Bioethanol from Cellulosic Raw Materials

Applied Bioethanol Technology in Brazil

Josef Dörfler

Partner of Fermentec Ltda - Brazil

Austria - Europe

Detmold, on April 24th, 2007

Detmold - April 24th, 07 Bioethanol Technology - Brazil 2

Presentation Outline

1. Sugar Cane Growing

2. The Brazilian Alcohol Industry – History and Development

3. International Trends in the Bioethanol Sector – Key Notes

4. Brazil/ Technology for Bioethanol Production

1. Sugar Cane Management

2. Sugar Cane Processing

3. Applied Fermentation Concepts

4. Destillation and Purification

5. Usage of Bioethanol as a Biofuel

6. Summary


1. Sugar Cane Growing Areas - Worldwide


1. Sugar Cane Growing Areas – Brazil at the Present

The main area for sugar canecultivation is located in Sao Paulo State.

Year 2006:

17.600.000.000 litresBioethanol (= 17.6 billionlitres) were produced in Brazil.

Source: CTC/ Copersucar



„Past“

Source: UNICA (2004)

1975:

Start of the nationale development program„Proalcool“.

1979:

Ramp up of the production capacity forserving the national fuel energy sector. 85% of the private cars in Brazil were usingbioethanol.

(market price in 1980: approx. 700 USD/m³)

„Phase of cheap Energy“ up to 1999:

„Market consilidation“ within the alcoholindustry sector

(market price in 1999: <= 200 USD/m³)



„Present and Future“

Source: UNICA (2004) and Amorim (2007)

Since 2000:

Ongoing increase of productioncapacities and improvement of the related technologies.

> 320 processing factories(combination: sugar & ethanol) are in operation now.

2006 to 2012:

Continous increase of processing volumefrom 17.6 billion up to 28 billion litres/ year (forecast statement).

77 new plants will be established.


3. International Trends in the Bioethanol Sector – Key Notes

NOW:

•Worldwide gasoline consumption of approx. 1.200 billion litres/ year.

•Only 2,5% of that amount is from bioethanol source.

FORECAST:

•Bioethanol growth rates of more than 25% per year are expected forthe next years.

•All countries in the world are/ will strongly invest into bioethanolfacilities.

•The further improvement of bioethanol technology is driven by national and international R&D-programs.


3. International Trends and Competition in the Bioethanol Sector –Worldwide Installed Production Capacities

Region of Production Year 2004 Year 2005 Year 2007 *)

(billion litres) (billion litres) (billion litres)

Brazil 14.6 16.7 19

USA 14.3 16.6 20

European Union 2.6 3.0

Asia 6.4 6.6

China 3.7 3.8

India 1.7 1.7

Africa 0.6 0.6

Total World 41.3 46.0

Source: EC-Commission Paper „EU-Strategy for Biofuels“ (2006)

*) forecasted quantities by the national governments (2007)

„Hot Spots“ of fast growing markets forethanol plants


4.1. Brazilian Bioethanol/ Sugar Cane Management - Productivity

The sugar content (succrose) of sugar cane is in the range13% to 17%.

Year of seeding: no harvest

1st harvest year: 120 tons/ ha

2nd harvest year: 100 tons/ ha

3rd harvest year: 90 tons/ ha

4th harvest year: 80 tons/ ha

5th harvest year: 70 tons/ ha


4.1. Brazilian Bioethanol/ Sugar Cane Management - Harvesting

Harvest period in the Sao Paulo State region: March to September (8 months)

„Burning“ of the field


4.1. Brazilian Bioethanol/ Sugar Cane Management – Economic Values

Prices and Yields:

market price: approx. 17 USD/ ton (13 €/ ton) of sugar cane (end of 2006)

sugar content: 13 – 17 % (w/w) in sugar cane

alcohol yield: approx. 85 litres/ ton sugar cane


• The sugar cane is containing directly fermentable sugars – no thermal and enzymatic conversion is required.

• The sugar is extracted by water.

• The pictures below are from sugar cane processing.

4.2. Brazilian Bioethanol/ Sugar Cane Processing - Extraction


4.2. Brazilian Bioethanol/ Sugar Cane Processing – Energy Generation

•The remaining biomass „bagasse“ is used as an energy source for co-generation of steam and electricity.

•The Brazilian sugar factories are „energy – selfserving“. The surplus of electric power is sold to the country`s energy market.


The carbon- and energy balance of the alcoholic fermentation process by yeast.

Source: Fermentec/ Brazil (2006)

= 64,6 ml EtOH

4.3. Brazilian Bioethanol/ Applied Fermentation Concepts –The Scientific Base


•The yeast recycling process issuccessfully applied and improvedin the Brazilian ethanol industrysince 1980.

•The requirement for applicationthat concept is a nutrient solutionwith low insoluble solids.

•Through yeast recycling a highlyefficient conversion rate from sugarto ethanol can be realized.

Picture: The biggest Brazilian plantsare applying „yeast recycling“ and are getting technological consultingfrom Fermentec.

4.3. Brazilian Bioethanol/ Applied Fermentation Concepts –Yeast Recycling is the Key for High Productivity


4.3. Brazilian Bioethanol/ Applied Fermentation Concepts –Batch Process


4.3. Brazilian Bioethanol/ Applied Fermentation Concepts –Continues Process


• > 75% of production is done as batch process.

• Typical size of fermentation vessels is 500 m³ up to 1500 m³.

• Typical time of a batch is up to 10 hours. Therefore 2 batches per day can beperformed one vessel.

• Conversion yields up to 92% (sugar -> ethanol) are realized.

Picture:

Headquarter of Fermentec Ltda. in Piracicaba/ Sao Paulo State – Brazil

www.fermentec.com.br

4.3. Brazilian Bioethanol/ Applied Fermentation Concepts –Some Process Characteristics in Large Scale

http://www.fermentec.com.br/


4.3. Brazilian Bioethanol/ Applied Fermentation Concepts –Vessel Design

7 „Batch“ fermenters, each 1500 m³ The „state of art“ design of the vessels at the bottom (recyclingpump and heat exchanger)


The continous centrifugationprocess

The separated yeast is treated and reused for the next batch

4.3. Brazilian Bioethanol/ Applied Fermentation Concepts –Yeast Separation and Treatment


„sugar solution“ „yeast cream“ „wine – beer“ „wine without yeast“ destilled alcohol

4.3. Brazilian Bioethanol/ Applied Fermentation Concepts –Different Steps of the Alcohol Process


Columns for ethanol destillation and purification – different qualities areproduced:

Hydrated Alcohol (with 96% Ethanol)

Anhydrous Alcohol (with 99,5%– 99,8% Ethanol)

4.4. Brazilian Bioethanol/ Destillation and Purification


A huge tank farm with a capacityof 150.000 m³ ethanol

A smaller tank farm …

In front the cooling towers for the fermentation unit

4.4. Brazilian Bioethanol/ Destillation and Purification


5. Usage of Bioethanol as a Biofuel (1)

Fuel prices in Brazil

(from October 2006)

1 Euro = 2,7 Real

Diesel 66 € Cent/ L

Gasoline 89 € Cent/ L

Alcohol 46 € Cent/ L


At each gasoline station in Brazil bioethanol is available for running the „flex fuel“ cars. Hydrated alcohol (96%) can be used for those cars.

5. Usage of Bioethanol as a Biofuel (2)


6. Summary (1)

428 million tons of sugar cane wereprocessed in 320 factories during2006.

77 further factories are underplanning and construction now.

Brazil and US are competing for the leading position in ethanolproduction. Actual values for 2006:

USA: 18.9 billion litres

Brazil: 17.6 billion litresSource: Amorim (2007), International Sugar Journal (March 2007)


6. Summary (2)

• 40% of the Brazilian gasolineconsumption in the private carsector is from the renewablesource ethanol

•Since the year 2005 the sharefor „flex fuel vehicles“ isreported more than 70% of the sold cars on the Brazilianmarket.


Thank you for your attention !

Contact:

Dr. Josef Dörfler, MBA Zivilingenieur für Lebensmittel- & Gärungstechnologie3281 Oberndorf

Austria - Europe

E-Mail: [email protected].: 0043 7483 7110

Further details: www.fermentec.com.br

mailto:[email protected]

http://www.fermentec.com.br/

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Bioethanol from Cellulosic Raw Materials