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CTBE Virtual Sugarcane Biorefinery Proposal: concept, objectives and execution plan
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CTBE Virtual Sugarcane Biorefinery Proposal: concept, objectives and execution plan


Presentation of Antonio Bonomi for the "Workshop Virtual Sugarcane Biorefinery" …

Presentation of Antonio Bonomi for the "Workshop Virtual Sugarcane Biorefinery"

Apresentação de Antonio Bonomi realizada no "Workshop Virtual Sugarcane Biorefinery "

Date / Data : Aug 13 - 14th 2009/
13 e 14 de agosto de 2009
Place / Local: ABTLus, Campinas, Brazil
Event Website / Website do evento:

Published in Technology
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  • 1. CTBE Virtual SugarcaneBiorefinery Proposal: concept,objectives and execution planCentro de Ciência e Tecnologia do Bioetanol – CTBEAntonio on Virtual Sugarcane Biorefinery:assessing success of new technologies August, 2009
  • 2. Content(1) Motivation and Concept(2) Objectives(3) Scope(4) Execution Plan • Mathematical Modeling and Simulation Net • Integrated Process Simulation • Sustainability Parameters • Assessment and Validation(5) Activities and Schedule(6) Expected Benefits
  • 3. Motivation How to measure the success level in R&D&I activities ? Basic Science Publications Technology Development ? In order to solve this dilemma, CTBE decided to build theVirtual Sugarcane Biorefinery Program
  • 4. Concept - VSB • CTBE’s Programs Mathematical• Associated Institutions Modeling Net • Stakeholders • Processes • Unit Operations Process Virtual Biorefinery Alternatives • Simulation Assessment of • Process Optimization (industrial and • Impacts Calculation Success Level agricultural) • Comparison with Standard Biorefinery Input - Virtual Impacts: Economic Life Cycle • economic And Risk Assessment Output Sugarcane • environmental Assessment (LCA) Assessment Biorefinery • social (VSB)
  • 5. Concept - Biorefinery • Food and Feed Grains, Feedstock(s)biological raw material various, • Lignocellulosic Biomass, mixed • Forest Biomass, • Municipal Solid Waste. • Bioprocesses,Processing Technologies • Chemical Processes, various, • Thermo-chemical Processes, combined • Thermal Processes, • Physical Processes. Products • Fuels, Substances • Chemical, Basic and Energy • Materials, Principles various, multi product systems • Specialties, of a • Commodities, Goods. Biorefinery (Kamm and Kamm, 2004)
  • 6. Objectives(1) Optimize concepts and processes.(2) Assess different biorefinery alternatives.(3) Assess stage of development of new technologies.
  • 7. ScopeBasic routes to be designed / technically assessed: Route 1: ethanol (1st generation), sugar, electricity; Route 2: ethanol (2nd generation) – hydrolysis; Route 3: liquid fuels – synthesis gas; Route 4: alcoholchemistry; In all routes sugarcane Route 5: sugarchemistry; agricultural technologies Route 6: lignocellulosechemistry; are included Route n: other routes.
  • 8. ScopeDevelopment stages: Basic Biorefinery: definition of standard production units, considering the defined routes, including both industrial and agro technologies. Optimized Biorefinery: construction of mathematical models for the operation units – optimization of the production (agriculture and industrial) units. Integration with a Net of Institutions. Aggregated Biorefinery: aggregation of the concepts of raw-material production and product and by- product uses.
  • 9. Execution Plan Mathematical Modeling and Simulation Net Sub-Net 1 Sub-Net 2 Simulation Optimization Platform Strategies NET Virtual Optimized Modeling and Simulation Sub-Net 3 Sub-Net 4 SugarcaneMathematical Models Sustainability Impacts Biorefinery Agricultural Technologies
  • 10. Execution PlanIntegrated Process Simulation Sub-Net 1• Simulation Platform - commercial packages (ASPEN Plus, SuperPro Designer, Hysys) - major characteristics: ⇒ large variety of process/operations; ⇒ elaborate mass and energy balances; ⇒ design and evaluate the cost of equipments; ⇒ Data Basis (adequate/update); ⇒ calculate required raw materials and utilities; ⇒ characterize effluents; ⇒ elaborate sustainability analysis.
  • 11. Execution PlanIntegrated Process Simulation• Basic Biorefinery - Gathering Process Data Production Profile ⇒ technical literature; ⇒ judicious survey + set of experimental measurements at a production unit. - Examples: ⇒ MACEDO et al., 2008 – sample of 44 sugarcane mills Central-South region of Brazil. ⇒ IPT, 1990 – Handbook for Energy Conservation in the sugar and ethanol industry.
  • 12. Execution PlanIntegrated Process Simulation Sub-Net 2• Optimized Biorefinery - development and application of techniques for the optimization of subsystems composed by integrated operations – examples: ⇒ power and heat co-generation; ⇒ water net consumption. - integrated processes optimization (example: amount of surplus electricity) depends on: ⇒ adopted technology for production; ⇒ steam consumption; ⇒ amount of fibers (bagasse and straw).
  • 13. Execution PlanIntegrated Process Simulation• Optimized Biorefinery Sub-Net 3 - mathematical modeling of unit operations: ⇒ selection and definition of priorities; ⇒ simulation platform / literature (to be adapted); ⇒ formulation of a new model. - mathematical modeling formulation: ⇒ state variables identification; ⇒ models formulation (phenomenological, input-output, etc.); ⇒ experimental data (lab, pilot plant or industrial plant); ⇒ models fitting; ⇒ statistical evaluation; ⇒ model validation (by other group).
  • 14. Execution PlanSustainability Parameters Sub-Net 4• In order to analyze the most relevant impacts, the following tools will be used: - economic and risk analysis ⇒ profitability and investment calculations and risk evaluation; - life cycle analysis ⇒ environmental aspects related to a product from utilized raw material, production, distribution and final use; - input-output analysis ⇒ modifications in the level of activity of each sector, as a function of the changes in the demand for products of one or more sectors.
  • 15. Execution PlanAgricultural Technologies Sub-Net 5• Modeling of agricultural operations.• Characteristics of the produced sugarcane and interactions with the Biorefinery• Environmental aspects related with the agricultural sector (irrigation, no-till farming, fertilization, LUC, iLUC, transportation, others).
  • 16. Execution PlanAssessment and Validation• VSB Premises - completely transparent; - plausible; - involvement of the interested parts (stakeholders and associated institutions); - stakeholders should help solving conflicts; - practical and feasible standard application models; - adoption of compromise solutions – cannot be modified unless a new agreement is reached; - several stages of evaluation and validation.
  • 17. Execution PlanAssessment and Validation• VSB Program Working Plan - participation of international and national referees;• Validation of Mathematical Models - as soon as a MM is constructed by Institution A, it should be validated by Institution B.• Validation of Obtained Results - should be periodically submitted and evaluated by the stakeholders.
  • 18. Activities and Schedule
  • 19. Activities and Schedule 2nd Generation Ethanol Basic Flowsheets Preliminary Simulation Evaluation with P.S. Optimized Simulation Aggregated Simulation Evaluation with O.S. Evaluation with A.S.
  • 20. Expected Benefits(1) Research Institutions • focus research activities; • coordinated financial support; • identification of research priorities; • assessment of research success.(2) Government Organizations • support for government planning; • definition of government priorities.(3) Funding Agencies • definition of support priorities; • assessment of research success.(4) Companies – Entrepreneurs • support for planning; • selection of projects – business opportunities; • assessment of research success.
  • 21. Building TeamCTBE Associated InstitutionsVSB Program • FEQ/UNICAMP• Antonio Bonomi (Coordinator) • NIPE/UNICAMP• Mirna Scandiffio (LCA)• Marcelo Cunha (IO, Economic Analysis) • DEQ/EPUSP• Charles Dayan (Mathematical Modeling)• Marina Dias (Simulation Platform) • DEQ/UFSCar• Specialists (Agriculture, Biorefineries, • CTC Ethanol Distribution and Use, Residues Disposal, others) • IPTOther Programs (strong interaction): • UEM• Basic Science • UFPE• Pilot Plant• Low Impact Mechanization others• Sustainability
  • 22. OBRIGADO ! Bonomi e Equipe
  • 23. Execution PlanSustainability Parameters• Economic Assessment and Risk Analysis - investment calculation; - profitability analysis (net profit, gross margin, return on investment, payback time, etc.); - risk analysis – expected values based on probability distribution of each input variable subject to uncertainty.
  • 24. Execution PlanSustainability Parameters• Economic Assessment and Risk Analysis - Results of the Risk Analysis Model Ethanol from sugarcane bagasse (US$/liter) Accumulated Lower Higher Process Expected Value Occurence Value Value Probability (*) Diluted H2SO4 0.373 52% 0.268 0.520 Concentrated HCl 0.507 52% 0.343 0.688 Organosolv 1.348 55% 0.867 1.970 Enzymatic Hydrolysis 0.388 51% 0.275 0.534 AEX 0.691 54% 0.457 1.020 Pentoses and Glucose 0.453 52% 0.327 0.587 (*) Accumulated probability of occurrence from the lower to the expected value. IPT, 2000
  • 25. Execution PlanSustainability Parameters• Life Cycle Analysis - LCA - systematic approach, aiming at identifying the environmental aspects related to the life cycle of a product, from its production up to its final use; - it includes analysis of: ⇒ raw materials ⇒ production ⇒ distribution ⇒ use / disposal products and by-products. ISO, 2006
  • 26. Execution PlanSustainability Parameters• Life Cycle Analysis - LCA - Normalized potential impacts for the ethanol LCA OMETTO et al., 2009
  • 27. Execution PlanSustainability Parameters• Input-Output Analysis (IO) - input-output models are used to: ⇒ quantify the modifications in the level of activity of each sector, as a function of the changes in the demand for products of one or more sectors; ⇒ structural modifications due to technological changes of the production sectors. - general equilibrium models are used to capture the alteration in the use of production factors and in the production of goods as a function of modifications in the relative prices. - used to compare impacts and indicators related to the variables: ⇒ level of activity in a sector; ⇒ collection of taxes; ⇒ generated employment; ⇒ energy use (renewable); ⇒ distribution of income; ⇒ GHG emissions; ⇒ added value; ⇒ others.
  • 28. Execution PlanSustainability Parameters• Input-Output Analysis (IO) - Sector index of incorporated energy in the final demand Incorporated Renewable Sector Energy energy (toe/R$1,000) participation Pulp, paper and paper products 0.280 75.9 % Coke and refined petroleum products 1.135 5.3 % Ethanol from sugarcane 1.463 96.5 % Chemicals 0.132 40.5 % Weighted average 0.119 39.0 % CUNHA and PEREIRA, 2008