Juice Extractions Systems for Sugar and Ethanol Production: Influences on Electricity Generation and Final Products Exergetic Costs, Proceedings of ECOS 2007, pp. 727-734. , Padova, Italy, 25-28 June 2007Hoekstra, R.G., Energy consequences of diffusion versus milling (1995) Proc. South African Sugar Technologists Association, pp. 205-207. , Durban, South Africa, JuneModesto, M., Zemp, R., Nebra, S.A., Ethanol production from sugar cane: Assessing the possibilities of improving Energy efficiency through exergetic cost analysis (2009) Heat Transfer Engineering, 30 (4), pp. 272-281Oliverio, J.L., Avila, A.C.R.D., Faber, A.N., Soares, P.A., Juice extraction systems: Mills and diffusers - The Brazilian experience (2013) Proc. Int. Soc. Sugar Cane Technol, 28, pp. 1-18Palacios-Bereche, R., (2011) Modeling and Energetic Integration of the Ethanol Production from Sugarcane Biomass, , (in Portuguese), Ph.D Thesis, University of Campinas, São Paulo, BrazilPalacios-Bereche, R., Mosqueira-Salazar, K.J., Modesto, M., Ensinas, A.V., Nebra, S.A., Serra, L.M., Lozano, M.A., Exergetic analysis of the integrated first and second generation ethanol Production from Sugarcane (2013) Energy, 62, pp. 46-61Palacios-Bereche, R., Ensinas, A.V., Modesto, M., Nebra, S.A., New alternatives for the fermentation process in the ethanol production from sugarcane: Extractive and low temperature fermentation (2014) Energy, 70, pp. 595-604Rein, P., (2007) Cane Sugar Engineering, , Verlag Dr. Albert Bartens K. G, Berlin, GermanyVan Hengel, A., Diffusion as steam saver (1990) Zuckerind, 115 (7), pp. 551-55

Reduction of water consumption in an integrated first- and second-generation ethanol plant

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)The aim of this study was to estimate the increase in industrial water consumption and withdrawal in a conventional sugarcane ethanol mill due to the introduction of second-generation ethanol production by a bagasse hydrolysis process, and to identify opportunities of water reuse, in order to minimize water withdrawal. Simulations in ASPEN PLUS software were performed for mass and energy balances. Three cases were evaluated: a conventional ethanol production plant (Case I), and two second-generation plants incorporating bagasse hydrolysis differing only in their glucose concentration processes, namely by evaporation (Case II), and by membrane separation (Case III). Results show that external withdrawals of 738 L/t of cane for Case 1,955 L/t of cane for Case II and 853 L/t of cane for Case III are required to cover the water deficit of the plant. These values are lower than the mandated limit of 1000 L/t of cane for the sugar cane industry in the State of Sao Paulo. Moreover, for Cases II and III, which need large additional amounts of water for the hydrolysis stage, water usages of 10.77 and 9.38 L of water per litre of ethanol produced were achieved, approaching the figure of 9.34 L water per litre of ethanol produced by the conventional plants (Case I). This highlights the high potential for reduction practices based on the concept of energy and water integration. (C) 2013 International Energy Initiative. Published by Elsevier Inc. All rights reserved.175531535Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)FINEP [01/06/004700]Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)CNPq [135595/2008-8, 556212/2010-0, 304820/2009-1, 470481/2012-9]FAPESP [2011/05718-1, 2011/51902-9]FINEP [01/06/004700

Thermal Integration Of Different Plant Configurations Of Sugar And Ethanol Production From Sugarcane

The sugarcane industry represents one of the most important economic activities in Brazil producing sugar and ethanol for the internal and external markets. Most of the sugarcane plants in Brazil have been projected to produce both sugar and ethanol, prioritizing one over the other according to market prices. There are also plants dedicated only to ethanol production. Nevertheless, this change in the production pattern affects parameters in their production such as water consumption, steam demands, bagasse surplus and electricity production. Thus, the aim of this study is to evaluate the production parameters for different configurations of sugarcane plant: (a) all sugarcane juice is destined to produce ethanol without sugar production and (b) distribution of 50 %/50 % of total recoverable sugars in sugar and ethanol production. Simulations in ASPEN PLUS® software were performed in order to evaluate the mass and energy balances and thermal integration using the Pinch Method was applied in order to minimize the utilities consumption.39Special Issue11471152(2009) Fuel Bioethanol: An Opportunity to Brazil, , CGEE (Centre for Strategic Studies and Management in Science, Technology and Innovation) , Brasilia DF, Brazil, (In Portuguese)Dias, M.O.S., Modesto, M., Ensinas, A.V., Nebra, S.A., Filho, R.M., Rossell, C.E.V., Improving bioethanol production from sugarcane: Evaluation of distillation, thermal integration and cogeneration systems (2011) Energy, 36, pp. 3691-3703Ensinas, A.V., Nebra, S.A., Lozano, M.A., Serra, L.M., Design of evaporation systems and heaters networks in sugar cane factories using a thermoeconomic optimization procedure (2007) International Journal of Thermodynamics, 10 (3), pp. 97-105Ensinas, A.V., Nebra, S.A., Exergy analysis as a tool for sugar and ethanol process (2009) Handbook of Exergy, Hydrogen Energy and Hydropower Research, pp. 125-160. , G. Pélissier, A. Calveted (Eds.) Nova Science Publishers Inc., NewYork, USA(2014) Dados Preliminares Do Balanço Energético Nacional 2013, , www.epe.gov.br, EPE (Empresa de Pesquisa Energética) accessed 24.02.2014Martinez-Hernandez, E., Sadhukhan, J., Campbell, G.M., Integration of bioethanol as an in-process material in biorefineries using mass pinch analysis (2013) Applied Energy, 104, pp. 517-526Linnhoff, B., Manson, D.R., Wardle, I., Understanding heat exchangers networks (1979) Computer and Chemical Engineering, 3, pp. 295-302Higa, M., Freitas, A.J., Bannwart, A.C., Zemp, R.J., Thermal integration of multiple effect evaporator in sugar plant (2009) Applied Thermal Engineering, 29, pp. 515-522Palacios-Bereche, R., Ensinas, A.V., Nebra, S.A., Energy consumption in ethanol production by enzymatic hydrolisis - The integration with the conventional process using Pinch Analysis (2011) Chemical Engineering Transactions, 24, pp. 1189-1194Palacios-Bereche, R., Mosqueira-Salazar, K.J., Modesto, M., Ensinas, A.V., Nebra, S.A., Serra, L.M., Lozano, M.A., Exergetic analysis of the integrated first- and second-generation ethanol production from sugarcane (2013) Energy, 62, pp. 46-61(2014) RFA (Renewable Fuel Association), , www.ethanolrfa.org/pages/statistics, Statistics Data accessed 24.02.2014Urbaniec, K., Zalewski, P., Zhu, X.X., A decomposition approach for retrofit design of energy systems in the sugar industry (2000) Applied Thermal Engineering, 20, pp. 1431-144