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Integrated 1st & 2nd Generation Bioethanol Production from Sugarcane

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This document discusses biofuels production from sugarcane bagasse. It describes the multi-step process of producing ethanol from bagasse, including pretreatment, hydrolysis, fermentation and distillation. The process yields 4.23 liters of fuel ethanol from 70 kg of sugarcane bagasse starting material. Additionally, the document outlines the economics of bagasse bioethanol, noting its potential to be a competitive energy source. Issues related to the environmental and social impacts of sugarcane production are also briefly discussed.

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1

Suman Swami Onyedika Egbujo Emmanuel Ogbughalu Dominic Smith Priyesh Waghmare

2

Introduction  Biofuels are a wide range of fuels which are in some way derived from biomass.  Different generations of biofuel according to source: GENERATIONS FEEDSTOCK First Sugarcane, grains and seeds -as soya bean ,sorghum, corn etc Second Agricultural residues such as Sugarcane bagasse, corn straw and industrial waste. Third Algae

3

Biofuels vs Fossil fuels  Fossils are depleting and biofuels are used to complement them.  Biofuels are carbon neutral.  Cars are compatible with Fossil fuels.  Fossil fuel readily available.

4

Ethanol technicalities in Car Engines  Performance.  Cold start.  Mileage.  Sludge problem.  Corrosion.  Higher ethanol blends.

5

Bagasse:  Fibrous matter that remains after sugarcane stalks are crushed to extract their juice.  Production: Each 10 tons of sugarcane = 3 tonnes of wet bagasse. Source: ceesdghana.org  Quantity of bagasse produced = size of sugarcane industry.  Chemical analysis: Cellulose 45-55%, hemicellulose 20-25%, lignin 18-24%, ash 1-4%, waxes <1%.

6

First Generation Process SUGAR JUICE SUGARCANE CLEANING EXTRACTION TREATMENT SUGARCANE JUICE BAGASSE CONCENTRATION DEHYDRATION DISTILLATION CENTRIFUGATION FERMENTATION ‘SOILDS’ ANHYDROUS INTEGRATION ETHANOL OF 2nd GENERATION SUGARS

7

Detoxification To purification Alkaline neutralisation detoxification Ethanol , waste mixture Bagasse -Lignin (30%) Overliming -Cellulose (40%) -Calcium hydroxide -Hemicellulose (30%) -4hrs -300C Hexose and Pentose Fermentation Removes 50% of waste – precipitates out Liquid fraction – -Hydroxymethylfurfural Co-fermentation Degraded hemicellulose -aliphatic acid Pentose sugars – primarily xylose Yeast - Hexose -phenolic compounds Recombinant yeast – Pentose -pentose metabolism Yield = 60% pentose (xylose) pathways Pretreatment -360C Pretreatment separates lignin -24hrs and hemicellulose, reduces Filtration -1- part yeast cellulose crystallinity and Separates solid and -4-parts reducing sugar increases porosity liquid fraction mixture -5-parts nutrient broth -Dilute HCl -HCl conc. = 1.2% v/v Yield = 80% ethanol -15 parts acid to 1 part bagasse -1210C Solid fraction – Cellulose Hydrolysis Sugars used for cell -4Hrs Cellulose maintenance Lignin Degrade cellulose to Pentose metabolism has -Yield = 38% - reducing sugars glucose (saccharification) reduced efficiency in the form of hemicellulose and cellulose -using conc. HCl -15% v/v -1800C -4hrs -30Bars Neutralises Yield = 35% hexose -NaOH (glucose) from solid fraction Second Generation Process Hexose (glucose) from sugarcane – first generation

8

Detoxification To purification Alkaline neutralisation detoxification Ethanol , waste mixture Bagasse 100Kg of bagasse = Overliming 30Kg lignin Yield = 60% pentose (xylose) 6.81Kg of ethanol 40Kg cellulose 10.64Kg of water 30Kg hemicellulose >2.128Kg of yeast Total liquid = 17.45Kg 70Kg worth of reducing 4.79Kg of pentose (xylose) sugars 30% hemicellulose Hexose and Pentose 7.98Kg Fermentation Pretreatment Co-fermentation -Yield = 38% - reducing sugars 26.6Kg -1- part yeast – 2.128Kg in the form of hemicellulose Filtration 4.79 + 3.72 = 8.51Kg of -4-parts reducing sugar and cellulose Separates solid and reducing sugars mixture – 8.51Kg liquid fraction -5-parts water suspension – 10.64Kg Yield = 80% ethanol 40% Cellulose = 10.64Kg 30% Lignin = 30Kg (not broken down) Cellulose Hydrolysis 3.72Kg Hexose (glucose) Degrade cellulose to glucose (saccharification) Yield = 35% hexose Neutralises (glucose) from solid -NaOH fraction Second Generation Process: Hexose (glucose) from Mass Balance sugarcane – first generation

9

Hybrid Purification 4.23L Ethanol Yield 6.5% from 70Kg starting material FUEL ETHANOL 99.5% AZEOTROPE ETHANOL 65% (4.42L Ethanol) AZEOTROPE ETHANOL 96% (4.24L Ethanol) “Distillation 2” de Dehydration Supernatant Distillation 17.45L= 6.8L Ethanol 10.64L Waste Supernatant Water Water Water Centrifugation: Lignin, Yeast

10

Dehydration Methods Used.  Lime (calcium oxide) or rock salt  Addition of an entrainer. Adding small quantities of benzene or cyclohexane.  Molecular Sieves  Membranes :  Can not be exposed to high water concentration  Fouling by fusel oils  Pressure reduction

11

SiftekTM Membrane & System  Produced by Vasperma, gas separation solutions.  This system can be integrated in a bio-ethanol plant.  Replacing the 2nd distillation column and the molecular sieve units for the dehydration process.  Potential of reducing energy consumption by up to 50%.

12

SiftekTM Membranes  Hydrophilic polymer membrane  Exceptional thermal mechanical and solvent resistance properties  Membrane is a proprietary formulation based on polyimide  Provides high flux and water/ethanol selectivity.

13

BY PRODUCTS Vinasse:- Distillation step.  Biodigestion of vinasse-electric power.  1 m3 of bioethanol 115 m3 of biogas 169 kWh of bioelectricity.  As fertilizers  Single cell protein production.  Non-structural bricks.  Animal feed.  Thermophilic digesters Biogas Vinasse methane.

14

Carbondioxide: Fermentation step  Washed to recover the bioethanol.  Carbonated beverages and dry ice, sodium bicarbonate manufacturing and treatment of effluents.  760 kg of CO2 1000 L of anhydrous bioethanol. Fusel oil : Distillation step  Alcohol components acetic acid and butyric acid esters.  Flavour and fragrance manufacturing.  Ethylbutyrate is used as pineapple-banana flavours in the food industry.

15

Second class ethanol: This type is used in Pharma, cosmetics and food industry. Lignin:  Wood adhesive.  Emulsions and dispersants.  Carbon fibre precursor. Other products: Bagasse -Bioelectricity: cogeneration system.  One ton of sugarcane - 250 kg of bagasse -500 kg to 600 kg of steam -electric power production.

16

Economics of bagasse bioethanol fuel:  Potential to be competitive energy resource but needs favourable policies.  Does not compete with food production  Cheaper compared to food crops (price per ton)  Reduce solid waste disposal costs.  Cellulosic ethanol is US$0.59/litre. At this price, it will cost US$120 to substitute a barrel of oil (159 L).

17

Cost and efficiency Source: Goldemberg 2008 Source: eubia.org

18

The Economic Competitiveness of Alcohol Fuel Compared with Gasoline Source: Goldemberg 2008

19

Production costs: Comparison of the production costs (€/1000 liters) of ethanol in Brazil, United States and Germany. Source: Goldemberg 2008

20

Commercialization Refineries are been built by companies like Iogen, Abengoa and Broin while companies like Novozymes, Diversa and Dyadic are producing enzymes which will enhance cellulosic ethanol future. Fuel Ethanol Production by Country(Millions of U.S. liquid gal/yr) Country/Region 2009 2008 2007 United States 10,750.00 9,000.00 6,498.60 Brazil 6,577.89 6,472.20 5,019.20 European Union 1,039.52 733.60 570.30 China 541.55 501.90 486.00 Thailand 435.20 89.80 79.20 Canada 290.59 237.70 211.30 India 91.67 66.00 52.80 Colombia 83.21 79.30 74.90 Australia 56.80 26.40 26.40 Other 247.27 World Total 19,534.99 17,335.29 13,101.70 Source: Wikipedia.org

21

Brazil: Ethanol - Transport sector Year policy Results 1976 mandatory fluctuated between 10 - 25% 1993 mandatory 20% E20 2007 mandatory 25% E25 2003 Introduction Flex-Fuel vehicles 2008 E25-Flex vehicles 18% of Brazils total energy consumption - transport sector 2009 Flex-Fuel vehicles- 92.3% of share -SUCCESS

22

Issues: Environmental and Social Impacts of Sugarcane Production  Deforestation  99.7% of sugarcane plantations are located at least 2,000 kilometres (1,200 mi) from the Amazonia  Fertilizer – water pollution  Effects on food prices  Bagassosis

23

Conclusion:  By integrating 1st & 2nd generation sugarcane ethanol fuel production, we can simultaneously increase yield and efficiency, whilst reducing costs and recycling co- products.  Renewable energy source, which can be very competitive with any other fuel source in terms of cost and efficiency. Its benefits are unparalleled as it converts waste to energy fuel which does not contest on food crops.  However, more research and development is necessary for 2nd generation fuel production.

24

References:  Biomass- based energy fuel through biochemical routes: A review (2007) R.C. Saxena , D.K. Adhikari, H.B. Goyal.  Improving bioethanol production from sugarcane : evaluation of distillation, thermal integration and cogeneration systems (2010) Marina O.S. Dias et al.  Membrane- Based Ethanol Dewatering System (2010) Pierre Cote et al.

More Related Content

Integrated 1st & 2nd Generation Bioethanol Production from Sugarcane

  • 1. Suman Swami Onyedika Egbujo Emmanuel Ogbughalu Dominic Smith Priyesh Waghmare
  • 2. Introduction  Biofuels are a wide range of fuels which are in some way derived from biomass.  Different generations of biofuel according to source: GENERATIONS FEEDSTOCK First Sugarcane, grains and seeds -as soya bean ,sorghum, corn etc Second Agricultural residues such as Sugarcane bagasse, corn straw and industrial waste. Third Algae
  • 3. Biofuels vs Fossil fuels  Fossils are depleting and biofuels are used to complement them.  Biofuels are carbon neutral.  Cars are compatible with Fossil fuels.  Fossil fuel readily available.
  • 4. Ethanol technicalities in Car Engines  Performance.  Cold start.  Mileage.  Sludge problem.  Corrosion.  Higher ethanol blends.
  • 5. Bagasse:  Fibrous matter that remains after sugarcane stalks are crushed to extract their juice.  Production: Each 10 tons of sugarcane = 3 tonnes of wet bagasse. Source: ceesdghana.org  Quantity of bagasse produced = size of sugarcane industry.  Chemical analysis: Cellulose 45-55%, hemicellulose 20-25%, lignin 18-24%, ash 1-4%, waxes <1%.
  • 6. First Generation Process SUGAR JUICE SUGARCANE CLEANING EXTRACTION TREATMENT SUGARCANE JUICE BAGASSE CONCENTRATION DEHYDRATION DISTILLATION CENTRIFUGATION FERMENTATION ‘SOILDS’ ANHYDROUS INTEGRATION ETHANOL OF 2nd GENERATION SUGARS
  • 7. Detoxification To purification Alkaline neutralisation detoxification Ethanol , waste mixture Bagasse -Lignin (30%) Overliming -Cellulose (40%) -Calcium hydroxide -Hemicellulose (30%) -4hrs -300C Hexose and Pentose Fermentation Removes 50% of waste – precipitates out Liquid fraction – -Hydroxymethylfurfural Co-fermentation Degraded hemicellulose -aliphatic acid Pentose sugars – primarily xylose Yeast - Hexose -phenolic compounds Recombinant yeast – Pentose -pentose metabolism Yield = 60% pentose (xylose) pathways Pretreatment -360C Pretreatment separates lignin -24hrs and hemicellulose, reduces Filtration -1- part yeast cellulose crystallinity and Separates solid and -4-parts reducing sugar increases porosity liquid fraction mixture -5-parts nutrient broth -Dilute HCl -HCl conc. = 1.2% v/v Yield = 80% ethanol -15 parts acid to 1 part bagasse -1210C Solid fraction – Cellulose Hydrolysis Sugars used for cell -4Hrs Cellulose maintenance Lignin Degrade cellulose to Pentose metabolism has -Yield = 38% - reducing sugars glucose (saccharification) reduced efficiency in the form of hemicellulose and cellulose -using conc. HCl -15% v/v -1800C -4hrs -30Bars Neutralises Yield = 35% hexose -NaOH (glucose) from solid fraction Second Generation Process Hexose (glucose) from sugarcane – first generation
  • 8. Detoxification To purification Alkaline neutralisation detoxification Ethanol , waste mixture Bagasse 100Kg of bagasse = Overliming 30Kg lignin Yield = 60% pentose (xylose) 6.81Kg of ethanol 40Kg cellulose 10.64Kg of water 30Kg hemicellulose >2.128Kg of yeast Total liquid = 17.45Kg 70Kg worth of reducing 4.79Kg of pentose (xylose) sugars 30% hemicellulose Hexose and Pentose 7.98Kg Fermentation Pretreatment Co-fermentation -Yield = 38% - reducing sugars 26.6Kg -1- part yeast – 2.128Kg in the form of hemicellulose Filtration 4.79 + 3.72 = 8.51Kg of -4-parts reducing sugar and cellulose Separates solid and reducing sugars mixture – 8.51Kg liquid fraction -5-parts water suspension – 10.64Kg Yield = 80% ethanol 40% Cellulose = 10.64Kg 30% Lignin = 30Kg (not broken down) Cellulose Hydrolysis 3.72Kg Hexose (glucose) Degrade cellulose to glucose (saccharification) Yield = 35% hexose Neutralises (glucose) from solid -NaOH fraction Second Generation Process: Hexose (glucose) from Mass Balance sugarcane – first generation
  • 9. Hybrid Purification 4.23L Ethanol Yield 6.5% from 70Kg starting material FUEL ETHANOL 99.5% AZEOTROPE ETHANOL 65% (4.42L Ethanol) AZEOTROPE ETHANOL 96% (4.24L Ethanol) “Distillation 2” de Dehydration Supernatant Distillation 17.45L= 6.8L Ethanol 10.64L Waste Supernatant Water Water Water Centrifugation: Lignin, Yeast
  • 10. Dehydration Methods Used.  Lime (calcium oxide) or rock salt  Addition of an entrainer. Adding small quantities of benzene or cyclohexane.  Molecular Sieves  Membranes :  Can not be exposed to high water concentration  Fouling by fusel oils  Pressure reduction
  • 11. SiftekTM Membrane & System  Produced by Vasperma, gas separation solutions.  This system can be integrated in a bio-ethanol plant.  Replacing the 2nd distillation column and the molecular sieve units for the dehydration process.  Potential of reducing energy consumption by up to 50%.
  • 12. SiftekTM Membranes  Hydrophilic polymer membrane  Exceptional thermal mechanical and solvent resistance properties  Membrane is a proprietary formulation based on polyimide  Provides high flux and water/ethanol selectivity.
  • 13. BY PRODUCTS Vinasse:- Distillation step.  Biodigestion of vinasse-electric power.  1 m3 of bioethanol 115 m3 of biogas 169 kWh of bioelectricity.  As fertilizers  Single cell protein production.  Non-structural bricks.  Animal feed.  Thermophilic digesters Biogas Vinasse methane.
  • 14. Carbondioxide: Fermentation step  Washed to recover the bioethanol.  Carbonated beverages and dry ice, sodium bicarbonate manufacturing and treatment of effluents.  760 kg of CO2 1000 L of anhydrous bioethanol. Fusel oil : Distillation step  Alcohol components acetic acid and butyric acid esters.  Flavour and fragrance manufacturing.  Ethylbutyrate is used as pineapple-banana flavours in the food industry.
  • 15. Second class ethanol: This type is used in Pharma, cosmetics and food industry. Lignin:  Wood adhesive.  Emulsions and dispersants.  Carbon fibre precursor. Other products: Bagasse -Bioelectricity: cogeneration system.  One ton of sugarcane - 250 kg of bagasse -500 kg to 600 kg of steam -electric power production.
  • 16. Economics of bagasse bioethanol fuel:  Potential to be competitive energy resource but needs favourable policies.  Does not compete with food production  Cheaper compared to food crops (price per ton)  Reduce solid waste disposal costs.  Cellulosic ethanol is US$0.59/litre. At this price, it will cost US$120 to substitute a barrel of oil (159 L).
  • 17. Cost and efficiency Source: Goldemberg 2008 Source: eubia.org
  • 18. The Economic Competitiveness of Alcohol Fuel Compared with Gasoline Source: Goldemberg 2008
  • 19. Production costs: Comparison of the production costs (€/1000 liters) of ethanol in Brazil, United States and Germany. Source: Goldemberg 2008
  • 20. Commercialization Refineries are been built by companies like Iogen, Abengoa and Broin while companies like Novozymes, Diversa and Dyadic are producing enzymes which will enhance cellulosic ethanol future. Fuel Ethanol Production by Country(Millions of U.S. liquid gal/yr) Country/Region 2009 2008 2007 United States 10,750.00 9,000.00 6,498.60 Brazil 6,577.89 6,472.20 5,019.20 European Union 1,039.52 733.60 570.30 China 541.55 501.90 486.00 Thailand 435.20 89.80 79.20 Canada 290.59 237.70 211.30 India 91.67 66.00 52.80 Colombia 83.21 79.30 74.90 Australia 56.80 26.40 26.40 Other 247.27 World Total 19,534.99 17,335.29 13,101.70 Source: Wikipedia.org
  • 21. Brazil: Ethanol - Transport sector Year policy Results 1976 mandatory fluctuated between 10 - 25% 1993 mandatory 20% E20 2007 mandatory 25% E25 2003 Introduction Flex-Fuel vehicles 2008 E25-Flex vehicles 18% of Brazils total energy consumption - transport sector 2009 Flex-Fuel vehicles- 92.3% of share -SUCCESS
  • 22. Issues: Environmental and Social Impacts of Sugarcane Production  Deforestation  99.7% of sugarcane plantations are located at least 2,000 kilometres (1,200 mi) from the Amazonia  Fertilizer – water pollution  Effects on food prices  Bagassosis
  • 23. Conclusion:  By integrating 1st & 2nd generation sugarcane ethanol fuel production, we can simultaneously increase yield and efficiency, whilst reducing costs and recycling co- products.  Renewable energy source, which can be very competitive with any other fuel source in terms of cost and efficiency. Its benefits are unparalleled as it converts waste to energy fuel which does not contest on food crops.  However, more research and development is necessary for 2nd generation fuel production.
  • 24. References:  Biomass- based energy fuel through biochemical routes: A review (2007) R.C. Saxena , D.K. Adhikari, H.B. Goyal.  Improving bioethanol production from sugarcane : evaluation of distillation, thermal integration and cogeneration systems (2010) Marina O.S. Dias et al.  Membrane- Based Ethanol Dewatering System (2010) Pierre Cote et al.

Editor's Notes

  1. The purification step involves a distillation step and a dehydration step. Typically, 2 distillation columns are used. Distillation, only concentrates the ethanol to a certain extent. Another step has to be introduced to further purify the ethanol, a dehydration step. After distillation, what is produced is call an AZEOTROPE. Azeotrope is a water/ethanol mix