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...
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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
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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)
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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
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Case Study:
Sugarcane in Brazil:
Conversion pathways
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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
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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 ???
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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
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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
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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)
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1G+2G BRFs will evolve to 1G2G
and possibly to 2G only BRFs at
much higher processing scales…
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Café com Física
IFSC/USP
Obrigado…
Paulo Seleghim Jr.
seleghim@sc.usp.br
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