Commodity Production Costs Report
Ethanol from Sugarcane Bagasse (Digestion with SO2-Ethanol-Water Solution)
Ethanol Operating Costs & Plant Construction Costs
This report approaches the economics of second generation Ethanol production from sugarcane bagasse in Brazil 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.
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.
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The process under analysis comprises four major sections: (1) Pretreatment; (2) Cellulose Hydrolysis and Fermentation; (3) Hemicelluloses Hydrolysis and Fermentation; and (4) Purification.
Pretreatment. The biomass is cooked with a solution of SO2, ethanol and water and it is fractionated into three lignocellulosic components: hemicelluloses, cellulose and lignin. Cellulose is washed and the filtrate is sent to a stripping column to recover SO2 and ethanol to be recycled. The columns bottom stream is concentrated via evaporation.
Cellulose Hydrolysis and Fermentation. Cellulose is hydrolyzed by enzymes yielding glucose monomers. The insoluble lignin is separated and sent to the hemicelluloses hydrolysis section. The glucose is then fermented to generate Ethanol.
Hemicelluloses Hydrolysis and Fermentation. The concentrated stream from the pretreatment area is mixed with the lignin from the enzymatic hydrolysis and pumped to the auto-hydrolysis reactor where hemicelluloses is hydrolyzed to monomer sugars, such as xylose. The hydrolyzate is neutralized to precipitate soluble lignin, which is then separated and burned to generate steam and energy to supply plant demand. The monomer sugars are fermented to ethanol.
Purification. The broths from fermentation steps are fed to the concentration column, where a side stream with 50% ethanol is obtained. The column bottoms, containing residual lignin, spent fermentation microorganisms and non fermented sugars are sent to a pressure filter, where the insoluble solids are dewatered to also be sent to the cogeneration unit at OSBL to generate steam and electricity. The side stream is fed to a rectifying column, which further concentrates the Ethanol to about 93% (near azeotropic composition).
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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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Other Ethanol Production Cost Reports
Ethanol and Sugar Production from Sugarcane
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.
Details: 150 kta Brazil-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
Ethanol Production from Sugarcane
This study provides an economic analysis of hydrous Ethanol production in Brazil using a typical process based on sugarcane feedstock. In this process, sucrose is extracted from sugarcane and it is fermented to produce hydrated Ethanol. The sugarcane bagasse is burned for electricity generation.
Details: 150 kta Brazil-based plant | Q3 2024 | 107 pages | Issue F | From $799 USD
Ethanol from Corn Stover (Digestion with SO2-Ethanol-Water Solution)
This report presents a techno-economic analysis of second generation Ethanol production from corn stover in the United States using a 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: 80 kta United States-based plant | Q3 2024 | 107 pages | Issue H | From $799 USD
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