Commodity Production Costs Report

Ethanol and Sugar Production from Sugarcane

Ethanol Operating Costs & Plant Construction Costs

150 kta United States-based plant | 107 Pages | Issue E | Q3 2024
Starting at $799 USD | See Report Editions Prices

This report presents a techno-economic study of hydrous Ethanol and raw sugar production from sugarcane using a typical process in Brazil. In this process, part of the sugarcane juice is used in the production of raw sugar and part is fermented to produce hydrous Ethanol. The sugarcane bagasse is burned for electricity generation.

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.

Key reference(s): ?

Ethanol Production Cost Report Process Schematic

The process under analysis comprises four major sections: (1) Pretreatment; (2) Sugar Production; (3) Fermentation; and (4) Distillation.

Pretreatment. The sugarcane is milled to extract its juice. The sugarcane bagasse – solid residue from the milling – is directed to a cogeneration unit, where it is burned for steam and electricity generation. The juice is neutralized with lime in an agitated vessel and sent for clarification in a flocculator and decanter. The resulting clarified juice has a part sent to the evaporation process for raw sugar production, while the other part undergoes the fermentation process for Ethanol production.

Sugar Production. Treated cane juice is sent to multiple-effect evaporators to adjust the sugar concentration before crystallization. The concentrated cane juice goes through vacuum calandrias, cooling crystallizers, and centrifuges, producing two final streams: raw sugar and molasses. The raw sugar is dried and then stored in a warehouse, while molasses is filtered and sent as a substrate for fermentation process aimed at Ethanol production.

Fermentation. The molasses and treated cane juice 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. To separate the yeast biomass from the broth, centrifuges are used, and the recovered yeast returns to the fermenters after an acid treatment.

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 most of water is separated by the bottom. An Ethanol/water mixture is withdrawn as a side stream. The Ethanol stream is then conducted to a rectifying column where Hydrous Ethanol (93 wt%) is obtained as distillate.

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  • Process Consumptions
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 80 Pages | 22 Tables | 9 Images

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  • Operating Cost Summary
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


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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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  • 107 Pages | 34 Tables | 22 Images
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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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