Ethanol may be produced using sugarcane bagasse as raw material through the Organosolv process with dilute acid hydrolysis, thus increasing ethanol production with the same cultivated sugarcane area. In this work simulations of bioethanol production from sugarcane juice and bagasse are carried out using software UniSim Design. A typical large scale production plant is considered: 1000 m(3)/day of ethanol is produced using sugarcane juice as raw material. A three-step hydrolysis process (pre-hydrolysis of hemicellulose, Organosolv delignification and cellulose hydrolysis) of surplus sugarcane bagasse is considered. Pinch analysis is used to determine the minimum hot utility obtained with thermal integration of the plant, in order to find out the maximum availability of bagasse that can be used in the hydrolysis process, taking into consideration the use of 50% of generated sugarcane trash as fuel for electricity and steam production. Two different cases were analyzed for the product purification step: conventional and double-effect distillation systems. It was found that the double-effect distillation system allows 90% of generated bagasse to be used as raw material in the hydrolysis plant, which accounts for an increase of 26% in bioethanol production, considering exclusively the fermentation of hexoses obtained from the cellulosic fraction. (C) 2009 The Institution of Chemical Engineers. Published by Elsevier B.V All rights reserved.