Sugarcane: Agricultural Production, Bioenergy and Ethanol PDF
Preview Sugarcane: Agricultural Production, Bioenergy and Ethanol
Sugarcane Agricultural Production, Bioenergy, and Ethanol Sugarcane Agricultural Production, Bioenerg y, and Ethanol Edited by Fernando Santos Universidade Estadual do Rio Grande do Sul, Porto Alegre, RS, Brazil Alu´ızio Bor´em Universidade Federal de Vi¸cosa, Vi¸cosa, MG, Brazil Celso Caldas Central Anal´ıtica LTDA, Maceio, AL, Brazil AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON NEWYORK(cid:129)OXFORD(cid:129)PARIS(cid:129)SANDIEGO SANFRANCISCO(cid:129)SINGAPORE(cid:129)SYDNEY(cid:129)TOKYO AcademicPressisanimprintofElsevier AcademicPressisanimprintofElsevier 125,LondonWall,EC2Y5AS. 525BStreet,Suite1800,SanDiego,CA92101-4495,USA 225WymanStreet,Waltham,MA02451,USA TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UK Copyrightr2015ElsevierInc.Allrightsreserved. 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ForInformationonallAcademicPresspublications visitourwebsiteathttp://store.elsevier.com/ TypesetbyMPSLimited,Chennai,India www.adi-mps.com PrintedandboundintheUSA List of Contributors Wellington Sacco Altran Ra´ızen (cid:1)Unidade Gasa,Andradina (cid:1)SP, Brazil Ma´rcio Henrique PereiraBarbosa Federal University ofVic¸osa, Vic¸osa,MG, Brazil Thales Velho Barreto VelhoBarretoInc.andECO,TechnologyandIndustrialEquipmentInc,Brazil Alu´ızio Bore´m Universidade Federal de Vic¸osa, Vic¸osa, MG, Brazil Jose´ Bressiani Canaviallis, Maceio, AL, Brazil Celso Caldas Central Anal´ıtica LTDA, Maceio, AL, Brazil ClaudioSoares Cavalcante CSC Engenharia, Campinas, Sa˜o Paulo, SP, Brazil AntoˆnioCarlos Duarte Coelho Federal Universityof Pernambuco,Recife, PE, Brazil Aline Carvalho da Costa School of ChemicalEngineering, State University ofCampinas, Campinas, SP, Brazil AntoˆnioAlberto da Silva Universidade Federal de Vic¸osa, Vic¸osa, MG, Brazil AlexandreFerreira da Silva Embrapa Milho eSorgo,Sete Lagoas, MG, Brazil Lu´ıs Cla´udio Ina´cio da Silveira Federal University ofVic¸osa, Vic¸osa, MG, Brazil Fernando Medeiros de Albuquerque F. Medeiros Consultoria, Recife, PE, Brazil Leonardo Angelo deAquino Federal Universityof Vic¸osa, Vic¸osa, MG, Brazil Francisco de Assis Dutra Melo Universidade Federal Rural dePernambuco, Recife, Pernambuco, PE, Brazil MariaBernadete S. de Campos UniversidadeFederaldeSa˜oCarlos,UFSCAR,Sa˜oJoa˜oDelRei(cid:1) MG,Brazil PedroHenrique de Cerqueira Luz UniversidadedeSa˜oPaulo,Pirassununga(cid:1)SP(cid:1)FZEA(cid:1)USP VictorFrancisco Arau´jo de Medeiros Barbosa Universidade Federal de Vic¸osa, Vic¸osa, MG,Brazil Rubens Alves de Oliveira Federal Universityof Vic¸osa, Vic¸osa, MG, Brazil WilliansXavier de Oliveira Fundac¸a˜o Getu´lio Vargas, Sa˜oPaulo, SP, Brazil Se´rgio de Oliveira Proco´pio Embrapa Tabuleiros Costeiros, Aracaju, SE, Brazil Joa˜o Nunes deVasconcelos Federal Universityof Alagoas, Maceio´, AL, Brazil Ronaldo Medeiros dosSantos University ofBrasilia, Bras´ılia, DF,Vic¸osa, MG, Brazil Valdir Diola Department ofPlant Physiology, Universidade Federal de Vic¸osa, Brazil; In memoriam Jorge A.Doe Texas A&M University,College Station, TX, USA xix List of Contributors LuizCarlos C.B. Ferraz Universidade deSa˜o Paulo, ESALQ, Sa˜o Paulo, SP, Brazil Evander Alves Ferreira Universidade Federal dosVales do Jequitinhonha eMucuri,Diamantina, MG, Brazil Ivo Fouto AGN Bioenergy, Sa˜o Paulo, SP, Brazil Leandro Galon Universidade Federal daFronteira Sul, Erechim, RS, Brazil Jose´ MarinaldoGleriani Universidade Federal de Vic¸osa, Vic¸osa, MG, Brazil DaniellaMacedo Imaflora, Piracicaba, SP, Brazil Newton Macedo Imaflora, Piracicaba, SP, Brazil Walter Maccheroni AGN Bioenergy,Sa˜o Paulo,SP, Brazil Fernando Bomfim Margarido Santelisa Vale, Brazil Paulodo CarmoMartins Federal Universityof Juiz deFora, Juiz deFora, MG, Brazil Sizuo Matsuoka VignisS.A., Santo Antonio dePosse, State of Sa˜o Paulo, Brazil WilsonR.T. Novaretti Federal UniversityofJuiz de Fora, Juiz de Fora, MG,Brazil Ange´lica Maria Patarroyo Universidade Federal de Minas Gerais, Belo Horizonte, MG, Brazil Sarita Caˆndida Rabelo BrazilianBioethanolScienceandTechnologyLaboratory—CTBE/CNPEM, Campinas,SP,Brazil Ma´rcioMota Ramos Federal Universityof Vic¸osa,Vic¸osa, MG, Brazil Marco Lorenzzo Cunali Ripoli John Deere (cid:1)Latin America, Indaiatuba, SP, Brazil TomazCaetanoCannavam Ripoli Universidade deSa˜oPaulo (cid:1)Escola Superior deAgricultura “Luiz deQueiroz”, Sa˜o Paulo, SP, Brazil; In memoriam Fernando Santos Universidade Estadual do RioGrande do Sul, Porto Alegre, RS, Brazil Carlos AlbertoAlves Varella FederalRuralUniversityofRiodeJaneiro,RiodeJaneiro,RJ,Brazil Carlos Eduardo Vaz Rossell Brazilian Bioethanol Science andTechnology Laboratory—CTBE/ CNPEM,Campinas,SP, Brazil Godofredo Cesar Vitti Universidade de Sa˜o Paulo, Piracicaba (cid:1)SP (cid:1) ESALQ (cid:1)USP xx Foreword Sugarcane crops have been established in Brazil since nearly five centuries ago. At that time, sugar cane brandy and brown sugar were special products. For almost a century, Brazil has had cars fueled by ethanol and has been an important player in world sugar production and exports. However, in the last 35 years the industry experienced its most impressive leap in production and productivity, based on absolutely spectacular technological progress. The Proa´lcool Program, the largest program on energy alternatives resulting from the seventies’ “oil shocks”, conferred a new face to the sugarcane production chain. Soon after, the introduction of the Program for Sugarcane Payment by Sucrose Contents produced one of the greatest technological revolutions of 20th century agribusiness: new varieties were developed, as well as different cropping practices, planting and harvesting dates, fertilizer formulas, everything changed; mechanization evolved greatly, and techniques were vigorously implemented in all segments of the agricultural industry. All such advancements made Brazil become, in a sustainable and highly competitive manner, the world’s largest exporter of sugar and ethanol. The prospects for the future are even more promising: the so-called “green economy”, so widely used by the world’s greatest leaders, opens up amazing opportunities for agroenergy, whether for biofuels, bioelectricity, or for bagasse pellets as an alternative to firewood in the fireplaces of cold countries. All of these topics are well addressed in this timely and notable book. At this moment in history, when global warming represents a major challenge, the role of the sugarcane production chain transcends national boundaries. However, there is a concerning aspect: the lack of coordination among sector policies, both in the public and private spheres. So far, we have not defined the amount of ethanol we should or want to produce, in what period of time, and for which market (cid:1) internal or external? There are no long-term contract models. xxi Foreword We have not defined who will be in charge of logistics, storage, production contracts, or final product certification. There is no liaison between the areas of technological development and human resources training. Nothing is defined as to the future of hydrated ethanol. Nothing is organized on the issue food3energy, a ridiculous theme that still gets media attention because of minor interests of other sectors. The production system, so well described by Barbosa Lima Sobrinho in the Sugarcane Production Statute in the forties, turned to dust with IAA’s end. Sugarcane suppliers, who “deliver” their production to plants, and do not sell it, are in an extremely awkward position in terms of links in the production chain, since they cannot choose who they sell to: they can only sell to industries nearby their agricultural area. This renders the production chain uneven. In addition, since the end of IAA, the process lacks arbitration, even though Consecana is a good beginning. Finally, in such a promising segment for Brazil, at such an important time, this lack of coordination may inhibit the country’s progress, even as regards leading a global geopolitical shift, with the exportation of technology to poor tropical countries in Latin America, Africa, and Asia for them to produce agroenergy associated with food. For all this, we welcome the publishing of this enlightening book, written by some of the foremost experts in each of the topics addressed. Dr. Roberto Rodrigues Former Secretary of Agriculture xxii Preface Sugarcane is native to the warm temperate to tropical regions of South Asia, and is used for sugar, ethanol and spirit production. Sugarcane is the world’s largest crop by production quantity. In 2014, the FAO estimated that it was cultivated on about 29.0 million hectares, in more than 90 countries, with a worldwide harvest of 1.84 billion tons. Brazil was the largest producer of sugar cane in the world. The next five major producers, in decreasing amounts of production, were India, China, Thailand, Pakistan and Mexico. Caneaccountsforover80%ofsugarproduced;mostoftherestismadefromsugarbeets. Sugarcanepredominantlygrowsinthetropicalandsubtropicalregions,andsugarbeet predominantlygrowsincoldertemperateregionsoftheworld.InIndia,betweenthesixthand fourthcenturiesBC,thePersians,followedbytheGreeks,discoveredthefamous“reedsthat producehoneywithoutbees”.Theyadoptedandthenspreadsugarandsugarcaneagriculture. Afewmerchantsbegantotradeinsugar(cid:1)aluxuryandanexpensivespiceuntilthe18th century.Beforethe18thcentury,cultivationofsugarcanewaslargelyconfinedtoIndia. Sugarcaneplantations,likecottonfarms,wereamajordriveroflargehumanmigrationsinthe 19thandearly20thcenturies,influencingtheethnicmix,politicalconflictsandcultural evolutionofvariousCaribbean,SouthAmerican,IndianOceanandPacificislandnations. Sugarcane became an even more important crop with the importance of bioenergy in today’s society. Bioenergy is renewable energy made available from materials derived from biological sources and sugarcane is currently the major source of biofuel. The Brazilian sugarcane industry employs modern agronomic management practices to enhance productivity and protect the environment. In fact, Brazil is the leader in sugarcane production and research. Written by experts in each topic addressed, the intention is that this book will be used by new and advanced students, as well as serving as a reference book for those interested in the sugarcane crop and processing. Instructors are encouraged to select specific chapters to meet classroom needs. Readers will also benefit from the list of references that accompany each chapter. The Editors xxiii CHAPTER 1 Agricultural Planning Fernando Bomfim Margarido1 and Fernando Santos2 1Santelisa Vale, Brazil 2Universidade Estadual do Rio Grande do Sul, Porto Alegre, RS, Brazil Introduction Nowadays, management involves less risk than it used to. However, the responsibility involved is much greater, considering the technological processes surrounding an administrative decision. According to the classical definition, it could be said that managing means planning, organizing, directing and controlling. On the basis of this definition, planning means deciding in advance what should be done for a particular purpose to be achieved, namely, to maximize agricultural and industrial yield and, thus, profits. That is the starting point for good management. The sugar and ethanol sector in Brazil is going through one of its best periods. There has been significant change in the sector’s dynamics resulting in reduced competitiveness among industrial units, expansion of cultivated areas and adjustments in strategies adopted by companies. This chapter addresses planning through technical expertise aimed at operational practices. It is, therefore, a simplified view of planning. 1.1 Planning The main role of agricultural managers is to foment the activity. In simple terms, fomenting the agricultural activity means guaranteeing the supply of raw materials for the industry, which involves, in the case of sugarcane culture, agricultural production, soil conservation and preparation, planting, crop practices for cane-plants, harvesting, crop practices for the ratoon and supplying mills with raw material during the harvest period. Such supply relates not only to the total quantity of cane to be crushed over the harvest period, but also the constant hourly supply, involving the concept of logistics throughout the plantation, observing machinery size and personnel availability. The agricultural production system is relevant for strategic planning in industrial units, so as to anticipate production, storage and marketing of final products. Sugarcane.DOI:http://dx.doi.org/10.1016/B978-0-12-802239-9.00001-3 1 ©2015ElsevierInc.Allrightsreserved. 2 Chapter 1 According to Pinazza (1985), high productivity levels derive from four basic types of factors: physical, structural, institutional and development factors. Physical factors represent the edaphic and climatic conditions of a region and agricultural production. Institutional factors involve government action by means of implementation of agricultural policies. Development factors are related to the research system, and to what extent knowledge generates increased productivity. Structural factors refer to the management system adopted, and have a decisive influence on the strategic and operational performance of mills and distilleries. Agricultural planning observes industrial planning, therefore, the starting point is the amount one plans to process along the next three growing seasons. It is important to take into account that the agricultural sector requires planning at least 2 years ahead, since it is necessary to arrange partnership agreements, prepare the soil and wait for harvest time (cid:1) on average, the first cut is carried out 11/ years after planting. 2 1.1.1 Planning for Planting In agricultural planning, it is important to know the productive potential of the region vis-a`-vis climate, soil quality and resources available for production (use of vinasse, irrigation and fertilization). This information is especially necessary for the introduction of a new unit. When a unit is already in operation, one can look at productivity history over the last 5 or 6 years. Historical data older than 10 years are not pertinent, since varieties will not behave in the same way after such a period. The technical area is very important as, at this point, it is necessary to survey the amount of arable land available at the various properties, their productive potential, the opportunities to purchase raw materials in regional markets, the options of land renting or production partnerships; in addition, the technical area should analyze the edaphic zoning (per production environment), topography (feasibility of mechanical harvesting), climate characteristics in the region (temperature, rainfall, light, photoperiod, water balance, frost) and the region’s road system, anticipating the flow of production. In some cases, these factors make it unfeasible to locate a production unit in a particular area, for example, where high toll fees would increase transportation costs, or areas with a ban on sugarcane burning (as of 2012, in the State of Sa˜o Paulo) on slopes with over 12% gradient or with the presence of stones. It should be noted that, for sugarcane production in the past, soil fertility was the sole determinant of land value, but currently, topography and presence of obstacles in the area are also determining factors. Table 1.1 shows an example of a balanced sugarcane plantation, considering theoretical average productivity of the site and areas with equal size in each category of cutting. Table 1.2 considers that first cut sugarcane has been used for planting and that 1ha produces seedlings to plant 7ha. It should be noted that, in this case, the area where the first cut took place was smaller.
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