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Prospects of Ethanol A Sustainable Bio-fuel

Prospects of Ethanol A Sustainable Bio-fuel. TWIN CRISES. * Fossil fuel era entering its sunset years * Environmental degradation Transportation Sector is the Major Offender > 50% of Petroleum products are consumed by Transportation sector. ESTIMATED WORLD OIL SUPPLY.

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Prospects of Ethanol A Sustainable Bio-fuel

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  1. Prospects of EthanolA Sustainable Bio-fuel

  2. TWIN CRISES * Fossil fuel era entering its sunset years * Environmental degradation Transportation Sector is the Major Offender > 50% of Petroleum products are consumed by Transportation sector

  3. ESTIMATED WORLD OIL SUPPLY

  4. PATHS TO REDUCE HAZARDS OF PETROLEUM DEPENDENCE • Conservation • Fuel Diversity • Use of Alternative clean-burning Fuels • Energy Independence

  5. INDIA’S PETROLEUM NEED • Imports about 70% of its petroleum requirement • About 74 Million Tones of crude oil and petroleum products imported in 2001-02 at a huge cost of Rs. 78,000 crore • Since ethanol-blended gasoline was introduced in some US States, ethanol production in USA has doubled from 20 million barrels in 1996 to over 40 million barrels in 2001. • A new federal energy bill is also expected to mandate that 5 billion gallons of ethanol per year be added to gasoline over the next 10 years.

  6. Sugarcane– A major indigenous sources for ethanolproduction - extracted from molasses, a by-product of the sugar industry. • India produces 1.3 billion litres of ethanol from molasses, albeit the total installed capacity of distilleries is nearly three times i.e. 3.2 billion litres. • Brazil has an experience of over 70 years in blending and can help India to develop faster in this field. • The Government of India signed an MOU with Government of Brazil on 8th April 2002 for transfer of technology for blending of ethanol with auto fuels.

  7. Selected three locations commissioned at Miraj and Manmad in Maharashtra and at Bareilly in Uttar Pradesh in the year 2001. More projects have been /are being commissioned in Uttar Pradesh , Punjab Andhra Pradesh • Petrol blended with 5% ethanol w.e.f. 1.1.2003 in 9 major sugar growing states of Andhra Pradesh, Gujrat, Haryana, Karnatka, Maharashtra, Punjab, Tamil Nadu, Uttar Pradesh and Goa as well as the Union Territories of Daman & Diu, Dadara & Nagar Haveli, Chandigarh and Pondicherry during Phase I and rest of the States/Union Territories during Phase II

  8. Govt’s decision--Increase ethanol content upto 10% in petrol at the three ongoing pilot projects in Maharashtra and Uttar Pradesh after amending the Bureau of Indian Standards (BIS) specifications for petrol suitably. • Total petrol consumption in the country during 2001-02 - about 7 million tonnes. • Petrol consumption in nine States and four Union Territories to be covered in the first phase of implementation of ethanol-petrol blend project --over 4.6 million tonnes i.e. approximately 65%. • At this level of consumption, the estimated ethanol required for blending with petrol - in the range of 32 to 35 crore litres per year.

  9. 5% blend of ethanol and petrol would be extended to the entire country in second phase. • To 10% in petrol in the third phase after BIS specifications are modified. No modification is required in vehicles with 10% ethanol blend. • In the next phase ethanol will also be blended in diesel. • India use 80% diesel and 20% petrol against Brazil pattern of consumption of 10% diesel and 90% petrol.

  10. HYDROGEN METHANOL NATURAL GAS PROPANE ELECTRICITY SOLAR ENERGY P SERIES BIODIESEL ETHANOL ALTERNATIVE FUELSIdentified by US Department of Energy

  11. ETHANOL-HISTORICAL PERSPECTIVE • In 1880 Henry Ford designed a car solely on ethanol • Subsequently Ford designed its popular model “T” operable on ethanol and or gasoline. • Extensively used during World War II in Germany

  12. From 1920-1924,Standard Oil Company marketed 25% by vol. of absolute ethanol in Gasoline in Baltimore area. Project stopped because of • High corn prices • Problems of transportation and storage

  13. ADVANTAGES OF ETHANOL • Octane enhancement* / Anti-knocking Agent • Use of higher CR due to high knock resistance • Oxygenating Agent • Fuel extender/Fuel Replacement * Higher octane number than gasoline reduces engine knock and results in higher energy efficiency.

  14. BLENDS WITH PETROL • Ethanol can be blended in various proportions with Petrol • Usually blended from 5 % to 10% by volume to Gasoline • Brazil has an experience of over 70 years in blending and now they have 24% of ethanol by volume added to Gasoline.

  15. ETHANOL ADDED TO PETROL REFERRED TO AS • Absolute Alcohol • Anhydrous Alcohol • Dehydrated Alcohol • Power Alcohol Specifications of fuel-grade ethanol for blending with Petrol ---ASTM D 4806

  16. ETHANOL PRODUCTION ROUTES • Fuel ethanol or absolute Alcohol is produced by dehydration (removal of water molecules) of Rectified Spirit (RS)or Industrial alcohol • Commercial routes of dehydration of RS -Molecular sieve Technology -Pervaporation (membrane technology) -Azeotropic distillation

  17. COMPARISON OF DIFFERENT ROUTES FOR PRODUCING ETHANOL FROM VARIOUS TYPES OF FEEDSTOCKS Technology Processing I. Sugar based feedstocks available in India Complexity (Sugar-cane molasses & & juice, sugarbeet, etc.) Cost of Conversion Increasing II. Starch based feedstocks available in India (Foodgrains, etc.) III. Cellulose based feedstocks available abroad (Biomass & MSW) Biomass : Agro-industrial, Agricultural & forestry residues, energy crops/ plantations

  18. Process I Ethanol Distillation Juice Treatment Fermentation Sugar-cane Molasses Juice Extraction Washing Secondary Juice or Sugar Sugar Production Juice Treatment Schematic diagram of sugar and ethanol production process from sugarcane

  19. Process II Amyloglucosidase & yeast Amylase & heat Cereal Saccharification & Fermentation Milling Gelatinization Ethanol Heat Distillation Stillage Heat Distillers’ Dried Grain and Solubles (DDGS) (can be used as animal-feed) Schematic diagram of ethanol production process from cereal grains

  20. Biomass Process III Pretreatment Steam Hemicellulose Extraction Water Hydroxide Lignin Sodium Lignin Extraction Cellulose Hydrolysis Enzyme Production Hemicellulose Hydrolysis Fermentation Fermentation Distillation Ethanol Schematic diagram of ethanol production process from biomass

  21. FUMIGATION • Prof Paul Schweitzer fumigated the induction system of a diesel engine with different volatile fuels while injecting diesel to improve air utilisation of the diesel engine & to boost power.

  22. DISADVANTAGES OF GASOLINE-ETHANOL BLENDS • May corrode some engine parts • Cold start problems-Startability poor below 15 Degree C- • Higher volume-based fuel consumption(needs larger fuel tanks in Vehicles) • More aldehyde emissions-controlled by Catalytic Converter • Phase separation problems

  23. ETHANOL: WORLD PERSPECTIVE *Brazil,USA,France,Indonesia,Philipines, Guatemala, Costa Rica,Argentina,Republic of South Africa, Kenya have the experience of using Ethanol as a Transport fuel * India’s present initiatives are well-known * Thailand,Sudan,Australia,Japan are getting ready to plunge into massive Ethanol programmes

  24. ETHANOL: WORLD PERSPECTIVE • World production is growing from 10Billion litres in 1980 to 32-33 Billion litres in 2000 • The bulk of production comes from Brazil and USA • Thailand, China Govts plan to produce large scale Ethanol • Synthetic Ethanol capacity likely to develop also

  25. ETHANOL: WORLD PERSPECTIVE • In France, ethanol is produced from grapes that are of insufficient quality for wine production. • Some Canadian provinces promote ethanol use as a fuel by offering subsidies of up to 45 cents per gallon of ethanol. • India is initiating the use of ethanol as an automotive fuel. A move has been made by distilleries in India to use surplus alcohol as a blending agent or an oxygenate in gasoline. Based on experiments by the Indian Institute of Petroleum, a 10 percent ethanol blend with gasoline and a 15 percent ethanol blend with diesel are being considered for use in vehicles in at least one state.

  26. US EXPERIENCE • Clean air act amendment of 1990 mandated sale ofoxygenated fuels in areas with unhealthy levels of CO • Each year more than 1.5 billion gallons are added to gasoline to increase octane and improve emission quality • Presently ethanol-blended fuels represent more than 12% of motor gasoline sales.

  27. US EXPERIENCE • Established as an oxygenate in Reformulated Gasoline (RFG) • Used in 17 states in the US and also in US capital • In 1999 March California issued an order to phase out MTBE (Methyl Tertiary Butyl Ether) which was causing ground water pollution. Such a change in situation improves the prospects of Ethanol

  28. US EXPERIENCE • Since ethanol-blended Gasoline was introduced in US, production was more than doubled—from 20 million barrels in 1996 to over 40 million barrels in 2001. • In US, gasoline is blended with 10% Ethanol whereas in Brazil the blending percentages are 22-26%

  29. ETHANOL IN AUSTRALIA • Has exhaustive resources for biomass available for development program • Approximately 1200 to 1600 bio-ethanol plants ranging from 10 million litres to 100 million litres required to meet Australia’s transportation needs

  30. MILESTONES IN AUSTRALIA’S PROGRAM • A very effective Greenhouse Gas Abatement Program in operation now • By 2005- 2% of Australia’s transport fuels from ethanol (more than 540 Million litres) • By 2010---5% of Australia’s transport fuels - (>1.4 billion litresTargeted)By 2025---40% (> 11Billion litres) • By 2040---85% targetted from Bioethanol

  31. ETHANOL PROGRAM IN THAILAND • Petroleum Authority of Thailand (PTT) in collaboration with Ministry of Science Technology and Environment (MOSTE) • National Ethanol Development Committee (NEDC) set up in Jan 2000 • Presently approximately 564 million litres per annum–mostly from Molasses • Plentlily available Tapioca (Cassava) being studied as raw material

  32. BRAZILIAN EXPERIENCE • Brazil produces more than 16 billion litres per annum and export around the world. • Launched World’s first Major program (PROALCOOL) in 1975--to use hydrated alcohols directly as 100% fuel for Cars. • Ethanol program involves blends of both 24%(E24) anhydrous ethanol/petrol and 100% neat ethanol. • 100%Ethanol cars have problems of lower acceleration and maintainance problems. Sugarcane and derivatives main feedstock

  33. ETHANOL IN BRAZIL • Today, Brazil has around 19 million vehicles running with Otto Cycle engines (gasoline and ethanol), where, roughly, 16 million are “gasohol” and 3 million are ethanol driven cars. • Prompted by the increase in oil prices in the 1970s, Brazil introduced a program to produce ethanol for use in automobiles in order to reduce oil imports. • Brazilian ethanol is made mainly from sugar cane. Pure ethanol (100% ethanol) is used in approximately 40 percent of the cars in Brazil. The remaining vehicles use blends of 24 percent ethanol with 76 percent gasoline.

  34. Brazil consumes nearly 4 billion gallons of ethanol annually. In addition to consumption, Brazil also exports ethanol to other countries. • Flexible fuel vehicles that work with any gasoline (E22) and hydrous ethanol mixtures • Serving the consumer, who will be able to choose the fuel having a lower price or better performance; • Technology already known (+ 1.8 million vehicles in the USA); • For the technology currently used in Brazil (stoichiometric mixture and 3-way catalyst), it would be an intelligent commitment). .

  35. ETHANOL IN CANADA • Was initiated for economic reasons—now finding environmental and rural economic pay back • Present annual production is around 238 million litres • E10 (10% ethanol and 90% gasoline) available in 1000 retail stations in Canada. Ethanol production from Cellusose planned

  36. Ethanol is widely available in proportions of 5-10% ethanol blended with gasoline. • Higher-level blends exist but are not commercially available in Canada at this time. • First blended with gas and sold in Manitoba twenty years ago, today ethanol is offered at approximately 1,000 locations in six provinces (the four Western provinces, Ontario and Quebec).

  37. Canada's annual ethanol production is approximately 225 million litres per year, some of which is exported to the United States. • Quebec as well as a federal government commitment to increase ethanol production by 750 million litres per year. • Reduced net emissions of greenhouse gases. • Studies in the U.S. and Canada ---replacement of gasoline with ethanol means a reduction in total life cycle emissions of greenhouse gases (expressed as “carbon dioxide equivalents”) of at least 25%.

  38. ETHANOL IN THAILAND • Thailand has entered into a MOU with a Brazilian state agency to jointly develop ethanol in a project for producing the plant extracted fuel within two years. • Thailand has promoted ethanol production from agricultural products, such as cassava and molasses, as ethanol can replace demand for fuel additive (MTBE) in gasoline, which will contribute to foreign currency saving as well as mitigation of air pollution problems resulting from fossil fuel combustion.

  39. ETHANOL IN INDIA Historically in the mid-1930’s, petrol /alcohol blends were used in the city bus service of Bangalore on an experimental measure, thanks to the vision of the then Dewan of Mysore, Sir Mirza Ismail.The alcohol from the Mandya sugar factory was available for this purpose first as a blend in petrol cars and subsequently as a sole fuel for both petrol and diesel vehicles.

  40. High anti-knock value and better performance in terms of power and efficiency. • It is only recently (since the 1970s) that interest was shown in the use of ethanol and methanol as diesel fuels. • Alcohols are very difficult to burn by compression-ignition, because of their low Cetane Number • The main research in diesel-alcohol technology was to find ways and means to force alcohol to ignite by compression in the diesel engine.

  41. The bi-fuel system developed by the Prof H. A. Havemann and his colleagues at the Indian Institute of Science (IISc) Bangalore, in the early 1950s, was the subject of the earliest original published work in technical literature regarding alcohol diesels. • Essentially, this method involves giving carburetor benefits to a diesel engine. • Since alcohol and diesel oil does not mix, these fuels are sent through two different routes - by induction and injection. • Part of the fuel-energy is supplied by inducting ethanol through a carburetor, while only a small quantity of diesel fuel is injected in the conventional injection system.

  42. Professor Paul Schweitzer referred to the research efforts at Bangalore on the novel attempts to burn a low-cetane fuel like alcohol by “fumigating” it to the induction manifold. • Pennsylvania State Railway also showed interest in applying this technique for using alcohol in diesel locomotives. • The UK experience, in King's College, was aimed at improving combustion characteristics of a diesel engine by introducing small quantities of “Secondary fuels” in the induction manifold and promote smooth pressure rise and low smoke emission.

  43. Research in IISc, IITs, Universities (and CSIR research laboratories (IIP)---, absolute or anhydrous alcohol was not essential for fumigation, in contrast to the blending practice for petrol engines. • Anhydrous alcohol is expensive. Rectified spirit can be used for diesel engines. Water, indeed, is a blessing in disguise as nitric oxide emissions level from diesel engine gets reduced because of water in the alcohol and the low combustion temperatures caused by high latent heat of alcohol.

  44. Making emulsions of ethanol in diesel fuel by the use of surfactants is an accepted practice in Sweden. • Ethanol with ignition improvers has now become an established bus fuel. Blends of 85 per cent diesel and 15 per cent ethanol are made from renewable sources such as sugar-cane, molasses and cellulose from bagasse.

  45. ETHANOL USE IN INDIA • Alcohol Tests for Internal combustion Engines in IISc, Bangalore in 1950s • Studies on neat alcohol and blends carried out in IOC R&D,IIT D,IIT M, IIP and many other research /academic institutes • Gasohol with 5%v/v widely studied under variable operating/climatic conditions

  46. ETHANOL PRODUCTION IN INDIA • Produces 1.3 Billion litres from Molasses • Total installed capacity about 3.2 Billion tonnes. Hence adequate scope of higher production • August 99--5% , in compliance with BIS • 10% pilot trial announced and subsequently planned in the whole country

  47. BIOMASS-BASED ETHANOL • Agricultural crops and wastes Rice straw,Wheat straw,bagasse etc • Municipal Solid waste Paper,cardboard,municipal sludge etc • Industrial waste Wood chips,saw dust, food processing waste paper mill sludge etc

  48. ETHANOL - SAFETY • Less flammable than gasoline • Fires - less frequent and less severe when spills or release of vapour occur • Safer than gasoline to store, transport • Water soluble and biodegradable.land and water spills are harmless. • Dispersing and decomposing quickly

  49. EMISSIONS Emissions vary with engine design • E85 with respect to gasoline - produces fewer toxics - benzene and toluene - 15% reduction in ozone forming voc - 40%co reduction---particulate reduction 20% -10% reduction in NOx emissions • Sulfate emissions reduced by 80% • Higher acetaldehyde emissions

  50. MAINTENANCE • Maintenance practices are similar to conventionally-fueled vehicles • FFVs 20% of Biodiesel , derived from locally available non-edible sources can be mixed with conventional diesel FEVs are specially designed for Ethanol’s slightly more corrosive properties • Ethanol-Gasoline blend beyond 10% have to modify the engine and fuel delivery system

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