Feasibility Studies for Integrated Process for Generation ... · PDF fileSugar mill Electricity For households, businesses, farms Alcohol For vehicles and ... zTask 5 : Economic Analysis

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Feasibility Studies for Integrated ProcessFeasibility Studies for Integrated Process forforGeneration of Electricity, Alcohol & other productsGeneration of Electricity, Alcohol & other products

from Sugarcane (Bagasse) and Agriculturalfrom Sugarcane (Bagasse) and AgriculturalResiduesResidues

Business Information

Dr. R. N. PandeyMAXIMA LABORATORIES (CANADA) INC.

&CANADIAN CONSORTIUM OF CLEAN ENERGYAND ENVIRONMENTAL TECHNOLOGIES INC.

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(A brief presentation on an Environmentally Friendly Program forSustainable Energy and Increased Profitability to Sugarcane Factories)

http://www.chemisar.com/index.html

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Click here to view homepage

Evaluation of an economicallyattractive, fully diversified andenvironmentally sound integratedprocess for sugar cane utilizationMaximize sugar mills revenues,profits and their long term financialperformance via diversificationHelp sugar mills gain additionalincome

Presentation Outline (in Brief)Presentation Outline (in Brief)


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SugarcaneField

Sugar millElectricityFor households,businesses, farms

Alcohol

For vehicles andother products

Sugar

For eating

Sugarcane biomass toSugarcane biomass tovarious productsvarious products


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MissionMission

Evaluation of an economicallyattractive, fully diversified andenvironmentally sound integratedprocess for sugar cane utilizationMaximize sugar mills revenues,profits and their long term financialperformance via diversificationHelp sugar mills gain additionalincome


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MissionMission

HELP to mitigate GLOBAL WARMINGby providing renewable energysource with no net emission ofcarbon dioxide

cont.


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Objectives of the Feasibility StudyObjectives of the Feasibility Study

Prepare a plan for the integrated facilitybased on a comprehensive feasibilitystudyEconomic Evaluation of a completeutilization of sugarcane and agricultureresidues in the regionIn order to meet the above objectives, thefollowing tasks are performed as shown inthe next page under “How will it be done”


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How will it be done?How will it be done?

Task 1: Meeting with the sugarmillManagement & walk-through survey of thefacilities to observe the current process.Task 2 : Collect Data on Process, Water &Waste Water Management, facilities review,production level, mass & energy balance,local, state & federal environmental laws

Comprehensive Work Program (Feasibility Study)


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Task 3 : Assessment of quality &quantity of the other biomassmaterials available & their transportcosts to the mill, such as cane trash &tops, wheat straws, rice husks, mangowaste, potato residue and otherbiomass in the region for continuedoperation of the mill throughout theyear

cont.


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Task 4 : Testing & characterization ofbiomass samplesTask 5 : Economic Analysis of theProposed Integrated Process ofSugarcane Factory and Bioenergy centreTask 6 : Project specific Greenhouse gasemission baseline studies shall beconductedTask 7: Project Design Document

cont.


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Proposed Integrated and Diversified Proposed Integrated and DiversifiedSugarcane FactorySugarcane Factory

Sugarcane/Trash & Tops, Other Biomass

Sugar Mill

Power and SteamGeneration

BagasseSteamFermentation to

Ethanol

Juice/Molasses

Sugar

CO2 to Algae Pond

AnimalFeed

Ethanol

Aqueous Streamfor Irrigation etc.

Transport Fuel

Public Utility


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• Power and steam generation from cane residue

• Ethanol for transportation fuel by fermentation.

• Production of chemicals and fertilizers.

• Animal feed production.

• Carbon dioxide utilization by algae growth.

• Utilization of aqueous stream generated.

Proposed Sugar mill facility to Proposed Sugar mill facility toinclude:include:


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List of Commercial Products ofList of Commercial Products ofProposed facilityProposed facility

Sugar, Molasses, RumPower & SteamLigninGypsumCarbon dioxideDehydrated Ethanol*Protein for Animal FeedWater for Crop Irrigation

Carbonated drinks

Fire extinguisherDry Ice

Note: These products are further high-lightedon the next page with their estimated quantities.


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Some Quantitative Estimates of Products ofSome Quantitative Estimates of Products ofProposed Integrated ProcessProposed Integrated ProcessSugar Factory Products

FeedstockProductionSugarCane

FeedstockPreparation

PreparedCane

Juice Extraction Sugar

Rum

11%

(1,800,000 tns)(210,000 tns)

Bagasse31%

(558,000tns)

BioenergyPower Plant

Molasses

4%(72,000 tns)


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Some Quantitative Estimates of Products ofSome Quantitative Estimates of Products ofProposed Integrated ProcessProposed Integrated Process

Biofuel & Other Products

cont.

PreparedTrash & Tops

From feedstockpreparation

(180,000 tns)

Hydrolysis&

Treatment 15%Lignin

To Bioenergy PowerPlant

(27,000 tns)

Fermentation&

Distillation

ETHANOLDehydrated

(45,000,000 Litres)

CarbonDioxide

(25,200 tns)

AlgaePonds

CarbonatedDrinks

FireExtinguisher

Dry IceProcessing

15%

AnimalProtein

(27,000 tns)

CropIrrigation


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Reflection on the Major EconomicReflection on the Major EconomicAdvantagesAdvantages

Sugar mill revenues multiply by a factor ofabout 2Ethanol can be easily blended withgasoline thereby reducing dependence onpetroleum driven fuelsMaximize energy efficiency andprofitability of Sugar mills


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Environmental AdvantagesEnvironmental Advantages

A Sustainable renewable fuel for the 21stcenturyBagasse is a biomass material and thusthere is no net emission of Carbon DioxideWhen Coal or other fossil fuels aredisplaced by bagasse or other biomassmaterial there are enormous savings ofGreenhouse gas (GHG) emissions toprevent climate change


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CO2 causes Global Climate change.Increase: 0.5% per year. Since 1960atmospheric CO2 is up more than 10%.The longer the period we use oil and coalto produce CO2, the tougher will be thecrisis which will follow.It is therefore imperative to increase theuse of our sustainable energy alternative.

cont.


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IMMEDIATE OBJECTIVE : Slow down theGreenhouse Effect, Stabilize the CO2concentrationThe combined capability of the sugarmills, for example, the 450 in India, &many more in each of the other 80Countries of the world, by using theproposed Integrated Process, have thepotential to meet the Global GHGreduction objective

cont.


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Typical Example of Per-Capita Carbon DioxideTypical Example of Per-Capita Carbon DioxideEmissions (tonnes) per year by various countriesEmissions (tonnes) per year by various countries

Brazil 1.39China 2.27Czech Republic 13.04Japan 8.79Russia 14.11Swaziland 0.33India 0.88Malaysia 3.74UK 9.78US 19.13Canada 18.19 (assuming 564 megatonnes

emission per year)

CountryPer Capita CO2(metric tonnes)


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Current Focus:Current Focus:

As seen CO2 emissions of developing countries are lowerthan developed countriesGrowth for necessity of developing countries wouldrequire Energy consumption to approach developedcountry as a modelProposed Integrated Process directs away from pollutingsources to non-polluting sustainable energyThe favorable impact on Air Quality and Global Climatechange shall be phenomenal in the long term and has thepotential to meet the Kyoto Protocol

Fulfilling the upcoming Energy demand from non-polluting sources


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HIGHLIGHTS OF SOME OF THE RECENTHIGHLIGHTS OF SOME OF THE RECENTAND CURRENT RESEARCH PROJECTSAND CURRENT RESEARCH PROJECTS

AT THE TECHNOLOGY CENTREAT THE TECHNOLOGY CENTRE


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Direct Conversion of Natural Gas toDirect Conversion of Natural Gas toValue-added ProductsValue-added Products

NaturalGas

Ethylene &Other

Olefins

ChlorohydroCarbons

MethylChloride

PetrochemicalFeedstock

Gasoline &Distillates

Para-xylene

Syngas

Hythane

OxidativeCoupling

OxyhydroChlorination

Oligomerization

Oligomerization

Alkylation

Partial Oxidation

Controlled Oxidation


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Conversion of Natural Gas to Gasoline viaConversion of Natural Gas to Gasoline viaOxidative coupling and OligomerizationOxidative coupling and Oligomerization

REACTOR 1OxidativeCoupling

REACTOR 2Oligomerization

CO2 / H2ORemoval

ProductRecovery

olefins

CO2 / H2O Gasoline

RecycleNG

O2

The project focuses on conversion of naturalgas to gasoline-boiling range hydrocarbons viaan integrated approach of oxidative couplingand oligomerization. Natural gas reacts withoxygen in the Reactor 1 over a metal oxidebased catalyst to produce olefins,predominantly ethylene and propylene. Thereactor effluent is then fed to Reactor 2 whereolefins undergo oligomerization over a zeolitebased catalyst to produce gasoline rangehydrocarbons.

Reactor 1: Oxidative Coupling

Methane + Oxygen

Reactor 2: Oligomerization

Olefins

Olefins (Ethylene, propylene)

Gasoline

600-800o C

600-800o C

Catalyst

Catalyst


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Chemisar Fluidized Bed Reactor System ForChemisar Fluidized Bed Reactor System ForStudying Methane Oxidative Coupling ProcessStudying Methane Oxidative Coupling Process


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Conversion of Natural Gas to Para-xylene viaConversion of Natural Gas to Para-xylene viaOxyhydrochlorination and AlkylationOxyhydrochlorination and Alkylation

REACTOR 1Oxyhydro-chlorination

CO2 / H2ORecovery

CO2 / H2O

RecycleNG

O2

This project focuses on the conversion of natural gas to p-xylene via theintegrated approach of oxyhydrochlorination and alkylation. Para-xyleneis an important industrial feedstock used in the manufacture of polyesterfibres and film, Polyethylene Terephthalate (PET) and PolybutyleneTerephthalate.

Natural gas reacts with oxygen and hydrogen chloride over a mixedchloride catalyst in the oxyhydrochlorination reactor, producingchlorohydrocarbons. MeCl is separated from the chlorohydrocarbonmixture and fed to a second reactor to which toluene is introduced. MeClreacts with toluene over a shape selective catalyst producing x-xylene.

Reactor 1: Oxyhydrochlorination

Methane + Oxygen

Reactor 2: Toluene Methylation

Methyl chloride + Toluene

Methyl Chloride

p-Xylene

300-400o C

325-400o C

Catalyst

Catalyst

MethylChloride

Purification

REACTOR2

Alkylation

P-XyleneHCl

Chlorohydro-carbons

MeCl

HClRecovery Product

Recovery


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Reactor Assembly to Study Production of P-XyleneReactor Assembly to Study Production of P-Xyleneby Alkylation of Toluene with Methyl Chlorideby Alkylation of Toluene with Methyl Chloride


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Industrial Use of p-XyleneIndustrial Use of p-Xylene(p-xylene is an important feedstock)(p-xylene is an important feedstock)

p-xylene

PhthalicAnhydride

DimethylTerephthalate

Plastic Bottle

Isophthalic/Terephthalic

Acid

Benzoic Acid

Polyethylene Terephthalate Polybutylene Terephthalate


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Conversion of Natural Gas to Gasoline viaConversion of Natural Gas to Gasoline viaOxyhydrochlorination and OligomerizationOxyhydrochlorination and Oligomerization

REACTOR 1Oxyhydro-chlorination

CO2 / H2ORecovery

chlorohydro-carbons

CO2 / H2O Gasoline

RecycleNG

O2This project is focused on conversion of natural gas toliquid fuels by the integrated process ofoxyhydrochlorination and oligomerization.

Natural Gas reacts with oxygen and hydrogen chlorideover a mixed chloride catalyst in anoxyhydrochlorination reactor to producechlorohydrocarbons. The chlorinated hydrocarbons arefed to the second reactor where they are oligomerizedto gasoline.

Reactor 1: Oxidative Coupling

CH4 + O2 + HCl

Reactor 2: Oligomerization

Chloromethane

Gasoline

300-400o C

600-800o C

Catalyst

Catalyst

HCl HClRecovery

ProductRecovery

REACTOR 2Oligomerization

Chloromethane


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Synthesis Gas Production by Partial OxidationSynthesis Gas Production by Partial Oxidationof Methane Using Membrane Reactorof Methane Using Membrane Reactor

This project focuses on the development ofmembrane reactor technology for theproduction of synthesis gas by partialoxidation of methane. Methane reacts withoxygen over a catalyst in an H2-permeablemembrane reactor, producing synthesis gas(a mixture of CO and H2). Membrane reactorpermits continuous and selectivewithdrawal of H2 from the reaction zone, sothat conversion yield surpassingthermodynamic equilibrium values can beachieved.

Membrane Reactor: Partial Oxidation

Methane + Oxygen Syngas (mixture of CO and H2)600-750o C

Catalyst


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Conversion of Natural Gas to HythaneConversion of Natural Gas to Hythane(a Fuel of the Future)(a Fuel of the Future)

Preheater

NG

This project deals with the conversion of Natural Gas toHythane fuel. Hythane, a mixture of Hydrogen andNatural Gas (10% - 20% hydrogen, 80 - 90% natural gas)is receiving considerable attention as a promisingalternative fuel.

Our laboratories have developed a process for on-siteproduction of Hythane at gas filling stations. It involvescontrolled oxidation of methane with water vapour overa metal based catalyst at temperature between 300 and400oC

Hythane600-750o C

Catalyst

MEAScrubber

CatalyticReactor

400oC, 1atm

Methane + Water

Sulfur compounds

Vehicles GasBlender

Methanator

Heat Recovery

CH4, H2

CH4, H2, CO2, CO (if any)

CO2

Feed GasPretreatment

CH

4 , H2 , C

O2 , C

O (if any)

Water Vapour

CH4

Advantages of Hythane Fuel

• Very low emissions of CO, NOx and THC

• Smaller volume of CO2 emissions as combustionproducts, compared with other fuels including naturalgas

• Increase of lean operating limits

Hythane


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Production of Gaseous and Liquid Fuels fromProduction of Gaseous and Liquid Fuels fromPitch Materials by Flash HydropyrolysisPitch Materials by Flash Hydropyrolysis

This project deals with production oftransportation of fuels from low-valuecarbonaceous materials such as pitchand tar.

• The pitch feedstock is pumped alongwith hydrogen at high pressure to flashhydropyrolysis reactor, maintained athigh temperature.

• The pitch is rapidly heated to hightemperature under flowing hydrogen.

• The high molecular weight material isconverted to fragments of lowermolecular weight, which react withhydrogen to form valuable gaseous andliquid fuels.

Gaseous Fuels + Liquid Fuels400-800o Cwith or without Catalysts

Pitch+ Hydrogen Flash Hydropyrolysis

(Methane, Ethane) (Gasoline, Diesel)


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Production of Gaseous and Liquid Fuels fromProduction of Gaseous and Liquid Fuels fromPitch Materials by Flash Pitch Materials by Flash HydropyrolysisHydropyrolysis cont.


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Feasibility Studies for Integrated Process for Generation ... · PDF fileSugar mill Electricity For households, businesses, farms Alcohol For vehicles and ... zTask 5 : Economic Analysis