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ABSTRACT
Ethanol from sugarcane is an efficient and renewable biofuel that
appears as a solution to the problems of rural development, diversification of
energy sources, fossil fuel savings, as well as contributing to the reduction of
local pollutants from vehicle exhausts and net reductions in greenhouse gas
(GHG) emissions. During the 30 years of the Brazilian Alcohol Program, Brazil
has developed a significant experience in the various aspects of sugarcane
ethanol production.
Therefore the Brazilian experience is considered as a good example to
be replicated in other developing countries. When discussing this replication
some issues must be addressed:
1. the environmental sustainability of sugarcane and alcohol
production
2. the economic competitiveness of ethanol compared to gasoline
and, if necessary, adequate policies to improve it.
INDEX
1.
INTRODUCTION .................................................................................... 4
2.
THE ENVIRONMENTAL SUSTAINABILITY OF SUGARCANE
AND ALCOHOL PRODUCTION...................................................................... 5
3.
THE ECONOMIC COMPETITIVENESS OF ALCOHOL FUEL
COMPARED TO GASOLINE......................................................................... 10
4.
PERSPECTIVES FOR THE REPLICATION OF BRAZILIAN
ETHANOL PROGRAM IN OTHER DEVELOPING COUNTRIES.................. 13
5.
CONCLUSIONS ................................................................................... 23
6.
REFERENCES ..................................................................................... 25
ANNEX .......................................................................................................... 29
1. INTRODUCTION
Sugarcane ethanol is already well known as an efficient and renewable
biofuel. In Brazil, since 1975 when the alcohol program (Proalcool) started, it
has promoted rural development, diversification of energy sources, lower
dependence on oil imports, reduction in local pollutants from vehicle exhausts
and net reductions in greenhouse gas (GHG) emissions.
These objectives were reached with the development of Proalcool
through the several lessons learned, as discussed in this paper. Proalcool
was created to increase the production of alcohol for fuel purposes in face of
rising oil prices on the international market. In the early stages of the alcohol
program, sugarcane ethanol use became viable to consumers through a
pricing policy applied to fuels in Brazil. As the efficiency and cost
competitiveness of ethanol production evolved over time, and fuel prices were
liberalized, the need for this support declined and the support was eliminated
in 1999. Thus, governmental incentive did exist in the past, but today the
industry has matured significantly and relies exclusively on private investments.
The positive results of the ethanol production program were possible
due to the technological achievements, infrastructure investments and
management in both sugarcane and ethanol production. Due to these
developments, Brazil is nowadays the global benchmark in sugarcane-based
ethanol production (Goldemberg et al, 2003). As a consequence of the
observed cost reduction, subsidies were fully eliminated by 1997 and are no
longer applied on anhydrous nor on hydrated ethanol. Hydrated ethanol is
sold to consumers for less than 70 per cent (by volume) of the gasoline price,
corresponding to ethanol break-even price vis--vis gasoline. Thus, alcohol is
economically competitive with gasoline without any subsidies. These are the
two main fuels used in cars in Brazil, since diesel vehicles manufactures in the
country are heavy duty, commercial.
Brazilian lessons can indeed be reproduced in many regions of some
other developing countries, contributing to a global expansion of ethanol
biofuel, considering:
4
12.3%
5.2%
17.5%
SUB-TOTAL CULTURES
34.9%
Natural forests
14.2%
Reforesting
5.0%
SUB-TOTAL FORESTS
19.2%
Pastures
45.9%
TOTAL
100.0%
land costs vary, but in So Paulo, where 60% of Brazilian sugarcane is produced, a conservative estimate is around
US$ 2,700-3,500 per hectare (PROCANA, 2005)
6
2001
2005
Cattle (heads)
13,154,649
14,072,447
Pasture (hectares)
10,288,887
10,010,491
1.28
1.41
Density (heads/hectare)
In Brazil there are soils that have been producing sugarcane for more than
200 years with ever-increasing yield. Good agricultural practices (protection
against erosion, compactation and moisture losses, correct fertilization etc.)
increase the sustainability of the culture. Land area available for biofuels must
not depend on deforestation nor competition with food. Sugarcane crops must
not create any pressure on Amazon deforestation2, but atention must be paid
to indirect effects from sugarcane expansion over cattle areas, what can push
these activities over Amazon. Figure 1 below shows the map of Brazil,
including the Amazon region; it shows also that most areas occupied with
sugarcane are in Southeastern region and, moreover, the So Paulo State.
Amazon deforestation is indeed a problem to be addressed but the main pressure on it is from soy crops and not
from sugarcane.
7
are being phased-out, through a strict legal enforcement and allowing energy
benefits of mechanization from higher surpluses of electricity produced from
sugarcane by products (State Law 11241/2002); also, havesting burning
practices are controlled / authorized by So Paulo State Secretary for the
Environment according to atmospheric conditions.
spill offs and other accidents are rare and of low impact;
Stillage
www.cetesb.sp.gov.br
9
OF
ALCOHOL
FUEL
(2 0 0 4 ) U S $ / G J
100
1980
10
2004
1986
1990
2002
1995
1999
50000
100000
150000
200000
3
Ethanol Cumulative Production (thousand m )
250000
300000
There are differences on Brazilian taxes for fuels, including alcohol and gasoline. Ethanol and flexible vehicles have
lower IPI (Federal tax for industrialized products) when compared to gasoline; also, some state taxs (ICMS) have
lower taxes for ethanol. These taxes take into account the environmental benefits of alcohol. Besides these taxes
there is a special tax called, CIDE (Contribution fot Intervention in Economic Domain), a Federal tax on oil fuels.
CIDE gives differentiated values according to each fuel; natural gas and ethanol are exempted. The current level for
CIDE on gasoline is R$ 280 per cubic meter (US$ 0.0957/liter in 2004 US dollars); for diesel oil is R$ 70 per cubic
meter (Brazil, Decree # 4565/2003). In 2004, the average prince of gasoline net of taxes was R$ 0.74837 per liter
(www.anp.gov.br.), weighted averaged for Brazil. Adding the R$ 0.28 per liter value of CIDE, the total value attributed
to pure gasoline to be compared to the price of ethanol net of taxes comes to R$ 1.02837 per liter, average value for
2004. This value translates into US$ 55.88 per barrel, which is practically identical to the average price of midgrade
gasoline in the US during the same period, of US$ 56.28 per barrel, equivalent to US$ 1.32 per gallon (Energy
10
mills since 2003, processing 2 million tones of sugarcane per year each one)
demonstrates the economic competitiveness of Brazilian sugarcane ethanol.
During the 2003-2004 season, the country exported 2.5 billion liters 6 of
ethanol.
In fact, sugarcane feedstocks represent a dominant share in the cost
buildup of ethanol. The economic cost of production is in the range of
US$0.180.25 per liter of gasoline-equivalent (average export price of ethanol
in the period 2001-2003 was US$ 0.23 per liter). Nowadays, the initial
investment for a compatible industrial plant (processing capacity of 2 million
tonnes of sugarcane per year) is around US$ 60 million (in 2005 prices).
Located in the Center-South of Brazil, such plant yields on average 79.39
liters of anhydrous ethanol equivalent (82.86 liters of hydrous) per tonne of
sugarcane. Price paid per tonne of sugarcane is US$11.4 (UNICA, 2005). A
simple calculation, without interest rates, considering the price and a plant
lifetime of 25 years would lead to a feedstock cost of US$ 0.143 per liter of
ethanol and an investment cost around US$ 0.017 per liter of ethanol
produced. But investments are affected by the extremely high interest rates in
Brazil: banks add their spreads to 19.75% per year, which is the basic official
rate in August 2005.
Production costs of ethanol from sugarcane are low not only due to
geographic conditions but also because of the extremelly favourable energy
balance.
Table
shows
the
energy
balance
of
sugarcane
ethanol,
demonstrating that more than eight units of energy are produced from each
unit of fossil fuel consumed. The finding opens important opportunities for
participation of developing countries in the Kyoto Protocols Clean
Development Mechanism.
Information Agency, US Department of Energy, U.S. Refiner Motor Gasoline Prices by Grade and Sales Type,
Washington, DC, 2005)
6 According to the Ministry of Agriculture, Livestock and Food Supply (2005), the main importers of Brazilian ethanol
in 2004 were India (480 million liters), the U.S. (425 million liters), South Korea (280 million liters), Japan (220 million
liters) and Sweden (190 million liters)
11
This favorable energy balance is mainly due to the fact that all energy
needs in sugarcane mills are provided without any external energy source.
Sugarcane bagasse
Bagasse is the by-product from sugarcane crushing; it corresponds to 30% (in weight) of sugarcane, 50% wet.
When sugarcane is harvested manually it must be burnt before harvesting and so tops and leaves (trash), are lost (30% of the
sugarcane). Recent studies from Copersucar/GEF (PROJECT BRA/96/G31) evaluated possibilities for the harvesting of
greencane and the amount of trashto be left in thefields and the amount to be burnt in boilers for cogeneration.
12
cane per harvesting season were able to change from existing old equipments
(21 bar boilers) to more efficient ones (40 or 60 bar boilers and more efficient
steam turbines), increasing their capacity for surplus generation from 2.3 MW
to 9.3 MW and providing renewable electricity to local consumers.
Considering the energy balance for different crops, not whitstanding
the variations in figures provided by different studies, there is no doubt that
sugarcane is definetely the most efficient feedstock in terms of replacement of
fossil fuels (CO2), as shown in Figure 2.
12
10
8
6
4
2
0
Sugarcane
Sugar beet
Wheat straw
Corn
Wood
ethanol feedstock
13
The unique exception is the plastic polyamide 6.6 (Nylon), which in presence of hydrous ethanol adsorbs water
and swells, increasing the component dimensions; the polyamide 6.6 absorbs the water and, for this case, it is
necessary to substitute it for another plastic (usually, polyamide 12). For the application with gasoline or ethanolgasoline blends, there are not problems with the polyamide 6.6, since these fuels do not have significant water
content.
10
Considering that ethanol is a polar substance and gasoline is an unpolar substance, there is not solubility
between both, but only miscibility, which, in general, is good and stable. Two factors have influence on this miscibility:
the presence of water and the characteristics of hydrocarbons of gasoline (resulting from the production process).
However, with the use in low concentration of anhydrous ethanol (up to 10%) and with the increase of cracked
gasoline application (instead direct distilled gasoline), there are not reports on separation problems in the countries
were this blend is used, even in the countries with cold weather.
11
Alliance of Automobile Manufacturers (2005)
12
In 1975, performance and emission tests were developed in Brazil, adding increasing volumes of anhydrous
ethanol to gasoline. The study concluded that the 20% +- 2 % ethanol blend yielded good results in terms of fuel
consumption and emissions.
14
5%
Exhaust System
Intake Manifold
Motor Oil
Basic Engine
Catalytic Converter
Fuel Tank
Evaporative System
Ignition System
Fuel Filter
Pressure
Fuel
Fuel Pump
Fuel Injection
Carburetor
Ethanol Content in
the Fuel
(Figure 4).
5- 10%
P
N
10-25%
25-85%
85%
Consequently, to obtain the same output, it is necessary to burn more ethanol than gasoline, raising the fuel
consumption
According to the Brazilian National Energy Balance 2004 (MME, 2005) the lower heating values (LHV) of diesel
fuel, automotive gasoline, anhydrous ethanol and hydrous ethanol are respectively 35.50, 32.20, 22.34 and 21.33
MJ/liter of fuel
14
15
ratio comparing neat hydrous ethanol with gasoline was assessed by tests15
equal to 0.8067. Flexible fuel vehicles, adjusted to have a similar power
performance with both fuels, have lower ratios, of approximately 70% (UNICA,
2005a)
In Brazil, the recently introduced flex-fuel vehicles16 can operate with
up to 100% hydrated ethanol17 . This concept is different from US flex-fuel
models, which can use a maximum of 85% ethanol, due to problems of
corrosion, cold start and phase separation inside the tank at very low
temperatures. When using 100% ethanol, eventual problems of cold start are
solved through the use of a little gasoline reservoir for instant automaticallyactivated gasoline injection, as it is done in Brazil in any alcohol or flex
vehicles.
140
20
0
Power
Gasoline 0%
Max Speed
Gasohol 22%
95,5 %
89,3 %
40
103,2 %
105,3 %
60
102,1 %
106,4 %
80
103,3 %
110,0 %
100
105,5 %
129,4 %
120
Consumption
(L/100km)
Ethanol 100%
15
16
16
World
OECD
Non-OECD
countries
countries
Gasoline consumption
Billion litres/yr
1165
838
327
Billion litres/yr
175
126
49
Million ha*
29
21
Million ha
383
116
217
Million ha
1455
496
959
suitable"
17
The huge success of these flex fuel vehicles is due to the freedom of choice for the consumers, depending of the price of each
fuel at the pump station. Alcohol prices can be up to 70% of gasoline pricesand a global ethanol market, allows the utilization of
FFVs, which can address eventual fossil or renewable fuel shortages. Volkswagen, General Motors, Fiat, Ford, Peugeot, Renault
are some of manufacturers producing flex-fuel vehicles in Brazil - a fleet of 700,000 units in 2005
18
Source: FAOSTAT (2005)
http://faostat.fao.org/faostat/form?collection=Production.Crops.Primary&Domain=Production&servlet=1&hasbulk=0&version=e
xt&language=EN
17
From Table 4 it can be seen that considering the blend of 10% (in vol)
of ethanol to gasoline the sugarcane area necessary would be 29 million
hectares, much less than the 383 million hectares of suitable and very
suitable sugar crops mentioned by FAO, 2005.
In fact, Brazil is endowed with vast agricultural areas. Plentiful land,
favorable climatic conditions and low cost labor were indeed necessary for the
success of alcohol program based on sugarcane. But several other tropical
countries can handle a large alcohol program like Brazil. Although sugarcane is
a highly intensive culture possible to be produced in regions that have an
average temperature above 20oC and plenty of available sunlight and water, it
does not imply that areas covered with forestry are the most suitable for the
culture. Figure 8 gives an idea of the regions that meet these conditions; from
this figure it can be seen that most are developing countries.
Biofuels produced by developing countries correspond to a significant
opportunity for job creation and rural development. Conclusions from a recent
workshop organized by STAP/GEF/WorldBank shows that biofuels can offer
a sustainable and carbon neutral alternative to petroleum fuels, provided that
environmental safeguards are put in place, and that sustainable land
management is applied. This would exclude the production of biofuels from
cleared forest land for example, and biofuels with negative or uncertain GHG
emission reductions. The potential negative impacts on soil, water and
biodiversity in the case of large-scale monoculture plantations must also be
recognized. Hence, the question of the role of biofuels in mitigating climate
change is also a question of natural resource management, pertaining to the
land degradation, biodiversity, POPs and international waters focal areas of
the GEF.
Among commercial biofuels today, sugarcane ethanol gives the highest
land use efficiency for GHG mitigation, and is therefore an attractive biofuel
from a GHG perspective. Provided environmental externalities are addressed
in the production, and no natural ecosystems are converted, sugarcane
ethanol has a significant potential for reducing GHG and improving energy
security. Sugarcane ethanol also offers the distinct advantage of generating
18
20
inexpensive. The distillation process is also efficient (despite the fact that
there is still room for further improvements in efficiency) and available at low
costs. The cogeneration process from bagasse has also undergone significant
improvement in recent years and high efficient steam systems using
sugarcane bagasse are commercially available.
Althought, in the case of Brazil, alcohol production for the blend of up
to 25% cannot be a candidate for CDM projects (because this situation
corresponds to a baseline before the base year for Kyoto Protocol) other
developing countries can start such a program and would be excellent
candidates for CDM.
http://www.fao.org/ag/AGL/agll/gaez/ds/da.htm?map=24
21
2.
deforested land: these countries must start since the very beginning, including
the choose for the best crop to be used for biofuels
For countries in the first group, when interested in the alcohol
production, it would be necessary a preliminary global (technical / economic /
environmental / social) evaluation of the alcohol production. If perspectives
are positive, existing policies could be discussed, together with perspectives
for changes, including:
consumption;
crops production, other cultures, rainfall and water demand and other physical
conditions;
22
23
24
6. REFERENCES
Abrantes, R., A Emisso de Aldedos e Hidrocarbonetos Policclicos
Aromticos de Veculos Comerciais a Diesel, CETESB, SIMEA 2003, So
Paulo, Brazil.
Air Quality Impacts of the Use of Ethanol in California Reformulated Gasoline,
California Air Resources Board, Sacramento, USA, 1999.
Alliance of Automobile Manufacturers (2005) World Wide Fuel Charter 1998
http://www.autoalliance.org/archives/000090.html
Anderson, L.G. et alii, Effects of Using Oxygenated Fuels on Carbon
Monoxide, Formaldehyde and Acetaldehyde Concentrations in Denver, Air &
Waste Management Association'
s 90th Annual Meeting & Exhibition, Toronto,
Ontario, Canada, June 8 - 13 1997.
ANFAVEA (2005) Ethanol Fuel Vehicular Application Technology.
Presentation of Henry Joseph Jr. (Brazilian Automotive Industry Associations
Energy & Environment Commission anfavea@anfavea.com.br) at
CEPAL/CENBIO/USP Seminar So Paulo, August 17th, 2005
Apace Research Ltd., Intensive Field Trial of Ethanol/Petrol Blend in Vehicles,
EDRC Project N 2511, Australia, December 1998. Available at
http://journeytoforever.org/biofuel_library/EthanolApace.PDF
CARB (2004) California Air Resources Board data base
CAPCOA (1993) California Air Pollution Control Officers Association Air
Toxics "Hot Spots" Program, Revised 1992 Risk Assessment Guidelines.
CETESB (2003) Relatrio de Qualidade do Ar no Estado de So Paulo.
Companhia de Tecnologia de Saneamento Ambiental
CETESB (2004) Air Quality Report 2003
Cdigo Florestal (1965) Federal Law 4771/65
COELHO, S.T., GOLDEMBERG, J., LUCON, O., GUARDABASSI, P.
Brazilian sugarcane ethanol: lessons learned. Volume X, Number 2, June,
2006. Available at: ESD www.ieiglobal.org/ESDv10n2/brazilethanol.pdf
Coelho, ST; Lucon, O; Guardabassi, P (2005) Biofuels advantages and
trade
barriers.
UNCTAD/DITC/TED/2005/1
www.unctad.org/Templates/Download.asp?docid=5741&lang=1&intItemID=13
97
F.O.
Licht
(2005)
World
http://www.distill.com/berg/
Ethanol
Production
FAO
(2005)
Sugarcane
http://www.fao.org/ag/AGL/agll/gaez/ds/da.htm?map=24
http://www.fao.org/ag/AGL/agll/gaez/ds/ds.htm
2001.
Apud
potentials
and
25
FAOSTAT
(2005)
http://faostat.fao.org/faostat/form?collection=Production.Crops.Primary&Doma
in=Production&servlet=1&hasbulk=0&version=ext&language=EN
FAOSTAT
(2005)
Primary
crops
http://faostat.fao.org/faostat/form?collection=Production.Crops.Primary&Doma
in=Production&servlet=1&hasbulk=0&version=ext&language=EN
Goldemberg, J (2002) Brazilian Energy Initiative. www.worldenergy.org/wecgeis/focus/wssd/goldemberg.pdf
Goldemberg, J., Coelho, S. T., Nastari, P. M., Lucon, O. (2003) "Ethanol
learning curve- the Brazilian experience", Biomass and Bioenergy, Vol 26/3
pp
301-304.
http://www.iee.usp.br/biblioteca/producao/2004/Artigos%20de%20Periodicos/
BiomassandBioenergyVolume26.pdf
Goldemberg, J (2004) The case for renewable energies. Renewables 2004
Conference,
Bonn,
http://www.renewables2004.de/pdf/tbp/TBP01rationale.pdf
EPA (2005) IRIS - Integrated Risk Information System: Acetaldehyde (CASRN
75-07-0) http://cfpub.epa.gov/iris/quickview.cfm?substance_nmbr=0290
EPA (2005) IRIS - Integrated Risk Information System: Formaldehyde
(CASRN
50-00-0)
http://cfpub.epa.gov/iris/quickview.cfm?substance_nmbr=0419 .
IEA (2004) Biofuels for Transport - An International Perspective. International
Energy Agency, ISBN 92-64-01512-4
International Energy Agency (2003) Energy Statistics Of Non-OECD
Countries, 2000-2001 - II.9
IPCC (2001) Third Assessment Report (TAR) "Climate Change 2001"
http://www.ipcc.ch/activity/tar.htm and http://www.ipcc.ch/pub/online.htm
Macedo, I.C.; Leal, M.R.L.V. and Siflva, J.E. A.R (2004) Assessment of
greenhouse gas emissions in the production and use of fuel ethanol in Brazil.
So
Paulo
State
Environment
Secretariat.
Also
at
www.unica.com.br/i_pages/files/pdf_ingles.pdf
Macedo, IC (2005) Evoluo e Perspectivas do Etanol. Seminar Brazilian
Experience with Ethanol Fuel, CEPAL - S. Paulo, 15-19 Aug
Magnetti Marelli (2005) Personal communication to Olimpio Alvares Jr,
CETESB
Mnsson, T., Clean Vehicles with Biofuel - A State of the Art Report, KFBReport 1998:18, Sweden, 1998.
Ministry of Agriculture, Livestock and Food Supply - Secretariat of Production
and Agrienergy (2005) Sugar and ethanol in Brazil, Brasilia - July 2005
26
28
ANNEX
HC
(g/km)
(g/km) (g/km)
(g/km)
(g/km) (km / l )
0.40
0.11
0.12
0.004
194.0
11.2
0.77
0.16
0.09
0.019
183.0
7.5
0.50
0.05
0.04
0.004
210.0
10.3
0.51
0.15
0.14
0.020
200.0
6.9
NA
NA
NA
Fuel
Gasohol
dedicated
(E22)
Ethanol
dedicated
(E100)
NOx
Aldehydes CO2
Autonomy
Table 1. Average emission factors for 2003 light vehicle models (1.6 and
1.8 liters) in Brazil. Source: CETESB, 200420
20
Weighed average by production volume, according to Brazilian standard NBR 6601. In 2003, for gasohol models
1.0 l engines are dominant; for ethanol, from 1.0 to 1.8 l. In 2004, for gasohol models there are engines between 1.0 l
and 2.0 l; for ethanol, 1.0 l. In flex-fuel vehicles, engines from 1.6 e 1.8 l are dominant. Part of the production was
tested with gasohol and the other part with neat ethanol. The largest differences due to engine size were observed in
CO2 emissions. Gasohol for tests: blend of 78 % gasoline and 22 % anhydrous ethanol (v/v). Emission tests were
performed according to the FTP 75 procedure.
29
21
CETESB (2003) obtained in 1993 the concentration ratio acetaldehyde/formaldehyde based on ambient air
monitoring data. The results were in the range of 1.7-1.8 and in 1996/1997, 1.6-2.1. Comparing these figures to the
typical values encountered in Los Angeles, Atlanta and Chicago (0.18 - 0.96), the higher concentrations of
acetaldehydes were observed in So Paulo due to the intensive ethanol use as an automotive fuel. It must be
emphasized that during this monitoring campaign period, only a very small portion of the Brazilian light-duty fleet was
equipped with catalytic converters - which help significantly in the reduction of aldehydes emissions.
22
Compressed Natural Gas
30
31