Biorrefinarias: Máquinas de Produção de Energia e Armazenamento Geológico de

CarbonoPaulo Seleghim Jr.

seleghim@sc.usp.br

Café com FísicaCafé com FísicaIFSC/USPIFSC/USP

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The problem...

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Power to sustain our life processes

Power to support our lifestyle

2500 cal/day

120 W

90 W

2000 W

500 EJ/year

2300 W7 billion people

industry + agriculture (28% = )

transportation sector (27% )

services + residences (36% )

Energy use by humankind

Typical sugarcane millTypical sugarcane millNon-renewable Carbon based economy

CO2

energychemical compounds

seleghim@sc.usp.br

petroleum

Typical sugarcane millTypical sugarcane millFossil carbon based economy

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The solution...

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Typical sugarcane millTypical sugarcane millRenewable neutral carbon based economy

energybiochemical compounds

CO2

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Typical sugarcane millTypical sugarcane millFossil carbon based economy

Typical sugarcane millTypical sugarcane millFossil carbon based economy

Already engenders tremendous socio-economic impacts on…

HUMAN CONDITION !

Typical sugarcane millTypical sugarcane millRenewable negative carbon based economy

energy - biochemical compounds

CO2

CO2

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CO2

Typical sugarcane millTypical sugarcane millFossil carbon based economy

Typical sugarcane millTypical sugarcane millFossil carbon based economy

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Case Study:Sugarcane in Brazil:

Industrial Reference Unit

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0

5

10

15

20

25

30

0 10 20 30 40 50 60 70 80 90 100 110 120

frequency (%)

area (kha)

$

plantation external

limit (r)

filed operations cost ~ r3

economies of scale ~r2

viability limit

Typical sugarcane mill

state of São Paulo

Agriculture / Industry equilibrium

Typical sugarcane millAgro-Industrial Reference Unit – Processing Scales

30 kha500 tsc/h

lowerviability limit

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Agricultural production + Logistics + Industrial Processing

20 – 40 kha

sunlight water CO2

sugar(35 t/h)

ethanol(42 m3/h)

electricity(50 MW)

solids1-10 t/h

vinasse500 m3/h

CO2

2 t/h

harvesting500 t/h

field op.

water1000 t/h

nutrients (1 ton/h)

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200 MUS$

Agro-Industrial Reference Unit – Processing Scales

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Carbon capture and storage

Fermentation: 2 tCO2/h

Bagasse and straw combustion: 89 tCO2/h

Potential CO2 capture for a reference sugarcane mill

Annual CO2 capture and storage by the sugarcane sector One mill: 0.43 MtCO2/year

Number of mills: 450 average proc. rate 500tsc/h

Annual CCS: 292 MtCO2/year

Annual CO2 Brazilian emissions

~ 400 MtCo2/year

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Case Study:Sugarcane in Brazil:

Conversion pathways

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dewatering

water

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

boiler andturbines

sugar cane500 tc/h

ethanol43-76 m3/h

juice

bagasse150 t/h

sugar0-65 t/h

CO2

2 t/h

vinasse500 m3/h

electricity40-50 MW

straw

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dewatering

dewatering

water

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

boiler andturbines

sugar cane500 tc/h

ethanol43-76 m3/h

juice

bagasse

150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

CO2

2 t/h

vinasse500 m3/h

electricity20-30 MW

bagasse150 t/h

straw

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dewatering

dewatering

water

CO2

2 t/h

vinasse500 m3/h

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

boiler andturbines

sugar cane500 tc/h

ethanol43-76 m3/h

juice

bagasse150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

photo-bioreactor

extractionseparation

transes-terification

biodiesel /chemicals

broth

glycerin

nutrientsnutrients

waterwater

electricity10-20 MW

bagasse150 t/h

straw

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chemicals

waterwater

dewatering

dewatering

water

CO2

2 t/h

vinasse500 m3/h

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

boiler andturbines

sugar cane500 tc/h

ethanol43-76 m3/h

juice

bagasse150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

anaerobic digestion

electricity10-20 MW

bagasse150 t/h

straw

methane

nutrientsnutrients

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dewatering

dewatering

water

CO2

2 t/h

vinasse500 m3/h

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

sugar cane500 tc/h

electricity~10 MW

ethanol43-76 m3/h

juice

bagasse150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

CO2

bagasse150 t/h

straw

chemicals

waterwater

anaerobic digestion

methane

nutrientsnutrients

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Production of supercritical CO2 from oxycombustion

cyclone condensereconomizer

biomass

boiler

superheater

power cycle

evaporator

N2

water

supercritical CO2 unit

air

CO2

CO2

air separation unit

oxyfuel boiler

scCO2

power

O2

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Temperature oC

Entropy kJ/kg/oC

separaçãoH2O

pressão de injeção no

reservatório

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Carbon capture and storage

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Carbon capture and storage

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Carbon capture and storage

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Carbon capture and storage

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Carbon capture and storage

Oil and gas 2.5 Gtenough for 6 years

Saline aquifers 2000 Gtenough for 5000 years

Pre-salt ???

CO2 storage capacity (CarbMap project)

Sugarcane sector 292Mta,

total Brazilian emissions 400Mta…

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Example of commercial plants in operation

Reference sugarcane mill: 0.43 MtCO2/year

Global CCS Institute 2012, The Global Status of CCS: 2012

Example of commercial plants in operation

Reference sugarcane mill: 0.43 MtCO2/year

Global CCS Institute 2012, The Global Status of CCS: 2012

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First feasibility studies:

robust optimal operation

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operatingparamete

rs

Process optimization approach

uniform random

ethanol +electricity + scCO2

characteristicdistributions

Inputs that miximize outputs

How to set the control variables in order to increase probability of optimal

conversion, given the variability of all uncontrolled variables ?

dewatering

dewatering

water

CO2

2 t/h

vinasse500 m3/h

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

Ox

yco

mb

ust

ion

bo

iler a

nd

turb

ine

s

electricity~10 MW

ethanol43-76 m3/h

juice

bagasse150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

CO2

bagasse150 t/h

straw

chemicals

water

anaerobic digestion

methane

nutrients

seleghim@sc.usp.br

Process optimization approach

Monte Carlo simulations (simplified example)

dewatering

dewatering

water

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

boiler andturbines

juice

bagasse

150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

CO2

2 t/h

vinasse500 m3/h

bagasse150 t/h

straw

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Process optimization approach

control variable

stochastic variables

dewatering

dewatering

water

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

boiler andturbines

juice

bagasse

150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

CO2

2 t/h

vinasse500 m3/h

bagasse150 t/h

straw

Monte Carlo simulations (simplified example)

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Process optimization approach

Modeling equations…

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Simulation variables

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Carbon capture and storage by a sugarcane mill

Optimization approach – operation envelope

power(MW)

ethanol(m3/h)

baseline ethanolproduction (meth,min)

baseline powergeneration (Wmin)

maximum powergeneration (Wmax)

maximum ethanolproduction (meth,max)

energyconservation

operatingenvelope

target operating region

dewatering

dewatering

water

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

boiler andturbines

ethanol43-76 m3/h

juice

bagasse

150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

CO2

2 t/h

vinasse500 m3/h

electricity20-30 MW

bagasse150 t/h

straw

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Carbon capture and storage by a sugarcane mill

Optimization approach – operation envelope

power(MW)

ethanol(m3/h)

baseline ethanolproduction (meth,min)

baseline powergeneration (Wmin)

maximum powergeneration (Wmax)

maximum ethanolproduction (meth,max)

energyconservation

operatingenvelope

target operating region

scCO2

dewatering

dewatering

water

CO2

2 t/h

vinasse500 m3/h

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

Ox

yco

mb

ust

ion

bo

iler a

nd

turb

ine

s

electricity~10 MW

ethanol43-76 m3/h

juice

bagasse150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

CO2

bagasse150 t/h

straw

chemicals

water

anaerobic digestion

methane

nutrients

seleghim@sc.usp.br

power(MW)

ethanol(m3/h)

baseline ethanolproduction (meth,min)

baseline powergeneration (Wmin)

maximum powergeneration (Wmax)

maximum ethanolproduction (meth,max)

energyconservation

operatingenvelope

target operating region

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Carbon capture and storage by a sugarcane mill

Optimization approach – operation envelope

scCO2

dewatering

dewatering

water

CO2

2 t/h

vinasse500 m3/h

molasses

mechanicalprocessing

juiceextraction

cookingcrystallization

juicefermentation

sugarcentrifugation

winedistillation

Ox

yco

mb

ust

ion

bo

iler a

nd

turb

ine

s

electricity~10 MW

ethanol43-76 m3/h

juice

bagasse150 t/h

sugar0-65 t/h

fermentable sugars

bagassepre-treatment

cellulosehydrolization

NFFs

CO2

bagasse150 t/h

straw

chemicals

water

anaerobic digestion

methane

nutrients

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Processing pathways (hem. are fermented or burned)

Conversion of sugarcane into ethanol and electricity

de-wateringcombustion

de-wateringcombustion

hydrolysisfermentation

cellulose hemicellulose lignin sucroseashes water

ethanol energy

c1 c2 c3

C6H10O5 C5H8O4 C73H139O13

pre-treatmentfermentation

fiber sucroseashes water

a f s w

tops + leaveswater + sucrose

bagassejuice straw

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energy conservation limit

Process optimization approach

control results: fiber + water contents

More fiber and less water

(53%) litigation: dewatering versus sc water content

13% to 25% fiber

70 %to 55% water

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Process optimization approach

burning x hydrolysis (hemicelluloses are burned)

optimality optimality

Two optimal operating states85% + 15%

15%t +o 85%

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Process optimization approach

burning x hydrolysis (hemicelluloses are fermented)

Much more robust conversion process !

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Process optimization approach

more lignin, more hemicellulosesless cellulose

fiber composition (hemicelluloses are burned)

Process optimization approach

idem, slightly more robust process

fiber composition (hemicelluloses are fermented)

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sucrose/starch (+water)

lignocellulosic fiber (-water)

Industrial biorefineries evolution

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1G+2G BRFs will evolve to 1G2G and possibly to 2G only

BRFs at much higher processing scales…

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Obrigado…Paulo Seleghim Jr.

seleghim@sc.usp.br

Café com FísicaCafé com FísicaIFSC/USPIFSC/USP