Simultaneous Optimization and Integration of Multiple Process Heat Cascade and Site Utility Selection for the Design of a New Generation of Sugarcane Biorefinery

Biorefinery plays a crucial role in the decarbonization of the current economic model, but its high investments and costs make its products less competitive. Identifying the best technological route to maximize operational synergies is crucial for its viability. This study presents a new superstructure model based on mixed integer linear programming to identify an ideal biorefinery configuration. The proposed formulation considers the selection and process scale adjustment, utility selection, and heat integration by heat cascade integration from different processes. The formulation is tested by a study where the impact of new technologies on energy efficiency and the total annualized cost of a sugarcane biorefinery is evaluated. As a result, the energy efficiency of biorefinery increased from 50.25% to 74.5% with methanol production through bagasse gasification, mainly due to its high heat availability that can be transferred to the distillery, which made it possible to shift the bagasse flow from the cogeneration to gasification process. Additionally, the production of DME yields outcomes comparable to methanol production. However, CO₂ hydrogenation negatively impacts profitability and energy efficiency due to the significant consumption and electricity cost. Nonetheless, it is advantageous for surface power density as it increases biofuel production without expanding the biomass area.