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Date: 11/11/2008 Energy balance of soybean-based biodiesel production in Argentina Agr. Eng. M.S. Lidia B. Donato Environmental Eng. Ignacio Roberto Huerga Agr. Eng. Jorge A. Hilbert N° Doc IIR-BC-INF-10-08 Introduction The general object of this paper is to establish the energy balance of soybean-based biodiesel production in Argentina. In relation to fuels, the energy balance is basically the difference between the energy available per unit of fuel and the energy necessary for its production (extraction or cultivation of the raw material), transportation to the industrial plant, industrialization (transformation and distillation) and transportation to its final destination. This balance must seek to lower or eliminate the environmental impact of the biodiesel production and, as it replaces fossil fuels, to ensure that the environmental impact of the substitute is lower than that produced by the original non-renewable fuel. We define environmental impact as a relatively long and complex process of analysis, as objective as possible, of the effects of a planned human action (known as a project) and the possibility of —— avoiding them, reducing them to acceptable levels or compensate for them. In general, the extraction and use of fossil fuels has an important, complex impact on the environment. It is well known that their combustion generates gases such as CO2 and residual hydrocarbons that can enter the atmosphere, sometimes unburned, generating an opaque vault over the surface of the earth and producing what is known as the “greenhouse effect”. This vault absorbs the infrared heat reflected on the surface of the earth, increasing the temperature of the air in its proximity. Increasing levels of CO2 raise the atmosphere’s uptake coefficient, and solar radiations reflected on the ground or the sea surface crash against the opaque CO2 dome as their wave lengths decrease. Should the emission of this gas or of others that contribute to the greenhouse effect continue to increase, as is the case with hydrocarbons such as methane, it is estimated that the planet’s temperature will continue to rise with very negative climatic consequences. On the other hand, and in accordance with the Kyoto Protocol, signed by an important number of industrialized countries but not by the United States, an emission compensation mechanism has been created that allows those nations that emit greenhouse effect-producing gases at higher levels than those agreed upon to buy carbon credits from countries like Argentina, which are not obligated at the moment to reduce their emission levels, from projects to replace fossil fuels with bio-renewable fuels. It is also necessary to consider all types of effluents that may be caused by biofuel production, from the agricultural stage to the delivery of the product at the distribution centers, as well as the pollution that may result from manufacturing the consumables required for its production. Occasionally, this production may involve non-renewable byproducts, such as oil- and natural gas-based fertilizers, which should be replaced, whenever possible, by others of renewable origin or that will not cause substantial negative environmental impact. This is already being done, with very encouraging results, in the case of cane cultivation with bio fertilizers. All these factors must be taken into account to define whether a biofuel project will generate less environmental impact than that produced by the fuels that may replace this biofuel, or to consider whether it is necessary to study and define operations and/or procedures that may reduce that impact during the life of the project. It is important to carry out a Life Cycle Analysis of the project, a decision support method that makes it possible to identify environmental impact linked to the product, its processes and associated activities at each and all stages, such as cultivation, harvest and transportation, as well as everything related to

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Page 1: Energy balance of soybean-based biodiesel production in ...oscarment1.yolasite.com/resources/BMyE biodiesel soja.pdf · Energy balance of soybean-based biodiesel production in

Date: 11/11/2008

Energy balance of soybean-based biodiesel production in

Argentina

Agr. Eng. M.S. Lidia B. Donato Environmental Eng. Ignacio Roberto Huerga Agr. Eng. Jorge A. Hilbert

N° Doc IIR-BC-INF-10-08

Introduction

The general object of this paper is to establish the energy balance of soybean-based biodiesel production in Argentina. In relation to fuels, the energy balance is basically the difference between the energy available per unit of fuel and the energy necessary for its production (extraction or cultivation of the raw material), transportation to the industrial plant, industrialization (transformation and distillation) and transportation to its final destination.

This balance must seek to lower or eliminate the environmental impact of the biodiesel production and, as it replaces fossil fuels, to ensure that the environmental impact of the substitute is lower than that produced by the original non-renewable fuel.

We define environmental impact as a relatively long and complex process of analysis, as objective as possible, of the effects of a planned human action (known as a project) and the possibility of ——avoiding them, reducing them to acceptable levels or compensate for them.

In general, the extraction and use of fossil fuels has an important, complex impact on the environment. It is well known that their combustion generates gases such as CO2 and residual hydrocarbons that can enter the atmosphere, sometimes unburned, generating an opaque vault over the surface of the earth and producing what is known as the “greenhouse effect”. This vault absorbs the infrared heat reflected on the surface of the earth, increasing the temperature of the air in its proximity. Increasing levels of CO2 raise the atmosphere’s uptake coefficient, and solar radiations reflected on the ground or the sea surface crash against the opaque CO2 dome as their wave lengths decrease.

Should the emission of this gas or of others that contribute to the greenhouse effect continue to increase, as is the case with hydrocarbons such as methane, it is estimated that the planet’s temperature will continue to rise with very negative climatic consequences.

On the other hand, and in accordance with the Kyoto Protocol, signed by an important number of industrialized countries but not by the United States, an emission compensation mechanism has been created that allows those nations that emit greenhouse effect-producing gases at higher levels than those agreed upon to buy carbon credits from countries like Argentina, which are not obligated at the moment to reduce their emission levels, from projects to replace fossil fuels with bio-renewable fuels.

It is also necessary to consider all types of effluents that may be caused by biofuel production, from the agricultural stage to the delivery of the product at the distribution centers, as well as the pollution that may result from manufacturing the consumables required for its production. Occasionally, this production may involve non-renewable byproducts, such as oil- and natural gas-based fertilizers, which should be replaced, whenever possible, by others of renewable origin or that will not cause substantial negative environmental impact. This is already being done, with very encouraging results, in the case of cane cultivation with bio fertilizers.

All these factors must be taken into account to define whether a biofuel project will generate less environmental impact than that produced by the fuels that may replace this biofuel, or to consider whether it is necessary to study and define operations and/or procedures that may reduce that impact during the life of the project.

It is important to carry out a Life Cycle Analysis of the project, a decision support method that makes it possible to identify environmental impact linked to the product, its processes and associated activities at each and all stages, such as cultivation, harvest and transportation, as well as everything related to

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the stages of industrialization and transportation of fuels to their selling points. In addition, gaseous effluents that may be generated by their use must also be considered. In each instance, all inputs and outputs of the system under study must be identified and inventoried to evaluate both resource consumption and emissions into the environment so that the different environmental impacts of each stage can then be determined. Finally, minimizing actions and accessible improvements must be defined, so as to have tools to make the Environmental Balance as positive as possible.

Materials and methods

To calculate the energy requirements of soybean biodiesel production, the cycles were separated in two stages: the agricultural stage, which includes from the cultivation activities that precede sowing to stocking of the grain, and the industrial stage, which considers transforming the grain into biofuel and transporting it to its selling points. The energy balance itself, that is, the value that results from deducting the input energy (direct plus indirect energy) at both stages from the output energy contained in the gallons of biofuel produced, is obtained by these processes.

The different sequences of operations and the consumables used in the characteristic areas of cultivation were taken into account.

At the agricultural stage, different productive systems were considered: conventional farming, no-till farming and no-till farming with leading technology, which involves high density sowing with sowing machines that ensure an adequate distribution of the seed and a uniform emergence of the crop, reduction of the distance between rows to obtain quick coverage of the ground, the use of pre-inoculated and/or cured high germination seeds, good handling of the stubble, and fertilization and proper treatment with herbicides and insecticides.

Two types of energy, direct and indirect, are considered within the agricultural stage. Direct energy is that contained in the diesel oil used in cultivation activities that precede sowing, implantation, protection and harvesting of the crops, and in the fuel used to transport the harvested grain from the agricultural unit to the drying and storage plant, commonly referred to as short freight (less than 30 km). Finally, also considered is the diesel oil used in the drying process that takes place at the storage plant, for a first reduction of the humidity percentage of the harvested grain before it enters the industrial plant.

On the other hand, indirect energy used at the agricultural stage is the energy contained in the consumables used (seed, fertilizers and agrochemicals) to produce a certain amount of grain per hectare, which shall be considered as raw material for the process of transformation into biofuels.

To determine energy consumption at the industrial stage, and integral description of the process was made first, considering the different variables and parameters that influence it, and creating a mass balance in which the products and byproducts can be observed in each case.

Later, different studies were reviewed which show the energy requirements, mainly thermal and electrical. Although these studies have been conducted by countries with developed technologies and experience in industrial biofuel production (the United States, Germany, Brazil, and Italy, among others), they may be considered to have an approximate idea of the required consumption since the same technologies are being used in Argentina with a more intensive use of the facilities, and this would mean equivalent or greater efficiencies than those taken as a reference.

Based on the energy values obtained for the agricultural and industrial stages, the energy balance itself is developed by finding the difference between the resulting energy (products and byproducts) and the sum of all the energies entering the system. These values constitute an approximation to the total energy efficiency.

It is important to point out that this study is to be considered “exploratory”. Its main limitations focus on the industrial stage of biofuel production (in which data from experiences in other countries were taken to determine energy consumption), assumptions made within it and the assignment of energy values to byproducts. To make these details more precise, it will be necessary to perform studies of plants functioning in Argentina.

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Results

Estimate of energy consumption in cultivation, implantation, protection and harvest of crops

To determine the total number of liters of diesel oil per hectare required by cultivation, implantation, and protection, the different sequences of operations used in characteristic areas of cultivation, whether conventional or no-till, and the latter with or without leading technology.

The sequences of operations involved in each crop are detailed below (Márgenes Agropecuarios, 2007):

First-crop Soybean:

Conventional 33.1 L/ha

1. Southeast Bs. As.: 2 Double disc; 1 Vertical-tillage cultivator with tine harrow; 1 Sowing; 1 Fertilization and 3 Sprayings.

No-till sowing 17.1 L/ha

North and west of Bs. As., Santa Fe, South of Entre Ríos, South of Córdoba, South of Sgo. del Estero, Salta and Southwest Bs. As.:

1 No-till sowing; 1 Fertilization and 6 Sprayings.

No-till sowing with leading technology 17.1 L/ha

South of Santa Fe: 1 No-till sowing; 1 Fertilization and 6 Sprayings.

Second-crop Soybean:

No-till sowing 13.5 L/ha

Southeast Córdoba, North of Bs. As., South of Sta. Fé and West of Bs. As.: 1 No-till sowing and 4 Sprayings.

Fuel consumption per operation was calculated using Costo Maq software, which has an important database of over 30 years of test results of agricultural machines on a static bench and on the field, under varied operating conditions, that makes it possible to obtain results closer to reality (Donato et al., 2007; 2006, 2003).

To calculate diesel oil consumption during the harvest of the grain, the data was used of the average work capacity of two categories of harvesters that represent a high percentage of the machines used in our country. (Márgenes Agropecuarios, 2007 and Bragachini et al., 2001).

Table 1 - Harvest: work capacities of the main crops

CROP WORK CAPACITY (ha/h)

Soybean 4.30 – 7.00

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The average diesel oil consumption of a harvester was considered 46 L/h and that of a tractor used for carrying operations was considered 14 L/h, for a total of 60 L/h as harvesting consumption per hour. Using these data in Table 2, diesel oil consumption per hectare was calculated for the harvest.

Table 2 – Harvest: Fuel consumption per hectare

CROP Average work capacity

(ha/h) Consumption per hour (L/h)

Consumption per hectare (L/ha)

Soybean 5.65 60 10.62

Using the data from Tables 1 and 2, Table 3 was made, in which fuel consumption per hectare can be observed for the agricultural operations involved.

Table 3 –Fuel consumption per hectare

CROP OPERATIONS CONSUMPTION

(L/ha)

HARVEST CONSUMPTION

(L/ha)

TOTAL OPERATIONS

(L/ha)

Conventional first-crop soybean 33.10 10.60 43.70

No-till first-crop soybean 17.10 10.60 27.70

No-till first-crop soybean with leading technology 17.10 10.60 27.70

No-till second-crop soybean 13.50 10.60 24.10

Fuel consumption estimate for transportation (short freight)

Following reliable sources to estimate the amount of fuel required to transport the grain from the fields to the broker, that is, what is commonly known as short freight, 2 liters of diesel oil per ton of grain transported was taken as a base. (INTA Manfredi, personal communication)1.

Based on the above assumption, as well as on the mean yields considered for the harvest and the total harvested surface of the country, the amount of diesel oil involved in this instance was calculated (Table 4).

Table 4 – Fuel consumption of the main crops per hectare

CROP YIELD (ton/ha)

SHORT FREIGHT CONSUM. (L/ton)

TOTAL TRANSPORTAT. CONSUMPTION

(L/ha))

Conventional first-crop soybean 2.80 2.00 5.60

No-till first-crop soybean 2.80 2.00 5.60

No-till first-crop soybean with leading technology 4.50 2.00 9.00

No-till second-crop soybean 2.20 2.00 4.40

1 INTA Manfredi. Manfredi Experimental Agricultural Station. INTA. 2005.

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Grain drying

Two stretches were considered in the process of drying the grain: 1st stretch from the field to the storage plant, and 2nd stretch from the storage plant to the oil factory. Only 10% of the production of the 1st stretch is dried with diesel oil; the rest is dried with liquefied gas or natural gas. According to reliable sources (Mega S.A., personal communication)2, none of what is dried for the oil industry (2nd stretch) is dried with diesel oil, due to cost and security issues.

The total kilocalories per ton of crop (Table 5) were calculated based on the difference in humidity between the harvested grain and that required at the storage plant, and the kilocalories necessary per ton to reduce the humidity percentage. There was no data available for rapeseed.

Table 5 –Fuel consumption per ton of grain dried

CROP

Initial Humidity

Final Humidity (%)

kcal/ton/ point

total kCal /ton

L/ton

Soybean 16→13 10,000 30,000 3.75

Once the total kilocalories per ton of grain were obtained, and knowing that one liter of diesel oil is equivalent to 8,000 kCal, the liters necessary to reduce the humidity to the percentage required per ton of gain were calculated. Based on the liters per ton and the crop yield (ton/ha), the diesel oil consumption required for drying per crop per hectare was calculated (Table 6).

Table 6 – Fuel consumption per hectare used in the grain drying process

CROP YIELD (ton/ha)

DRYING CONSUMPTION

(L/ton)

LITERS CONSUMED

(L/ha)

Conventional first-crop soybean 2.80 3.75 10.50

No-till first-crop soybean 2.80 3.75 10.50

No-till first-crop soybean with leading technology 4.50 3.75 16.88

No-till second-crop soybean 2.20 3.75 8.25

Liters of diesel oil per hectare consumed at the agricultural stage.

Table 7 shows the total L/ha diesel oil consumed during the agricultural stage according to the productive system used. This result was obtained by adding the liters of diesel oil used in the agricultural operations of tilling, implantation, protection and harvest of the crops (Table 3), to the liters used in transportation of the grain (short freight) from the farm to the storage plant, and the liters used in the first drying of the grain.

2 MEGA S.A. grain dryers. November 2005.

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Table 7 –Fuel consumption per hectare at the agricultural stage of the crop

CROP TOTAL

OPERATIONS (L/ha

TOTAL TRANSPORT. (L/ha)

TOTAL DRYING (L/ha)

TOTAL AGRICULT. STAGE (L/ha)

Conventional first-crop soybean

43.70 5.60 10.50 59.80

No-till first-crop soybean 27.70 5.60 10.50 43.80

No-till first-crop soybean with leading technology

27.70 9.00 16.88 53.58

No-till second-crop soybean 24.10 4.40 8.25 36.75

Transformation of the liters of diesel oil per hectare in direct energy (MJ/ha)

In Table 8, the liters per hectare consumed at the agricultural stage of the crops were transformed into kCal/ha, bearing in mind that one liter of diesel oil equals 8,000 kCal and that 1 calorie equals 4,18 joule.

Table 8 – Direct energy in MJ/ha used during the agricultural stage

CROP

TOTAL AGRICULT STAGE (L/ha)

ENERGY (kCal/ha)

ENERGY (kJ/ha)

ENERGY (MJ/ha)

Conventional first-crop soybean

59.80 478,400 1,999,712 2,000

No-till first-crop soybean 43.80 350,400 1.465.672 1,465

No-till first-crop soybean with leading technology

53.58 428,600 1,791,548 1,792

No-till second-crop soybean 36.75 294,000 1,228,920 1,229

Estimate of the energy required by the consumables involved in the production of the crops

A calculation was made of the consumption of indirect energy involved in the production (implantation and care) of the crop, that is, the energy needed by the seed, fertilizers and agrochemicals. The same areas and production systems described in the preceding chapter were used (Márgenes Agropecuarios, 2007).

Based on the data found in the bibliography consulted, Table 9 was developed with the energy equivalents of the consumables used in the production of the crops studied.

Table 9 –Energy equivalents of consumables used during the agricultural stage

CONSUMABLE UNIT ENERGY (MJ/unit))

REFERENCE

Soybean seed kg 16.62 Denoia et al, 2006

Corn seed kg 32.99 Denoia et al, 2006

Sunflower seed kg 23.00 UTFSM – Chile, 2007

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Sorghum seed kg 32.99 Denoia et al, 2006

Rapeseed seed kg 27.00 UTFSM – Chile, 2007

Fertilizers:

N kg 77.41 Dos Santos et al, 2000

P kg 14.00 Dos Santos et al, 2000

K kg 9.68 Dos Santos et al, 2000

S kg 6.04 Dos Santos et al, 2000

Herbicides L 418.00 Dos Santos et al, 2000

Insecticides L 364.00 Dos Santos et al, 2000

Fungicides L 272.00 Dos Santos et al, 2000

Inoculants L 11.30 Dos Santos et al, 2000

Table 10, developed with the charts in Annex 1, shows the indirect energy used at the agricultural stage of soybean cultivation per productive system and area. Total indirect energy was the average of the different areas with the same production system.

Table 10 –Indirect energy in MJ/ha used during the SOYBEAN agricultural stage

CROP INDIRECT ENERGY (MJ/ha)

TOTAL INDIRECT ENERGY (MJ/ha)

Conventional first-crop soybean

4,024

No-till first-crop soybean 5,531

N. Bs. As./S. Sta. Fe 5,259.17

S. Entre Ríos 5,005.96

S. Córdoba 6,318.66

W. Bs. As. 5,324.57

S. Sgo. del Estero 6,274.95

Salta 5,655.48

Southwest Bs. As. 4,876.78

No-till second-crop soybean

Southeast Córdoba 3,605.68 3,548

N. Bs. As./S. Sta. Fe 3,354.88

N. Bs. As./S. Sta. Fe 3,605.68

West Bs. As. 3,625.88

No-till first-crop soybean with leading technology

4,427

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Estimate of energy consumption during the industrial stages

The industrial stage of the biofuel production process includes de extraction of oil from the oleaginous plant and the transformation of that oil into biodiesel. The variability of the process will influence the consumption of raw materials and the use of resources.

There are different methods to obtain oil from the grain, which can be classified in two groups: mechanical and chemical. The former include the extraction of oil by pressing, and the latter extract the oil by means of solvents. There is a third kind of process that is a combination of both. In Argentina, surveys show that there are 15 businesses (whose combined production capacity is 52,000 tons) that use extraction by solvent; 7 businesses that combine processes (production capacity: 18,000 tons) and 6 businesses that extract by means of presses (production capacity: 730 tons)

In all cases, the grain must be prepared before the process is started. Preparation includes sampling, sifting and drying, according to the specific requirements of the processes.

In the particular case of soybean, an average of 17% of the weight of the grain is obtained in oil, 80% in byproducts and 3% is waste. The grain must enter the process with 10% - 10.5% humidity. The first step is breaking the grain, which must be reduced to one eighth of its original state. It is later laminated and subjected to steam before entering the extraction process. At this stage the solvent (hexane) is added, and the mixture is sent to distillation. After distillation, the evaporated solvent is condensed and stored, while the crude oil is sent to storage tanks and the solid residue is compacted and dried.

The biodiesel production process has different variables and configurations, which depend on the raw material used (type of oil and its composition) and on the production capacity and form of operation of the plant. Before biodiesel production, the oil to be used must be treated. If it is an unused oil (extracted from the seed), it must be degummed. If it is used, it must be filtered and then dried to reduce its water content.

The main difference between one raw material and another is the amount of free fatty acids associated to its triglycerides. These will determine whether an acid or alkaline catalysis takes place in the biodiesel production process. Fat transesterification takes place with acid catalysis, while, in most oils, transesterification is alkaline.

The most convenient methodology for the small producer is the Bach process, which operates on a certain amount of material, using an alkaline catalyst, in most cases sodium hydroxide (Na(OH)).

The stages of this process are:

� Preliminary mixing: At this stage, alcohol is mixed with the catalyst and the corresponding methoxide is obtained.. Depending on the temperature, agitation and the type of alcohol, the reaction may take from 5 minutes to 1 hour.

� Transesterification: The main reaction of the process, in which the oil reacts with the methoxide, at a temperature of 65°C (minimum values of 25°C and maximum values of 85°C were studied) during one hour (minimum 20 minutes and maximum 2 hours). The reaction takes place at atmospheric pressure, although some experiences have been recorded in which the reactors work at higher pressure. The alcohol- triglyceride ratio is 6:1 (it is performed with 100% excess), while the amount of catalyst added is 1% of the weight of the mixture.

� This is the main stage due to the transformation of triglycerides in methylesters. The efficiency adopted is 93%, that is, 930 kg de biodiesel are obtained from 1,000 kg of oil3.

� Neutralization: An acid (sulfuric or hydrochloric) is added to neutralize the alkalinity obtained by the product with the addition of caustic soda. This step is carried out before sedimentation.

3 Transesterification efficiency values of between 85% and 94% were studied by the NREL (National Renewable Energy

Laboratory, USA). However, most studies adopt a transformation of 93%.

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� Separation: In the Bach processes, glycerin and biodiesel separation takes place in settling tanks. Based on the density difference, a “heavy” current (glycerin with impurities) and a “light” current (biodiesel with impurities) are obtained. The presence of alcohol in both phases may make separation difficult. If the sedimentation process takes place at a higher temperature, separation of the phases may be optimized because a temperature increase causes a decrease in viscosity and an increase of separation speed. The type of separator (centrifugal or gravity) also influences sedimentation time, which can go from 1 to 8 hours.

� Biodiesel purification: Biodiesel purification consists of three stages:

� Alcohol evaporation: Alcohol is recovered through evaporation. Care must be taken that there is no alcohol residue exist in the effluents.

� Washing: Water is added to eliminate impurities that may remain in the biodiesel, such as glycerin, alcohol and soaps. The water generated as an effluent may be used again in the purification of glycerin.

� Drying: It consists in eliminating the water that may remain in the final product

� Glycerin purification: Glycerin purification takes place in two stages.

� First stage – Refining: Refining may be physical or chemical. If physical, a flash distillation is produced at a temperature between 65° C and 93° C. If chemical, soaps must be removed with aluminum sulfate or ferric chloride, and purification finalized with activated carbon or clay.

� Second stage: Washing with steam injection followed by bleaching with activated carbon.

The following diagram shows biodiesel production based on the crops to study, according to the oil content and its transformation into biodiesel

Soybean

The following table shows, in general, the mass balances of the biodiesel production process from the grain. The main consumables and byproducts obtained have been included. The basis for calculation has been to adjust the variables of the process to obtain 1,000 kg of oil. The process flow diagram is included in ANNEX 2.

Table 17 – Mass balance per crop, for biodiesel production.

CROP ITEM

SOYBEAN4

Raw materials

Grains 5,880 kg

Consumables

Hydroxide 6 kg Na(OH)

Alcohol (methanol) 355.5 kg

Acid 6 kg (sulfuric)

Water 320 kg

4 Several sources

Grain 1000 kg

OIL EXTRACTION

Oil 190 kg

TRANSESTERIFICATION

Biodiesel 170 kg

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Hexane

Product

Oil 1,000 kg (17%)

O

Biodiesel 930 kg

Byproduct

Flours/pellets 4,700 kg

Glycerin 110 kg

Waste

Residual waters 63 kg

It can be observed that the main variable influencing the amount of biodiesel generated is the oil content of the grain. The amounts of hexane that enter the oil extraction process were not included because hexane is recovered by cooling and reused. The same happens with alcohol in the transesterification process. Alcohol is used in excess and part of it is recovered and reused.

Energy consumption analysis in an industrial process.

Since there have not been any experiences developed in the country regarding energy consumption at the industrial stage, previous studies were adopted to obtain the energy consumption parameters of the biodiesel production process. The results cover oil extraction (more commonly carried out by pressing and solvent) and its transformation into biofuel.

The survey was conducted based on documents that studied energy consumption in small and medium scale production plants. Lab scale studies were omitted, since their efficiency may turn out to be greater.

The following table shows the energy consumption values reviewed per liter of biofuel produced, based on the different sources consulted.

Table 18 – Studies on energy consumption in the biodiesel process

Document Name

Data Comments

8.1 MJ/l (SOYBEAN) of energy consumed in the industrial process

15 MJ/l (SOYBEAN) of energy consumed in the industrial process

9.6 MJ/l (RAPESEED) of energy consumed in the industrial process

17.8 MJ/l (SUNFLOWER) of energy consumed in the industrial process

Lobato et. al 2007

12.9 MJ/l (RAPESEED) of energy consumed in the industrial process

The industrial process contemplates the production of oil and biodiesel.

Universidad Técnica Federico Santa María 2006

Shows values of 17 to 15 MJ/L in the industrial process, for sunflower and rapeseed.

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Vicente et al 2007. 5 MJ generated per MJ used in sunflower-based biodiesel production

Talens et al 2006 1.47 MJ generated per MJ consumed in the sunflower production process. TOTAL:

Bears in mind the energy of the byproducts

Energy uses Heat (kcal/ton biodiesel produced)

Minimum: 95,022.7 Maximum value: 617,922.2 Average: 329,793.5

Electricity (kWh/ton biodiesel produced) Minimum: 9.0 Maximum value: 40.0 Base line: 28.9 APPROX TOTAL = 2 MJ/L

For soybean oil based biodiesel production process procurement

Sheman, et al 2005. Biodiesel energy balances based on SOYBEAN. The final balance is 3:1. The energy required at each stage of the process is the following: (MJ cons/MJ ob) Agriculture: 0.0656 21.08% Transportation 0.0034 1.09% Oil obtaining 0.0796 25.61% Transportation 0.0072 2.31% Transesterification 0.1508 48.49% Transportation 0.0044 1.41% Total 0.3110 100.00%

Includes all stages of the process.

Pimentel D. et al 2005

Energy consumption in the process of obtaining biodiesel based on soybean: • Electricity: 2,562 MJ/L • Steam: 4.96 MJ/L • Total process w/o considering the energy

contained in the seed: 15 MJ/L • Total process (w/ the energy contained in the

seed): 43.66 MJ/Lt Energy consumption in the process of obtaining biodiesel based on sunflower: • Electricity: 2,.562 MJ/L • Steam: 4.96 MJ/L • Total process w/o considering the energy

contained in the seed: 13.23 MJ/L • Total process (w/ the energy contained in the

seed)): 72.05 MJ/L

In the energy consumption of the process, the author considers the energy contained in the seed or the oil. In the energy consumption analysis, fossil energy to produce biofuel (15 MJ/L for soybean and 13.23 MJ/L for sunflower) will be taken into consideration

Elsayed M. A. et al 2003 Oil extraction process: 2.47 MJ/L Biodiesel production process: 5.02 MJ/L.

Rapeseed-based biodiesel production.

Given the variability of the data obtained, it is recommended to obtain more precise data from operating plants for a better analysis. The energy balance of the production process may also vary according to the type of process and the efficiency of the equipment used.

Energy contained in products and byproducts

Energy generation in the biodiesel production process is varied, and its analysis is conducted based on the uses for which its byproducts are destined. As it happened when discussing the energy obtained from bioethanol products, it is important to consider the definitions developed in that section.

The product obtained from the process, biodiesel, is used as an alternative fuel. To perform the energy balance, its lower calorific power is taken, which lies between 35 MJ/L and 33 MJ/L. The

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study by Talents et al obtains an energy value of 31,35 MJ/kg, lower than that of other studies. These values are referenced in different international standards, in which calorific power constitutes an important parameter to consider, since, to a certain extent, it characterizes the energy delivered by the fuel. 35 MJ/L is taken as a reference value.

With respect to byproducts, the discussion is similar to that of the bioethanol process. In this case, the following considerations will be taken into account:

� For glycerin, the lower calorific power will be considered. In some cases, glycerin can be used as fuel in the production process, although its energy value is low due to its water content. In other cases, the purification of glycerin allows its use for other purposes (in the chemical, pharmaceutical and cosmetic fields, according to Larrosa).

For the energy balance performed later, the lower calorific power of glycerin will be considered, estimated at 16,5 MJ/kg of glycerin.

� Regarding the energy of the flours obtained, there is information collected on their protein power, as there are used as animal feed. It would not be coherent to hypothesize that the flour will be destined to the generation of thermal or electric energy, since its main destination is feeding. The correct procedure for this case in point would be to learn how much energy is consumed to produce a feed with the same protein characteristics as those obtained in the industrial process. Since that information is not available, and in order to have a reference value to perform the energy balance, the data on gross energy of the flour, estimated at 18 MJ/kg, will be used (for all three cases in general)

The following table summarizes some values of the calorific powers of biodiesel and its byproducts cited by different authors.

Table 19 – Calorific powers of biodiesel and derived byproducts

SOURCE CROP BIODIESEL NCP(MJ/L)

GLYCERIN NCP (MJ/kg)

Flour Gross Energy (MJ/Kg)

Lobato et al 2005 Soybean 33.3 16.55 16.84

Larrosa et al General 35

Stout et al 2000 Soybean 35.24

Fukuda et al Soybean 33.5

Energy balance itself

Based on data obtained at the industrial and agricultural stages, the energy balance was performed. It must be taken into account that the data corresponding to the agricultural stage were taken in Argentina, while those corresponding to the industrial stage were collected from experiences carried out in other countries.

As in most of the studies, to obtain the energy balance the net energy values (NEV) will be looked at and the relationship between energy inputs and outputs. The net energy value expresses the amount of energy that would be generated, taking byproducts into account or not. The energy relation would give an idea of how much energy is generated in relation to that consumed.

For this study in particular, both are defined as follows:

� Net energy value = Generated energy – Consumed energy

� Energy relation = Generated energy / Consumed energy

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The different existing relations will be found in order to compare the results with those of other studies performed. The unit to be used shall be MJ consumed or generated per liter of biofuel generated. Consumed and generated energies shall be calculated separately, making the respective unit transformations.

Table 20 – Energy consumption in biofuel production at the agricultural stage

ENERGY CROPS

Direct MJ/ha Indirect MJ/ha TOTAL Yield ton/ha

Consumption MJ/ton

Conventional first-crop soybean 2000 4024 6024 2.80 2151.4

No-till first-crop soybean 1465 5531 6995 2.80 2498.2

No-till first-crop soybean with leading technology 1792 4427 6219 4.50 1382

No-till second-crop soybean 1229 3548 4777 2.2 2171.4

The fuel used for the different operations is considered direct energy, and the gross energy in the seeds, fertilizers, agrochemicals and other elements added at this stage is considered indirect energy. The energy consumption per ton of grain produced is obtained by multiplying the total energy consumed by the yield.

Table 21 – Energy output in biofuel production at the agricultural stage

CROPS Yield ton/ha Consumption

MJ/ton

Biofuel production (L/ton)

Energy consumed/ liter (MJ/L)

Conventional first-crop soybean 2.80 2151.4 180.0 12.0

No-till first-crop soybean 2.80 2498.2 180.0 13.9

No-till first-crop soybean with leading technology 4.50 1382.0 180.0 7.7

No-till second-crop soybean 2.20 2171.4 180.0 12.1

Diesel oil consumption for long freight is 7.7 L/ton. Bearing in mind the calorific power of diesel oil (8,000 kcal/L), transforming the result to MJ and operating so as to obtain the energy consumption in relation to biofuel production, the following table results

Table 22 – Energy output in biodiesel production for transportation to the oil refinery plant

CROPS Energy consumption per long freight

(MJ/ton)

Biofuel Production (L/ton)

Energy consumption per transport to oil refinery (MJ/L)

Soybean 257.9 180 1.43

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As for the industrial process, the maximum and minimum values reported in the studies cited in the bibliography for the crops involved. In the case of sweet sorghum, the values taken are those of the bioethanol production process from corn in the dry milling process.

Table 23 – Energy output in biodiesel production at the industrial stage

Energy output of the process MJ/L CROPS

Maximum Minimum

Soybean 15.00 8.00

The energy balances collected bear in mind the energy of the consumables (methanol, sodium hydroxide, potassium hydroxide, sulfuric acid, water and enzymes). Values below those reported in different publications were not taken into consideration. Energy consumption per liter of biofuel lies between 7 and 18 MJ/L both for the biodiesel and the bioethanol process; therefore, the values within this range were specified.

It is important to decide whether to contemplate transportation from the biofuel plant to the selling point. For those values, an average of 4.8 L of diesel oil per ton transported between “short freight” and “long freight” is adopted.

Table 24 – Energy output in biodiesel production for transportation to the selling point

CROP

Energy consumption per freight to selling point (MJ/ton)

Biofuel production (L/ton)

TOTAL (MJ/L)

Soybean 160.77 180 0.89

The total energy consumption for the biodiesel production was obtained by adding the industrial and agricultural stages to the different transfers of intermediate products. The maximum and minimum values related to the industrial stage will be taken, since, as discussed before, the value obtained in this stage is influenced by the different technologies used.

Table 25 – Energy consumption per liter of biofuel generated

Industrial Process TOTAL CROPS Farm (MJ/L)

Transp. to oil refinery

Maximum Minimum

Transp. to selling pt.

Max. Min

Conventional first-crop Soybean 12 1.43 15 8.00 0.89

29.32 22.32

No-till first-crop soybean 13.9

1.43

15 8.00 0.89 31.22 24.22

No-till first-crop soybean w/leading technology 7.7

1.43

15 8.00 0.89 25.02 18.02

No-till second-crop soybean 12.1

1.43

15 8.00 0.89 29.42 22.42

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Energy generated.

The energy generated is the product obtained from the process. The results of biodiesel manufacture are products used as fuels (biodiesel; possibly also glycerin) and as foods.

The energy content of biodiesel is measured on the basis of the lower and higher calorific powers previously defined. The lower calorific power will be considered in order to make a conservative analysis. The value assigned was:

� Biodiesel calorific power: 35 MJ/L

It is at this point that most studies on “Life Cycle Analysis” focus: how to assign energy values to byproducts. The four methods developed were shown, selecting the best suited in each case for which reference values are found.

In order to transform the energy values of the byproducts to the unit of reference (MJ/L of biofuel), the amount generated will be taken (in mass units) and divided by the liters of biodiesel this raw material generates:

Amount of glycerin generated: 110 kg

Amount of biodiesel generated: 1057 L

Kg of glycerin per L of biodiesel = 110 kg of glycerin/1057 L of biodiesel = 0.104 kg/L.

Energy value assigned to glycerin: 16.5 MJ/kg

Energy obtained from glycerin per liter of biofuel:

16.5 MJ/kg x 0.104 kg/L = 1.72 MJ/L

Table 26 – Energy generated by byproducts

BYPRODUCT Energy Value (MJ/kg)

CROP Amt.

Generated (kg)

LTS OF BIOFUEL

.

AMT KG/LTS BIOFUEL

TOTAL ENERGY BYP. (MJ/L BIO)

Flour 18 Soybean 4,700 1,057 4.45 80.04

Glycerin 16.5 Soybean 110 1,057 0.10 1.72

It may be observed that the energy generated from the flours is produced in greater amounts, due to the large mass of material generated. Due to its low generation and its low calorific power, glycerin has a lower impact, while the byproducts of the milling of corn and sorghum have similar energy contents.

The table below shows the percentage of energy generated by products and byproducts, in relation to the total energy generated:

Table 27 – Percentage of energy delivered by products and byproducts

PROD E BYPROD E

CROP TOTAL (MJ/L)

% TOTAL %

Soybean 35 30 81.75 70

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Energy balance

With the values above, the following tables were developed with the corresponding energy balances. Two tables were developed so as to obtain results for the maximum and minimum consumption of fossil energy. In each of the tables, in turn, the net energy values (NEV) and the energy relation (Generated energy/Consumed energy) is calculated both without considering byproducts and taking them into consideration.

Table 28 - Energy balance of biofuels with maximum fossil energy consumption

INPUTS BALANCE

CROPS MAXIMUM CONSUMPT. Prod. E Bypr. E NEV 1 NEV 2 ER 1 ER 2

Conventional first-crop Soybean

29.32 35.00 81.75 5.68 87.43 1.19 3.98

No-till first-crop soybean

31.22 35.00 81.75 3.78 85.53 1.12 3.74

No-till first-crop soybean w/leading technology

25.02 35.00 81.75 9.98 91.73 1.40 4.67

No-till second-crop soybean

29.42 35.00 81.75 5.58 87.33 1.19 3.97

Table 29 – Energy balance of biofuels with minimum fossil energy consumption

INPUTS BALANCE

CROPS MINIMUM CONSUMPT. Prod. E Bypr. E NEV 1 NEV 2 ER 1 ER 2

Conventional first-crop Soybean 22.32 35.00 81.75 12.68 94.43 1.57 5.23 No-till first-crop soybean 24.22 35.00 81.75 10.78 92.53 1.45 4.82 No-till first-crop soybean w/leading technology 18.02 35.00 81.75 16.98 98.73 1.94 6.48 No-till second-crop soybean 22.42 35.00 81.75 12.58 94.33 1.56 5.21

Notes:

All values in the tables are expressed in MJ/L.

References

NEV 1 = Prod E– Consumption NEV 2 = Prod E + Bypr E – Consumption ER 1 = Prod E /Consumption ER 2 = (Prod E + Bypr E)/Consumption

Discussion of the results.

� Biodiesel:

There is something very peculiar about soybean byproducts. Their energy relation values vary between 1.12 (no-till first crop soybean with maximum energy consumption) and 1.94 (no-till first crop soybean with leading technology, with minimum energy consumption) if the byproducts

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generated are not taken into account. If we do consider these, energy relation values vary between 3.74 and 6.48, for the same systems mentioned before. In the latter case, it is important to bear in mind that 70% of the energy generated by soybean cultivation comes from its byproducts.

It is important to point out that no studies have been found in which the energy relation is as high as the maximum value found for soybean (6.48). Sheehan et al. (1998) consider a relation of 3 energy units generated per unit of fossil energy consumed. Lobato (2007) also finds that the net energy balance varies between 1.16 and 3.38 according to the values assigned to byproducts.

If we consider the byproducts and take the total energy generated (whether as a substitute for fossil fuels, as food or for other uses) no-till first-crop soybean with leading technology shows the highest relation. It is worth noticing that in any of the cases the result of the relation between the energies generated and those consumed was higher than one, which means there exists energy generation.

Conclusions

� In general terms it can be observed that the energy balances shown above are mostly positive, even under the worst conditions (maximum energy consumption values of the process; lack of consideration of the value of the byproducts, lower calorific power)

� The bibliography consulted shows a certain homogeneity regarding the energy relation results obtained. However, diverse methods are applied to quantify the byproducts in terms of energy.

� More energy consumption takes place during the industrial phase. However, this is the main point to study in real cases in Argentina, since the energy variable will be tied to the technology used.

� The energy values assigned to the byproducts influence the final result.

� Energy consumption values obtained at the agricultural stage are reliable at the time of performing a new energy balance.

Limitations and opportunities resulting from the study

� It is imperative to conduct real studies of energy consumption in small, medium and large scale biodiesel and bioethanol plants in Argentina. The data used in this study were collected from bibliography and papers developed in Europe and the USA, where there is leading technology for biodiesel production. The variables of the industrial process influence the final results.

� It is also important to assign an adequate energy value to the byproducts. This should be done by finding the energy consumption of plants producing substitutes or products that can be replaced by the byproducts obtained from biodiesel, such as balanced foods, animal nutrition diets, and so on. This would provide information about whether or not there exists energy savings.

� The results shown earlier are obtained on the basis of assumptions. It is difficult to be certain when conducting a global scale study. This paper has attempted to offer a general view of energy consumption in biofuel production.

� It is necessary to conduct a sensitivity study of the variables, provided we have access to true data at all the phases of production.

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ANNEX (*)

Soja 1° Convencional 4024 Mj/ha

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

unidad/ha unidad/ha Mj/unidad MJ/ha

Semilla RR kg/ha 70.00 16.62 1163.40Inocul.+ Fungicida L/ha 1.40 283.30 396.62Superfosfato Triple kg/ha 50.00 10 14.00 140.00Sencorex L/ha 1.10 418.00 459.80Acetoclor L/ha 2.50 418.00 1045.00Lorsban Plus L/ha 0.70 364.00 254.80Lorsban 48 E L/ha 1.40 364.00 509.60Cipermetrina L/ha 0.15 364.00 54.60TOTAL 4023.82

Soja 1° SD 5531 Mj/ha

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

N. Bs. As./S. Sta. Fe unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 4.00 418.00 1672.00Metsulfuron Metil kg/ha 0.01 418.00 3.342,4 D 100% L/ha 0.50 418.00 209.00Semilla RR kg/ha 70.00 16.62 1163.40Inocul.+ Fungicida L/ha 1.40 283.30 396.62Fosfato Monoamónico 23% P kg/ha 40.00 9.2 14.00 128.80

11% N 4.4 77.41 340.60Roundup Max kg/ha 1.50 418.00 627.00Decis Forte L/ha 0.05 364.00 18.20Lorsban 48 E L/ha 1.40 364.00 509.60Cipermetrina L/ha 0.15 364.00 54.60Opera L/ha 0.50 272.00 136.00TOTAL 5259.17

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

S. Entre Ríos unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 5.00 418.00 2090.00Metsulfuron Metil kg/ha 0.01 418.00 3.342,4 D 100% L/ha 0.30 418.00 125.40Semilla RR kg/ha 70.00 16.62 1163.40Inocul.+ Fungicida L/ha 1.40 283.30 396.62Superfosfato Triple kg/ha 50.00 10 14.00 140.00Roundup Max kg/ha 1.10 418.00 459.80Decis Forte L/ha 0.05 364.00 18.20Lorsban 48 E L/ha 0.60 364.00 218.40Cipermetrina L/ha 0.10 364.00 36.40Endosulfan L/ha 0.60 364.00 218.40Opera L/ha 0.50 272.00 136.00TOTAL 5005.96

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INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

S. Córdoba unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 7.00 418.00 2926.00Metsulfuron Metil kg/ha 0.01 418.00 4.182,4 D 100% L/ha 0.50 418.00 209.00Semilla RR kg/ha 80.00 16.62 1329.60Inocul.+ Fungicida L/ha 1.60 283.30 453.28Roundup Max kg/ha 1.10 418.00 459.80Decis Forte L/ha 0.05 364.00 18.20Lorsban 48 E L/ha 1.40 364.00 509.60Cipermetrina L/ha 0.25 364.00 91.00Endosulfan L/ha 0.50 364.00 182.00Opera L/ha 0.50 272.00 136.00TOTAL 6318.66

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

O. Bs. As. unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/haRoundup Full L/ha 3.50 418.00 1463.00Metsulfuron Metil kg/ha 0.01 418.00 3.34Semilla RR kg/ha 70.00 16.62 1163.40Inocul.+ Fungicida L/ha 1.40 283.30 396.62Fosfato Monoamónico 23% P kg/ha 40.00 9.2 14.00 128.80

11% N 4.4 77.41 340.60Roundup Max kg/ha 2.70 418.00 1128.60Lorsban 48 E L/ha 1.40 364.00 509.60Cipermetrina L/ha 0.15 364.00 54.60Opera L/ha 0.50 272.00 136.00TOTAL 5324.57

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

S. Sgo. del Estero unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 7.00 418.00 2926.00Semilla RR kg/ha 80.00 16.62 1329.60Inocul.+ Fungicida L/ha 1.60 283.30 453.28Metsulfuron Metil kg/ha 0.00 418.00 1.672,4 D 100% L/ha 0.50 418.00 209.00Lorsban 48 E L/ha 1.40 364.00 509.60Cipermetrina L/ha 0.45 364.00 163.80

Endosulfan L/ha 1.50 364.00 546.00Opera L/ha 0.50 272.00 136.00TOTAL 6274.95

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INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

Salta unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 6.00 418.00 2508.00Semilla RR kg/ha 80.00 16.62 1329.60Inocul.+ Fungicida L/ha 1.60 283.30 453.28Roundup Max kg/ha 1.10 418.00 459.80Decis Dan L/ha 0.50 364.00 182.00Lorsban 48 E L/ha 1.40 364.00 509.60Cipermetrina L/ha 0.10 364.00 36.40

Taspa L/ha 0.15 272.00 40.80Opera L/ha 0.50 272.00 136.00TOTAL 5655.48

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

Sudoeste Bs. As. unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 6.00 418.00 2508.00Semilla RR kg/ha 80.00 16.62 1329.60Inocul.+ Fungicida L/ha 1.60 283.30 453.28Superfosfato Triple kg/ha 40.00 8 14.00 112.002,4 D 100% L/ha 0.35 418.00 146.30Lorsban 48 E L/ha 0.70 364.00 254.80Cipermetrina L/ha 0.20 364.00 72.80TOTAL 4876.78

Soja 2° SD 3548 Mj/ha

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

Sudeste Córdoba unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 2.50 418.00 1045.00Semilla RR kg/ha 80.00 16.62 1329.60Inocul.+ Fungicida L/ha 1.60 283.30 453.28Roundup Max kg/ha 1.10 418.00 459.80Decis Dan L/ha 0.50 364.00 182.00Opera L/ha 0.50 272.00 136.00TOTAL 3605.68

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

N. Bs. As./S. Sta. Fe unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 2.50 418.00 1045.00Semilla RR kg/ha 80.00 16.62 1329.60Inocul.+ Fungicida L/ha 1.60 283.30 453.28Pivot H L/ha 0.50 418.00 209.00Decis Dan L/ha 0.50 364.00 182.00Opera L/ha 0.50 272.00 136.00TOTAL 3354.88

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INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

N. Bs. As./S. Sta. Fe unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 2.50 418.00 1045.00Semilla RR kg/ha 80.00 16.62 1329.60Inocul.+ Fungicida L/ha 1.60 283.30 453.28Roundup Max kg/ha 1.10 418.00 459.80Decis Dan L/ha 0.50 364.00 182.00Opera L/ha 0.50 272.00 136.00TOTAL 3605.68

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

Oeste Bs. As. unidad/ha unidad/ha Mj/unidad MJ/ha

Glifosato L/ha 2.00 418.00 836.00Semilla RR kg/ha 80.00 16.62 1329.60Inocul.+ Fungicida L/ha 1.60 283.30 453.28Roundup Max kg/ha 1.30 418.00 543.40Lorsban 48 E L/ha 0.70 364.00 254.80Cipermetrina 25% L/ha 0.20 364.00 72.80Opera L/ha 0.50 272.00 136.00TOTAL 3625.88

Soja 1° SD Tecn. Punta 4427 Mj/ha

INSUMOS Unidad CantidadCantidad ppio.

activoEnergía Energía

unidad/ha unidad/ha Mj/unidad MJ/ha

Semilla RR kg/ha 60.00 16.62 997.20Inocul.+ Fungicida L/ha 1.20 283.30 339.96Roundup Full L/ha 4.00 418.00 1672.00Roundup Max kg/ha 1.50 418.00 627.00Fertilizante Azufre S-15 kg/ha 120.00 18 6.04 108.72Decis 5% L/ha 0.10 364.00 36.40Lorsban 48 E L/ha 1.40 364.00 509.60Cipermetrina L/ha 0.15 364.00 54.60Fungicida Sphere L/ha 0.30 272.00 81.60TOTAL 4427.08

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