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Bioethanol Production BBioetanol-00ioetanol-00 IInglês.inddnglês.indd 1 111/11/20081/11/2008 116:23:446:23:44 S47s Sugarcane-based bioethanol : energy for sustainable development / coordination BNDES and CGEE – Rio de Janeiro : BNDES, 2008. 304 p. ISBN: 978-85-87545-27-5 1. Bioenergy. 2. Biofuel. 3. Bioethanol. 4. Sugarcane. I. Banco Nacional de Desenvolvimento Econômico e Social. II. Centro de Gestão e Estudos Estratégicos. CDD 333.953 BBioetanol-00ioetanol-00 IInglês.inddnglês.indd 2 111/11/20081/11/2008 116:23:456:23:45 Technical staff Coordination – BNDES and CGEE BNDES CGEE Armando Mariante Carvalho Junior Antonio Carlos Galvão Julio Cesar Maciel Ramundo Marcelo Khaled Poppe Carlos Eduardo de Siqueira Cavalcanti Paulo de Sá Campello Faveret Filho (supervision) Nelson Isaac Pfefer (supervision) Sergio Eduardo Silveira da Rosa Artur Yabe Milanez Organization and technical oversight Luiz Augusto Horta Nogueira – Unifei Contributing writers and consultants Luiz Augusto Horta Nogueira – Unifei Joaquim Eugênio Abel Seabra – Unicamp Gustavo Best – FAO/ECLAC consultant Manoel Regis Lima Verde Leal – Cenea Marcelo Khaled Poppe – CGEE Institutional support – ECLAC and FAO ECLAC FAO Adrián Rodríguez Alberto Saucedo José Javier Gómez Guilherme Schuetz Joseluis Samaniego Manlio Coviello Martine Dirven Acknowledgements Adhemar Altieri – Unica Isaias de Carvalho Macedo – Unicamp Alfred Szwarc – Unica João Carlos Ferraz – BNDES Aluysio Antonio da Motta Asti – BNDES Luis Augusto Barbosa Cortez – Unicamp André Correa do Lago – MRE Marcio Nappo – Unica Antonio Barros de Castro – BNDES Rafael Capaz – Unifei Antonio Dias Leite – consultant Rafael Pontes Feijó – BNDES Arnaldo Vieira de Carvalho – BID Rogério Cezar de Cerqueira Leite – Unicamp Edmar Fagundes de Almeida – UFRJ Tammy Klein – IFQC BBioetanol-00ioetanol-00 IInglês.inddnglês.indd 3 222/12/20082/12/2008 116:50:316:50:31 BBioetanol-00ioetanol-00 IInglês.inddnglês.indd 4 111/11/20081/11/2008 116:23:456:23:45 Contents Foreword 13 Preface 17 1. Bioenergy and biofuels 23 1.1 Bioenergy basics 25 1.2 Evolution of bioenergy and biofuels 32 2. Ethanol as vehicle fuel 37 2.1 Technical and environmental aspects of ethanol 39 2.2 Economic and institutional aspects of fuel ethanol 51 2.3 Ethanol logistics chains 57 3. Bioethanol production 63 3.1 Bioethanol production feedstock and technologies 65 3.2 Sugarcane bioethanol 68 3.3 Corn bioethanol 78 3.4 Bioethanol based on other feedstocks 84 3.5 Productivity, emissions and energy balances 87 4. Co-products of sugarcane bioethanol 99 4.1 Sugar and derivates 101 4.2 Bioelectricity 104 4.3 Other co-products of sugarcane bioethanol 114 5. Advanced technologies in the sugarcane agroindustry 119 5.1 Hydrolysis of lignocellulosic residues 121 5.2 Gasification for fuels and electricity production 128 5.3 Using bioethanol as a petrochemical or alcohol-chemical input 135 5.4 Biodegradable plastics production 138 5.5 Biorefinery: multiple products and integral use of raw materials 142 6. Sugarcane bioethanol in Brazil 145 6.1 Evolution of bioethanol fuel in Brazil 147 6.2. Sugarcane agroindustry in Brazil 155 6.3 Technological research and development 162 7. Sustainability of sugarcane bioethanol: the Brazilian experience 171 7.1 Environment and sugarcane energy 173 BBioetanol-00ioetanol-00 IInglês.inddnglês.indd 5 111/11/20081/11/2008 116:23:456:23:45 7.2 Land use 187 7.3 Economic viability of sugarcane bioethanol 194 7.4 Job and income generation in the bioethanol agroindustry 200 7.5 Certification and sustainability in the bioethanol agroindustry 207 8. Perspectives for a global biofuels market 211 8.1 Overall potential for biofuels production 213 8.2 Biofuel supply and demand: current scenario 219 8.3 Bioethanol supply and demand projections for 2010-2015 223 8.4 Policies to support and promote biofuel 236 8.5 Food – bioenergy linkages 240 8.6 Key factors to induce a global bioethanol market 250 9. An outlook for bioethanol fuel 257 Appendix 267 References 273 BBioetanol-00ioetanol-00 IInglês.inddnglês.indd 6 111/11/20081/11/2008 116:23:456:23:45 Index of boxes, figures, graphs and tables Boxes Ethanol in aircraft engines 50 Organic sugar possibilities 103 The evolution of electricity production at a Brazilian sugarcane mill 111 First steps of ethanol-chemical industry in Brazil 137 Genetic improvements and availability of cultivars 164 Figures 1 The process of photosynthesis 27 2 Average annual rainfall 28 3 Technological routes for the production of bioenergy 31 4 Solubility of water in gasoline-ethanol blends 45 5 A model of ethanol production, storage and demand 58 6 Gasoline and ethanol logistics in Brazil 60 7 Technological routes for ethanol production 66 8 Typical sugarcane biomass structure 68 9 Distribution of the 350 sugarcane processing mills in Brazil 73 10 Sugar and sugarcane-based bioethanol production flowchart 75 11 Typical structure of corn biomass 79 12 Distribution of corn production in the United States 80 13 Flowchart of wet-milling corn-based bioethanol production 82 14 Flowchart of dry-milling corn-based bioethanol production 83 15 Biofuel lifecycle diagram 88 16 Analysis of sensitivity for sugarcane bioethanol in 2005/2006: use of energy and energy ratio 93 17 Analysis of sensitivity for sugarcane bioethanol in 2005/2006: GHG emissions and GHG net avoided emissions 94 18 Common setup of cogeneration system in the sugarcane agroindustry 106 19 Schematic of the process of ethanol production by hydrolysis of biomass 122 20 Schematic exhibition of a BIG/GT-CC system 131 21 General flowchart of methanol, hydrogen and diesel production through the biomass gasification (Fischer-Tropsch) 133 22 Flowchart of PHB production from sugarcane sugar 141 23 Complete integrated biomass-biofuel-biomaterial-bioenergy cycle 142 24 Locations of new sugar and alcohol plants in Brazil 158 BBioetanol-00ioetanol-00 IInglês.inddnglês.indd 7 111/11/20081/11/2008 116:23:456:23:45 25 Percent occupation of the main sugarcane varieties in Brazil from 1984 to 2003 165 26 Example of satellite image from monitoring of vegetation coverage 184 27 Potential unirrigated sugarcane cultivation 191 28 Potential sugarcane cultivation with “salvation irrigation” 191 29 Areas cultivated with sugarcane 193 30 Overview of the key elements in the methodology to assess the bioenergy potential from dedicated bioenergy crops 214 31 Bioenergy contribution to the primary and secondary energy supply in 2007 220 Graphs 1 Global use of arable lands 29 2 Bioenergy’s share of the Brazilian energy supply 33 3 Per capita bioenergy consumption vs. per capita income 35 4 Evolution of gas emissions from new vehicles in Brazil 48 5 Indifference price curve for anhydrous ethanol price according the price of sugar price 52 6 International sugar price (NYBOT Nº 11 Contracts) 54 7 Indifference price for ethanol vs. sugar in the international market 54 8 Average ethanol productivity per area for different crops 67 9 Distribution of world ethanol production in 2006 67 10 Leading sugarcane producing countries in 2005 69 11 Per capita consumption of sugar in several countries 104 12 Electric power generating capacity of cogeneration systems expected to be installed in sugar and bioethanol mills in the State of São Paulo in coming years 110 13 Value of used bagasse for electricity production 110 14 Value of used bagasse for ethanol production 112 15 Energy use (a) and Emissions of Greenhouse Gases (b) in the production of various types of plastics 139 16 Evolution of the production of sugarcane, ethanol and sugar in Brazil 153 17 Average levels of anhydrous ethanol in Brazilian gasoline 153 18 Evolution of production of hydrated ethanol vehicles and share in new vehicle sales 154 19 Primary energy sources utilized in Brazil in 2007 155 20 Distribution of the annual processing capacity of sugar and ethanol plants in Brazil 156 21 Production profiles of sugar and ethanol plants in Brazil during the 2006/2007 harvest 157 22 Evolution of agricultural, industrial and agroindustrial productivity in sugar and ethanol plants in Brazil 160 BBioetanol-00ioetanol-00 IInglês.inddnglês.indd 8 111/11/20081/11/2008 116:23:456:23:45 23 Evolution of prices paid to ethanol producers in Brazil 161 24 Consumption of fertilizers by the main crops in Brazil 182 25 Soil loss and rainwater runoff for some Brazilian crops 183 26 Annual deforestation of the Brazilian Amazon 187 27 Rural Brazilian property land-use 188 28 Evolution of the area used by the principal crops in Brazil 189 29 Land-use in Brazil 189 30 Evolution of prices paid to producer, not including taxes: US gasoline and Brazil sugarcane bioethanol 195 31 Price structure of regular gasoline, hydrated bioethanol and diesel oil (Rio de Janeiro, March 2008) 196 32 Evolution of average consumer prices for hydrated bioethanol and regular gasoline in Brazil and the relationship between them 197 33 Structure of sugarcane production costs in Brazil’s Center-South in 2005 198 34 Breakdown of operation and maintenance costs for an independent sugarcane bioethanol production distillery in the Central-South in 2005 199 35 Average productivity of sugarcane agroindustry workers in Brazil 202 36 Bioenergy potential per biomass type 215 37 Distribution of ethanol production by region in 2007 223 38 Bioethanol-gasoline blend that can be produced from the conversion of molasses available out of sugar production 229 39 Agricultural land requirements to produce bioethanol for a 10% gasoline blend 230 40 Biofuels supply and demand estimates for 2010 and 2015 235 41 Price indexes for crude oil and
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