Beruflich Dokumente
Kultur Dokumente
www.elsevier.com/locate/enconman
b,*
Faculdade de Engenharia Mecanica, Universidade Estadual de Campinas, Caixa Postal 6122, CEP 13083-970 Campinas-SP, Brazil
b
Departamento de Ingeniera Mecanica, Universidad de Zaragoza, C/ Maria de Luna, 3, 50018 Zaragoza, Spain
Available online 31 August 2007
Abstract
The sugarcane industry represents one of the most important economic activities in Brazil, producing sugar and ethanol for the internal and external markets. Moreover, thermal and electric energy is produced for self-consumption, using sugarcane bagasse as fuel in
cogeneration plants. Almost all the sugarcane plants in Brazil are self-sucient in terms of energy supply and in the last few years some
of them have been selling their surplus electricity for the grid. The reduction of process steam requirements and the use of more ecient
cogeneration systems are new alternatives to increase the surplus electricity generation. The purpose of this paper is to analyze the steam
demand reduction on sugar and ethanol process and alternatives for cogeneration systems in sugarcane plants, aiming at the surplus
electricity generation increase.
2007 Elsevier Ltd. All rights reserved.
Keywords: Sugar; Ethanol; Cogeneration; Biomass energy; Thermal integration
1. Introduction
Sugarcane production is one of the most important economical activities in Brazil, mainly due to its high eciency
and competitiveness. In this segment are found sugar factories, alcohol distilleries and integrated sugar and alcohol
plants that can produce both products from the sugarcane.
In the last few years electricity is becoming a new product
too, since sugarcane bagasse can be used as fuel in cogeneration systems.
Currently, there are more than 300 sugarcane plants in
operation in Brazil [1]. A total of 394.4 Mt of cane were
processed in the last harvest season (2005/2006) for sugar
and ethanol production [2].
Nowadays almost all sugarcane plants in Brazil are selfsucient in thermal, mechanical and electrical energy.
Generally low eciency cogeneration systems based on
steam cycle with live steam at 22 bar and 300 C are found
*
0196-8904/$ - see front matter 2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.enconman.2007.06.038
in these plants [3]. Reduction of process steam requirements and more ecient cogeneration systems can increase
the surplus of electric power generated. Currently, cogeneration systems begin to operate with live steam generation
pressure higher than 60 bar [4] attending the plant energy
requirements and producing surplus electricity that can
be sold. The total electricity generation capacity installed
in the sugarcane plants using bagasse in Brazil is around
2300 MW [5].
The purpose of this paper is to analyze the steam
demand reduction on sugar and ethanol process and alternatives for the cogeneration systems in sugarcane plants,
aiming at the surplus electricity generation increase. A
base case, with high process steam demand was simulated. This case intends to represent the thermal energy
consumption of typical sugar and ethanol plants in Brazil.
A thermal integration procedure was implemented in an
improved case, reducing the steam demand reduction.
Dierent alternatives of cogeneration systems were simulated for both cases, considering steam cycles and biomass
gasication based cycles.
2. Process description
In sugarcane segments in Brazil most of the plants produce sugar and ethanol in integrated plant. Some of them
use sugarcane juice for sugar production, being the molasses, a by-product of sugar process, used to produce ethanol
in annexes distilleries. The use of sugarcane juice for sugar
and ethanol production is very common too, reducing the
sugar production in order to produce more ethanol. Plants
which use half of the juice for sugar production and half
for ethanol production were considered in this paper.
Fig. 1 shows the sketch of the plant with the basic process
steps described below:
Sugarcane preparation and juice extraction: washing system is used to remove excessive amounts of soil, rocks
and trash delivered with the sugarcane before entering
the extraction system. After washed, sugarcane is prepared using rotating knives and shredders that reduce
the cane fed to the mill into small pieces suitable for
the subsequent extraction process. Juice extraction system separates the bagasse and the juice by compression
of the sugarcane. The bagasse is used as fuel at the
cogeneration system and the raw juice produced is delivered to the treatment system.
Juice treatment: some non-sugar impurities are separated by the addition of some chemical reactants as sulphur, lime, among others, being juice heating necessary
for the purication reactions. After that, the juice
passes through a ash tank, before entering the clarier. The precipitate formed into the clarier is separated from the claried juice and directed to lters.
After ltration, part of the juice returns to the process
ahead the clarier, and lter cake is rejected. The claried juice can be then directed to the evaporation system. Treatment of juice for ethanol and sugar
production can be very similar deferring on the sulphur
addition step, used exclusively for sugar production.
Juice evaporation: juice for sugar production is concentrated in a multiple-eect evaporator. Exhausted steam
from the cogeneration system is used as thermal energy
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Table 1
Parameters adopted for the process simulation base case
Parameters
Value
14
50
14
86
3
70
65.0
7.6
2.5
127.4
16
12
Mass base.
Table 2
Exhausted steam consumption base case
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Heating
step
1
2
3
4
Treated juice
Fermented
liquor
Tin
(C)
Tout
(C)
Hot
streams
Tin
(C)
Tout
(C)
35.0
78.5
85.4
97.3
78.5
85.4
97.3
105.0
Condensate
Vapour 4th
Vapour 3rd
Vapour
2nd
105.0
94.4
103.9
110.2
38.4
90.9
102.3
109.6
1
2
3
4
35.0
79.9
85.5
97.1
79.9
85.5
97.1
105.0
Stillage
Vapour 4th
Vapour 3rd
Vapour
2nd
100.0
94.4
103.9
110.2
40.5
90.9
102.3
109.6
97.0
104.6
110.2
109.6
104.6
112.0
Vapour
2nd
Vapour 1st
115.4
115.0
1
2
3
30.0
77.5
80.0
77.5
80.0
90.0
Mash
Vapour 4th
Vapour 3rd
95.1
94.4
103.9
36.9
90.9
102.3
Table 4
Exhausted steam consumption improved case
Stream
Stream
9.8
9.8
16.3
10.5
0.1
8.4
20.2
23.7
0.1
14.8
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Table 5
Process steam demand
Steam demanda (kg steam/t cane)
Base case
Improved case
a
540
278
Table 6
General parameters adopted for cogeneration systems
Parameter
Value
25
1.013
7542
85
80
80
96
96
a
b
Wet base.
LHV base.
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Table 7
Parameters adopted for congurations III and IV
Parameter
Value
a
2.3
35
11
1050
85
85
85
10
5
Ref. [19].
Biomass is dried from 50% to 15% of moisture content [21].
for steam generation in a HRSG operating at one pressure level. High moisture content of available bagasse at
sugar process makes dryer system necessary for the gasication process, what makes the use of two pressure
levels at the HRSG not justiable [20]. An extraction
condensation steam turbine operates with steam generated by the HRSG, having an extraction at 2.5 bar for
the process (Fig 5).
Fraction (% volume)
Air
CO
CO2
CH4
C2H4
H2
H2O
N2
0.5
21.7
11.4
2.9
1.0
16.3
3.2
43.0
Table 9
Parameters of live steam
Fig. 5. Sketch of conguration IV.
L1
L2
L3
Pressure (bar)
Temperature (C)
60
80
100
480
510
540
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6. Results
6.1. Conguration I
Table 10
Bagasse surplus for conguration I
Bagasse surplus (%)
L1
L2
L3
Base case
Improved case
7.7
5.8
4.2
52.5
51.5
50.7
Table 11
Electricity surplus for conguration I
Surplus electricity production (kWh/t cane)
L1
L2
L3
Base case
Improved case
54.7
62.9
69.8
14.2
18.5
22.0
L1
L2
L3
Base case
Improved case
65.8
71.7
76.3
90.1
95.9
100.6
Table 13
Possible steam production with available bagasse for conguration IV
Steam production (kg steam/t cane)
L1
L2
L3
332
316
302
L1
L2
L3
Table 16
Performance parameters for improved case
Congurations
Improved case
EUF (LHV %)
171.2
172.0
172.2
PHR
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gex(%)
L1
L2
L3
L1
L2
L3
L1
L2
L3
II
III
IV
84.28
84.22
84.17
0.25
0.28
0.30
26.01
26.73
27.32
52.98
54.07
54.96
0.75
0.79
0.82
23.10
23.93
24.60
75.37
75.37
75.37
0.56
0.56
0.56
29.93
29.93
29.93
69.76
69.91
69.96
1.19
1.19
1.19
34.86
34.97
35.01
W e Qu
Ef
where We is the net electricity power output, Qu is the useful heat rate delivered to the process and Ef is the fuel energy consumed. The net electricity power (We) considers
the electricity generated by the steam and gas turbines, discounting the electricity consumed by pumps, compressors
and dryers where applicable. Ef considers the energy content of the consumed fuel.
Power-to-heat ratio
PHR
We
Qu
Exergetic eciency
6.5. Performance parameters assessment
Many performance parameters for cogeneration systems
are found in the literature but not all of them are considered relevant to a combined heat and power plant like
cogeneration systems of sugarcane plants, providing heat
for the process and surplus electricity to be sold to the grid.
Some of performance parameters presented by Horlock
[24] and Huang [25] have been calculated for the dierent
conguration analyzed in this paper (Eqs. (1)(3)). Tables
15 and 16 show the values calculated for base and
improved cases, respectively.
Table 15
Performance parameters for base case
Congurations
II
EUF (LHV %)
L1
L2
L3
84.28
84.22
84.17
77.11
78.22
79.10
PHR
L1
L2
L3
0.25
0.28
0.30
0.25
0.28
0.30
gex (%)
L1
L2
L3
26.01
26.73
27.32
25.35
26.17
26.85
gex
W e Bq
Bf
where Bq is the exergy of useful heat delivered to the process and Bf is the exergy of the consumed fuel. Exergies
of vapour and gases streams were calculated following
standard procedures [26]. The bagasse exergy was evaluated based on Sosa-Arnao and Nebra [27] procedure.
The energy utilization factor (EUF) considers the useful
heat (Qu) and the net electricity produced by the plant (We)
as products with equal weights. This criteria is considered
not satisfactory to compare the dierent congurations,
once electricity is dicult to produce and more valuable
than useful heat [24]. Power heat ratio and exergetic eciency are considered more useful to compare cogeneration
systems [24,25].
For the base case conguration I showed to be more
interesting for surplus electricity generation. It can consume great part of the bagasse produced by the process
and generates almost the same electricity than conguration II, with similar exergetic eciency.
Conguration III showed to be not interesting even for
improved case. Its PHR indicates the deciency of this conguration to produce electricity, being respectively 46%
and 213% lower than conguration II and IV for live steam
level L3.
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The adoption of conguration IV together with the process steam demand reduction of improved case show the
advantage of combined cycle. This conguration presents
the highest exergetic eciency and PHR when compared
with other congurations.
References
7. Conclusions
The analysis performed in this paper showed that the
process steam demand for sugar and ethanol plants can
be reduced signicantly with process thermal integration,
being important to promote better use of energy in these
industries.
For traditional steam cycles with back-pressure turbines
(conguration I), a signicant amount of surplus bagasse
can be obtained with process steam demand reduction,
allowing its use as raw material for other by-products of
the sugarcane plants, as additional ethanol or chemicals.
At short term, a large amount of surplus electricity generation can be obtained in sugar and ethanol plants with
high process steam demand (base case) using steam cycles
at higher levels of live steam generation. For those plants
with reduced steam demand (improved case), steam cycles
with condensationextraction turbines (conguration II)
allow a considerable increase on surplus electricity
generation.
Biomass gasication based power cycles can be very
important alterative for surplus electricity generation in
sugarcane plants at long term. Steam demand reduction
showed to be necessary, being the improved case presented in this paper, adequate for combined cycles and
bagasse gasication systems. If technical and economical
barriers of bagasse gasication process are overcome,
conguration IV could increase more than 70% the surplus electricity generation in sugarcane plants. Sugarcane
trash could be recovered in the harvest stage and used as
additional fuel, increasing even more the electricity
generation.
As a nal comment from the obtained results it can be
concluded that there is a potential for increasing signicantly the electricity production using sugarcane bagasse
and trash as fuels, mainly with process steam demand
reduction. This fact is very important in the present context, where the reduction of CO2 emissions in order to prevent global warming, is becoming a priority in the
international agenda. Further, it could represent in the
next future, a new interesting source of income for the
sugarcane factories, which could take benets from the
mechanisms considered in Kyoto protocol, e.g. clean development mechanisms, international CO2 emissions trade
and so on.
Acknowledgements
The authors would like to acknowledge Usina Cruz
Alta, Guarani and Santa Isabel engineers, technicians
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