Typical sugarcane mill
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Café com Física IFSC/USP Biorrefinarias: Máquinas de Produção de Energia e Armazenamento Geológico de Carbono Paulo Seleghim Jr. seleghim@sc.usp.br The problem... seleghim@sc.usp.br 2 Energy use by humankind Power to sustain our life processes 2500 cal/day 2000 W 120 W 90 W Power to support our lifestyle 500 EJ/year industry + agriculture (28% = ) 2300 W 7 billion people transportation sector (27% ) services + residences (36% ) 3 Non-renewable Carbonmill based Typical sugarcane economy CO2 energy chemical compounds petroleum seleghim@sc.usp.br Fossil carbon based economy Typical sugarcane mill The solution... seleghim@sc.usp.br 6 Renewable neutral carbon Typical sugarcane millbased economy energy biochemical compounds CO2 seleghim@sc.usp.br Fossil carbon based economy Typical sugarcane mill Fossil carbon based economy Typical sugarcane mill Already engenders tremendous socioeconomic impacts on… HUMAN CONDITION ! Renewable negative carbon Typical sugarcane mill based economy energy - D biochemical compounds CO2 CO2 seleghim@sc.usp.br CO2 Fossil carbon based economy Typical sugarcane mill Fossil carbon based economy Typical sugarcane mill Case Study: Sugarcane in Brazil: Industrial Reference Unit seleghim@sc.usp.br 13 Agro-Industrial Reference Typical sugarcane mill Unit – Processing Scales Agriculture / Industry equilibrium filed operations cost ~ r3 $ economies of scale ~r2 viability limit state of São Paulo frequency (%) 30 25 20 15 10 lower viability limit 5 0 0 10 20 30 40 50 60 70 80 90 100 110 120 area (kha) 30 kha 500 tsc/h plantation external limit (r) Agro-Industrial Reference Unit – Processing Scales Agricultural production + Logistics + Industrial Processing sunlight water CO2 water 1000 t/h 20 – 40 kha CO2 2 t/h 200 MUS$ harvesting 500 t/h sugar (35 t/h) ethanol (42 m3/h) electricity (50 MW) field op. solids 1-10 t/h vinasse 500 m3/h nutrients (1 ton/h) seleghim@sc.usp.br 15 Carbon capture and storage Potential CO2 capture for a reference sugarcane mill Fermentation: 2 tCO2/h Bagasse and straw combustion: 89 tCO2/h Annual CO2 capture and storage by the sugarcane sector One mill: 0.43 MtCO2/year Number of mills: 450 average proc. rate 500tsc/h Annual CCS: 292 MtCO2/year Annual CO2 Brazilian emissions ~ 400 MtCo2/year seleghim@sc.usp.br 16 Case Study: Sugarcane in Brazil: Conversion pathways seleghim@sc.usp.br 17 sugar cane 500 tc/h mechanical processing straw dewatering water juice extraction bagasse 150 t/h electricity 40-50 MW juice cooking crystallization sugar centrifugation sugar 0-65 t/h boiler and turbines molasses juice fermentation wine distillation ethanol 43-76 m3/h CO2 2 t/h vinasse 500 m3/h seleghim@sc.usp.br sugar cane 500 tc/h mechanical processing straw dewatering water juice extraction bagasse bagasse 150 t/h electricity 20-30 MW juice dewatering cooking crystallization bagasse pre-treatment boiler and turbines NFFs sugar centrifugation sugar 0-65 t/h molasses fermentable sugars juice fermentation wine distillation ethanol 43-76 m3/h cellulose hydrolization CO2 2 t/h vinasse 500 m3/h seleghim@sc.usp.br sugar cane 500 tc/h mechanical processing straw dewatering water juice extraction bagasse bagasse 150 t/h electricity 10-20 MW juice dewatering bagasse pre-treatment cooking crystallization boiler and turbines NFFs sugar centrifugation molasses fermentable sugars cellulose hydrolization glycerin sugar 0-65 t/h juice fermentation wine distillation ethanol 43-76 m3/h CO2 2 t/h transesterification photobioreactor vinasse 500 m3/h seleghim@sc.usp.br broth extraction separation biodiesel / chemicals nutrients water sugar cane 500 tc/h mechanical processing straw dewatering water juice extraction bagasse bagasse 150 t/h electricity 10-20 MW juice dewatering bagasse pre-treatment cooking crystallization boiler and turbines NFFs sugar centrifugation molasses fermentable sugars cellulose hydrolization methane sugar 0-65 t/h juice fermentation CO2 2 t/h chemicals anaerobic digestion wine distillation ethanol 43-76 m3/h vinasse 500 m3/h seleghim@sc.usp.br nutrients water sugar cane 500 tc/h mechanical processing straw water juice extraction bagasse bagasse 150 t/h juice dewatering bagasse pre-treatment cooking crystallization NFFs sugar centrifugation molasses fermentable sugars cellulose hydrolization Oxycombustion boiler and turbines dewatering electricity ~10 MW CO2 methane sugar 0-65 t/h juice fermentation CO2 2 t/h chemicals anaerobic digestion wine distillation ethanol 43-76 m3/h vinasse 500 m3/h seleghim@sc.usp.br nutrients water Production of supercritical CO2 from oxycombustion CO2 power cycle oxyfuel boiler supercritical CO2 unit power boiler cyclone condenser economizer scCO2 biomass superheater evaporator water O2 air N2 CO2 air separation unit seleghim@sc.usp.br 23 Temperature oC pressão de injeção no reservatório separação H2O Entropy kJ/kg/oC 24 25 Carbon capture and storage 26 Carbon capture and storage 27 Carbon capture and storage 28 Carbon capture and storage 29 Sugarcane sector 292Mta, total Brazilian emissions 400Mta… Carbon capture and storage CO2 storage capacity (CarbMap project) Oil and gas 2.5 Gt enough for 6 years Saline aquifers 2000 Gt enough for 5000 years Pre-salt ??? seleghim@sc.usp.br 30 Example of commercial plants in operation Reference sugarcane mill: 0.43 MtCO2/year Global CCS Institute 2012, The Global Status of CCS: 2012 Example of commercial plants in operation Reference sugarcane mill: 0.43 MtCO2/year Global CCS Institute 2012, The Global Status of CCS: 2012 First feasibility studies: robust optimal operation seleghim@sc.usp.br 33 Process optimization approach Inputs that miximize outputs straw dewatering water juice extraction bagasse bagasse 150 t/h juice dewatering bagasse pre-treatment cooking crystallization NFFs sugar centrifugation molasses fermentable sugars cellulose hydrolization Oxycombustion boiler and turbines operating parameters mechanical processing electricity ~10 MW ethanol + electricity + scCO2 CO2 methane uniform random sugar 0-65 t/h juice fermentation CO2 2 t/h chemicals anaerobic digestion wine distillation vinasse 500 m3/h ethanol 43-76 m3/h nutrients water characteristic distributions How to set the control variables in order to increase probability of optimal conversion, given the variability of all uncontrolled variables ? seleghim@sc.usp.br Process optimization approach Monte Carlo simulations (simplified example) mechanical processing straw dewatering water juice extraction bagasse bagasse 150 t/h t/h juice dewatering cooking crystallization bagasse pre-treatment boiler and turbines NFFs sugar centrifugation sugar 0-65 t/h molasses fermentable sugars juice fermentation wine distillation cellulose hydrolization CO2 2 t/h vinasse 500 m3/h seleghim@sc.usp.br Process optimization approach Monte Carlo simulations (simplified example) control variable mechanical processing straw dewatering juice extraction water bagasse bagasse 150 t/h t/h juice dewatering cooking crystallization bagasse pre-treatment boiler and turbines NFFs sugar centrifugation molasses sugar 0-65 t/h fermentable sugars juice fermentation wine distillation cellulose hydrolization CO2 2 t/h vinasse 500 m3/h stochastic variables seleghim@sc.usp.br Process optimization approach Modeling equations… seleghim@sc.usp.br Simulation variables mechanical processing straw dewatering water Carbon capture and storage by a sugarcane mill juice extraction bagasse bagasse 150 t/h t/h electricity 20-30 MW juice dewatering cooking crystallization bagasse pre-treatment boiler and turbines NFFs sugar centrifugation sugar 0-65 t/h Optimization approach – operation envelope molasses fermentable sugars juice fermentation wine distillation cellulose hydrolization CO2 2 t/h vinasse 500 m3/h ethanol 43-76 m3/h ethanol (m3/h) maximum ethanol production (meth,max) energy conservation target operating region operating envelope baseline ethanol production (meth,min) baseline power generation (Wmin) maximum power generation (Wmax) seleghim@sc.usp.br power (MW) 39 mechanical processing straw water Carbon capture and storage by a sugarcane mill bagasse bagasse 150 t/h juice dewatering bagasse pre-treatment cooking crystallization NFFs sugar centrifugation molasses fermentable sugars cellulose hydrolization Oxycombustion boiler and turbines dewatering juice extraction electricity ~10 MW CO2 methane sugar 0-65 t/h Optimization approach – operation envelope juice fermentation CO2 2 t/h chemicals anaerobic digestion wine distillation vinasse 500 m3/h water ethanol 43-76 m3/h ethanol (m3/h) maximum ethanol production (meth,max) energy conservation target operating region operating envelope baseline ethanol production (meth,min) baseline power generation (Wmin) maximum power generation (Wmax) scCO2 seleghim@sc.usp.br nutrients power (MW) 40 mechanical processing straw water Carbon capture and storage by a sugarcane mill bagasse bagasse 150 t/h juice dewatering bagasse pre-treatment cooking crystallization NFFs sugar centrifugation molasses fermentable sugars cellulose hydrolization Oxycombustion boiler and turbines dewatering juice extraction electricity ~10 MW CO2 methane sugar 0-65 t/h Optimization approach – operation envelope juice fermentation CO2 2 t/h chemicals anaerobic digestion wine distillation vinasse 500 m3/h water ethanol 43-76 m3/h ethanol (m3/h) maximum ethanol production (meth,max) energy conservation target operating region operating envelope baseline ethanol production (meth,min) baseline power generation (Wmin) maximum power generation (Wmax) scCO2 seleghim@sc.usp.br nutrients power (MW) 41 Conversion of sugarcane into ethanol and electricity Processing pathways (hem. are fermented or burned) juice bagasse water + sucrose straw a f s w ashes fiber sucrose water fermentation pre-treatment C6H10O5 ashes C5H8O4 de-watering combustion C73H139O13 cellulose hemicellulose lignin c1 c2 c3 tops + leaves sucrose hydrolysis fermentation water de-watering combustion ethanol energy seleghim@sc.usp.br 42 energy conservation limit Process optimization approach control results: fiber + water contents (53%) litigation: dewatering versus sc water content More fiber and less water seleghim@sc.usp.br 13% to 25% fiber 70 %to 55% water Process optimization approach burning x hydrolysis (hemicelluloses are burned) optimality Two optimal operating states seleghim@sc.usp.br optimality 85% + 15% 15%t +o 85% Process optimization approach burning x hydrolysis (hemicelluloses are fermented) Much more robust conversion process ! seleghim@sc.usp.br Process optimization approach fiber composition (hemicelluloses are burned) more lignin, more hemicelluloses less cellulose Process optimization approach fiber composition (hemicelluloses are fermented) idem, slightly more robust process Industrial biorefineries evolution sucrose/starch (+water) lignocellulosic fiber (-water) seleghim@sc.usp.br 49 1G+2G BRFs will evolve to 1G2G and possibly to 2G only BRFs at much higher processing scales… seleghim@sc.usp.br 50 Café com Física IFSC/USP Obrigado… Paulo Seleghim Jr. seleghim@sc.usp.br
