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Integrated 1st & 2nd Generation Bioethanol Production from
Sugarcane
Suman SwamiOnyedika Egbujo
Emmanuel OgbughaluDominic Smith
Priyesh Waghmare
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IntroductionBiofuels are a wide range of fuels which are
in some way derived from biomass.Different generations of biofuel according to
source:GENERATIONS FEEDSTOCK
First Sugarcane, grains and seeds -as soya bean ,sorghum, corn etc
Second Agricultural residues such as Sugarcane bagasse, corn straw and industrial waste.
Third Algae
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Biofuels vs Fossil fuels
Fossils are depleting and biofuels are used to complement them.
Biofuels are carbon neutral.
Cars are compatible with Fossil fuels.
Fossil fuel readily available.
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Ethanol technicalities in Car Engines
Performance.
Cold start.
Mileage.
Sludge problem.
Corrosion.
Higher ethanol blends.
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Bagasse:Fibrous matter that remains after sugarcane stalks are crushed to extract their juice.
Production: Each 10 tons of sugarcane = 3 tonnes of wet bagasse.
Quantity of bagasse produced = size of sugarcane industry.
Chemical analysis: Cellulose 45-55%, hemicellulose 20-25%, lignin 18-24%, ash 1-4%, waxes <1%.
Source: ceesdghana.org
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First Generation Process
SUGARCANE CLEANING SUGAR EXTRACTION
JUICE TREATMENT
JUICE CONCENTRATION
‘SOILDS’
FERMENTATIONCENTRIFUGATIONDISTILLATIONDEHYDRATION
ANHYDROUS ETHANOL
SUGARCANE BAGASSE
INTEGRATION OF 2nd GENERATION SUGARS
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Pretreatment
Pretreatment separates lignin and hemicellulose, reduces cellulose crystallinity and increases porosity
-Dilute HCl -HCl conc. = 1.2% v/v-15 parts acid to 1 part bagasse -1210C -4Hrs
-Yield = 38% - reducing sugars in the form of hemicellulose and cellulose
DetoxificationAlkaline neutralisation detoxification
Overliming -Calcium hydroxide -4hrs -300C
Removes 50% of waste – precipitates out-Hydroxymethylfurfural-aliphatic acid-phenolic compounds
Yield = 60% pentose (xylose)
Cellulose Hydrolysis
Degrade cellulose to glucose (saccharification)
-using conc. HCl -15% v/v-1800C-4hrs-30Bars
Yield = 35% hexose (glucose) from solid fraction
Hexose and Pentose Fermentation
Co-fermentationYeast - HexoseRecombinant yeast – Pentose-pentose metabolism pathways
-360C-24hrs-1- part yeast-4-parts reducing sugar mixture-5-parts nutrient broth
Yield = 80% ethanol
Sugars used for cell maintenancePentose metabolism has reduced efficiency
Bagasse -Lignin (30%)-Cellulose (40%)-Hemicellulose (30%)
Filtration Separates solid and liquid fraction
Liquid fraction – Degraded hemicellulose Pentose sugars – primarily xylose
Solid fraction – CelluloseLignin
Neutralises-NaOH
Hexose (glucose) from sugarcane – first generation
To purificationEthanol , waste mixture
Second Generation Process
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Pretreatment
-Yield = 38% - reducing sugars in the form of hemicellulose and cellulose
DetoxificationAlkaline neutralisation detoxification
Overliming
Yield = 60% pentose (xylose)
Cellulose Hydrolysis
Degrade cellulose to glucose (saccharification)
Yield = 35% hexose (glucose) from solid fraction
Hexose and Pentose Fermentation
Co-fermentation
-1- part yeast – 2.128Kg-4-parts reducing sugar mixture – 8.51Kg-5-parts water suspension – 10.64Kg
Yield = 80% ethanol
Bagasse 100Kg of bagasse =30Kg lignin40Kg cellulose30Kg hemicellulose
Filtration Separates solid and liquid fraction
Neutralises-NaOH
Hexose (glucose) from sugarcane – first generation
To purificationEthanol , waste mixture
70Kg worth of reducing sugars
26.6Kg
30% hemicellulose 7.98Kg
40% Cellulose = 10.64Kg30% Lignin = 30Kg (not broken down)
3.72Kg Hexose (glucose)
4.79Kg of pentose (xylose)
4.79 + 3.72 = 8.51Kg of reducing sugars
6.81Kg of ethanol10.64Kg of water >2.128Kg of yeastTotal liquid = 17.45Kg
Second Generation Process: Mass Balance
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Hybrid Purification
Supernatant
de
FUEL ETHANOL 99.5%
AZEOTROPE ETHANOL 65%
Water
17.45L=6.8L Ethanol10.64L Waste Supernatant
Centrifugation:Lignin, Yeast
(4.42L Ethanol)
4.23L EthanolYield 6.5% from 70Kg starting material
Dehydration
Distillation
“Distillation 2”
Water
AZEOTROPE ETHANOL 96% (4.24L Ethanol)
Water
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Dehydration Methods Used.Lime (calcium oxide) or rock saltAddition of an entrainer. Adding small
quantities of benzene or cyclohexane.Molecular SievesMembranes :
Can not be exposed to high water concentration
Fouling by fusel oilsPressure reduction
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SiftekTM Membrane & SystemProduced by Vasperma, gas separation solutions.
This system can be integrated in a bio-ethanol plant.
Replacing the 2nd distillation column and the molecular sieve units for the dehydration process.
Potential of reducing energy consumption by up to 50%.
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SiftekTM MembranesHydrophilic polymer membrane Exceptional thermal mechanical and solvent
resistance propertiesMembrane is a proprietary formulation based
on polyimideProvides high flux and water/ethanol
selectivity.
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BY PRODUCTSVinasse:- Distillation step.Biodigestion of vinasse-electric power. 1 m3 of bioethanol 115 m3 of biogas 169 kWh of bioelectricity.
As fertilizers
Single cell protein production.
Non-structural bricks.
Animal feed.
Thermophilic digesters Biogas Vinasse methane.
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Carbondioxide: Fermentation step Washed to recover the bioethanol.
Carbonated beverages and dry ice, sodium bicarbonate manufacturing and treatment of effluents.
760 kg of CO2 1000 L of anhydrous bioethanol.
Fusel oil : Distillation stepAlcohol components acetic acid and butyric acid esters.
Flavour and fragrance manufacturing.
Ethylbutyrate is used as pineapple-banana flavours in the food industry.
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Second class ethanol: This type is used in Pharma, cosmetics and food
industry.
Lignin:Wood adhesive.Emulsions and dispersants.Carbon fibre precursor.Other products:
Bagasse -Bioelectricity: cogeneration system.One ton of sugarcane - 250 kg of bagasse -500 kg
to 600 kg of steam -electric power production.
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Economics of bagasse bioethanol fuel:
Potential to be competitive energy resource but needs favourable policies.
Does not compete with food production
Cheaper compared to food crops (price per ton)
Reduce solid waste disposal costs.
Cellulosic ethanol is US$0.59/litre. At this price, it will cost US$120 to substitute a barrel of oil (159 L).
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Cost and efficiency
Source: eubia.orgSource: Goldemberg 2008
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The Economic Competitiveness of Alcohol Fuel Compared with Gasoline
Source: Goldemberg 2008
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Comparison of the production costs (€/1000 liters) of ethanol in Brazil, United States and Germany.
Production costs:
Source: Goldemberg 2008
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Commercialization Refineries are been built by companies like Iogen, Abengoa and Broin while
companies like Novozymes, Diversa and Dyadic are producing enzymes which will enhance cellulosic ethanol future.
Fuel Ethanol Production by Country(Millions of U.S. liquid gal/yr) Country/Region 2009 2008 2007
United States 10,750.00 9,000.00 6,498.60Brazil 6,577.89 6,472.20 5,019.20European Union 1,039.52 733.60 570.30
China 541.55 501.90 486.00Thailand 435.20 89.80 79.20 Canada 290.59 237.70 211.30 India 91.67 66.00 52.80Colombia 83.21 79.30 74.90Australia 56.80 26.40 26.40Other 247.27World Total 19,534.99 17,335.29 13,101.70
Source: Wikipedia.org
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Brazil: Ethanol - Transport sectorYear policy Results
1976 mandatory fluctuated between 10 -25%
1993 mandatory 20% E20
2007 mandatory 25% E25
2003 Introduction Flex-Fuel vehicles
2008 E25-Flex vehicles 18% of Brazils total energy consumption -transport sector
2009 Flex-Fuel vehicles- 92.3% of share -SUCCESS
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Issues: Environmental and Social Impacts of Sugarcane Production
Deforestation99.7% of sugarcane plantations are located at least
2,000 kilometres (1,200 mi) from the Amazonia
Fertilizer – water pollution
Effects on food prices
Bagassosis
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Conclusion:By integrating 1st & 2nd generation sugarcane ethanol fuel
production, we can simultaneously increase yield and efficiency, whilst reducing costs and recycling co-products.
Renewable energy source, which can be very competitive with any other fuel source in terms of cost and efficiency. Its benefits are unparalleled as it converts waste to energy fuel which does not contest on food crops.
However, more research and development is necessary for 2nd generation fuel production.
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References:
Biomass- based energy fuel through biochemical routes: A review (2007)
R.C. Saxena , D.K. Adhikari, H.B. Goyal. Improving bioethanol production from sugarcane :
evaluation of distillation, thermal integration and cogeneration systems (2010)
Marina O.S. Dias et al. Membrane- Based Ethanol Dewatering System (2010) Pierre Cote et al.