praj’s ‘integrated 2 generation smart bio-refinery’aidaindia.org/pdf/delhi2018/dr. tushar...

© Praj Industries Ltd CONFIDENTIAL www.praj.net

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Praj’s ‘Integrated 2nd GenerationSmart Bio-Refinery’

26th March 2018

• Indian ethanol scenario

• Praj 2G ethanol technology overview

• Praj 2G ethanol – Demonstration Project Highlights

• Models for setting up 2G projects in India

• Praj Offerings

Contents

Incauca Plant, Colombia2

© Praj Industries Ltd CONFIDENTIAL www.praj.net 2

Indian Ethanol Scenario

3© Praj Industries Ltd CONFIDENTIAL www.praj.net

Ethanol Demand & Supply scenario in India

Sectoral alcohol demand in India 2015 / 16

Particulars 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22

Petrol Sale

Projection

(8.38 % CAGR)

2759.6 34000 3241.5 3513.1 3807.5 44000

Ethanol Requirement

(@ 5% blending) 138 170 162 175 190 220

(@ 10% blending) 276 340 324 351 380 440

(@ 20% blending) 551 680 648 702 761 880

*All figures in crore liters


Sectoral alcohol demand in India 2016 / 17

• Low molasses

availability

• High molasses

prices

• Lower ethanol

price

Building success ladder 1G �� 2G

Quick scale-up & technology

Commercialization

Technology & Integration engineering

Project & construction management

Engineering&

Manufacturing

Over 3 Decades of rich experience of ethanol industry along with Praj’s core competencies enabled us in developing sustainable future ready

technologies


Praj’s core competencies

Research & Development

Knowledge base

of

750 References

75 countries

5 Continents

16

Patents

Praj 2G ethanol Technology – Overview


– technology optimization journey

Pilot Plant Operations

2009-15

Optimization on customer preferred biomass & Engineering package for commercial scale units

2014 -15

Execution of 12 TPD 2nd Gen Bio refinery

Operational Since Dec-2016

2016-17

Technology optimization journey

Biomass to Bio refinery

Operational since – January 2009

Raw material processing capability –

Rice straw, Wheat straw,

Sugarcane Bagasse, Cane trash, Pith

Corn Cobs + Corn Stover

Cotton stalk & Empty fruit bunches

Pilot plant trials validated work done at

laboratory & bench scale with Consistence

performance


Indian Feedstock Comprehensive mapping & Analysis

•600 + samples of

Lignocellulosic biomass from

India, Latin America, N.

America and Europe

•100 corn residue samples

from USA

Global Feedstock mapping

• 400 + samples across India :

Sugarcane residues, Corn

residues , Rice Straw,

Cotton stalk

Feedstock type distribution

• Validated analytical

methods from NREL USAAccomplishments

• Evaluation of newer

feedstock's like Empty Fruit

bunches from Palm, grasses,

MSW etc.

Continuous Program

Robust technology which can handle Regional & Seasonal Variability of

feedstock

Robust technology which can handle Regional & Seasonal Variability of

feedstock

Analysis done using standard NREL lap method


End-to-End Holistic & Integrated solution

© Praj Industries Ltd Confidential www.praj.net

Performance parameters at par with global benchmarks

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‘enfinity’ - Key technology highlights

Co-Fermentation

• Yeast strain for efficient utilization of C5 (pentose ) and C6 (hexose)

sugars

• Higher yield

• Lower reaction time

• Higher tolerance to solids

Proprietary end to end process

design

• Multi-feed capability

• Pre-treatment

• Efficient degradation of biomass to sugars

• Less Corrosive Process

• Better biological processing ability

• Efficient enzymatic hydrolysis

• Thermally integrated process to achieve low net energy usage

• Water recycled; achieve zero process liquid discharge

Enzyme Flexibility

• Proven technology on multiple enzymes

• High yields with different enzyme strains

Intellectual

Property

• LC Ethanol Technology –

• Process patent filed and already granted in India, SA, Kenya;

pending approval in other countries

• Four more patent applications in progress

© Praj Industries Ltd Confidential www.praj.net 10


Pretreatment Feedstock Handling

Feedstock Preparation System

Enzymatic Hydrolysis

Fermentation

Distillation &

Dehydration

Waste Water

Treatment

End to End integrated process

Value Chain

Leveraging expertise in Process optimization & Integration

Multi-Feedstock, Multi Product ‘SMART Bio Refinery’

CO2

Bio Fertilizers

Corn

Residues

Rice/Wheat

Straw

Sugarcane

Residue

Cotton Stalk

IndustrialAlcohol

Fuel Ethanol220-325 Liters

Bio-

Chemicals*

Power export

RectifiedSpiritBio-CNG

2nd

Gen

Multi-FeedstockMulti-Product


Praj innovative 2G Bio refinery provides higher returns

Praj expertise in technology scale-up

Praj has rich expertise of over 3 decades of technology scale-up


Quick scale-up & commercialization expertize

• End to end solutions from feedstock

processing to final product

• Integration engineering – water/energy

optimization

• Front end engineering & design (FEED)

• Process & equipment design

• SKID mounted systems

• PMC, EPCM Services

6 KLPD

1200 KLPD

Praj’s 1G Ethanol Plants – across globe

100 KLPD

200 KLPD

2nd Gen Pilot �� Demo �� Commercial Scale

Praj’s Integrated 2G ethanol Bio-refinery –Demonstration Project


8th Apr2016

Ground-

Breaking.

25th Dec2016

Mechanical

Completion

Jan/Feb2017

Sugarcane Bagasse

Campaign Trials

Mid Feb2017

Rice Straw

Campaign

Start

Apr2017

OMC’s Due

Diligence Run

7th May2017

Inauguration

Journey of Success

Key Highlights of Praj’s Integrated Demo Plant

• Integrated Bio refinery Demonstration Plant : Capacity – 1 MLPA Ethanol production

• Multi feedstock processing capability: Rice (paddy) Straw, Cotton stalk, Corn Cobs &

Corn Stover, Sugar Cane bagasse & Cane trash, Wheat Straw etc.

• Multi-product - The plant is designed to produce Bio-ethanol, Bio-gas / Bio-CNG, Bio

fertilizer, Provision for Production of Bio chemicals, Isobutanol – Jet fuel

• End to End Technology demonstration from feedstock processing till end product and

waste water treatment

• Zero Process Liquid Discharge

• Process Integration for optimization of Energy & Water consumption

Oil Marketing Company officials witnessed demo plant operations


Inauguration of Demo Plant – 7th May 2017


Praj ‘s 2G demonstration plant

MATERIAL HANDLING SYSTEM



PRETREATMENT SECTION

SOLID LIQUID SEPERATION SECTION

DISTILLATION

SECTION

Ethanol

Lignin Cake



HYDROLYSIS AND CO-FERMENTATION

2G ENZYME STORAGE

Hydrolyzed Slurry



WASTE WATER TREATMENT

Flare

Unit


Key highlights : Demo Plant

• Demo Plant operations stabilized, Dream run conducted from

7th March to 12th March 2017

• Operating at rated capacity of 12 MT/day dry biomass

processing

• Targeted parameters – Global Efficiency and Yields

achieved on the Sugarcane bagasse & Rice straws

• BPCL & EIL team consisting of 5 members visited Demo plant

from 10th to 13th April 2017 for review of the Plant

performance

• IOCL CFT of 7 members visited Demo plant from 10th to 14th

April 2017 for plant performance review

• Senior executives of Working group of biofuels, IOCL, HPCL,

BPCL, MRPL, EIL (team of 25 delegates) visited the Demo

Plant on 12th April 2017

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BPCL Team @ Praj Demo

Plant

IOCL Cross Functional Team @

Praj Demo Plant

Senior Executives of Working group of Biofuels, IOCL, BPCL, HPCL

MRPL, EIL @ Praj Demo plant

Oil Marketing Company officials witnessed demo plant operations

Status of 2G Ethanol commercial projects


Update on Commercial Projects

BPCL

• Received Purchase Order from Bharat Petroleum Corporation Limited

(BPCL), for Praj’s proprietary technology, basic engineering and design

package (BEDP)

• This is a major milestone towards commencement of work on the 2nd

Generation ethanol bio refinery with production capacity of 100 kiloliter

per day to be set up by BPCL at Bargarh, Odisha.

• The Purchase Order was awarded to Praj after the performance

evaluation of its 2nd generation integrated bio refinery demonstration

plant located in Maharashtra.

• Majority of the BEDP is ready for Execution


Update on Commercial Projects

• IOCL

• Signed MoU with IOCL for two commercial projects

• Panipat – Under finalization

• HPCL

• Praj is the only company short listed through global

tendering process (by Engineers India Ltd)





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Model for Setting up 2G ethanol projects in India





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Model # 1 : Bagasse to ethanol attached to Sugar

Cooling tower

COGEN Fermentation Distillation

Dehydration

Ethanol Storage

Enzymatic Hydrolysis

Pre-treatment

S/LSeperation

Black liquor concentrator

Waste Water treatment

Existing Production facility

Pretreated slurry

Lignin cake


Biomass


Hydrolyzed

slurry

Pre-treatment Pre-treatment

Enzymatic

Hydrolysis

Enzymatic

Hydrolysis

2G “Bolt-On”

Module

Fermentation

Distillation

Dehydration

Utilities

Existing 1G Bio-

ethanol

complex

Existing Sugar

Factory

Existing Sugar

FactoryExisting

Cogeneration

Existing

Cogeneration

• Many 1G ethanol plants operate

150 - 200 days / annum

• Additional 150-180 days operation

using 2G bolt-on module

• Results in year round operations

of bio-ethanol complex

• Higher asset utilization

• Fewer unit operations hence

lower capEx

• Substantial increase in ethanol

production capacity at lower

capEx

Model # 2 Bolt on: Sugar mill attached distillery

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Sweet Sorghum to Ethanol


Why Sweet Sorghuum


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• No food / Industrial applications

• Net energy positive.

• Provide Juice and Bagasse

• Viable (low cultivation cost / high land productivity -

yields).-Local benchmarks…Molasses, Juice etc

• Provide fuel for steam / electricity.

• Large cultivation window around tropics (Equator

+/- 20 Deg)

• Cultivable for one cycle in moderate temperate

regions and two seasons if climate permit

• Complement local crops like sugarcane.


2G “Bolt-On”

Module

Fermentation

Distillation

Dehydration

Utilities

Existing 1G Bio-

ethanol

complex

Existing Sugar

Crushing Plant

Existing

Cogeneration

• Shortage of molasses – Sweet

sorghum can crushed

• Sweet sorghum crop can be

planted as intercrop in Sugarcane

and harvested in 3-4 months

• Results in additional operation of

Molasses based distillery

• Sweet sorghum juice can be used

in fermentation & bagasse to be

used as pre-treatment to produce

2G ethanol

• Higher asset utilization

• More ethanol production per year

Model # 3 Sweet Sorghum based Bolt on model to Sugar/Ethanol complex

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Pre-treatment

Enzymatic

Hydrolysis

Bagasse Juice

Hyd

roly

ze

d s

lurry

Sweet

sorghum

Lignin

cake

Praj - One Stop Shop in 1G/2G Ethanol Industry

Concept Development &

Feasibility Study

License & Basic Engineering

Detail Engineering

Supply of critical process equipment

Procurement & Inspection

Project Management

Construction Management

Commissioning / O&M Support

After Sales Service

Single Point Responsibility ��End to End Solutions = Comfort to Project Developer/Investor


Sustainability through 20% EBP

*Note: 1) GHG emission saving from farm (by avoiding burning) – 19000 MT CO2 equivalent 2) GHG emission saving from ethanol production process – 42700 MT CO2

equivalent 3) GHG emission saving from ethanol blending – 60000 MT CO2 equivalent 4) Total GHG emission saving from farm to fuel for 100 KLPD plant is 121000 MT CO2

equivalent/year

#1USD = 66 INR ## Average tax revenue to government from 100 KLPD rice straw to ethanol plant is INR 30 Crores/ Annum

*Assuming 1500 Jobs for 100 KLPD plant covering ( 50 jobs for plant operations + 100 Village Level Entrepreneurs + 1350 Unskilled labor for biomass sourcing & supply chain)

& 1.5 Lac income / Job **Assuming yield of 1.15 MT/Ha Rice Straw & Total land required for 100 KLPD plant will be 120000 MT/Year ***Assuming INR600/MT of rice

straw realization to farmer ****Assuming INR 900/MT of rice straw realization to rural entrepreneurs


Thank youDr Tushar PatilMob: +91 9766642466Email: [email protected]


praj’s ‘integrated 2 generation smart bio-refinery’aidaindia.org/pdf/delhi2018/dr. tushar...

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