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Optimization of Sugar and Ethanol Production Process Through Laboratory Testing and Factory Wash Analysis

Learn about the affination of crop raw sugar, the impact of wash time and volume in the factory, and optimizing centrifuge wash for sugar pol and color. Explore sugarcane biomass conversion to energy and cost analysis for co-generation. Discover insights from Brazil's ethanol production and plans for expanding sugarcane production to substitute gasoline.

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Optimization of Sugar and Ethanol Production Process Through Laboratory Testing and Factory Wash Analysis

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  1. June 2006 Laboratory affination of 2005 crop raw sugar

  2. November 2006: Factory: Effect of wash time

  3. 0.008 gallons / second / nozzle A nine-nozzle manifold 0.07 gallons / second

  4. Effect of wash volume A 3 second wash = 0.21 gallons water at 250 – 350 Lb sugar / cycle 3 seconds = 0.5 - 0.7 % on sugar 1 – 1.4 % sugar to run-off

  5. need to test spray nozzles use the data to optimize centrifuge wash from the standpoint of sugar pol and sugar color vs. boiling house impact and cost

  6. Factory Wash water P2 V2 Air supply V3 Western States 48x36” V1 Pressure Vessel With Water or peroxide Sugar sample P1 Digital scale

  7. Sugarcane biomass (“trash”) Collection and transportation cost Separation at the mill Conversion to energy (co-generation)* fermentable sugars / ethanol

  8. Density of cane at different trash yields

  9. Cost of trash delivered to mill

  10. Conversion to • NOW • energy (co-generation) • 1 t CLM = 95 kWh gross • = 85 kWh net = $5 • IN THE FUTURE? • fermentable sugars / ethanol • 1 t CLM = 39 gallons EtOH • $40 - $80 (gross)

  11. Cost of trash delivered to mill

  12. *cost of CLM that goes to juice extraction -$8/t or -$24/acre for “conventional” cane (at 2% pol in bagasse)

  13. dry cleaning of billeted cane – optimize & standardize design trash preparation - shredding, cleaning & conveying

  14. Observation from trip to Brazil, April 2007

  15. present retail cost in Brazil ethanol (hydrous) US$2.7/gal gasoline (25% ethanol anhydrous) US$4.5 /gal production cost of ethanol US$1.1/gal Plans to expand sugarcane production in Brazil to substitute 5 – 10% of world gasoline will require 6 x present sugarcane production energy optimization of sugar and sugar ethanol process biomass ethanol

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