Ethanol production from lignocellulosic materials is often conceived considering independent, stand-alone production plants; in the Brazilian scenario, where part of the potential feedstock (sugarcane bagasse) for second generation ethanol production is already available at conventional first generation production plants, an integrated first and second generation production process seems to be the most obvious option. In this study stand-alone second generation ethanol production from surplus sugarcane bagasse and trash is compared with conventional first generation ethanol production from sugarcane and with integrated first and second generation; simulations were developed to represent the different technological scenarios, which provided data for economic and environmental analysis. Results show that the integrated first and second generation ethanol production process from sugarcane leads to better economic results when compared with the stand-alone plant, especially when advanced hydrolysis technologies and pentoses fermentation are included.

Much of the controversy surrounding second generation ethanol production arises from the assumed competition with first generation ethanol production; however, in Brazil, where bioethanol is produced from sugarcane, sugarcane bagasse and trash will be used as feedstock for second generation ethanol production. Thus, second generation ethanol production may be primarily in competition with electricity production from the lignocellulosic fraction of sugarcane. A preliminary technical and economic analysis of the integrated production of first and second generation ethanol from sugarcane in Brazil is presented and different technological scenarios are evaluated. The analysis showed the importance of the integrated use of sugarcane including the biomass represented by surplus bagasse and trash that can be taken from the field. Second generation ethanol may favorably compete with bioelectricity production when sugarcane trash is used and when low cost enzyme and improved technologies become commercially available.

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The majority of current sugarcane mills in Brazil are annexed plants, producing both ethanol and sugar; the other plants are dedicated only to ethanol production (autonomous distilleries). This study focuses on the technical, environmental, and economic impacts of these first generation sugarcane processing facilities in Brazil using an innovative framework, the so called Virtual Sugarcane Biorefinery. Results showed that optimization technologies presents potential for reducing environmental impacts and improve economic results in comparison to base scenarios for both annexed and autonomous plants. It was also observed that annexed plants that diverted more sugarcane juice for sugar production were more profitable, considering the average prices for the past 10 years in Brazil. In addition, results indicate that scenarios considering more flexibility in annexed plant are more profitable than the conventional annexed one (diverting 50% of the sugarcane juice to sugar and 50% to ethanol production) if increases in prices were to occur. This study shows quantitatively the benefits of optimization techniques and allows understanding the real benefits of the sugarcane plant flexibility in the Brazilian context.

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