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Synthesis and parameter optimization of a combined sugar and ethanol production process integrated with a CHP system

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  • Morandin, Matteo
  • Toffolo, Andrea
  • Lazzaretto, Andrea
  • Maréchal, François
  • Ensinas, Adriano V.
  • Nebra, Silvia A.

Abstract

The combined sugar and ethanol production process from sugar cane is a paradigmatic application for energy integration strategies because of the high number of hot and cold streams involved, the external hot utility requirement at two temperature levels for juice evaporation and crystallization, and the electricity demand for juice extraction by milling. These conditions make it convenient to combine the sugar-cane process with a CHP system fuelled by bagasse, the main by-product from juice extraction. The strategies, tools and expertise on energy integration developed separately by the research teams authoring this paper are applied here jointly to optimize the synthesis and the design parameters of the process and of the total site starting from the basic idea of dissociating the heat exchanger network design problem from the total site synthesis problem. At first the minimization of the external heat requirement for the process alone is pursued and results show that a one third reduction can be achieved by optimal heat integration. Then the use of the by-product bagasse for on-site power generation is considered and two bagasse-fuelled CHP systems are optimized along with some parts of the sugar and ethanol production process in order to obtain maximum total site net power. Results show a variety of interesting scenarios of combined sugar, ethanol and electricity production plants with considerably high electricity output.

Suggested Citation

  • Morandin, Matteo & Toffolo, Andrea & Lazzaretto, Andrea & Maréchal, François & Ensinas, Adriano V. & Nebra, Silvia A., 2011. "Synthesis and parameter optimization of a combined sugar and ethanol production process integrated with a CHP system," Energy, Elsevier, vol. 36(6), pages 3675-3690.
    • Handle: RePEc:eee:energy:v:36:y:2011:i:6:p:3675-3690
    DOI: 10.1016/j.energy.2010.10.063
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    References listed on IDEAS

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    1. Alves, Moises & Ponce, Gustavo H.S.F. & Silva, Maria Aparecida & Ensinas, Adriano V., 2015. "Surplus electricity production in sugarcane mills using residual bagasse and straw as fuel," Energy, Elsevier, vol. 91(C), pages 751-757.
    2. Dias, M.O.S. & Junqueira, T.L. & Jesus, C.D.F. & Rossell, C.E.V. & Maciel Filho, R. & Bonomi, A., 2012. "Improving bioethanol production – Comparison between extractive and low temperature fermentation," Applied Energy, Elsevier, vol. 98(C), pages 548-555.
    3. Toffolo, Andrea, 2014. "A synthesis/design optimization algorithm for Rankine cycle based energy systems," Energy, Elsevier, vol. 66(C), pages 115-127.
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    5. Pina, Eduardo A. & Palacios-Bereche, Reynaldo & Chavez-Rodriguez, Mauro F. & Ensinas, Adriano V. & Modesto, Marcelo & Nebra, Silvia A., 2017. "Reduction of process steam demand and water-usage through heat integration in sugar and ethanol production from sugarcane – Evaluation of different plant configurations," Energy, Elsevier, vol. 138(C), pages 1263-1280.
    6. Varbanov, Petar Sabev & Fodor, Zsófia & Klemeš, Jiří Jaromír, 2012. "Total Site targeting with process specific minimum temperature difference (ΔTmin)," Energy, Elsevier, vol. 44(1), pages 20-28.
    7. Tock, Laurence & Maréchal, François, 2012. "Co-production of hydrogen and electricity from lignocellulosic biomass: Process design and thermo-economic optimization," Energy, Elsevier, vol. 45(1), pages 339-349.
    8. Lazzaretto, Andrea & Morandin, Matteo & Toffolo, Andrea, 2012. "Methodological aspects in synthesis of combined sugar and ethanol production plant," Energy, Elsevier, vol. 41(1), pages 165-174.
    9. Kravanja, Philipp & Modarresi, Ala & Friedl, Anton, 2013. "Heat integration of biochemical ethanol production from straw – A case study," Applied Energy, Elsevier, vol. 102(C), pages 32-43.
    10. Dias, Marina O.S. & Junqueira, Tassia L. & Jesus, Charles D.F. & Rossell, Carlos E.V. & Maciel Filho, Rubens & Bonomi, Antonio, 2012. "Improving second generation ethanol production through optimization of first generation production process from sugarcane," Energy, Elsevier, vol. 43(1), pages 246-252.
    11. Salgado Junior, Alexandre Pereira & Carlucci, Fabio Vogelaar & Grespan Bonacim, Carlos Alberto & Novi, Juliana Chiaretti & Pacagnella Junior, Antonio Carlos, 2014. "Investment Potential for New Sugarcane Plants in Brazil Based on Assessment of Operational Efficiency," International Food and Agribusiness Management Review, International Food and Agribusiness Management Association, vol. 17(2), pages 1-24, May.
    12. Horvath, Christopher & Hwang, Yunho & Radermacher, Reinhard & Gerstler, William & Tang, Ching-Jen, 2014. "Waste heat and electrically driven hybrid cooling systems for a high ambient temperature, off-grid application," Energy, Elsevier, vol. 66(C), pages 711-721.
    13. Díaz Pérez, Álvaro A. & Escobar Palacio, José C. & Venturini, Osvaldo J. & Martínez Reyes, Arnaldo M. & Rúa Orozco, Dimas J. & Silva Lora, Electo E. & Almazán del Olmo, Oscar A., 2018. "Thermodynamic and economic evaluation of reheat and regeneration alternatives in cogeneration systems of the Brazilian sugarcane and alcohol sector," Energy, Elsevier, vol. 152(C), pages 247-262.
    14. Palacios-Bereche, M.C. & Palacios-Bereche, R. & Ensinas, A.V. & Gallego, A. Garrido & Modesto, Marcelo & Nebra, S.A., 2022. "Brazilian sugar cane industry – A survey on future improvements in the process energy management," Energy, Elsevier, vol. 259(C).
    15. Antonio Bizzo, Waldir & Lenço, Paulo César & Carvalho, Danilo José & Veiga, João Paulo Soto, 2014. "The generation of residual biomass during the production of bio-ethanol from sugarcane, its characterization and its use in energy production," Renewable and Sustainable Energy Reviews, Elsevier, vol. 29(C), pages 589-603.
    16. Lim, Jeng Shiun & Abdul Manan, Zainuddin & Hashim, Haslenda & Wan Alwi, Sharifah Rafidah, 2013. "Towards an integrated, resource-efficient rice mill complex," Resources, Conservation & Recycling, Elsevier, vol. 75(C), pages 41-51.
    17. Wang, Ligang & Lampe, Matthias & Voll, Philip & Yang, Yongping & Bardow, André, 2016. "Multi-objective superstructure-free synthesis and optimization of thermal power plants," Energy, Elsevier, vol. 116(P1), pages 1104-1116.
    18. Ahlström, Johan M. & Pettersson, Karin & Wetterlund, Elisabeth & Harvey, Simon, 2017. "Value chains for integrated production of liquefied bio-SNG at sawmill sites – Techno-economic and carbon footprint evaluation," Applied Energy, Elsevier, vol. 206(C), pages 1590-1608.
    19. Verma, Om Prakash & Mohammed, Toufiq Haji & Mangal, Shubham & Manik, Gaurav, 2017. "Minimization of energy consumption in multi-stage evaporator system of Kraft recovery process using Interior-Point Method," Energy, Elsevier, vol. 129(C), pages 148-157.
    20. Hegely, Laszlo & Lang, Peter, 2020. "Reduction of the energy demand of a second-generation bioethanol plant by heat integration and vapour recompression between different columns," Energy, Elsevier, vol. 208(C).
    21. Sennai Mesfun & Leonidas Matsakas & Ulrika Rova & Paul Christakopoulos, 2019. "Technoeconomic Assessment of Hybrid Organosolv–Steam Explosion Pretreatment of Woody Biomass," Energies, MDPI, vol. 12(21), pages 1-18, November.

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