Caña Brava, empresa productora de etanol en Piura

Caña Brava: Innovating Renewable Energy in Peru

Introduction to Caña Brava

• Caña Brava operates under harsh conditions, focusing on renewable energy production in Peru since its official establishment in September 2006.

• The company specializes in producing ethanol, a significant compound for both Peru and the global market.

The Importance of Ethanol

• With an increasing global population projected to reach 8 billion by 2030, transportation contributes to 80% of environmental pollution.

• Traditional fuel sources are depleting; thus, transitioning to sustainable energy is crucial for environmental preservation.

Caña Brava's Operations

• Located in the Tirah Valley of Piura, Caña Brava is a pioneer in ethanol production with 9,500 hectares dedicated to sugarcane cultivation.

• Ethanol reduces carbon dioxide emissions from vehicles significantly compared to gasoline—10 kg per gallon for gasoline versus only 6 kg for ethanol.

Environmental Impact and Benefits

• The process of producing ethanol from sugarcane creates a renewable energy cycle that improves air quality year after year.

• Each gallon of ethanol produced absorbs more CO2 than it emits, showcasing the true value of biofuels.

Agricultural Practices at Caña Brava

• Initially cultivating barren land required significant effort to enrich soil with water and natural fertilizers before planting seeds.

• Water is sourced from irrigation channels connected to local rivers and distributed through an extensive network ensuring efficient nutrient delivery.

Efficient Irrigation Techniques

• Technified irrigation methods allow precise water application based on plant needs, saving up to 50% more water compared to traditional methods.

• This efficiency translates into substantial annual savings—60 million cubic meters of water conserved each year.

Pest Management Strategies

• Integrated pest management involves ecological control measures like traps and biological controls using beneficial insects produced on-site.

• These strategies help maintain crop health while minimizing damage from pests without harming neighboring ecosystems or humans.

Harvesting Process

• Mechanized harvesting occurs around the clock with nine machines operating efficiently without burning crops, yielding between 500 to 700 tons daily.

Overview of Ethanol Production Process

Harvesting and Initial Processing

• The primary goal is to send the maximum amount of sugarcane from the field to the factory while respecting future cutting standards (CFI). Each harvester is accompanied by a vehicle called "autogolpe" that transports cut stalks to the cane storage facilities.

Factory Reception and Milling

• Trucks deliver sugarcane to the reception area, initiating the milling process. The cane moves through a conveyor belt into hammer mills where it is processed.

Sugar Extraction and Byproducts

• In a diffuser, sugars are extracted from the crushed cane through hot water dilution. This process also produces bagasse, which serves as raw material for electricity cogeneration and steam generation in boilers.

Energy Generation

• Bagasse is used as fuel in generators producing 12 megawatts of power for factory operations and irrigation systems. A gas washer in the boiler captures combustion gases, returning them to ethanol production.

Fermentation Process

• The concentrated juice undergoes alcoholic fermentation using selected yeasts to convert sugars into alcohol. This mixture, referred to as "pino," then enters breathing towers where high temperatures yield rectified alcohol with 96% purity.

Purification and Storage of Ethanol

Final Purification Steps

• The alcohol undergoes dehydration processes achieving a typical purity level of 99.7% weight.

Storage and Exportation

• The produced ethanol is stored in a 5,000 cubic meter tank at the plant before being transported to tanks in Paita for maritime export or national market distribution.

Product Range and Market Orientation

Types of Products Offered

• Cañabrava offers four main products:

• Fuel alcohol mixed with gasoline for refineries.

• Anhydrous ethanol exported to Europe.

• CD2 and CD3 products aimed at various industrial markets like ink manufacturing.

Quality Control Measures

Laboratory Standards

• To maintain optimal quality standards amidst growing ethanol demand, an industrial laboratory analyzes ethanol's water percentage, acidity levels, superior alcohol content, ensuring it meets a minimum purity threshold of 99.7%.

Certifications Achieved

• Cañabrava holds ISO9001 certification guaranteeing product quality alongside SCC accreditation for sustainable biomass use that protects natural resources while reducing greenhouse gas emissions.

Community Engagement and Support Programs

Agricultural Support Initiatives

• Daily operations involve harvesting approximately 4,300 tons of sugarcane yielding around 370,000 liters of ethanol thanks to over 1,500 local workers contributing significantly towards community development initiatives.

Educational Programs

• Cañabrava supports local communities by providing agricultural assistance such as seeds and technical support while promoting quality education through programs aimed at improving rural schooling conditions.

Health Initiatives

• Medical support campaigns are conducted in collaboration with government institutions focusing on specialized healthcare access within rural areas surrounding their operations.

Environmental Responsibility

• Through initiatives like "Barrio Limpios," Cañabrava encourages community cleanliness efforts supported by employees' innovative ideas aimed at enhancing operational efficiency while fostering environmental stewardship.

Future Aspirations