Converting sugarcane biomass residues into electrical energy with the help of modern technology and equipment.
From sugarcane comes sugar, energy for humans; and ethanol, fuel for machines. What is left over from this process, the bagasse, the straw that remains in the field, can also be converted into energy. The processed material, biomass, generates heat energy, which in turn produces electrical energy.
Currently, Brazil is still not exploiting the full energy potential of sugarcane straw as much as it could. Studies show that about 50% of the straw produced could be used, benefiting agricultural land and the environment. For every 10,000 tons of sugarcane straw, it is possible to generate up to 153 megawatts.
Optimal use of sugarcane waste
Brazilian company in the energy and sugar sector, Gales Machado They develop high-quality products in parallel with social and environmental actions, with a focus on sustainable development. They already export organic sugar to Austria and the Netherlands. Investment in specialized workers and new technologies is yielding significant results.
On average, about 4.5 million tons of sugarcane are processed each year. All this generates approximately 250 million liters of ethanol and 205 thousand tons of sugar. In addition to the two main products (sugar and ethanol), Jalles Machado also produces latex and energy from sugarcane.
The use of biomass for energy generation is one of the company’s advantages. Using sugarcane bagasse and sugar straw, the company is developing a cogeneration process. This process began in 2000, with the installation of a thermoelectric plant.
The company has become a pioneer in Goiás in the field of cogeneration of power from sugarcane bagasse. In addition to meeting the plant’s electricity consumption, surplus production is sold, generating additional revenue.
Learn about the advantages and disadvantages of biomass energy.
Currently, the cogeneration capacity is 40 MW and 48 MW in two units, enough energy to supply a city of about 300,000 inhabitants. To convert all this waste, Jalles Machado invested in a shredder, model HG6000E, from the manufacturer Vermeer.
The equipment was purchased in 2015 after a careful market assessment. “We contacted consultants and companies that were grinding sugarcane straw to feed the boilers,” explains Eduardo Oliveira Pimenta, industrial maintenance manager at Jalles Machado.
Once collected and packed, the sugarcane straw feeds the crusher, which converts and prepares everything to feed the boilers. According to the industrial manager, the HG6000 electric crusher processes about 25 tons per hour. “We evaluated the options available on the market and decided that the equipment best suited our needs, at a cost that was compatible with our capabilities,” he says.
Initially, some technical difficulties limited operations. “After installing the bale feeding table and the dust extraction system, we improved operations significantly. Vermeer’s technical support has always been there and supported the search for solutions to the problems encountered,” recalls Eduardo.
Sugarcane Cogeneration Process
- The bagasse resulting from grinding sugarcane is sent to the boiler.
- Sugarcane is burned in the boiler to generate steam.
- High pressure steam is sent to the turbines of the electric power generators.
- The energy generated is consumed in the plant itself and the surplus is sold and supplied to the community.
Cogeneration process of energy by incorporating straw into sugarcane bagasse
- The straw is raked four days after the sugarcane is harvested;
- Balers collect straw into bales weighing about 400 kg;
- The bales are sent to the industry, where they will be crushed and shredded;
- The straw is incorporated into the bagasse which will supply the boiler to generate steam.
- High-pressure steam drives the turbines of power generators.
