Technology Development in Bioethanol Production in Indonesia

Wahono Sumaryono Deputy Chairman of BPPT for Agroindustry dan Biotechnology

The Asian Science and Technology Seminar Japan Science and Technology Agency (JST)-BPPT Jakarta, March, 8-9, 2007
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Presidential Regulation No. 5/2006

National Energy Policy

Promoting utilization of renewable source of energy: biofuels, solar energy, wind energy, ocean wave and current energy, geothermal etc. Energy efficiency and conservation. Optimalization on energy production Reduction of subsidy on fuel price Reduction of energy elasticity.

objectives Domestic Energy Supply Security goals 1. 2. Energy Elasticity from 1.84 (2006) to < 1 by 2025 Optimized primary Energy Mix by 2025, consisting of:

Petroleum < 20% Natural gas > 30% Coal > 33% Biofuels > 5% Other new & renewable energy > 5% (biomass, hydro, solar, wind, nuclear) 2 Liquified Coal > 2%

PROJECTED BIOFUEL CONSUMPTION (Mio KL) BIOETHANOL 2006 2007 2008 2009 2010 1,71 1,75 1,78 1,82 1,85 BIODIESEL 2006 2007 2008 2009 2010 1,19 1,20 1,22 1,23 1,24 BIO-OIL 2006 2007 2008 2009 2010 0,37 2,43 4,71 4,77 4,82

Source : Dept. of Energy & Mineral Resources, 2006

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THE PRODUCTION OF ETHANOL IN INDONESIA 2000 - 2006

Year 2000 2001 2002 2003 2004 2005 2006

THE EXISTING CONDITION

Productions of ethanol (KL) 110 000 125 000 125 000 130 519 132 000 175 000 176.000

Increase (%) 13.64 0 4.42 1.54 32.58 0.55

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Estimated Potential Land for Sugarcane Outside Jawa

(In addition of existing plantation)
No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Location South Sumatra North Sumatra Middle Kalimantan East Kalimantan South Sulawesi North Sulawesi Middle Sulawesi South-east Sulawesi Maluku West Nusatenggara East Nusatenggara Irian Jaya Total Area (Ha) Bruto 55 000 18 450 200 847 65 000 36 000 219 375 90 300 104 300 441 500 51 900 32 500 750 000 2 065 172 Netto 33 000 15 454 36 017 39 000 13 000 95 700 54 200 64 000 253 200 36 500 21 000 500 000 710 829
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Note : Existing Sugarcane Plantation : 391.000 Ha ~2,3 Mio Tons Sugar

Estimated Potential Land for Cassava Plantation

(in addition of existing plantation)
NO. 1 2 3 4 5 6 7 8 9 10 11 12 PROVINCE North Sumatera South Sumatera West Sumatera Lampung Central Java West Java East Java Yogyakarta East Nusa Tenggara South Sulawesi North Sulawesi East Kalimantan Total AREA (Ha) 23.000 37.000 19.500 47.000 29.000 42.000 33.000 9.500 25.000 38.000 33.000 18.000 336.000 PROJECTED PRODUCTION (Tons/year) 575.000 925.000 487.000 1.175.000 750.000 1.050.000 825.000 237.000 625.000 950.000 630.000 396.000 8.400.000 Potential Bioethanol Production (KL/year) 88.400 142.300 75.000 180.700 115.000 161.500 126.900 34.500 96.000 146.100 126.900 60.900 1.292.308
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Note : Existing plantation of cassava : 811.422 Ha ~ 13,28 Mio tons cassava

Average Productivity
No 1 2 3 4 5 6 Type of Raw Material Cassava Corn Sorghum Sweet potatoes Sago Sugarcane Harvesting (Months) 10 3,5-4 3,5-4 4 96 10 Productivity (Tons/Ha) 25 8 4,5 20 30 80 1x Freq of Harvesting Per Annual 1x 2x 3x 2x

Raw Material Balance in Bioethanol Production

NO 1 2 3 4 5 6 7 RAW MATERIAL Sugarcane Molasse Cassava Corn Sorghum Sweet potatoes Sago WEIGHT (Kg) 15 4 6,5 2,5 2,8 8 12 BIOETHANOL (L) 1 1 1 1 1 1 1
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Source : Research Center for Starch Development, BPPT, Lampung

Biofuels Implementation program

Self consumption
State Own Agricultural Co. (Palm Oil, Sugarcane, Jatropha, Cassava) Energy Selfsufficiency Village Government Driven Intended Investors: Specific Biofuels Zone, Big Plantation Palm Oil, Sugarcane, Cassava, Jatropha

Nat.Electrical Company

PLN

Biofuels Program

Target of

Export

2007-2025

Pertamina
Transportation industry
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Household

FLOW PROCESS IN BIOETHANOL PRODUCTION

Sugar STARCH LIGNOCELLULOSIC

ENZYME STEAM

LIQUIFACTION OF COOKING

PRETREATMENT

STEAM ENZYME ACID

ENZYME

SUCCHARIFICATION (HYDROLYSIS)

SACCHARIFICATIO N (HYDROLYSIS)

ENZYME ACID

MICROBES CELL

FERMENTATION 7 PURIFICATION

BIOETHANOL

STILLAGE

ANAEROBIC DIGESTER

FERTILIZER

BIOGAS

COMBUSTION

FLOW DIAGRAM BIOETHANOL PRODUCTION USING DIFFERENT RAW MATERIAL

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EQUIPMENT IN BIOETHANOL PRODUCTION

FERMENTATION

DEHYDRATION UNIT

MASHING UNIT

HYDROLISIS UNIT

UNIT DISTILLATION DISTILASI UNIT

CASSAVA

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Material Balance in Production of 8 KL FGE

Amylase Enzyme : 7 kg alpha-amylase 28 kg glucoamylase 14 tons sugar Slurry of Cassava Temp 90 C Hydrolysis Process (Glucose) Volume 90 KL Fermentation Process

50 tons cassava (14 tons starch)

Cassava

Raw Material Treatment

8 KL FGE Bioethanol 10 % Distillation Process Bioethanol 95-96 % Dehydration Process

FGE (99,5%)
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SEED IMPROVEMENT
1. Selective breeding, occulation (Cassava) 2. Radiation, selective breeding (Sorghum) 3. Selective breeding, biotech approach (Sugarcane)

Cassava Balitkabi (Res. Center for Peanuts-Cassava & Related Species-Dept of Agriculture)

Sugarcane P3GI (Res. Center for Sugarcane)

Sweet-stem Sorghum 1. BATAN (Radiation) 2. Res. Center for Cereals (Maros, South Sulawesi

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CULTIVATION IMPROVEMENT
Cassava Sugarcane Sweet-stem Sorghum

Average Nat. Prod. 16 18 tons/ha Res. Center for Starch Dev. ~25 tons/Ha Balanced fertilizer (in org + org) Current : 28,5 tons/ha Target : 35-40 tons/Ha

Average Nat. Prod. 79 80 tons/ha (State owned Co. & and private companies in Java, Lampung)

Demplot : 14 cultivars

Current : 90 tons/ha Target : 120 tons/Ha

Target : 8 tons/Ha

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Pre Treatment Optimization

(Hydrolysis process)

Existing :
Raw material Sugarcane Starch groups Acid (hydrolysis) Enzymatic (saccharification)

Projected :
Liqnocellulosic mat. (woody biomass) Mechano-chemical Treatment Hydrothermal treatment Separation Enzymatic (saccharification)

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Production of Bioethanol Using Liqnocellulosic Material

Acid Hydrolysis

Ethanol

Fermentation
Glucose (yeast)

Woody Biomass
Size reduction

glucose
T : 200 C, H2SO4 3% 10-15 min. Xylose (new microbe)

Xylose

Problem : Chemical bounding between cellulose, hemicellulose and lignine

is very difficult to be hydrolized using enzymatic approach (expensive). The microbes (yeast) is able to ferment glucose (C6) to be ethanol, but not able to convert xylose (C5) and others C5 sugars as hydolized product of fibers exploring others microbes.

Lignine + Waste
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ETHANOL FROM THE WHOLE PLANT OF SUGARCANE

DRY LEAVES

BAGASSE

JUICE

MOLASSES

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Biomass Source (2005)

Palm Oil Mills : Fruits shell ~ 5.06 Mio Tones (~ 4220kcal/kg dry weight) Empty Fruits Bunch ~ 16.06 Mio Tones (~ 3700 kcal/kg dry weight) Rice Mills : Rice Husk ~ 13.5 Mio Tones Sugar Mills : Bagasse ~ 36.7 Mio Tones Wood-based Industries > 50 Mio Tones Other Agricultural residues

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Fermentation Process
Strain Improvement
Current capacity of utilized strain : resistent up to 11 - 12% ethanol
Gradual adaption Genetic engineering

Target : ~ resistent up to 14% ethanol

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DISTILLATION OPTIMIZATION Existing : 2 Steps distillation

Ethanol 40%

95-96% Column Distillation 95 96%

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Projected : Membrane
Filtration Ethanol 40%

DEHYDRATION METHOD FOR BIOETHANOL (Leading to FGE 99,5 %)

- Azeotropic Distillation : operational cost is high, need solvent - Molecular Sieving : operational cost is low, no need solvent : operational cost is low, applied in pilot scale (to be developed into commercial scale)
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- Membrane Filtration

PROFILE OF ENGINE PERFORMANCE USING DIFFERENT FUEL

Parameters Power (kW) Force (N) Fuel Consumption (L/jam) Octane number Gasohol E-10 41,23 1856,1 30,39 91 Gasohol E-20 42,52 1913,3 31,24 94 Premium 30,97 1393,8 31,03 87 Pertamax 40,09 1804 27,38 94

Tested by Lab. for Thermodynamics & Motor Propulsion, BPPT

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PROFILE OF EMISSION TEST USING DIFFERENT FUEL Parameter CO (g/km) THC (g/km) Nox (g/km Premium Gasohol E-10 Pertamax 5.00 0.38 1.28 3.10 0.33 2.04 5.77 0.40 2.00

Premium : Pertaminas gasoline Gasohol E-10 : Premium 90% FGE 10% Pertamax : Premium + additive

Tested by Lab. for Thermodynamics & Motor Propulsion, BPPT

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