Agro-Industry of Ethanol
Agro-Industry of Ethanol
Agro-Industry of Ethanol
FA U-06
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Public Disclosure Authorized
SECTORAL LIBRARY
INTERNATIONAL RANK
FOR
RECONSTRICTIOW AND DFVP[OPUFNT
FEB 12 1986
Public Disclosure Authorized
<.S,
Agro-Industry Profiles
Public Disclosure Authorized
ETHANOL
F2
PROFILES IN THIS SERIES:
e.......e..............FAU-08
RICE .....
RUBBER. .. . . ....... oe
.......... . FAU-13
TEA ..e..e......e......e.....e..FAU-15
COTTON .......
. ................... FAU-17
FAU-19
SPICES AND ESSENTIAL OILS .................
ABSTRACT
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FOREWORD
The nature of project and sector work in the World Bank is such
that staff are often called upon to work outside their major
fields of specialization, if only to make an initial judgement on
the utility of further, often costly, investigation. Under these
circumstances, up-to-date and authoritative reference material is
essential.
The profiles in this series are designed for use by operational
staff with experience in the agricultural sector but who do not
have a technical knowledge of the particular commodity under
discussion. Their purpose is not to substitute for technical
expertise but to provide a reliable inhouse reference which will
help Bank staff to determine when and what expertise is needed in
the detailed evalutation of investment proposals in agro-
processing.
The conditions for any particular proposal are bound to be unique
in a number of respects, and the use of norms and general data in
project analyses could give rise to significant errors. On the
other hand, by providing responsible staff with a guide to the
issues on which appropriate expertise should be sought, these
profiles can contribute to the overall quality of agro processing
investment. Used with care, they should also facilitate broad
pre-screening such as may occur during sector work and
reconnaissance.
Questions, comments and further inquiries should be addressed to:
Agro-Industries Adviser
Finance and Agro Industry Unit
Agriculture and Rural Development Department
September 1985
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Ethanol from Sugarcane
CONTENTS
INTRODUCTION .................
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Ethanol from SuQarcane
DATA SHEET
NA - Not applLcable.
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INTRODUCTION
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GLOSSARY
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PROCESSING
* Fermentation
Fermentation is the process whereby an organic material is
converted from one form to another with enzymes produced by
living micro-organisms. In the fermentation of pasteurized cane
juice, sucrose is converted to ethanol, carbon dioxide, and heat.
About 5% of the sugar is consumed by the yeast in the process
(Solar Research Institute, 1980).
Most commonly used in cane juice fermentation are yeasts
belonging to the genus Saccharomvces. Their sensitivity to
variables such as temperature and pH affect fermentation
efficiency and ethanol yields.
The cane juice must be concentrated and pasteurized prior to its
innoculation with a yeast culture totalling 5-8% of its volume
(Paturau, 1969). Following a fermentation period of 24-72 hours,
a beer of 8-10% ethanol concentration is produced. The amount of
time required depends on the concentration of yeast cells in the
mash: greater concentrations result in faster conversion.
However, there is a point of diminishing returns, beyond which
the rate of increase in speed of conversion falls with an
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Figure 1: Flowchart of Ethanol Production
Cane
Bagasse Mil
Juice
f --Filtrate
Clarification -Mud Fitratin
Filter Cake
Sterilizati7on I'Ev'aporation
| Yeast | Coin
Preparation Antfoa
s ~~~~~~~~Antifoam
~~~a
Waer.
Acid 'Treatment Fermentation Carbon Dioxide
Recyclable Fermented
Yeast WaphCla
L ~~~~Centrif:ugi:ng-- P -Wash
Water Rectifcation
Benzene or
Cyclohexane for Dehydration Water &
Azeotropic Ethanol
Distillation
Anhydrous Ethanol
4
increase in yeast concentration. Using a yeast concentration of
150-180 grams/liter, a fermentation time of 12-18 hours has been
achieved in Brazil.
5
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Distillation
Distillation is the operation whereby ethanol is separated from
the stripped fermented wash. This is effected by a process of
repeated evaporation and condensation, which is possible because
of the difference in boiling temperatures between ethanol (172
degrees F or 77.7 degrees C) and water (212 degrees F or 100
degrees C) (Solar Research Institute, 1980). Evaporation causes
more ethanol than water to leave the solution; when the resulting
vapor is condensed, the concentration of ethanol is higher than
that of the original solution. This process is repeated until
the ethanol concentration reaches 95% (Ibid). At this level, the
ratio of ethanol molecules to water molecules in the vapor remain
constant and no further concentration is possible through
evaporation. This is known as a constant boiling point mixture
or azeotrope. The residual liquid containing relatively small
amounts of ethanol is recycled so that no ethanol is lost during
distillation.
A distillation column consists of two sections: a stripping
(beer) column and a rectifying (enrichment) column. (Figure 1.)
The bottom of the stripping column is heated by steam injection
or by an external calandria (known as a reboiler) if the stillage
is not to be diluted. The latter method would be used if the
stillage were substantially to be concentrated by evaporation.
Evaporation at one level occurs when the solution comes into
contact with a heating stage at the next lower level.
Condensation occurs when the vapor at a given level comes into
contact with the cooler stage immediately above it. The
concentrated ethanol vapor from the top of the rectification
column is condensed in an external condenser and a portion
refluxed to the column.
The 95% concentration of ethanol resulting from the distillation
operation is known as hydrous ethanol, i.e., ethanol containing
water. Anhydrous ethanol, which is usually 99.8% pure, is
produced by adding benzene to the hydrous solution and distilling
in another distillation column. The addition of benzene or
cyclohexane eliminates the constant boiling point mixture of 95%
ethanol/5% water, thereby allowing the evaporation of greater
concentrations of ethanol. The benzene is later separated from
the solution and recycled. Because alcohol vapor/air and
benzene/air mixtures are highly flamable, extreme care is needed
to avoid leaks of vapors and possible ignition.
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An alternative to dehydration by azeotropic distillation is
dehydration by use of a molecular sieve. The hydrous ethanol is
passed through a column of desiccant which absorbs only the
water. The desiccant is periodically regenerated by blowing a
hot gas through it or even by using a side stream of anhydrous
ethanol vapor. There are molecular sieves available that employ
either the liquid or the vapor phase.
OTHER FACTORS
Uses
Applications of ethanol fall into four principal categories
(World Bank, 1980): (1) as an alcoholic beverage; (2) as an
intermediate chemical for use in toiletries, cosmetics,
pharmaceuticals, etc.; (3) as a feedstock for the production of
other chemical materials; and (4) as a petroleum substitute and
octane enchancer.
The latter has acquired increasing importance with the rise of
petroleum prices during the past decade and its octane
enhancement value is becoming more important since the decision
to phase out lead in gasoline in the USA. As a petroleum
substitute ethanol can be used as a boiler fuel, a chemical
product or feedstock, a diesel substitute, or a gasoline
substitute.
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Figure 1: Distillation Column
Source: Fuel from Farms (1980)
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Condenser
Noncondensibles
To
Pump(^_ Ethanol
Oehydration
or Storage
Stillage
to
Storage
Stam
Beer
Column
Rectitying
Column
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Ethanol as a substitute for gasoline is either used in its
hydrous form as straight alcohol (94-95% pure) or mixed in its
anhydrous form with gasoline, up to a 20% ratio (Ibid). In
either case, it can significantly improve combustion efficiency
and octane rating. Use of pure ethanol requires modification of
gasolene engines, as does the use of 50% diesel/ethanol for
diesel engines. Little modification is needed when 20% ethanol
in gasolene is used. Ethanol is potentially important to
petroleum-deficit countries (such as Brazil, where the potential
has been partially realized) which are able to produce a sizeable
* biomass supply relatively cheaply.
Fermentation ethanol can be converted into the chemical raw
material ethylene by a dehydration process. Ethylene is the
single most important intermediate product in the petrochemical
industry, for the production of most large volume petrochemical
products. Dehydrogenation and oxidation convert fermentation
ethanol to acetaldehyde, another important chemical raw material.
Some of the chemicals which can be produced from ethylene and
acetaldehyde are illustrated in Figure 2.
Environmental Concerns
Disposal of stillage can cause environmental problems, in part
because of the large quantities produced: the volume of stillage
produced is equal to 10-13 times that of alcohol (World Bank,
1980). When this mix of 10% solids is concentrated to about 50%
solids and mixed with concentrates, it can be used as animal feed
(Ibid). But high evaporation costs may make the resulting feed
prices uncompetitive. Stillage can also be applied directly as a
fertilizer, however, because of its level of dilution (1%
nitrogen, 0.2% phosphate, and 1.5% potash), large volumes must be
applied to supply the necessary concentrations of nutrients
(Ibid). This results in high transport costs for all but the
closest of farms. A possible solution to this problem, as
attempted in parts of Brazil, is to pump the stillage to the top
of neighboring hills using surplus steam from bagasse to power
the pumps, and then use a system of gravity irrigation to
disperse the stillage. The excess is transported to more-distant
fields and sprayed on the soil. (Excessive application can
acidify soils and cause nutrient imbalances.) If use of the
. stillage is uneconomical, it must be treated in settling ponds
and aerated in order to reduce the biological oxygen demand level
(B.O.D.) before it can be discharged into rivers and streams.
The aeration of large volumes of stillage consumes a great deal
of electrical energy and even after the B.O.D. has been reduced
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to a level where the treated stillage will not harm aquatic life
the stillage retains a dark reddish brown color which causes
discoloration to rivers and streams.
The ultimate solution is incineration of the stillage, which can
be achieved when it is concentrated to approximately 60% solids.
This produces sufficient heat to generate steam for the
evaporator with some to spare, but the capital investment for
this solution is usually prohibitive.
Plant Capacity
While cost estimates for sugarcane-based alcohol production units
reveal that there are significant economies of scale in the
output range of 20,000 to 300,000 liters/day, the optimal plant
size is principally determined by raw material availability, fuel
consumption requirements, and operating days per year (World
Bank, 1980). Capital costs are relatively less critical.
Brazil is currently working on mini distilleries designed to
produce 5000 liters/day of ethanol, using stillage and residues
for biogas production.
10
Figure 2: Alcohol from Biomass:
Production of Chemicals from Ethanol by Major Process Routes
Source: World Bank (1980)
Intermediates End Products
By Dehydration Process
Ethanol
t y ene Oxide ~ ~ ~ ~ Etylee Clycols
Synthetic Fibers
+NH Anti-freeze
. Ethanol-amines
Surfactants
(+Alcohol) Gas Scrubbing
Glycol Ethers
Paints
Varnishes
Textiles
-Pipes and Tubes
+Chlorine Shoe Soles
Electrical
-Chlorinated Ceng
Degreasing
PE -Ld HP or
Hd LP grades
By Dehydrogenation Process
25% 1
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Vinyl Polyvinyl Acetates
_L... Acetate Latices
Monomer Resins
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BIBLIOGRAPHY
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ANNEX I:
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ETHANOL
EXAMPLE 1
Page 1 of 2
COUNTRY: Brazil
49,500 m3 of ethanol
US $ '000
Total Cost
(1978 prices)
Fixed Capital Investment
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ETHANOL
EXAMPLE 1
Page 2 of 2
US $ '000
Total Cost
(1978 prices)
Fixed Costs
depreciation 1683.00
maintenance, administration 891.00
Sub-Total Fixed Costs 2574.00
Variable Costs
chemicals, utilities 2871.00
labor 495.00
Sub-Total Variable Costs 3366.00
NOTES:
1. Exchange rate Brazilian Cr. $ 17.00 = US $ 1.00
2. Data are net of contingencies.
3. Local/foreign cost breakdown not available.
4. Production based on 150 m3/day x 330 working days/year.
0
ETHANOL
EXAMPLE 2
Page 1 of 2
COUNTRY: Brazil
27,000 m3 of ethanol
US $ '000
Total Cost
(1978 prices)
Fixed Capital Investment
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ETHANOL
EXAMPLE 2
Page 2 of 2
US $ '000
Total Cost
(1978 prices)
Fixed Costs
depreciation 1350.00
maintenance, administration 702.00
Sub-Total Fixed Costs 2052.00
Variable Costs
chemicals, utilities 135.00
labor 324.00
Sub-Total Variable Costs 459.00
NOTES:
1. Exchange rate Brazilian Cr. $ 17.00 = US $ 1.00
2. Data are net of contingencies.
3. Local/foreign cost breakdown not available.
4. Production based on 150 m3/day x 180 working days/year.
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ANNEX II:
CONVERSION TABLES
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WEIGHTS AND MEASURES
avoirdupois
Ton: short ton 20 short hundredweight, 2000 pounds;
0.907 metric tons;
long ton 20 long hundredweight, 2240 pounds;
1.016 metric tons.
Hundredweight cwt;
short hundredweight 100 pounds, 0.05 short tons; 45.359
kilograms;
long hundred weight 112 pounds, 0.05 long tons; 50.802
kilograms.
Pound lb or lb av; also *;
16 ounces, 7000 grains; 0.453 kilograms.
Ounce oz or oz av;
16 drams, 437.5 grains; 28.349 grams.
Dram dr or dr av;
27.343 grains, 0.0625 ounces; 1.771 grams.
Grain gr;
0.036 drams, 0.002285 ounces; 0.0648 grams.
Tro"
Pound lb t;
12 ounces, 240 pennyweight, 5760 grains; 0.373
kilograms.
Ounce oz t;
20 pennyweight, 480 grains; 31.103 grams.
Pennyweight dwt also pwt;
24 grains, 0.05 ounces; 1.555 grams.
Grain gr;
0.042 pennyweight, 0.002083 ounces; 0.0648 grams.
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METRIC SYSTEM
Square kilometer 2
sq km or km2;
1,000,000 square meters;
0.3861 square mile.
Hectare ha;
10,000 square meters;
2.47 acres.
Hectoliter hl;
100 liters; 3.53 cubic feet; 2.84 bushels;
Liter 1;
1 liter; 61.02 cubic inches; 0.908 quart
(dry); 1.057 quarts (liquid).
Deciliter dl;
0.10 liters; 6.1 cubic inchs; 0.18 pint
(dry); 0.21 pint (liquid).
Centiliter cl;
0.01 liters; 0.6 cubic inch; 0.338
fluidounce.
Metric ton MT or t;
1,000,000 grams; 1.1 US tons.
Quintal q;
100,000 grams; 220.46 US pounds.
Kilogram kg;
1,000 grams; 2.2046 US pounds.
Gram g or gm;
1 gram; 0.035 ounce.
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