Original title: Cana-de-açúcar: 2021 por Pontal, Marcos.
de
vilão
a
herói!
ISBN: 9798547795282 The contents of this book may be reproduced only with the disclosure of the source. Cover: Marcos Alexandre Machado (Marcos Pontal). Author's review: Marcos Alexandre Machado and Roseli Laurência Souza Machado.
Rua Fernando Costa, 278 — Vila Adelaide de Freitas 14180 - 000 - Pontal - SP Tel.: (16) 3953-2844 - Watsaap: +551698107-9175 E-mail: marcosmachado@visaoespiritual.com.br Website: www.velivros.visaoespiritual.com.br
SUMMARY
Preface.............................................................................4 Sustainable products........................................................5 Biodegradable plastic.....................................................14 Asphalt...........................................................................19 Power supply..................................................................23 Sugar is bad for your health...........................................28 Generation of energy from sugar....................................31 Avoid cracks in the concrete......................................... 33 Bagasse used in fiber cement........................................38 Hybrid car.......................................................................42 Cadmium adsorption .....................................................49 Ash for soil liming ..........................................................54 Bagasse can clean contaminated water.........................57 Electric energy from vinasse..........................................63 Sugar used to temper the wall........................................73 Afterword........................................................................77 Acknowledgments..........................................................78 About the author.............................................................79 Bibliography....................................................................80
PREFACE – 4
PREFACE For many years, sugarcane was seen as the villain of the environment, because they burned sugarcane, thus harming the environment and even the surrounding residents. Since if the cane cutters cut it without burning it, it would hurt, that's why all the mills burned the cane. With the arrival of the harvesters and also with the law prohibiting fires, this has changed a lot. In times of drought, then, there are some burnings, as it is difficult to inspect all the sugarcane fields in Brazil. Read this book and discover that sugarcane can have many uses that most of the time is not being used. It is not just to produce sugarcane, ethanol, bioplastics and bioelectricity, the products that use sugarcane as raw material are expanded every day. The novelty in the market is the production of cellulosic pulp for paper.
SUSTAINABLE PRODUCTS
SUSTAINABLE PRODUCTS – 6
Before the law that prohibited the burning of sugarcane, fires released approximately (64.8) million tons of carbon dioxide into the atmosphere each year, which contributes to the decrease in air quality and the increase in the greenhouse effect. In Brazil, with the ban on husking sugarcane (January 2018), mechanized harvesting of raw sugarcane is observed, where straw provides better industrial quality of sugarcane, greater protection of the soil against erosion, better retention of soil moisture, greater microbial activity in the soil and its enrichment in organic matter and weed control, with and suspension of the burning operation, have a lower environmental impact. But even so, many still curse mill owners when there are fires in dry periods, but as it is in this book, it is proven that fires harm mill owners, so it would not make sense to burn it, as there are fires even in small canes that would not be ready for milling. Thus, with the end of legalized burning, in the end, everyone gained, the population in general and the mills. Sugarcane is known for its peculiar characteristics,
SUSTAINABLE PRODUCTS – 7
being a thin plant with a cylindrical shape, large leaves and can reach up to six meters in height. The mills that work with sugarcane take advantage of everything from the plant, and you will find out more by reading this book. Brazil is the largest sugarcane producer and ranks first in the sugar production ranking and is the largest ethanol exporter in the world. The possibilities are huge to create sustainable products based on the bioeconomy and circular economy with sugarcane. Several companies have been doing their part to make even more use of sugarcane, an example of this is Ella Bulley, a materials explorer and multidisciplinary designer trained at the Central Saint Martins School of Art and Design, which is headquartered in London . She has united sugarcane with traditional crafts and production techniques with an approach innovative and stunning. With her instigating Saccharum project, she transforms sugarcane into a marble-like material, in bowls, vases and various dishes, and also created a beautiful corrugated fabric made from sugarcane cellulose, which
SUSTAINABLE PRODUCTS – 8
encouraged the group to develop eco-packaging. The process of transforming the raw material into boxes is carried out as follows: first, the sugarcane bagasse undergoes drying in ovens to be later sieved. After removing the smaller particles, the bagasse is crushed. To this material, a castor oil-based resin is added. The resin agglomerates the particles and forms a mixture that, when placed in molds, allows the production of panels. From the cane bagasse panels, packaging for the transport of food and beverages is made. The synthetic fabric called Ingeo, created by the company Nature Works, is made using dextrose and sucrose found in sugarcane. Using biotechnology, Ingeo was developed in partnership with to Cargill and Dow Chemical. The raw materials are made by fermenting sugar extracted from sugar cane and then converted into fiber to create tissue. When a garment made from 100% Ingeo ends up in a landfill, the garment will decompose in 60 to 90 days. There is also the company “Nature Works” which launched the Ingeo 3D850 PLA filament for 3D printing,
SUSTAINABLE PRODUCTS – 9
which offers heat and impact resistance rivaling ABS. PLA (polylactic acid) is a biodegradable polymer made from sugarcane, which has gained popularity in the 3D printing industry as it is biodegradable. Sugarcane fiber isn't used much in textiles, but in the denim world, it's impossible to ignore what Japanese company Toyo Industries has been doing for years in its Sugar Cane & Co brand. The premium jeans brand produces its collections of pants, jackets, shirts and other products with 50% sugarcane fibers and 50% cotton fibers. At two fibers are joined to weave the denim on a hand loom that had its design inspired by the old looms Japanese crafts from 50 to 100 years old. It is also possible to combine sugarcane residues, such as bagasse and straw, with derivatives of shrimp and lobster shells for the manufacture of materials with high added value. Incorporating drugs and enzymes for medical applications such as dressings for wounds and pressure ulcers. I work in a mill and when I had little scratches due to my carelessness, I placed the bagasse on top of the wound,
SUSTAINABLE PRODUCTS – 10
and there was an improvement. from the plant, thus proving that it is even possible to clean dirt from grease, which is normally removed only with the use of other products. The idea of using the same cellulose to obtain textile fibers for applications in the medical field, which had healing and bactericidal properties. Another way to use products made from sugarcane is what was discovered by the Italian manufacturer of mannequins Bonaveri, who launched the world's first biodegradable mannequin called BNATURAL made from Bplast, a PLA biopolymer containing 72% sugarcane, and BPaint, a range of colors produced 100% from plantbased oils and resins natural, orange peel solvents, and desiccant and naphtha free cobalt salts. Bonaveri partnered with Politecnico di Milano to overcome the challenge of creating the first mannequin made of natural and biodegradable materials that was environmentally conscious and aesthetically flawless. The survey has been carried out since 2012. In Lençóis Paulista, in the interior of São Paulo, the
SUSTAINABLE PRODUCTS – 11
company FibraResist was the first in the world to transform sugarcane straw into paper. The company innovated by looking for wood pulp substitutes using a very Brazilian material: cellulosic pulp, extracted from sugarcane straw. It was six years in trying to produce the material. The concern for the environment starts right from the farm. In plantations, sugarcane is not fully harvested. About 20% of it remains in the soil for nutrient replenishment.
The
rest
manufacturing
process,
goes which
to
an
initially
innovative consists
of
cleaning and crushing the straw. Next, a biodispersant is added to separate the lignin (natural glue from the straw). After a last hydration, the material is transformed into cellulosic pulp. This cycle was fully developed by the company and based on a system that avoids wasting water, the production of residues and air pollution. The green polyethylene I’m greenTM is the result of the combination innovation, technology and sustainability. After
a
few
development,
years
dedicated
Braskem's
green
to
research
ethylene
and
plant,
SUSTAINABLE PRODUCTS – 12
inaugurated in September 2010, marked the beginning of the production of green polyethylene on an industrial and commercial scale, making the company world leader in the biopolymers market. The company Tetra Pak, the world leader in carton packaging for food, has entered into an agreement with Braskem for the supply of low-cost polyethylene density (LDPE) I’m greenTM made from sugarcane, to compose the protective layers of your packaging as well as the lid. Since 2014, Tetra Park has been using green plastic as a component of its packaging layers produced in Brazil. The switch to green polyethylene means that 100% of Tetra Pak packaging produced in Brazil, around 13 billion, are made up of around 82% of materials from renewable sources. Coca-Cola has also done its part, launched a pioneering bottle made of 100% plastic from sugarcane. In other words, petroleum-derived plastic was left behind. The packaging of the "PlantBottle" according to the company, looks like the traditional ones. The recycling system is also the same, but plastic made from sugarcane and not
SUSTAINABLE PRODUCTS – 13
oil has a much smaller “environmental footprint”. The company's goal is to exclusively produce and use PlantBottles by 2020. PlantBottle's polyethylene made from sugarcane ethanol was developed by Braskem and is now being recycled in new materials for Ford Fusion Energi cars. The automaker Ford is taking advantage of Coca-Cola bottle technology to use inside its vehicles. The plastic fibers from PlasticBottle bottles were transformed into seat backs, seats, head rests, panel details.
BIODEGRADABLE PLASTIC
BIODEGRADABLE PLASTIC – 15
Nowadays, with the population's lack of awareness, several rivers are full of garbage, which ends up contaminating rivers and thus harming fishing, since garbage ends up killing fish in the rivers, so we have to think of a solution to avoid as much as possible that garbage remains in the rivers. Some people even clean the rivers, but even so, we need a faster solution, as plastic made from “oil” takes over 200 years to decompose. The company PHB Industrial brings a solution to this problem, it produces Biocycle, a biodegradable plastic made with sugar, on a pilot scale. Despite mastering the technology to manufacture several products with the polymer and to make its cost competitive when compared to conventional plastic, the company has not yet managed to increase its production to an industrial scale. The shortest way to bring Biocycle to market would be a partnership with the petrochemical industry, but they were not interested in the partnership. When we talk about the environment, we have to leave competition aside, it's not just a matter of money, it's a
BIODEGRADABLE PLASTIC –
16
matter of health, something that even money can't buy. Entrepreneurs in the petrochemical sector need to understand that we must do something to improve our quality of life, and for that, we have to invest more in plastics made from sugarcane or other raw materials that decompose quickly . Through a partnership with the Institute of Technological Research (IPT) and the Institute of Biomedical Sciences (ICB) of the University of São Paulo (USP), Copersucar managed to produce polyhydroxybutyrate (PHB), a polymer from the polyhydroxyalkanoate (PHA) family ) with physical and mechanical characteristics similar to those of synthetic resins such as polypropylene using only sugar fermented by natural bacteria of the alkali genus. In 1994, a pilot plant was installed at Usina da Pedra, in Ribeirão Preto, SP. In 2000, PHB Industrial was created and the technology belonged to the Grupo Pedra Agroindustrial, from Serrana, and Grupo Balbo, from Sertãozinho/SP. With support from FAPESP through the FAPESP
BIODEGRADABLE PLASTIC – 17
Innovative Research in Small Businesses Program (PIPE) and with the help of researchers from the Federal University of São Carlos (UFScar), the company developed the technology for the production of pellets, small cylindrical pellets made with a mixture of PHB and natural fibers, a raw material used by the manufacturing industry to produce plastic utensils. The technique of mixing PHB with vegetable fibers did not bring any cost reduction advantage. While a kilo of polypropylene costs around US$ 2, a kilo of PHB costs around US$ 5, thus making it difficult to sell the product. PHB is a hard material that can be used in the manufacture of injected and thermoformed parts, such as bottle caps, pens, toys and food or cosmetic jars. It can also be applied in the extrusion of sheets and fibers to serve the automotive industry. It is still used for production foams that replace styrofoam, which in this case is little recycled, since styrofoam is light and ends up not being much sought after by recyclable material collectors and not even junkyard owners are interested in buying them, showing even more the importance of
BIODEGRADABLE PLASTIC – 18
investing in the production of materials made from sugar derivatives. While in Brazil the market for PHB is restricted to niches
interested
in
manufacturing
products
with
ecological appeal at a higher price, in Europe the search for
biodegradable
products
is
great.
In
Europe,
hydroponic agriculture is strong and environmental legislation is strict. A lot of biodegradable material is used in greenhouses. With PHB, it is possible to manufacture clamps for plants or tubes for reforestation and then send the plastic waste to composting stations, where it is quickly absorbed by nature. While traditional plastics take over a hundred years to degrade, products made with PHB decompose in around 12 months and release only water and carbon dioxide. In addition to agriculture, the material can be used in the manufacture of packaging for food, cosmetics and other oily products that are difficult to recycle.
ASPHALT
ASPHALT – 20
Developed in the 1960s in Germany and currently used as a coating for European and American highways and airports, the SMA (Stone Matrix Asphalt) asphalt mixture has gained a new version in Brazil. To replace the cellulose fibers, which normally make up the mixture, researchers from the Fluminense Federal University (UFF) and the Fluminense Federal Institute of Education, Science and Technology (IFF), in Rio de Janeiro, created an asphalt that uses sugarcane bagasse. -of sugar. The function of the component in the “recipe” is to prevent the asphalt cement from running out during the mixing and application process. Due to its greater durability and resistance, SMA asphalt is recommended for roads with heavy traffic. In the country, the first application took place on the tracks of the Interlagos race track. The cost of SMA-type asphalt is about 30% higher to the common. However, the cost-effectiveness is greater. The main advantages are the greater adherence of the tire to the pavement and the reduction of water spray when it is raining.
ASPHALT – 21
When we make an investment in something, we always have to think about the cost-benefit, it may be that a larger investment lasts longer than a smaller investment, and in the end, we will spend less, but in many cases, due to a politician to get funds to do maintenance on a road, he wants the asphalt to last for a short time, because that way, more maintenance will be done on the site, having more opportunity to bid to hire companies, and thus divert money from works. The first highway to receive the new technology was BR-356, which connects the cities of Campos and São João da Barra, on the north coast of the State of Rio de Janeiro. The experimental section is about 200 meters long. In addition to the use of sugarcane bagasse, the stretch had another resource to reduce the environmental impact: the recycling of tires. The rubber was reused in the asphalt binder. Although the process of coating a highway with bagasse is more expensive, we have to find a way to make this new method cheaper, one of the ways, it would be by making the freight of the material cheaper, buying
ASPHALT – 22
sugarcane bagasse directly from mills, if it is works done close to mills, the company responsible for the work would buy directly from the mill, thus making the “freight” cheaper.
POWER SUPPLY
POWER SUPPLY – 26
We have to invest more in this energy category, because there is always that story of market supply, the more there is a product in stock, the cheaper it is, and the less there is, the more expensive it is. With more electricity supply alternatives available on the market, the price for the consumer becomes cheaper, so we have to support these alternatives, in which all plants supply energy to the city, so that it is cheaper for everyone. When dealing with sustainability, the most debated subjects are the use of fuels and renewable energy sources. Renewable energy is that which comes from natural resources that are naturally replenished over time. Also known as green energy and clean energy, it comes from sources that do not exist. possibility of temporary exhaustion. Brazil has gained prominence worldwide due to the use of renewable energy, especially when it comes to the production of ethanol for automotive use and electricity generated from waste from thesugar cane. The country that has a large part of the electricity from
POWER SUPPLY – 25
hydroelectric and thermal sources, already has the use of biomass as the third category of energy source used. In the production processes of sugarcane by-products, one ton of this ground raw material generates about 250 kg of sugarcane bagasse, without considering other byproducts such as straw and tips. The burning of this biomass to produce electricity is part of clean or green energy, being fully renewable and not producing major environmental impacts such as the burning of fossil fuels. The State of São Paulo has stood out in the production of energy through biomass, in particular through the use of sugarcane bagasse. The state already represents almost half of the country's sugar and ethanol production. Brazil lacks a lot of alternative energies to complement the hydroelectric system, mainly due to its total dependence on the level of dams and rains. As sugarcane production peaks precisely in the dry months (April to September), its use for energy generation has, year after year, gained prominence. Earlier this year, it rained a lot less in the state of São
POWER SUPPLY – 26
Paulo
than
it
did
last
year,
and
according
to
meteorologists next year, it will be worse, because the burnings in the Amazon forest have grown year after year, which harms the climate in the state of São Paulo. Even with the fact that burning biomass produces polluting gases, the need to constantly plant the raw material, in this case sugarcane, makes its energy production completely renewable and clean. The generation of energy through the burning of bagasse has several advantages, mainly in relation to the use of thermoelectric sources, such as the burning of mineral coal or oil. High competitiveness due to cost, as sugarcane is already planted for the production of ethanol, use of bagasse for energy production is highly viable, making energy cheap and competitive in the market. It makes up for the lack of rain, as much of the electricity
generated
hydroelectric
plants,
in
the
which
country depend
comes on
from
rainfall
to
guarantee the level of the reservoirs, burning sugarcane bagasse is a great way to supply the lowest electricity
POWER SUPPLY – 27
production in periods of dry. Reduction of greenhouse gas emissions: as it is completely renewable, sugarcane reduces pollution and aggravates the greenhouse effect. The production of this category of energy is a great incentive for the economy, as it allows the generation of jobs from farming to skilled workers in the plants. In addition to the environmental advantage compared to thermoelectric plants, sugarcane bagasse also has greater availability and better access. The use of sugarcane bagasse has the great attraction of also allowing the production of ethanol, in addition to enable the generation of new jobs and stimulate the country's economy. New
agricultural
technologies
have
considerably
increased the sector's productivity, making the use of sugarcane for energy production even more viable.
SUGAR IS BAD FOR YOUR HEALTH
SUGAR IS BAD FOR YOUR HEALTH – 29
Excessive sugar consumption is linked to an increased risk of having problems such as diabetes, obesity, high cholesterol, gastritis and constipation. Frequent
consumption
of
sugar
increases
the
opportunities for problems such as: tooth decay, obesity, diabetes, high cholesterol, liver fat, cancer, gastritis, high blood pressure, gout, constipation, memory impairment, myopia, thrombosis and acne . Furthermore, sugar provides only empty calories for the body, as it does not contain vitamins or minerals, essential nutrients for the proper functioning of the body. Sugar addicts the brain because it stimulates the production of a hormone called dopamine, responsible for the sensation of pleasure and well-being, making the body addicted to this food category. In addition to addiction, excess sugar also impairs memory and makes learning difficult, which leads to reduced performance in studies and work. The recommendation for sugar consumption per day is 25g, which is equivalent to a full tablespoon, but the ideal is to avoid as much as possible ingesting this food,
SUGAR IS BAD FOR YOUR HEALTH – 30
as the body does not need it to function well. In addition, the consumption of brown sugar or honey should be preferred, as they contain more vitamins and minerals than the refined product, less harmful to health. How much bad sugar does to us, right? But calm down! Here in this book, we will show in the next chapters, other things that we can use sugar, and thus prove that it is very useful and not only a “tempting” product but also a villain that harms our health.
GERATION OF ENERGY FROM SUGAR
GERATION OF ENERGY FROM SUGAR – 32
It took five years of study until the unprecedented result. First, scientists put biological yeast, which we use to make bread, into refined sugar. With fermentation, sugar turns to alcohol. Then the researchers add a little black wire, an electrode with a protein called ADH or alcohol dehydrogenase. It is an enzyme found in the human body and in foods such as tomatoes. The protein is able to extract electrons, charged particles, from ethanol, thus generating electricity. This process is very fast. In about ten minutes we have electric current. The Brazilian experience reveals a mystery. For more than 50 years, researchers around the world tried to find out how the protein acted when it came into contact with alcohol. For the first time, scientists at USP São Carlos were able to prove how this chemical reaction is, which transforms sugar into electrical energy. The research is on the cover of one of the most respected scientific journals in the chemical field in the world. The action of the enzyme to produce energy is not the only discovery.
AVOID CRACKS IN THE CONCRETE
AVOID CRACKS IN THE CONCRETE – 34
Probably many people have heard about the mixture of sugar with asphalt, but many did not know the mixture with cement and sand, know that you can also mix sugar in concrete. In some regions of Brazil, there is evidence of the use of sugar as a cement setting retarder, mainly used in slabs. Many
categories
of
sugar
and
kneading
water
contaminants can delay setting time, as they contain lignosulfonates in their chemical composition. Contamination of aggregates by certain categories of sugars can abruptly delay the beginning of cement setting when compared to a reference sample without addition. The results indicate that sugar alters the cement setting time, and this helps a lot in the mass strength, thus preventing cracking. Anyone in the sugarcane industry believes the news is encouraging, as it is another promising market for the commodity, since the greater the consumption of a product, the more expensive it becomes. If the population starts to use sugar in construction, the product will probably be in short supply, making it more expensive in
AVOID CRACKS IN THE CONCRETE – 35
the market, this would help mills, but harm consumers. To solve this problem, thus helping mills and customers, it would be better to plant more sugarcane, so the increase in production would not affect the increase in sales, look for new methods that already exist and plant more cane in the same square meter or harvest canes in a shorter period maintaining quality. With more cane to grind, it would be necessary to build more mills, increase crushing per day or reduce the days between harvests. Civil construction is using refined sugar to repair problems such as micro-cracks and cracks in concrete exposed to high temperatures. Mixed in small proportions with concrete, the substance is like a pitch, compact and sealing. According to industry professionals, the dough is great for coating or placing bricks in ovens, as it does not cracks with temperature. On average, the recommendation for use is around two cups of tea for each kilo of cement, but in order not to disturb the progress of the work, it would be easier to add the sugar and also the sand, in the work, to make it
AVOID CRACKS IN THE CONCRETE – 36
easier. Each cup of tea is equivalent to 100 grams of sugar, which in this case would need 200 grams for each kilo used, using half a bag of cement, which means 25 kilos, you would need to add 2.5 of sugar, which in this case is a bag of 5 kilos of sugar, and if it is a whole bag it would cost 10 kilos. There is still another sugarcane derivative that arouses interest in various sectors of civil construction. It is the ash from sugarcane bagasse, which has been presented as a good replacement for natural aggregators, such as sand, cement and gravel. This ash is the final product of bagasse burning in boilers. Which are often used a lot as fertilizers! The studies evaluated that for a replacement content of 30% to 50% there was an increase of up to 15% in compressive strength. This shows that concrete with sugar cane ash is more resistant than concrete with sand. Excellent data for the Brazilian reality, which produces 3.8 million tons of ash. Some people replace some of the sand with ash, others
.
AVOID CRACKS IN THE CONCRETE – 37
replace some of the cement. If you want to replace it with cement, it's easier for you to add the ash and more sand than to remove the cement, in this case, you can do it as follows, if the line you use is 1:2:3 (1 part of cement, 2 parts of sand and 3 parts of gravel), you can keep this same trace, in which case you would make half mass, put 10 kilos of ash, half a bag of cement and instead of 1 carriola of sand and add ¼ of sand in the carriola, and then I would put 2 gravel carriolas.
BAGASSE USED IN FIBER CEMENT
BAGASSE USED IN FIBER CEMENT – 39
Through a system created by the Brazilian researcher Ronaldo
Soares
Teixeira,
the
residual
sugarcane
bagasse from the industries can be reused for the manufacture of fiber cement. The
product,
called
Fiber
cement,
is
generally
composed of water, cellulosic pulp, synthetic fiber as some categories of plastic and cement. However, it is possible to replace some of these components by the fiber from the sugarcane bagasse and by the ash resulting from the burning of this material. Ronaldo, who is from the School of Engineering of São Carlos (EESC), wanted to find a way to use this waste normally discarded by the industry and use it to manufacture products such as roof tiles, partitions, water tanks, among others. He estimates that of each ton of sugarcane processed, 260 kilos are transformed into bagasse. In the study, the researcher used the fiber from sugarcane bagasse as a reinforcement in the production of fiber cement itself, and 30% of the mass cement was replaced by ash. Ash has a high concentration of silica,
BAGASSE
USED
IN
FIBER
CEMENT
–
40
with behavior of pozzolanic cement. Ash, in contact with water and together with hydrated lime, forms a binding compound, that is, it hardens. The product made with this raw material has resistance similar to that produced in industries. For this, the material underwent two curing processes (hardening) and to check its resistance, tests were carried out that simulated the exposure of the material under sunny and rainy conditions. The method used to create the fiber cement was extrusion, unprecedented in Brazil for this purpose. When the mixture of fiber cement components is placed in the extruder, the endless screw makes the mass flow under increasing pressure through the chambers, forcing it to come out in the desired shape, forming the fiber cement. The extruder is commonly used in the ceramic industry. The fiber cement feature is the same as in the previous chapter. Trace of 1:2:3 (1 part cement, 2 parts sand and 3 parts gravel), place 10 kilos of ash, half sack of cement and instead of 1 reel of sand and I would add ¼ of sand to the
.
BAGASSE USED IN FIBER CEMENT – 41
reel, and then put 2 reel of gravel.
HYBRID CAR
HYBRID CAR – 43
Let's then assess whether it pays to have a car with power and another with economy. An increasing number of people are thinking about a hybrid car when they decide to buy a new model. Many imagine that the first hybrid model was the Toyota Prius, but the reality is quite different. There are a few versions of which one was actually the first, but all date from a time when conventional cars themselves were still becoming popular. The oldest is from 1896, when the Armstrong Phaeton model appeared. It was made after an order from the Roger Mechanical Carriage Company to electrical engineer Harry E. Dey, who still had to turn to a third company, Armstrong Electric, to create the first prototype. Despite looking like a buggy with a steering wheel, the Armstrong Phaeton was one of the biggest innovations in the automotive industry, especially for its time. With a 6.5 liter 2-cylinder gasoline engine and Another electric drive, the hybrid could run on just one of the two. It also had a battery that was recharged by a dynamo
HYBRID CAR – 44
on the brakes, as well as an ignition that used the battery's accumulated energy, eliminating the need for a lever to start the engine. The most impressive detail: restored after suffering from a flood, it still works! Of course the Prius plays an important part in the hybrid story, as it was the first model to be mass-produced. Launched by Toyota in Japan in 1997, it reached other markets in 2001. Since then, several generations have been launched, and the Prius remains the most popular and best-selling model among hybrids. A hybrid car is one that works with two power sources and not just one, like the conventional cars we are used to seeing. In other words, in addition to the combustion engine, which can be gasoline (most common), diesel or ethanol, the car also has another propeller, electric. The main purpose of this mix is to combine the main positive characteristics of each one. When we talk about conventional models with a combustion engine, we see that their main function is to
HYBRID CAR – 45
generate the best possible performance. They still have good autonomy, which means they can run for great distances without having to refuel. On the other hand, as power increases, consumption also increases and more pollutants are released into the air. An electric motor, on the other hand, does not emit any pollutants, and has a much lower cost per kilometer run. However, this also has its downside, as these models tend to have a low autonomy, and still take longer to run again, since recharging it obviously takes longer than stopping to refuel a conventional model. But just thinking about the good it does for health, we come to the conclusion that it pays to have one. The main positive point of a hybrid car is that it combines the good autonomy and power of the combustion engine, with less pollutant emissions and economy of the electric propulsion system. To work together, the system of both was perfected, obtaining the best possible result. Basically, these models can
be
divided
into
three
types:
HYBRID CAR – 46
The first is the Hybrid in series, in this type, the motors act connected in sequence, or in series, with the output of one feeding the input of the other. It is usually the combustion engine that powers the electric motor, and only the latter acts on the wheels, leaving the former only to generate electricity. Examples of models of this type: Chevrolet Volt and the Opel Ampera. The second is the Hybrid in parallel, here the two thrusters are used to generate the necessary force, but only one of them acts, and the other helps to improve its performance. Examples of models of this type: Honda cars such as Civic Hybrid and Insight. The third is the mixed hybrid, or combined, it is a more common system among hybrid models, this operating category
uses
the
two
engines,
separately
or
simultaneously, and both can act on the wheels. If they act together, one is in charge of making the car go, while the other generates the electrical energy, everything being defined instantly by a computer.
HYBRID CAR – 47
Examples of models of this type are hybrid models from Toyota (like the Prius), Lexus (like the CT200h) and the Ford Fusion Hybrid. The fourth is the Hybrid Car, with differences when driving, regardless of the system used, the main objective is always economy. This is seen, for example, in the size of the combustion engine generally used, smaller than in other conventional models of the same size, and also in its operating cycle. The electric motor also has important features that contribute to this, such as regenerative braking. Every time the brake is applied, or even when the throttle is released, the electric motor runs in reverse mode, sending energy back to the batteries. The car's aerodynamics and the use of tires with less resistance also make consumption drop considerably. All this will not have the desired effect if the driving mode is not appropriate. As the proposal is fuel economy, no needless sudden acceleration. The all-electric mode of these models also works up to a certain speed (around 40 or 50 km/h). If it is possible to
HYBRID CAR – 48
stay within it, especially on short journeys, the savings will be greater. A precaution that every driver must take when driving a hybrid model, and that all automakers warn, is exactly that in electric mode it does not make any noise, which further proves the benefit it brings to health, since noises are generally bad for health and stress. When we talk about the hybrid car scenario in our country, it still weighs heavily that the government does not give so many incentives for its purchase. This may change soon, as in January this year the possibility of lowering the IPI tax rate for hybrid and electric cars was announced, which would drop from 25% to 7% (the same as for 1.0 models).
CADMIUM ADSORPTION
CADMIUM ADSORPTION – 50
Metals from anthropogenic activities contaminate the environment, inputs and raw materials and, consequently, the food chain, thus reaching everyone. Due to the accumulation of these metals, as well as their harmful consequences, studies are being carried out to assess the levels reached by such contaminations. As the metal adsorption capacity by sawdust was not exhausted in the first use, the possibility of a new contact was studied, reusing
the
remaining
solution,
maintaining
the
proportion. In a second step, times of 12, 8 and 4 hours were tested. Cadmium content was determined by atomic absorption spectrophotometry (EAA) in the contact solution, after separation of sawdust by filtration. From the results obtained, we can say that these residues can be used as adsorbents for heavy metals in the treatment of effluents. The constant demographic and industrial growth, added to the disorderly occupation and the inadequate use of water and soil, always results in pollution of the environment, being something to worry about. Other forms of soil contamination are residues from
CADMIUM ADSORPTION – 51
cement manufacturing, burning fossil fuels and urban waste and sewage sediment. In agriculture, a direct source of cadmium contamination is the use of phosphate fertilizers. It is known that the uptake of cadmium by plants is greater the lower the soil pH. In this aspect, acid rain represents a determining factor in the increase in metal concentration in agricultural products. Cadmium can interact with negatively charged groups existing in the cell wall (phosphoryls, hydroxyls, carboxyls and sulfhydryls) and, in this way, be adsorbed. The metal can also chemically interact with manoproteins and thus penetrate through the glucan layer, reaching the cytosol through transport proteins. Sugarcane, originally from India, is currently explored in almost the entire country, which has 5.4 million hectares cultivated, considered the largest world producer and the country with the greatest potential for expansion in planted area. These residues that remain in the soil and are not yet explored in Brazil, present quantities that vary with age, variety and location of planting, which can range between
CADMIUM ADSORPTION – 52
6 t.ha-1 and 22.8 t.ha-1 of straw. The amount of residues can reach 1/5 of the total weight of the sugarcane and, therefore, cause problems for post-harvest operations. It is estimated that, in addition to the amount of bagasse processed and used to feed boilers, there is a surplus of sugarcane bagasse corresponding to 8% in the adjacent distilleries and 12% in the autonomous ones, which could have other destinations (which have already been cited several here in this book), including being used to improve the quality of the environment. From the results obtained with the experiment that used the concentration of 25 mg Cd.L-1 of sawdust, significant differences were observed (P< 0.05) between the four times used. The times of 8, 12 and 16 hours showed differences significant (P < 0.05) and were considered efficient as to the adsorption process of the metal present in the initial solution. In the two subsequent reuse treatments, the low adsorbed concentration was probably due to the low concentration of the metal present in the respective remaining solutions, since the probability of contact between the metal and the sawdust was lower.
CADMIUM ADSORPTION – 53
For the two waste used (sawdust and bagasse of sugar cane) the time of 4 hours proved to be insufficient to promote adsorption. From the results obtained at the contact times of 8, 12 and 16 hours, it can be said that sawdust and sugarcane bagasse are agro-industrial residues that can be used as absorbent materials for heavy metals in the treatment of effluents, showing thus to uses in soil conservation.
ASH FOR SOIL LIMING
ASH FOR SOIL LIMING – 55
The biomass burning process generates ashes, which are mineral materials that are not part of the burning, and are not useful for companies in the forestry sector. The aim of this study was to characterize the ash produced by a biomass boiler in a period of one year and, at the same time, evaluate the use of this material as an input for the production of eucalyptus seedlings in the field and wheat seedlings in the laboratory. The work was divided into three chapters where the first one characterizes the ashes of a boiler over a period of one year, considering the different materials that are inserted. It was concluded that the ash has homogeneous characteristics regardless of origin or origin. The results showed that the addition of ash at lower dosages enabled better wheat development, and the presence productivity.
of
biochar
Eucalyptus
affected growth
germination was
evaluated
and by
replacing conventional liming by adding boiler ash to the soil. It was possible to verify the use of ashes from biomass boiler in the soil liming process for eucalyptus development. Thus, the results of the work showed the
ASH FOR SOIL LIMING – 56
feasibility of using biomass boiler residues in companies in the forest sector, enabling the application of the concept of multiple uses of planted forests. However, on the other hand, I mentioned earlier that the ash can be used to partially replace the cement used in civil construction, if the ash is used in this sector, there will be a lack of ash to be used in soil treatment, causing farmers to buy fertilizers. and so spend much more, so there is a difficulty in inserting the ashes as something correct to be used in civil construction.
BAGASSE CAN CLEAN CONTAMINATED WATER
BAGASSE CAN CLEAN CONTAMINATED WATER – 58
A new method to clean contaminated water was discovered by Brazilian researchers, who discovered that sugarcane bagasse, one of the main residues of the national agribusiness, can “clean” water contaminated with copper or chromium. The research carried out by scientists from the Federal University of São Carlos (UFSCar), in collaboration with Unifesp (Federal University of São Paulo) and with the support of FAPESP and the National Council for Scientific and Technological Development (CNPq), was published in two articles in the Specialized journal Environmental Science and Pollution Research. According to experts, a composite, a hybrid material that has different characteristics from its precursors, produced from bagasse and magnetic nanoparticles, managed to remove copper and chromium in an aqueous medium. The composite has adsorbent and magnetic properties, efficient in removing different contaminating chemical species present in the aqueous medium. After removal of the contaminant by the composite by
BAGASSE CAN CLEAN CONTAMINATED WATER – 59
adsorption process (by which chemical species are retained on the solid surfaces of the adsorbent), the material is removed from the aqueous medium by the action of a magnet, leaving the water clean. Its hybrid nature, which combines the properties of the biological
matrix
with
the
magnetic
properties
of
magnetite nanoparticles, allows the materials proposed in the work to be versatile. In other words, the material can also be applied to the removal of organic molecules, which reinforces its potential for treating water and effluents. The first authors of the research were students, Juliana Tosta Theodoro Carvalho and Thais Eduarda Abílio, under the Vasconcelos
supervision
of researcher Elma
Martins
from
Carrilho,
the
Neide
Polymeric
Materials and Biosorbents Laboratory (Lab-MPB), at the Federal University of São Carlos (UFSCar). ), at the Araras Campus, in collaboration with Georgia Labuto, from
the
Laboratory
of
Integrated
Sciences
(LabInSciences) of the Chemistry Department of the Federal University of São Paulo (Unifesp), in Diadem.
BAGASSE CAN CLEAN CONTAMINATED WATER
– 60
The research line is supported by FAPESP and of the National
Council
for
Scientific
and
Technological
Development (CNPq). The study is part of a series of other works that his group has been developing at the Lab-MPB (UFSCar), using biomass as biosorbents, a viable and efficient alternative
for
the
decontamination
of
aquatic
environments. With these materials, the proposal is to create fixed bed adsorption columns containing the adsorbent composites produced with biomass residues that would be discarded, considered garbage, to act as biosorbent filters. It is good that scientific production based on the use of this category of technology continues to grow in Brazil and boost the bioeconomy in the country. Copper is a malleable metal and a good conductor of electricity, which is why it is widely used in industry, civil construction and agricultural activities. It is widely used to control the proliferation of cyanobacteria in water reservoirs for human consumption. In small amounts, it is an essential element for living organisms, but in high
BAGASSE CAN CLEAN CONTAMINATED WATER – 61
concentrations in water it can cause nausea, vomiting and
diarrhea,
according
to
analyzes
by
the
Environmental Company of the State of São Paulo (Cetesb). So this discovery can help everyone, not just humans, but also animals in contaminated water. The technique can also be adapted for removing synthetic dyes, drugs, hormones and pesticides from water. Carrilho recalls that the magnetic nanocomposites studied by the group also have the potential to help remove oils (such as crude oil) from the surface of the water in cases of spillage. In laboratory tests, scientists have already managed to get other composites made from residues of biomass and magnetite that remove crude oil and other categories of oil spilled in water, with 80% efficiency. Unfortunately in Brazil, several cities still dump sewage into rivers, thus showing the importance of this discovery for cleaning the waters, but in the city where I live, I don't play anymore, the name of E.T.E (Sewer Treatment Station) is my grandfather's name, a tribute to him for
BAGASSE CAN CLEAN CONTAMINATED WATER
– 62
helping to clean up the city for years, he was called Pedro Leme Machado. As mentioned in previous chapters, bagasse can be used in various functions, so it is up to the mill owner to sell the bagasse to where he pays more.
ELETRIC ENERGY FROM VINASSE
ELETRIC ENERGY FROM VINASSE – 64
This is a theme that frequently appears when we are discussing the design criteria for the implementation of new industrial units, especially when the client wants to maximize the sale of electricity. The vinasse from sugarcane ethanol production is a liquid effluent with great potential for pollution. This potential is basically characterized by its organic load, evaluated by its chemical oxygen demand (COD), and by its potassium content. Potassium is an element that practically does not participate in physical chemical reactions during sugarcane processing. In this way, all the potassium found in sugarcane ends up in the vinasse, whether it is ethanol produced from juice, honey or a combination of the two. What can vary is its concentration, depending on the amount of vinasse produced per liter of ethanol, but it will all be there. When vinasse is applied to crops, its potassium content is decisive in calculating the maximum application rates per hectare per year. COD is not relevant, as long as there is no infiltration to the water table, as the organic matter disposed in the soil will be used by the sugarcane ratoon.
ELETRIC ENERGY FROM VINASSE – 65
When the vinasse undergoes an anaerobic digestion treatment, there can be a COD removal in the order of 80% to 90% at most. Again, potassium does not participate in the reactions, and the potassium that enters is the potassium that leaves the reactor. As the potassium content does not change and the outflow COD is still high for the disposal of the effluent in nature, this treatment cannot be made viable as a pollution control system. Therefore, the treatment is only viable, especially in Brazil, if the energy produced pays for the investment and operating costs. The energy source is mainly methane gas, contained in biogas
from
the
anaerobic
digestion
of
vinasse.
Anaerobic digestion is provided by bacteria that are properly selected and adapted to the effluent and the environment in the reactor. Most of the COD is converted, and the sludge resulting from the reaction (about 1.5% to 2.5% of the effluent at the inlet) should be removed from the reactor and properly disposed of as other waste. It can also be sold at a price of around R$ 60.00/t, as today the activated sludge market is a buyer.
ELETRIC ENERGY FROM VINASSE – 66
There are basically two categories of bacteria used in reactors. Mesophilic bacteria operate in a temperature range of 35 to 37 C, and thermophilic bacteria in a range of 55 to 57 C. Good temperature control is crucial for good process efficiency. In addition to temperature, pH control is also important. At the beginning of the process, as the pH of the vinasse is very low and the bacteria work in a basically neutral medium, it is necessary to use soda or another alkalinizer to neutralize the medium. As the reactors always work with high recirculation rates, as the process progresses, the alkalinizer consumption decreases rapidly. To define the process, the designer must face two essential tasks. It is necessary to try to adequately characterize the effluent in question and to try to determine, with pilot tests, the rate of expected COD removal and the characteristics of the biogas produced. The correct characterization of the effluent is essential for any project. Manufacturers such as Dedini, for example, which has already supplied numerous reactors for the brewing industry, have a large database about
ELETRIC
ENERGY
FROM
VINASSE
–
67
vinasse. However, for sugar mills that use sulfur in the process, knowing the hydrogen sulphide (H ₂S) content in the resulting biogas is also essential to determine the need for treatment before its use. High content of H ₂S in biogas may require, for example, internal combustion engines with special materials, which are much more expensive, or may cause undesirable corrosion in boiler heat exchangers. In Brazil, vinasse has COD in the range of 20 to 25 kg/m³ (coming from fermentation with juice) and from 30 to 35 kg/m³ (fermentation of juice and honey). As they say in the industry, COD in effluent means lost product. In this case, the highest COD in honey vinasse means that some
of
the
reducing
sugars
are
turned
into
unfermentable sugars during processing for sugar production, which are industrial losses. There are several categories of reactors for anaerobic digestion. In all cases, the engineering challenge is always to try to homogenize the medium as much as possible, in order to allow bacteria to come into contact with
organic
matter,
their
source
of
survival.
ELETRIC ENERGY FROM VINASSE – 68
Anaerobic lagoons, with a depth in the range of 4 to 6 m, can be used and must be lined with PAD-based geomembrane and also covered by the same material, for the collection of biogas. They are reactors that require large volumes, as the application rate (TA) varies from 2 to 3 kg COD/m³/day. Large volumes make it difficult to homogenize the medium and can create preferential paths, reducing the COD conversion rate. As the membranes cannot withstand internal pressures without leaks, they need exhaust systems to remove the biogas. They use mesophilic bacteria, operating at a temperature of 36 C, but even so temperature control is difficult in function of the large volumes that must be homogenized. UASB (Up-flow Anaerobic Sludge Blanket) reactors use thermophilic bacteria, operating at a temperature of 56 C, designed to operate with a TA in the range of 8 to 10 kg COD/m³/day. It is the category of reactor that is in operation at Usina São Martinho, processing around 10% of the vinasse produced and generating the energy necessary for the drying of yeast. Type IC (Internal Circulation) reactors use mesophilic
ELETRIC ENERGY FROM VINASSE – 69
bacteria, operating at a temperature of 36 C, and are designed for a TA of 25 to 30 kg COD/m³/day. The volumes are drastically reduced, mainly due to the use of the biogas generated for the homogenization of the environment. They can operate with enough internal pressure to pump the biogas to the next steps in the process. They are typically used in breweries for pollution control purposes. To assess the energy potential of a plant of this type, it is possible to exemplify the typical situation of a plant producing only ethanol, as indicated below: Typical ethanol/cane production: 0.090 m³/t Typical vinasse/ethanol production: 10/1 Typical vinasse COD: 20 kg/m³ Typical COD/cane production: 18 kg/t Reactor COD removal rate: 85% Biogas production: 0.35 to 0.40 nm3/kg COD removed Average concentration of methane in biogas: 60% to 80% Typical methane production: 0.26 nm3/kg COD
ELETRIC ENERGY FROM VINASSE – 70
Specific methane/cane production: 4.7 Nm3/t Lower calorific value of methane: 34450 kJ/Nm3 Equivalence with bagasse (PCI = 7325 kJ/kg): 4.7 kg of bagasse / Nm3 of methane Additional equivalent bagasse % cane: 2.2% Bagasse % typical cane: 26.5% Percentage increase, expressed in bagasse, . provided by methane: 8.3% Additional generation in steam cycle (68 bar / 520 C) with condensing turbine: 12.7 kW.h/tc Additional generation in Otto cycle internal combustion engines: 17.1 kW.h/tc The methane produced can basically be burned in boilers for steam generation or in internal combustion engines. If it is burned in boilers, we are talking about a condensation cycle, as there would be no consumption of process steam. It is a cycle with low efficiency, in the order of 30% only. With a regenerative system, with taps on
the
condensation
turbine
for
pre-heating
the
condensate, we generate about 0.50 kW.h/t of bagasse.
ELETRIC ENERGY FROM VINASSE – 71
Therefore, with the use of methane in the boiler, we would be producing an additional around 12.0 kWh/t cane. Although the energy recovery efficiency is lower, the advantage is that the equipment (boiler and condensing turbine) would already be available. If burned in internal combustion engines of good efficiency, we can achieve efficiencies of up to 38%. In electricity generation. Therefore, with the use of methane in engines, we would be producing an additional around 17.0 kW.h/t cane. These engines lose about 22% of the primary fuel energy in cooling water and oil, and about 40% in the flue gases. Thus, although there is an additional investment in engines, one can think of using the heat of these gases, which are at around 400 C, for drying yeast or for producing ice water, creating a cycle of greater efficiency than the condensation cycle. We will obtain the equipment installation costs. Complete type IC anaerobic digesters, including the H ₂S elimination system, cost from R$ 85.00 to R$ 95.00 per kg of COD applied per day. Internal combustion engines cost from R$1,700.00 to R$2,000 per kW installed,
ELETRIC ENERGY FROM VINASSE – 72
including the cooling tower system for the water circuit. The operating costs of the boiler and condensing turbine are known. The operating costs of the engines must be well evaluated, as they are equipment that use a lot of lubricating oil and filters. The operating costs of anaerobic digesters are estimated at between BRL 0.016 to BRL 0.018 per kg of COD applied, but it is necessary to confirm with the manufacturer, as the inputs can vary greatly from one technology to another. The total cost of operating the plant with internal combustion engines is around R$ 40.00 / MW.h. It is important to remember that, in all cases, it is necessary to discount the parasitic energy, represented by auxiliary equipment such as exhausters, pumps, cooling towers, etc. It should be in the about 10% range. Now it's time to do the math and, depending on the sale price of electricity, check if it pays.
SUGAR USED TO TEMPER THE WALL
SUGAR USED TO TEMPER THE WALL – 74
Adding refined sugar to cement can prevent cracking in concrete exposed to high temperatures As I said in previous chapters, sugar can be used in construction, but now I'll talk about its benefit in hot places like barbecue grills. Some civil engineers and foremen use this commodity to repair an old problem in construction: micro-cracks and cracks in concrete exposed to high temperatures. According to professionals in the field, refined sugar, the same one that is used to sweeten the coffee, mixed with cement in small proportions avoids the problem. On the internet, there is no lack of recipes to make the mixture and the users of the dough, from lay people to professionals in the sector, guarantee that it is just like pitch, because it is so strong, compact and sealing. This mass is great for coating or placing bricks in ovens, as it does
not
crack
with
temperature,
assesses
the
bricklayer's assistant Ricardo Príncipe, on a social networking site. Olivier Anquier, famous chef and TV presenter it also says on its website that mass has its positive principles. A valuable tip here is that the cement-
SUGAR USED TO TEMPER THE WALL – 75
-based spackle has sugar in the recipe. It is so that the oven seam does not crack in the heat. Professionals in the sugar-energy sector are also interested in the topic. Plínio Nastari is the CEO of Instituto Datagro and one of the most respected economic consultants in the sector, and he assumed that, having heard so much about the subject, he sought more information to satiate his curiosity. According to the principles of civil engineering, concrete has cracks and fissures due to the process of water loss, due to hydration and evapotranspiration, which it undergoes during drying, in its initial application. In a very short period of time, the loss of water increases with the rise in temperatures, which is why, in the process of concreting works, it is necessary to wet the concrete several times a day (a procedure called curing) and delay drying as much as possible. The use of refined sugar mixed with cement slows down the hydration reactions of the product and, in high levels, can even inhibit it totally. Adding a small amount of sugar to the dough will prevent full hydration or cement crystal formation. The resulting
SUGAR USED TO TEMPER THE WALL – 76
mortar will have a better deformation modulus and greater capacity to absorb deformations from thermal sources, such as in the case of barbecue grills, fireplaces and ovens. However, the indiscriminate use of dough with sugar can cause problems and its use should always be guided by a professional. Despite being indicated in small quantities, the product will increase the cost of the work.
AFTERWORD - 77
AFTERWORD I hope you have understood the importance of sugarcane to preserve the environment, mills can use what they produce or what is left over in various things, but there will be a lack of sugarcane for so many things you can do with it, so in this case, it is up to the mill owners to try to sell sugar, alcohol and what is left over from the cane for something more advantageous. We will preserve the environment and plant more sugarcane!
ACKNOWLEDGMENTS - 78
ACKNOWLEDGMENTS I thank God first for this opportunity and then my beloved wife Roseli, I also thank my mother Maria Rosa, Willian Alves, Fernando Camargo, Sebastião Reis and Diego Carvalho
God bless you all!
ABOUT THE AUTHOR - 79
ABOUT THE AUTHOR Born in Pontal-SP (São Paulo countryside), Marcos is married to Roseli Laurência, who corrects all his books and always encourages him. In March 2019, he released his first book (The History of Christian Films in Brazil — 462 Picture edition) in December he was a finalist in the International Christian Film Festival in the "Game" category, due to the game "The history of Christian films in Brazil" , based on the book of the same name. In 2020, he participated in several anthologies (9 publishers), thus participating in books and magazines in several publishers and has texts published on websites and blogs. In total, people from 37 countries read his texts, either for paid or free. In September 2020, the writer won the international literary competition “Poesia Solidária”, which was held by a resident of the country “São Tomé and Príncipe”. In March 2021, the writer was a finalist at the International Unproduced
Christian
Film
Screenplay"
Festival
in
the
category.
"Best
BIBLIOGRAPHY - 80
BIBLIOGRAPHY SITES Ciclo Vivo Fapesp G1 IG / Último Segundo Meia Colher Notícias Automotivas Pix Force Procknor Repositório Unesp Revista Globo Rural Revista Rpanews Scielo Stylo Urbano Tua saúde