Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: M
ICC - Volume: 241
ICC - Report ID: 241-M
ICC - Report Location: Brazil
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Ethanol from Sugarcane Bagasse (Hemicelluloses Extraction)
ICC - Show Overview: 1
ICC - Report Location ID: 6
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 241-C,241-E,241-F,241-H,241-J,241-Q,241-S,241-A,241-B,241-D,241-G,241-I,241-K,241-L,241-N,241-O,241-P,241-R,241-T
ICC - Related Reports List: 172-J,172-I
ICC - Report Location Code: BRA
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ICC - Prices: {"versions":{"1":{"1":"799","2":"799","3":"799"},"2":{"1":"1599","2":"1599","3":"1599"},"3":{"1":"2699","2":"2699","3":"2699"}},"currency":"USD"}
ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/241-M.jpg
ICC - Process Overview Text: <h6>Products</h6> <p><b>Ethanol</b>. Ethanol, or ethyl alcohol, is a volatile, flammable, and colorless liquid (pure form). It is miscible in all proportions with water, ether, acetone, benzene, and some other organic solvents. Ethanol has been produced by the fermentation of carbohydrates for thousands of years. In the 1930s, low oil prices enabled the production of industrial ethanol through direct and indirect hydration of petroleum-derived ethylene. The rising cost of crude petroleum has prompted research into the industrial manufacture of ethanol from biomass sources. Ethanol from biomass can be produced by the fermentation of starch (from corn), sugar (from sugarcane) or waste lignocellulosic biomass (such as corn stover or switch grass). The process varies depending on the feedstock used. Due to governments’ programs and technology advances, biomass has become the lowest cost raw material for ethanol production. Currently, ethanol is almost exclusively obtained from biomass and has become a renewable-based chemical. Global concerns about sustainability and global warming have inspired research into the use of renewable ethanol for ethylene manufacture, substituting petroleum-derived ethylene.</p> <p><b>Electricity</b>. Electricity is a versatile energy source utilized across various sectors, including manufacturing, transportation, and residential applications. It serves as the driving force for machinery, lighting, and electronic devices, and is increasingly employed in electrochemical processes and the production of hydrogen through electrolysis. Generated from renewable sources like wind, solar, and hydro, as well as fossil fuels and nuclear power, electricity plays a critical role in advancing sustainable energy solutions and enhancing efficiency in industrial operations.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Sugarcane Bagasse</b>. Sugarcane bagasse is the fibrous residue remaining after sugarcane stalks are crushed to extract juice. It is used as a biofuel, in paper production, and as a raw material for biodegradable composites. Collected from sugar mills, bagasse is stored in piles or bales. Its utilization contributes to waste reduction and renewable energy generation, supporting sustainable agricultural practices.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/241-M.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Pretreatment and Hydrolysis; (2) Fermentation; and (3) Distillation.</p><p>Pretreatment and Hydrolysis. To extract hemicelluloses from sugarcane bagasse, a plug flow reactor is utilized with high temperature liquid hot water. The resulting mixture is then filtered and undissolved solids are directed to a cogeneration unit, in which they are combusted for steam and electricity generation. On the other hand, the filtered liquid stream is concentrated in multiple-effect evaporators prior to undergoing hydrolysis. Dilute sulfuric acid is then used to further hydrolyze the hemicelluloses, while lime is administered to adjust the pH. Following this, another concentration step is taken before the liquid is sent for fermentation. All vapors produced during the evaporation processes are condensed and disposed of.</p><p>Fermentation. The monomer sugars obtained from hydrolysis process are directed to the parallel batch fermenters, where the sugar will be fermented to produce Ethanol by adding yeast in a controlled temperature. The gases obtained in fermenters, mainly containing carbon dioxide, are sent to a scrubber to recover Ethanol. </p><p>Distillation. At the end of fermentation, the concentration of Ethanol in the wine is about 10 vol%. To achieve the desired 93 wt% Ethanol, the wine passes through a Concentration Column, where residual solids and most of water is removed from the bottom. After a separation step, solids are directed to the cogeneration unit, where they are burned. An Ethanol/water mixture is withdrawn as a side stream from the concentration column and conducted to a rectifying column where Hydrous Ethanol (93 wt%) is obtained as distillate.</p>
ICC - Short Description: This feasibility study provides the economic analysis of second generation Ethanol production from sugarcane bagasse in Brazil. The process examined is similar to GreenPower, also developed by American Process. In this process, only hemicelluloses are extracted from biomass and are used to produce hydrous Ethanol via fermentation of monomer sugars.
ICC - Main Product: Ethanol
ICC - Plant Capacity: 80.00
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Ethanol from Sugarcane Bagasse (Hemicelluloses Extraction)

Ethanol Production Costs Report | Issue M | Q4 2024

Production Cost Report

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80 kta Brazil-based plant   |   Q4 2024   |   107 pages

This report presents a cost analysis of a 80 kta (kilo metric ton per annum) Brazil-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.

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Production Process Information

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Production Process Information

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Production Process Information

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

Operating Cost Summary

Production Costs Datasheet

Plant Capital Cost Details

Operating Cost Details

Plant Cost Breakdowns

Plant Capacity Assessment

Process Flow Diagrams

Costs in Different Countries Add-on

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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Ethanol production plant examined

Plant Capital Cost Details

Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements

Plant Cost Breakdowns

Breakdown of Ethanol process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline

Operating Costs Summary

Summary presenting the operating variable costs and the total operating cost of the Ethanol production plant studied

Operating Cost Details

Detailing of utilities costs, operating fixed costs and depreciation

Plant Capacity Assessment

Comparative analysis of capital investment and operating costs for different Ethanol plant capacities

Production Process Information

Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)

Process Consumptions

Raw materials and utilities consumption figures, by-products credits, labor requirements

Process Diagrams

Process flow diagrams (PFD), equipment list and industrial site configuration

Other Ethanol Production Cost Reports

Ethanol from Wood Chips (Hemicelluloses Extraction)

This feasibility study provides the economic analysis of second generation Ethanol production from wood chips in the United States. The process examined is similar to GreenPower, also developed by American Process. In this process, only hemicelluloses are extracted from biomass and are used to produce hydrous Ethanol.

Details: 100 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue L   From $799 USD

The cost analyses presented in this report target a 100 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Ethanol from Switchgrass (Digestion with SO2-Ethanol-Water Solution)

This feasibility study provides an economic analysis of Ethanol production from switchgrass in the United States using a biochemical conversion process similar to AVAP technology, developed by American Process. In this process, biomass is fractionated into cellulose, hemicelluloses and lignin by using a sulfur dioxide-ethanol-water solution. The cellulose and hemicelluloses obtained from biomass are converted to monomeric sugars, which are then used to produce Ethanol via fermentation.

Details: 200 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue O   From $799 USD

The cost analyses presented in this report target a 200 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Other Related Production Cost Reports

Ethylene from Ethanol (Similar to Hummingbird Process)

This study presents a techno-economic analysis of Green PG Ethylene production from hydrous ethanol in the United States using a dehydration process similar to the TechnipFMC’s Hummingbird process (former BP Chemicals). The reaction is carried out in multiple stage reactors with inter stage heaters in vapor phase.

Details: 210 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue I   From $799 USD

The cost analyses presented in this report target a 210 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Ethylene from Ethanol (Similar to Chematur Process)

This report provides the economics of Green Polymer Grade (PG) Ethylene production from hydrous ethanol in the United States using a dehydration process examined in this report is similar to the processes developed by Chematur and Petron. In this process, the reaction is carried out multiple reactors in series and a single furnace.

Details: 300 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue J   From $799 USD

The cost analyses presented in this report target a 300 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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