Since 2017, the corn ethanol industry has gone through rapid growth in Brazil, establishing itself as the delicate foundation of the country's bioeconomy. Representing 98% of the companies producing ethanol from corn in Brazil, the Brazilian Corn Ethanol Association (UNEM) has been supporting the cause of environmentally sustainable fuel production and at the same time markets for food and feed.
Brazil currently has 21 ethanol plants utilizing corn, with half devoted only to corn ethanol and the other half flex plants that convert ethanol from sugarcane as well. Another 22 plants have now been planned or are under construction and shall raise production from 2.2 billion gallons presently to about 3.5 billion gallons in the coming years.
Those plants frequently employ renewable power sources, such as eucalyptus wood chips, hence lessening carbon footprints. Brazil plans also to sell carbon credits, thereby rendering the price of its ethanol lower worldwide, particularly for market areas such as Europe and California.
Now, Brazilian ethanol may gain stronger competition in the international platform. Overall, the establishment of the corn ethanol industry in Brazil has very steady growth, thus adding value to the domestic corn and its consequent production as a source of renewable fuels.
A Decade of Growth: The Period from Inception to Growth
Although still a young industry, Brazilian corn ethanol development has been quite impressive. Productivity has increased by 87% during this century, and the cultivated area in corn has also expanded by about 70%. Such intense evolution has been the result of modern biotechnology, new agricultural practices, and the introduction of corn ethanol production technologies from the USA.
This industry is not only intensifying crop production but is also enhancing land-use efficiency. Unique to Brazil is a double cropping system wherein two crops can be harvested in one year on the same land. For instance, soybean in summer and corn in winter, allowing livestock to graze in between. In some areas, corn is planted also as a third crop to increase productivity without any deforestation.
Corn Ethanol: Food, Feed, and Fuel
A common concern among international audiences is the so-called “food versus fuel” debate. In Brazil, this conflict is largely mitigated through sustainable production systems. Corn ethanol production generates multiple outputs:
- Ethanol fuel: 440 liters per ton of corn
- DDGS (Distillers Dried Grains with Solubles): 212 kg per ton of corn, a highly nutritious animal feed
- Corn oil: 19 kg per ton of corn
- Excess electricity: Supplied back to the grid
By using renewable sources like wood chips and even bamboo for steam production, Brazilian corn ethanol plants create a circular, environmentally sustainable system that provides fuel, food, and feed.
Expanding Production and Global Exports
Currently, Brazil operates 24 corn ethanol plants, with another 16 under construction and an additional 16 planned. Production is spreading geographically, from the central west region to the northeast, south, and north of Brazil, while also incorporating alternative crops such as sorghum and wheat for ethanol production.
The DDGS export market is growing rapidly, especially in Asia. In just four years, exports rose from $1 million to nearly $190 million. China alone has shown interest in purchasing 5 million tons of DDGS, highlighting Brazil's potential to become a global leader in renewable feed and biofuels.
Flex-Fuel Technology and Sustainability
Brazilian vehicles, 77% of which are flex-fuel, can run on either ethanol or gasoline. This flexibility reduces greenhouse gas emissions and positions Brazil as a global leader in sustainable mobility. Moreover, ethanol-fed DDGS allows livestock to be produced more efficiently, reducing the carbon footprint per animal while meeting international food demands.
Looking Ahead: Innovation and Carbon Reduction
The future of Brazilian corn ethanol includes:
- Sustainable aviation fuels to reduce emissions in the aviation sector
- Maritime biofuels for shipping industries
- Bioenergy with carbon capture and storage (BECCS): The first plant will become carbon-negative by capturing CO₂ from ethanol production and storing it underground
With the government increasing ethanol content in gasoline to 30% and the upcoming COP 30 in Brazil, the industry is well-positioned to accelerate renewable energy adoption while supporting the food-plus-fuel model, simultaneously producing fuel, feed, and food sustainably.
Brazil’s corn ethanol industry demonstrates that biofuel production can coexist with agricultural growth, environmental sustainability, and global trade expansion. With increasing domestic production, international exports, and ongoing technological innovation, Brazilian corn ethanol is setting a benchmark for the world in sustainable bioenergy solutions.
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