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European Biomass Industry Association
Low cost production ofBioethanol from
Dr. Giuliano GRASSIEUBIA Secretary General
Rue dArlon, 63-65B-1040 Brussels Belgium
Sweet Sorghum
Low cost production of Bioethanol from sweet sorghum
Present context (I)
- World Production (2005)
- World Production (2015)
Brasil ~15 Billion li
USA ~ 14 Billion li
EU ~ 0,6 Billion li
46 Billion li(most fuel ethanol)
75 Billion li
- USA Bill estabilishing a Ren. Fuel Standard of 7,5 Billion gal./year*
Low cost production of Bioethanol from sweet sorghum
- Price (Nov 2005) Brasil (hydrous) ~ 460 $/ ton
Brasil (anhydrous) ~ 520 $/ ton
USA ~ 620 $/ton
EU (hydrous) ~ 700 $/ ton
EU (anhydrous) ~ 755 $/ ton
Present context (II)- Production cost (typical)
Brasil ~ 160 $/ton
EU ~ 600 $/ton
USA ~ 420 $/ton
Import duty (EU) ~ 190 /ton
Low cost production of Bioethanol from sweet sorghum
Why Sweet Sorghum for Bioethanol ?
Sweet Sorghum is an extraordinarily promisingmultifunctional crop for several reasons:
It requires common soil even with high % ofsand and it is also adapted to salty areas;
It requires low of water imputs ( ~ 200 m3 /ton), 1/3 of sugar canerequirements, 1/2 of corn;
It has a short growing cycle fromseeds (4/5 months), 1/3 of sugar cane;
A high productivity of several components (grains,sugars, lignocellulosic);
Many varieties are available for geneticimprovment (~4,000)
It can be grown in all continents, intropical, sub-tropical and temperateregions (covering sugar-cane most sugar-
beet areas);
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Low cost production of Bioethanol from sweet sorghum
Three main types of Sorghum
.
Low cost production of Bioethanol from sweet sorghum
Positive Environmental PerformanceSweet Sorghum absorbs large amount of CO2 (~45 t CO2/hax cycle);
1 ltr of bio-ethanol saves ~2,2 Kg CO2 (transport);
Low energy, chemical, irrigation water inputs;
Respect of biodiversity in large plantations (wide range of varieties);
Soil erosion loss (on marginal erodible sites) ~10 t/ha/y, within thetolerance level (11 t/ha/y);
Large amount of compost from Sweet Sorghum residues (~15d.t/ha/ycycle) can improve the sustainability of cropping;
NOTE
Sweet-Sorghum must be considered, multi-functional (energy) crop, nota competitor crop for the sugar market!
Low cost production of Bioethanol from sweet sorghum
Potential geographical areas for S. Sorghum
Sugarcane
Sugarbeet
Limit for cereals
Sweet
Sorghum
70
60
52
Low cost production of Bioethanol from sweet sorghum
Sweet Sorghum Etoh Productivity
5600
4200
5000
6700
5100
61006000
0
1000
2000
3000
4000
5000
6000
7000
ETOH (l/ha)
1
Sweet Sorghum variety
Typical productivity from different varieties
Shennong1(China)
Shennong1(Italy)Foralco(ITA)
Sofra(ITA)
Doina(RUM)
Carmen(RUM)
Doina(India)
F-135ST(India)
But the real cropdevelopmentfor ETOH is notyet started!
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Low cost production of Bioethanol from sweet sorghum
How to reach a low cost for Bioethanol?
By high productivity (this has been demonstrated)and control insupplying.
By the valorisation of all components of the crop:
Grains (80/t)
Sugars (50/t)
Lignocellulosic (25/t)
By the adoption and integration of modern processingtechnologies and production for industrial, energy, feed,commodities (Biorefinery concept)
By attributing a low-value premium to Bioethanol as much aspossible
By CO2 trading or green-certificates benefits
Low cost production of Bioethanol from sweet sorghum
Why a target figure of 250 /ton for the
bioethanol-cost is resonable?
Assuming that 60% of the ETOH production cost is due to thefeedstock (sugar cost) supply, this value is:
0.961*0.932*0.53*0.954
50 /t________________= 118 /t ETOH
Therefore the anticipated cost of bioethanol from sweet
sorghum is ca 200/t.
Conservative figure: 250 /t
1: Sugar extractionefficiency2. Fermentationefficiency3. ETOH/sugarconversion4: Industrialefficiency
Low cost production of Bioethanol from sweet sorghum
Which size of Integrated Sweet Sorghum
Complex could be economically viable in
the E.U. ?- Minimum plantations size (Decentralised production):
- Large plantations size (Centralised production) :
1000 ha
Bioethanol capacity (microdistillery): 6,000 m3/ y
1or 2level of integration
10,000 - 50,000 ha (or more)
Bioethanol capacity 60,000 - 300,000 m3/ y
Low cost production of Bioethanol from sweet sorghum
ETOHStorage &Sale
SweetSorghumPlantation
HarvestingCane
Crushing Sugar juicePurification
Fermentation
Distillation
Dehydratation
GrainsDrying &Stor.
Pelletisation
DDGStorage & Sale
Agro-pelletsStorage & Sale
CHPFor complex
operation
Typical Sweet Sorghum complex (1,000-50,000 ha)
Trashes Bagasse
Heatfor sale
GrainsMilling
Liquefaction &Saccarification
Pelletisation
Centrifugation
CO2
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Low cost production of Bioethanol from sweet sorghum
R = product energy outputproduct energy input
1. On field crop production: R ~ 202. Production of ETOH + DDG + Agropellets: R ~ 7.33. Production of ETOH + DDG + Green power plant (~28%): R ~ 4.34. Production of ETOH + DDG + Coal/pellets cofiring(~40%): R ~ 4.85. Production of ETOH + DDG + Biohydrogen: R ~ 4.6
(See figure next slide)
For comparison (co-products not considered)
Bioethanol from wheat: 1.1Bioethanol from corn: 1.3Bioethanol from sugar beat/potatoes: 1.76Bioethanol from sugar-cane: (Brasil): ~8
Energy performance of sweet sorghum
Low cost production of Bioethanol from sweet sorghum
Energy performance of sweet sorghum
7,3
4,84,6
4,2
3,0
3,5
4,0
4,5
5,0
5,5
6,0
6,5
7,0
7,5
R
1
Final product mix
ETOH+DDG+Agropellets
ETOH+DDG+Cofiring
ETOH+ DDG+H2
ETOH+DDG+greenPOWER
Low cost production of Bioethanol from sweet sorghum
Which R.O.I. can be expected ?
- Decentralised Bioethanol production: (~1,000 ha)
- Centralised Bioethanol production: (> 20,000 ha)
Investment: 6 mio
R.O.I. ~ 15 - 20 %
Investment: ~ 65 mio
R.O.I. ~ 20 - 25 %
( With Bioethanol market value: 500 /m3)
Low cost production of Bioethanol from sweet sorghum
Sweet Sorghum Complexes
1st level Bioethanol of integration Production (with HCP); DDG (animal feed) Agro-pellets CO2 recovery (in some cases)
2nd level
Bioethanol of integration Production DDG Green power
3rd level Bioethanol of integration production DDG Agro-pellets (for sale) Agro-pellets conversion in Bio-hydrogen (or Biofuels) Bio-methanol prod.: ~0.6 l of METH for each l of ETOH
Note: All these productions could becarried out now utilising existing
commercial technologies. Also bio-H2and Biomethanol production appear tohave reached competitiveness incomparison to natural gas at ~10
$/MMBtu
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Low cost production of Bioethanol from sweet sorghum
Markets for agro-pellets
Sweet Sorghum and sugar-cane plantations produce large amounts oflignocellulosic residues (Bagasse, trashes, etc..): 15-20 dry ton/ha
That means: 16,5 22 ton (Agropellets)/ha per year
Use of modern cogeneration technology for ETOH processings willmake thus available a large amount of Agro pellets for sale or otheruses:
13 19 ton/ha per year
1. Heat production
2. Green power production
3. Biohydrogen production
4. Siderurcical pellets
5. Biomethanol production
Possible uses:
Low cost production of Bioethanol from sweet sorghum
Agro pellets can economically substitute BTZ fuel (305 $/ton) forfuelling medium-large capacity boilers.
Infact assuming a cost of biomass: 50 $/dry ton
cost of pelletisation: 40 $/dry ton
cost of transport: 20 $/dry ton
Total cost = 110 $/ton (Agro pellets)
Corresponding to ~ 270 $/TOE = 260 $/ ton BTZ equivalent
Note: If CO2 trading in future will be available (i.e. 40/ t CO2) agro-pellets could get a benefits of ~ 60 / ton with large improvedcompetitiviness
1. Heat Production
Low cost production of Bioethanol from sweet sorghum
2. Green Power production
If green certificates (~0,1/KWhe) are available green powerco-production become very attactive. The best option will be coal agro-pellets cofiring (el 40%) withbenefit for each ton of agro-pellets ca 200 /ton. In decentralised green power generation the benefits for 1 ton ofpellets ca 140 /ton. Investments
Cofiring (+ 8 / kWe)Power plants (1600 2000 / kWe)Small co-generators (50 - 500 kWe: 1400 /kWe, not yetcommercial)
This economic benefit should be distributedbetween the farmers and the power producers
Low cost production of Bioethanol from sweet sorghum
World power supplySource: www.isofoton.it
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Low cost production of Bioethanol from sweet sorghum
3. Biohydrogen production
Industrial Biohydrogen (98% purity) could be producedcommercially in a very short time from Agro-pellets by a threesteps process (carbonisation of agro pellets + steam reforming +CO shifting) 55Kg of biohydrogen/ t pellets can be obtained incompetition with that derived from natural gas by S.R.
Production cost of H2 from Nat. Gas (at 10 $/MMBTU) ca 2,400 $/t
Biohydrogen from pellets (100$/t)ca 2,250 $/tCO2 potential benefitca 500 $/t
Real BioH2 cost ca 1,750 $/t
Low cost production of Bioethanol from sweet sorghum
4. Siderurgical pellets
Huge potential market for high-quality steel. Estimated productioncost of syderurgical charcoal pellets:~200/t
5. Biomethanol production
Utilising Bio-H2 (from bagasse) for cathalitic synthesis with CO2fermentation
~ 0,6 liter of Bio-Methanol for
1 liter of Bio-Ethanol produced
could be co-produced at competitive cost in comparison to thatderived from Nat. Gas
Low cost production of Bioethanol from sweet sorghum
Impact of R&D on Bioethanol cost reduction
1. Sweet Sorghum increased productivity
- Sweet Sorghum planting machine (gain: 1month)
- Conventional genetic improvement
- Sweet Sorghum DNA genome sequencing(8-10 M/2-3 years)
2. Stabilisation of humid ligno-cellulosic residues(multistage machines for very humid biomass)
3. Innovative Distillation and Deshydratation technology
Low cost production of Bioethanol from sweet sorghum
Sweet Sorghum Plantation
Agropellets machine
Harvester machine
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Low cost production of Bioethanol from sweet sorghum
Microdistillery
Small facility for new distillation technology
Large ETOH plant
Low cost production of Bioethanol from sweet sorghum
Thank you for yourattention!
EUBIA
Rue dArlon, 63-65B-1040 Brussels, [email protected]
European Biomass Industry Association
Low cost production of Bioethanol from sweet sorghum
Annex
Sweet Sorghum varieties productivity parameters:
Even if Indian varieties (hybrid S. Sorghum) seems to be the mostpromising for the future, chinese varieties are particular interestingbecause of their equilibrated spread between sugar,grains and drylignocellulosic productivity.
In future research priority on Sweet Sorghum should be focused onthe identification & development of on new varieties tolerant to colderand changeable climatic conditions.
Sweet Sorghum variety Fresh bio. (t/ha) Grains (t/ha) Sugar (t/ha) Dry Biom. (t/ha)
Shennong 1 (Cina) 70,0 5,2 7,4 14,3
Shennong 1 (Italy) 70,7 5,1 7,9 14,5
Foralco (Italy) 64,0 1,0 7,3 10,2
Sofra (Italy) 82,0 2,2 11,2 13,3
Doina (Romania) 96,4 8,5 7,3 17,3
Carmen (Romania) 89,5 5,8 7,1 18,0
F.135 ST (India) 100,0 7,6 7,6 22,6
Doina (India) 61,0 8,1 7,6 19,7
Low cost production of Bioethanol from sweet sorghum
Annex: Agronomical Practice
An intensive cultivation of SweetSorghum as energy crops requiresdedicated machines for harvesting toseparate the pannicle and leaves fromthe cane to facilitate the recovery ofgrains, lignocellulosic and sugar-juice.
Canes cutted into billets are ready for the cane crushingmachine wheresugar juice is sepatated from lignocellulosicmaterial.
Grains frompanniclesare ready to be dried forstorage
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Low cost production of Bioethanol from sweet sorghum
Annex: Sweet Sorghum Productivity
The productivity of
Sweet Sorghumdepends on manyparameters:climatic conditions,soil quality, varietyof sorghum inputsand agronomicpractice.
Typical values arepresented indiagrams.
Stem fresh, dry matterand sugar yield of SweetSorghum in various EUregions (trials). Rangeswithin regions are due tovarieties, years andtreatment effect.
Sugar t/ha
Low cost production of Bioethanol from sweet sorghum
For German high latitude sites (Braunshweig) S. Sorghum Korall varieties,
developed by KWS Co., had productivity parameters near to the standard ones.
Not only new machines have been developed to improve Sweet Sorghumcultivation but also new varieties of seeds and agronomic technique:
It has also been tested a planty machine for sweet sorghum cultivated insidegreen-house and followed by open field growing (temperature is > 10C) . Afterone month plants are moved in open field using a planting machine (as visible infigures below).This technology is not commercial.
Annex: Agronomical practice
Low cost production of Bioethanol from sweet sorghum
Sweet Sorghum planting machine (gain: 1 month)
for cold areas the crop emergence is obtained in green houses
Conventional genetic improvement
(large number of varieties is available)
Sweet Sorghum DNA genome sequencing
(750 Mbp long of the human genome)
A budget of 8-10 mio and 2-3 years period should be sufficient.
Benefits:
Improved yields
Cultivation in colder regions
Modification of sugars composition
Reduced inputs of chemicals
New conversion technologies
Annex: Impact of R&D on BioETOH cost
Low cost production of Bioethanol from sweet sorghum
Stabilisation of humid ligno-cellulosic reidues
A first commercial innovative mechanical drying and compactationtechnology 1-8 t / h is new apparing on the market. This new technology(not requiring pre-drying of humid biomass) is able to produce in particularagro-pellets from cane residues (bagasse-trashes) or any other type ofagriculture residues or mixtures (without binding compound) with lowenergy inputs (~70 kWhe/ t pellets) and reasonable processing cost (~ 35
/t in EU) Bulk density: 0,6 t/m3
This conversion of residues into agro-pellets open considerableopportunities for improving the economics of bioethanol. From agro-pellets (esy to handle, transport, storage use) can be co-produced byexisting commercial technologies:
Heat
Green-power
Biohydrogen
Synthetic biofuels
Annex: Impact of R&D on BioETOH cost
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Low cost production of Bioethanol from sweet sorghum
Innovative Distillation and Deshydratation technologyLow cost crystal-hydrated compounds absorb from ethanol-water solution preferentially ethanol molecules. It is expectedthat this fast absorption regeneration technology can implementdistillation from 3-5degree level up to 100% degree withconsiderable energy and investment reduction; therefore largeimpact on future bio-ethanol activity is expected.
Annex: Impact of R&D on BioETOH cost