Production of Bio-Methane from Sugar Cane Vinasse · Sugar cane cultivation • The ideal climate for cultivation of sugar-cane is given by a hot and humid season that provides germination

Production of Bio-Methane from Sugar Cane Vinasse

German-Brazilian Project proposal CLIB2021/IFG/UFG

Project Proposal


Speaker: Prof. Dr. Joachim W. Zang IFG - Federal Institute for Education, Science and Technology in

Goiás, Campus Goiânia Contact: [email protected]

Adress: IFG - Coord. de Pesquisa e Inovação do Campus Goiânia, Rua 75, no. 46, Centro, CEP: 72055-110, Goiânia, Goiás, Brazil

mailto:[email protected]

Sumário/Summary

1. Geography

2. German-Brazilian work-group. CLIB2021-IFG,UFG

3. Ethanol- and electricity production based on sugar cane in Goiás – residues: vinasse, straw, filter cake…

4. Biogas production from vinasse.

5. Possible impacts of the project on the brazilian energy matrix.

3

Bio-Methane from Sugar Cane Vinasse CLIB2021-IFG

The state of Goiás is located within the Brazilian Highlands in the center of Brazil. Goiás occupies a large plateau, the vast surface level is between 750 and 900 m above sea level. The seventh biggest state of the 26 Brazilian states occupies about 340.000 km2, about the size of Germany (357.000 km2)

© 2012 Prof. Dr. Joachim W. Zang, IFG, Brazil






Brazilian Midwest

Goiás:

Population 6.004.045 (IBGE, 2010)

Area: 340.086 km²

Population density: 17.6/km²

Germany

Population: 81.752.000 (Stat. Ämter, 2011)

Area: 357.112 km²

Population density: 229/km2

http://www.censo2010.ibge.gov.br/dados_divulgados/index.php?uf=52

http://www.statistik-portal.de/Statistik-Portal/de_zs01_bund.asp

Tropical Climate:

Mean monthly temperatures

vary between 22°C=71.6°F

and 26°C=78.8°F.

The year is divided in a

drought season from von

April–September…

The state is covered with a woodland

savanna known in Brazil as “Cerrado”,

although there are still tropical forests

along the rivers.

The state of Goiás


Goiás:

… and a rainy season

from October to March.

The total yearly

precipitation is about 1700

mm (Germany 580 mm)





Gross Domestic Product of the State of Goiás - Sustainable growth


http://www.segplan.go.gov.br/post/ver/119515/_pib-goiano-cresce-acima-da-media-nacional-em-2009-apesar-da-crise

Sugar cane production 2008-2009 growth +34%




• Project participants of CLIB2021:

DURAG, EVONIK-Degussa, Fraunhofer Institut, Schaumann Group, University of Bielefeld.

9

1. Work group Bio-Methane from Sugar Cane Vinasse


University of Applied Sciences of Trier

Prof. Dr. Ulrich Bröckel,

Director IMIP

Institut für Mikroverfahrenstechnik und Partikeltechnologie

10

1. Work group


11

1. Work group

Federal Institute of Goiás IFG Chemical Technology: Prof. Dr. Joachim W. Zang, Prof. Dr. Warde Antonieta da Fonseca-Zang, Prof. Dr. Sérgio Botelho de Oliveira. Mechanical Engineering: Prof. Jaír Dinoah.

Electrical Engineering: Prof. Dr. Elder Geraldo Domingues

Network Technologies: Prof. Dr. José Luis Domingos. Prof. MS. Wagner Bento


12

1. Work group

Federal University of Goiás UFG

Agronomy Department:


Prof. Dr. Wilson Mozena Leandro Prof. Dr. Alfredo Borges de Campos

www.ufg.br http://www.agro.ufg.br/

http://www.ufg.br/

http://www.agro.ufg.br/

1. Work Group

• Collaborator: Laboratório Nacional do Ministério de Agricultura, Pecuária e Abastecimento em Goiás [LANAGRO/MAPA]/National Laboratory of the Ministry of Agriculture, Livestock and Supply

Quím. Luis Sávio Teixeira, Chefe do Laboratório Nacional de Fertilizantes e Condicionadores de Solo/ Head of the National Laboratory for Fertilizers and Soil Conditioners.

http://www.agricultura.gov.br/

13 Bio-Methane from Sugar Cane Vinasse

CLIB2021-IFG




1. Work Group

• Collaborator: SIFAEG/Trade Unions of the sugar and ethanol industry in the State of Goiás. President: André Luiz Baptista Lins Rocha

• www.sifaeg.com.br


CLIB2021-IFG

http://www.sifaeg.com.br/

1. Work Group

• Collaborator: State secretary of Science and Technology – Goiás - SECTEC

Secretary: Mauro Netto Faiad

• State secretary of Industry and Trade – Goiás – SIC

Secretary: Alexandre Baldy


CLIB2021-IFG

1. Work Group

16

CentroAlcool Inhumas 22/09/2011


2. Ethanol Production from Sugar Cane

• Bioethanol is produced in Brazil leaving 10 to 18 liters of vinasse for every liter of ethanol.

For the project is planned the use of vinasse to produce bio-methane and fertilizer.

ethanol vinasse


CLIB2021-IFG

Sugar Cane, bioelectricity and vinasse.

• Sugar-Cane:

• Worldwide about 20.000.000 hectar of agricultural areas are used to produce sugar cane.

• Actually about 42% of sugar-cane is produced in Brazil on an area of about 7.000.000 hectar.


CLIB2021-IFG

Distribution of the 350 sugar-cane processing industries in Brazil

• (BNDS & CGEE, 2008).

19

State of Goiás


Ethanol in Goiás

Sugar Cane Saccharum (37 species)


CLIB2021-IFG

Sugar cane cultivation

• The ideal climate for cultivation of sugar-cane is given by a hot and humid season that provides germination and vegetative development,

• Followed by a cold and dry season to guarantee the maturation and the accumulation of sucrose in the stems.


CLIB2021-IFG

Sugar-cane cultivation

• The demand for fertilizers for the cultivation of sugar cane is reduced in large part because of industrial waste (vinasse) that is returned to the fields, e.g. all the potassium is supplied by fertigation with vinasse.


CLIB2021-IFG

Harvesting periods

Vary with the rainfall to allow the cutting and transportation and work to achieve the best point of maturation and accumulation of sugars.

• In the South-Central region of Brazil, the harvest is held from April to December,

• While in the Northeast sugar cane is harvested between August and April.


CLIB2021-IFG

Bioethanol Production

• The sugar cane can´t be stored more than a few days.

• Once in the production plant, the sugar cane is washed a goes on to the extraction system in four to seven mills in a sequence.


CLIB2021-IFG

Bioethanol Production

Simplified flow chart of Ethanol Production Process in Brazil


CLIB2021-IFG

Industrial Process • During the milling the juice containing the

saccarose is separated from the fibers (bagasse), which is used as fuel for destillation and co-generation of electrical energy.


CLIB2021-IFG

• The extracted juice is used to produce sugar or bio-ethanol.

• the first steps of the processes of sugar and ethanol production are similar.

27

Industrial Process


Industrial Process for Bio-Ethanol

• The juice is fermented during a 8 to 12 hours period,

• producing a wine with 7 to 10% ethanol content.


CLIB2021-IFG

Industrial Process •

During the following destillation process hidrated bioethanol is produced inicially with 96° GL leaving 10 to 18 liters of vinasse per liter of bio-ethanol.


CLIB2021-IFG

Residues of the industrial process

1- Vinasse: Between 800 and 1.000 liters per ton of processed sugar cane or 10 to 18 L per liter of bioethanol,

2- Filter cake: About 40 kg of humid filter cake per ton of processed sugar cane.

3- Burning ashes: About 17 kg per ton of burned bagasse (ELIA NETO, 2007).


CLIB2021-IFG

In Brazil these residuals are valorized

• as byproducts used as fertilizers and for irrigation;

• Reducing the need for mineral fertilizers and reducing the necessity for irrigation during the dry season.


CLIB2021-IFG

Bagasse as fuel to produce heat and electric energy in bio-ethanol plants

• Demand: about 12 kWh per ton of processed sugar cane.

• The use of bagasse (straw) in energy co-generation can produce enough energy for the process and makes it auto sufficient.


CLIB2021-IFG

Bioelectricity

• Tendency:

• The plants are transformed from ethanol and sugar production also to bio-electricity plants, producing more than 100 kWh of electric energy per ton of sugar cane.


CLIB2021-IFG

Productivity of bio-ethanol and sugar

• In case of exclusive production of bio-ethanol, from one ton of sugar cane can be produced 86 liters of hydrated bio-ethanol.

• When the objective is to produce sugar, beside the 100 kg of sugar 23 liters of bioethanol can be produced (CTC, 2005).

34

or + 86 L 100 kg 23 L 1 ton


Production in the State of Goiás – 2011-2012 harvesting period


CLIB2021-IFG

Source: http://www.ohoje.com.br/economia/09-12-2011-cai-producao-goiana-de-acucar-e-etanol/

• 45.200.000 t of sugar cane • 32 active production sites

• 1.750.000 t of sugar • 2.675.000.000 liters of ethanol

-> Leaving about 37.400.000.000 liters of vinasse.

http://www.ohoje.com.br/economia/09-12-2011-cai-producao-goiana-de-acucar-e-etanol/




















Vinasse – 37 billion liters in 2011

Vinasse irrigation channel – Source: Rosetta, 2007

Vinasse – Foto author, 2011.

Pipelines for vinasse conduction – Source: Rosetta, 2007

Irrigation with hidraulic cannon: Rosetta, 2007 36


4. Project Proposal CLIB 2021-IFG

Bio-methane from Sugar Cane Vinasse

Term: Biogas

• Biogas typically refers to a mixture of gases produced by the biological breakdown of organic matter in the absence of oxygen.

• Organic waste such as dead plant and animal material, animal dung, and kitchen waste can be converted into a gaseous fuel called biogas.

• Biogas is a type of biofuel. (Wikipedia, 2012).

• The gas methane CH4 is the principal component of biogas.


CLIB2021-IFG

Term: Biogas

• The composition of biogas varies depending upon the origin of the anaerobic digestion process:

– Methane (CH4): 40 – 70% Vol. of the produced biogas

– Carbon dioxide (CO2): 30 – 60% Vol. of the produced biogas

– Hydrogen (H2): 0 – 1% Vol.

– Hydrogen sulfide (H2S): 0 – 3% Vol.

– Water (H2O): 0 – 10% Vol.

– Oxygen (O2): 0 – 2% Vol.

– Traces of ammonia (NH3): 0 – 2,5 mg/m3


CLIB2021-IFG

Possible use of biogas in Goiás

• Co-generation of Electric and calorific Energy.

• Heating in industrial processes, for food, ceramics, mining, etc.

• Purification to bio-methane

– for use in combustion engines (Otto motors, car fuel)

– To use as raw material in the chemical industry (green chemistry).


CLIB2021-IFG


• Project proposal CLIB2021/IFG/UFG

• More than 37 million tonnes of vinasse incur annually in Goiás without a really strong economical and ecological outlet.

• This project proposes the production of pure bio-methane from vinasse for the use as motor-fuel.


CLIB2021-IFG


• If agricultural machines are equipped with methane-motors this fuel can be used close to the production site of a plant.

• In the State of Goiás exists only one gas-station for GLP-car-gas due to the big distance to the petrol-industry-centers of more than 1000 km.

42 Project proposal CLIB2021/IFG/UFG



• Bio-methane might find another high-volume market in the European Union because the target of reducing CO2-emission by 80% till 2050 (compared to 1990) puts an enormous pressure on the European fuel industry to provide sustainable energy.




• The process includes

• 1) the transformation of vinasse to biogas,

• 2) the purification of biogas to bio-methane and

• 3) storage of bio-methane.




• R&D Topics

• Technical and economical feasibility study

– State of the art of producing biogas from vinasse

– Options for technical and economical improvement

– Bio-methane markets




• R&D Topics

• Biogas fermentation

– Batch- of continuous processes

– Microbial population

– Vinasse composition / Additives

– Process parameters

– Productivity and yield of a standardized biogas quality

– Biogas reactor types

46

Project proposal CLIB2021/IFG/UFG



• R&D Topics

• Bio-methane purification

• Bio-methane storage and logistics

• Bio-methane marketing and distribution

47

Project proposal CLIB2021/IFG/UFG



• R&D Topics

• Usage of residual biomass form biogas-fermentation

• Usage of biogas in motors

– Specification of biogas

– Modification of motors



5. Impact on the Brazilian Energy Sector

5. Possible Impacts on the Brazilian Energy Sector

70% of the electric energy in Brazil is produced in

140 hydroeletric power plants

Hydroelectric Power Plant Serra da Mesa

Hydroelectric Power Plant of Corumbá

Energy production in the state of Goiás: 28.500.000 MWh (2010). About two thirds of this energy is transferred to other brazilian states.

Source:

<http://www.mme.gov.br/mme/galerias/arquivos/publicacoes/BEN/2_-

_BEN_-_Ano_Base/1_-_BEN_Portugues_-_Inglxs_-_Completo.pdf>


CLIB2021-IFG

State of Goiás – Hidroelectric power plants

Artificial Lake

Serra da Mesa, northern

region of Goiás.

Volume: 43,25 km3

Superfície: 1.784 km²

Power output: 1.275 MW

Source: Google Earth, 2008 © 2011 Prof. Dr. Joachim W. Zang, IFG, Brazil


CLIB2021-IFG




Ethanol production in Goiás Burning of the bagasse


CLIB2021-IFG

Produção de Etanol em Goiás.

Projeto: Biogás da vinhaça/

Biogas from vinasse

Vinasse – Foto author, 2011.

Pilot Plant installed in Germany. 750 KW. SCHAUMANN, 2011


CLIB2021-IFG

Sugar- and Ethanol-Industry in Goiás

37 billion of liters of vinasse = 37.000.000 m3 in Goiás per year.

One cubic meter of vinasse might produce up to 11,5 m3 of

biogas, from which it is possible to produce up to 169 kWh

electric power (Lamonica, 2006) without reducing its fertilizing

potential.

Sample Calculation


CLIB2021-IFG

Sugar- and Ethanol-Industry in Goiás

37.000.000 m3 vinasse x 11,5 m3 biogas /m3 vinasse =

425.500.000 m3 biogas or

37.000.000 m3 vinasse x 169 kWh/m3 vinasse = 6253 GWh

Actual annual production of energy in Goiás: 28500 GWh.

Sample Calculation



CLIB2021-IFG




Thank you for your attention.

Prof. Dr. Joachim Werner Zang

[email protected]

CLIB/IFG/UFG


CLIB2021-IFG


Documents

Production of Bio-Methane from Sugar Cane Vinasse · Sugar cane cultivation • The ideal climate for cultivation of sugar-cane is given by a hot and humid season that provides germination