BioStraw: indústria de biorrefino da palha do milho

Abstract

The production of agricultural inputs plays a fundamental role in the global economy, being particularly significant in Brazil, where it stands as one of the main pillars of the primary sector. Associated with this activity is the generation of large volumes of agricultural residues—such as stalks, roots, and husks—typically of low economic value. Among Brazil’s major crops, corn stands out with an annual production of approximately 132 million tons, mainly concentrated in the states of Mato Grosso, Paraná, Rio Grande do Sul, Goiás, and São Paulo, resulting in an estimated 43 million tons of corn straw. In this context, the industrial project of BioStraw proposes the implementation of a circular economy model focused on utilizing corn straw as a raw material for the production of biochar through the slow pyrolysis process. Biochar, the resulting carbonaceous product, acts as both a soil conditioner and a carbon sequestration agent, contributing to sustainable agricultural practices and increased productivity. The medium-sized company will be established in Lucas do Rio Verde (MT), a region strategically located near major crop areas and offering favorable tax incentives for industrial implementation. The enterprise aims to achieve an annual production of 12,000 tons of biochar, operating with energy self-sufficiency through the reuse of pyrolysis by-products in a cogeneration unit based on a water-tube boiler for steam generation. In addition, BioStraw will pursue certification and commercialization of 25,000 carbon credits resulting from carbon fixation in the final product. The project encompasses the contextualization and justification of the study, as well as market analysis and site selection for the company. It also includes the characterization of the enterprise, technical and operational process description, mass and energy balances, energy integration, and utility systems. Furthermore, it addresses the transportation system, waste treatment, and equipment sizing. Finally, the work presents the process flow diagram (PFD), industrial layout, and financial analysis of the project. The financial evaluation demonstrates the project’s feasibility, with an initial investment estimated at R$ 337,023,530.80, a Minimum Attractive Rate of Return (MARR) of 15%, a payback period of 7 years and 6 months, and an Internal Rate of Return (IRR) of 24%, highlighting the strong economic potential of the venture.