Ethanol from Sugarcane Bagasse (Hemicelluloses Extraction)
Ethanol Production Costs Report | Issue M | Q4 2024
| Report Details |
| 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.
Report Abstract
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.
The report provides a comprehensive study of Ethanol production and related Ethanol production cost, covering three key aspects: a complete description of the Ethanol production process examined; an in-depth analysis of the related Ethanol plant capital cost (Capex); and an evaluation of the respective Ethanol plant operating costs (Opex).
The Ethanol production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Ethanol plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Ethanol plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Pretreatment and Hydrolysis; (2) Fermentation; and (3) Distillation.
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.
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.
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.
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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
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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
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