ctbe virtual sugarcane biorefinery proposal: concept, objectives and execution plan
DESCRIPTION
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: http://www.bioetanol.org.br/workshop4TRANSCRIPT
CTBE Virtual Sugarcane Biorefinery Proposal: concept, objectives and execution plan
Centro de Ciência e Tecnologia do Bioetanol – CTBEAntonio [email protected]
Workshop on Virtual Sugarcane Biorefinery:assessing success of new technologies
August, 2009
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
Motivation
How to measure the successlevel in R&D&I activities ?
Basic Science Publications
Technology Development ?
In order to solve this dilemma,CTBE decided to build the
Virtual Sugarcane Biorefinery Program
Concept - VSB
VirtualSugarcaneBiorefinery
(VSB)
Virtual Biorefinery• Simulation
• Process Optimization• Impacts Calculation
• Comparison with Standard Biorefinery
EconomicAnd Risk
Assessment
Life CycleAssessment
(LCA)
Input -Output
Assessment
MathematicalModeling Net• Processes
• Unit Operations
Process Alternatives(industrial andagricultural)
Assessment ofSuccess Level
Impacts:• economic
• environmental• social
• CTBE’s Programs• Associated Institutions
• Stakeholders
Concept - Biorefinery
BasicPrinciples
of aBiorefinery
(Kamm and Kamm, 2004)
• Fuels,
• Chemical,
• Materials,
• Specialties,
• Commodities, Goods.
Products Substances and Energy
various, multi product systems
Processing Technologiesvarious,
combined
• Bioprocesses,
• Chemical Processes,
• Thermo-chemical Processes,
• Thermal Processes,
• Physical Processes.
• Food and Feed Grains,
• Lignocellulosic Biomass,
• Forest Biomass,
• Municipal Solid Waste.
Feedstock(s)biological raw material various,
mixed
Objectives
(1) Optimize concepts and processes.
(2) Assess different biorefinery alternatives.
(3) Assess stage of development of newtechnologies.
Scope
Basic 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;
Route 5: sugarchemistry;
Route 6: lignocellulosechemistry;
Route n: other routes.
In all routessugarcane
agriculturaltechnologiesare included
Scope
Development stages:
Basic Biorefinery: definition of standard production units,considering the defined routes, including bothindustrial and agro technologies.
Optimized Biorefinery: construction of mathematicalmodels for the operation units – optimizationof the production (agriculture and industrial)units. Integration with a Net of Institutions.
Aggregated Biorefinery: aggregation of the concepts ofraw-material production and product and by-product uses.
Execution Plan
Mathematical Modeling and Simulation Net
Modeling and Simulation
SimulationPlatform
MathematicalModels
OptimizationStrategies
SustainabilityImpacts
Virtual
Optimized
Sugarcane
Biorefinery
NET
Sub-Net 1 Sub-Net 2
Sub-Net 3 Sub-Net 4
AgriculturalTechnologies
Execution Plan
Integrated Process Simulation
• 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.
Sub-Net 1
Execution Plan
Integrated 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.
Execution Plan
Integrated Process Simulation
• Optimized Biorefinery
- development and application of techniques for the optimization of subsystems composed by integratedoperations – 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).
Sub-Net 2
Execution Plan
Integrated Process Simulation
• Optimized Biorefinery
- 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).
Sub-Net 3
Execution Plan
Sustainability Parameters
• In order to analyze the most relevant impacts, thefollowing 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 ormore sectors.
Sub-Net 4
Execution Plan
Agricultural Technologies
• 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).
Sub-Net 5
Execution Plan
Assessment and Validation
• VSB Premises
- completely transparent;
- plausible;
- involvement of the interested parts (stakeholders andassociated institutions);
- stakeholders should help solving conflicts;
- practical and feasible standard application models;
- adoption of compromise solutions – cannot be modifiedunless a new agreement is reached;
- several stages of evaluation and validation.
Execution Plan
Assessment 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, itshould be validated by Institution B.
• Validation of Obtained Results
- should be periodically submitted and evaluated by thestakeholders.
Activities and Schedule
Activities and Schedule
2nd Generation Ethanol
Basic FlowsheetsPreliminary Simulation
Evaluation with P.S.
Optimized SimulationAggregated SimulationEvaluation with O.S.Evaluation with A.S.
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.
Building Team
CTBE Associated Institutions
VSB Program• Antonio Bonomi (Coordinator)
• Mirna Scandiffio (LCA)
• Marcelo Cunha (IO, Economic Analysis)
• Charles Dayan (Mathematical Modeling)
• Marina Dias (Simulation Platform)
• Specialists (Agriculture, Biorefineries,
Ethanol Distribution and Use,
Residues Disposal, others)
Other Programs (strong interaction):• Basic Science
• Pilot Plant
• Low Impact Mechanization
• Sustainability
• FEQ/UNICAMP
• NIPE/UNICAMP
• DEQ/EPUSP
• DEQ/UFSCar
• CTC
• IPT
• UEM
• UFPE
others
OBRIGADO !
Bonomi e Equipe
Execution Plan
Sustainability Parameters
• Economic Assessment and Risk Analysis- investment calculation;
- profitability analysis (net profit, gross margin, return oninvestment, payback time, etc.);
- risk analysis – expected valuesbased on probabilitydistribution of eachinput variable subjectto uncertainty.
Execution Plan
Sustainability Parameters
• Economic Assessment and Risk Analysis- Results of the Risk Analysis Model
Ethanol from sugarcane bagasse (US$/liter)
Process Expected Value Accumulated Occurence
Probability (*)
Lower Value
Higher Value
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
Execution Plan
Sustainability Parameters
• Life Cycle Analysis - LCA- systematic approach, aiming at identifying the environmental
aspects related to the life cycle of a product, from its productionup to its final use;
- it includes analysis of:
⇒ raw materials
⇒ production
⇒ distribution
⇒ use / disposalproducts andby-products.
ISO, 2006
Execution Plan
Sustainability Parameters
• Life Cycle Analysis - LCA- Normalized potential impacts for the ethanol LCA
OMETTO et al., 2009
Execution Plan
Sustainability 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 theproduction sectors.
- general equilibrium models are used to capture the alteration in theuse of production factors and in the production of goods as afunction 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.
Execution Plan
Sustainability Parameters
• Input-Output Analysis (IO)
- Sector index of incorporated energy in the final demand
Sector
Incorporated
Energy
(toe/R$1,000)
Renewable
energy
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