value maximization through praj's 2nd generation “smart ... · value maximization through...

Value Maximization through

PRAJ's 2nd Generation

“Smart Bio Refinery”

Amol Sheth October, 17th 2016

Discussion Points

• Technology development & commercialization

• Praj‟s 2G Ethanol Technology

• Innovative Tech.

• Value Maximization

© Praj Industries Ltd CONFIDENTIAL www.praj.net 2

Technology

Development, Scale up

& Commercialization

© Praj Industries Ltd CONFIDENTIAL www.praj.net

Praj – R&D Capability

Innovation Centre Overview

80,000 sq ft of Labs, Pilot Plants, and

Offices

90 technologists - 25 PhDs, 65 Masters

5 Technology Centers of Excellence -

Biology, Chemistry, Engineering

18 Well Equipped Labs

Pilot Plants

1 MTPD (bone-dry) second

generation ethanol pilot plant

1 multi purpose pilot plant

Intellectual Property

Granted Patents – 16

Patent Applications Filed – 7

Patents Applications in Progress - 8

FOCUS

BIO Refinery Bio-Fuels, Bio-Chemicals

Environment

Health & Wellness


4

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

• Architectural & civil engineering

6 KLPD

(5.5 MGPY)

1200 KLPD (110 MGPY)

Praj‟s ethanol plants – across globe

100 KLPD

200 KLPD


Building success ladder 1G 1.5G 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 Industries Ltd Confidential www.praj.net 6

www.praj.net

Feedstock‟s – 1G vs. 2G

SO – What are these Sugars and Why Should I Care?

C6 H12 O6 – Hexose, Glucose is the main one

C5 H10 O5 – Pentose, Xylose is the main one

Technical Complexity



Feedstock mapping and testing

•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

USA. Accomplishments

• Evaluation of newer feedstock's like

Empty Fruit bunches from Palm, grasses,

MSW etc.

Continuous Program

Comprehensive mapping of Cellulosic Feedstocks –Regional & Seasonal Variability


Feedstock variation ….

Parameters Unit Test Values

Bagasse Bagasse

Pith

Corn

Residues

Cotton Stalk Palm EFB Rice

straw

Wheat

Straw

Total solids %w/w 70.0 47.0 90.97 91.78 87.48 85.68 93.3

Moisture %w/w 30.0 54.0 9.03 8.22 12.52 14.32 6.71

Glucan %w/w 38.0 34.80 29.04 30.57 31.82 32.2 32.0

Xylan %w/w 21.0 20.29 20.60 12.66 19.26 16.2 18.0

Arabinan %w/w 1.81 1.69 2.83 0.68 0.52 2.54 2.67

Acetate %w/w 2.74 2.43 2.14 2.51 1.57 1.2 1.52

Acid Insoluble lignin %w/w 19.0 22.8 16.11 21.18 18.0 11.0 14.0

Acid soluble lignin %w/w 4.0 4.5 4.45 3.16 4.17 3.2 3.5

Ash %w/w 3.0 5.52 7.02 7.60 8.25 16.0 12.5

Protein %w/w 2.5 2.67 3.41 5.26 4.24 4.5 5.5

Extractives (water) %w/w 4.0 2.47 4.66 10.14 10.57 16.0 15.0

Extractives (95% ethanol) %w/w 1.9 2.51 2.45 1.66 6.23 2.42 2.24

Analysis done using standard NREL lap method Robust technology which can handle feedstock variation


India - State wise biomass availability

State Total Biomass produced

(MMT)

Surplus Biomass available after current

utilization (MMT)

Surplus biomass CONVERTIBLE for

ethanol production (MMT)

Collectable Biomass (40%) of Convertible

(MMT)

Tamil Nadu 22.50 08.90 01.66 0.66 Rajasthan 29.90 08.60 00.25 0.10

Kerala 11.60 06.40 00.06 0.02 MP 33.30 10.30 02.03 0.81

Gujarat 29.10 09.10 04.92 1.97

Punjab 50.80 24.80 11.70 4.68 Karnataka 34.20 09.20 01.38 0.55

Orissa 20.10 03.70 01.30 0.52

West Bengal 36.00 04.30 00.77 0.30 Maharashtra 47.60 14.80 11.30 4.52

Chhattisgarh 11.30 02.10 00.43 0.17 Andhra Pradesh 24.90 04.30 00.26 0.10

Bihar 25.80 05.10 03.48 1.39 Haryana 29.10 11.30 02.07 0.83

Telengana 19.10 02.70 01.88 0.75

Uttrakhand 02.90 00.63 0.26 0.10

Uttar Pradesh 60.30 13.80 9.00 3.60

Jharkhand 03.60 00.89 0.43 0.17

Total 492.10 140.92 53.18 21.24


enfinity – Praj‟s 2G

Ethanol Technology


Our technology brings infinite possibilities to the

environment and energy challenges confronting mankind… by

making use of nature’s endless resources. That’s why we

proudly call it…..enfinity.

enfinity – Praj‟s 2G Ethanol Technology


Pretreatment Feedstock Handling

Feedstock Preparation System / Washing

Enzymatic Hydrolysis / Liquefaction

Fermentation Distillation & Dehydration

Waste Water Treatment

End to End integrated Process

2G ethanol/bio-chemicals plant processing biomass

Bio-Refinery

Addition of challenges


Choice of pre-treatment is critical.

It must take into account

Solids concentration

Compatibility with

Feedstock

Selection of enzymes

Fermentation organism

Limited size reduction to avoid high power requirement

Pre-treatment


Pervasive impact on

Size Reduction

Feedstock cleaning & Washing

Hydrolysis

Fermentation

Product Recovery

Residue Processing

Waste water treatment and water recycle potential

Leading to overall impact on Project economics

Pre-treatment


Following undesirable by-

products formed

Furfural

HMF

Acetic Acid

Phenolic

Aldehydes

Gypsum

Pre-treatment

Undesirable due to

Lower sugar production and

lower process efficiencies

Inhibit enzymes and

Inhibit fermentation micro-

organisms


Pre-treatment

Strategies

to deal with

inhibitors and toxins ?

MANAGE Toxins/ Inhibitors

REMOVAL of Toxins/ Inhibitors


Solid liquid separation - followed by

Membrane – Reverse Osmosis

OR

Activated carbon

OR

Ion exchange

Adds CAPEX

Compromises economics of the technology

Impacts OPEX - water, energy and waste water treatment

Removal of Toxins/Inhibitors


Adopt suitable hydrolysis strategy

Selection of enzymes

Mode of operation – Fed batch, Continuous, etc.

Solids concentration

Adopt suitable fermentation strategy

Selection of tolerant yeast / micro-organism

Mode of operation – Fed batch, Continuous etc.

Adapt culture / platform for WWTP

Bio-methanation – Impact of phenolic components

Incineration of residues – Impact of alkalinity

Needs investment in technology development

Managing Toxins/Inhibitors


Better flow characteristics

Better mixing efficiency

More efficient enzyme use

Higher enzymatic and

fermentation efficiencies

Fewer choking issues

Far lower erosion issues &

Process downtime

Benefits of low solids concentration in pretreatment


– 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 & Commercial offerings

2016

Technology optimization journey

Biomass to Bio refinery

Operational since – January 2009

Raw material processing capability –

Corn Cobs + Corn Stover

Sugarcane Bagasse, Cane trash, Pith

Rice straw, Wheat straw, Cotton stalk


22 © Praj Industries Ltd www.praj.net Confidential

Data on Feedstock processing at Pilot plant

Sugarcane Bagasse 120 MT

Corn Cobs 150 MT

Corn Stover 60 MT

Corn Residues (Mixed) 15 MT

Palm Residues 5 MT

Wheat Straw 5 MT

Rice Straw 40 MT

Bagasse Pith 20 MT

Processed > 400 Metric tons of diverse feedstocks over a span of 3 years and over

with 800,000 man hours of R&D spent on the pilot plant and still ongoing.

Material Handling

Washing

Pre-treatment

S/L Separation

Detoxification

Delignification

Enzymatic Hydrolysis

Co Fermentation

C5 Fermentation

Distillation & Dehydration

Waste Water Treatment 23

Technology Evolution via process flows

Material Handling

Washing

Pre-treatment

S/L Separation

Detoxification

Delignification


C6 Fermentation

C5 Fermentation



Material Handling

Washing

Pre-treatment

S/L Separation

Detoxification

Delignification


C6 Fermentation

C5 Fermentation



Material Handling

Washing

Pre-treatment

S/L Separation

Detoxification

Delignification


C6 Fermentation

C5 Fermentation



End-to-End Holistic & Integrated solution

© Praj Industries Ltd Confidential www.praj.net

Performance parameters at par with global benchmarks

24

Praj has made significant performance improvements over last three years

enfinity – Performance over the years


2011 2012 2013 2014 2015 2016 (P) 2017 (P)

182

208

254 264

270 275 290

261

284

302 317

325-330 333-338

342-347

Yield (Liters / Ton ) of Feedstock

Bagasse

Corn Cob

68.0

26.0

19.0 18.1 17.6 16.5

15.3

38.1

17.0 15.7 14.6 13.5 12.6 11.7

2011 2012 2013 2014 2015 2016 (P) 2017 (P)

Conversion Cost (Rs/Liter)

Bagasse

Corn Cob

Co-

Fermentation

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

sugars

• Higher yield

• Lower reaction time

• Higher tolerance to solids

Proprietary

robust end to

end process

• Multi-feed capability

• Pre-treatment

• Efficient degradation of biomass to sugars

• Better biological processing ability

• Efficient enzymatic hydrolysis

• Performance in spite of inhibitors

• No detoxification steps leading to lower capex and opex

• 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

• Enfinity Technology –

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

Kenya; pending approval in other countries

Summary : Technology highlights


Good integration, key to success

Pretreatment

Feedstock Handling

Feedstock Preparation

System / Washing

Enzymatic Hydrolysis / Liquefaction

Fermentation



Integrated 2G Bio refinery for Biofuels & Biochemical

Summary

End to end process and energy integration


Innovative Integrated

Bolt-on model


Integrated Bolt-On

Hydrolyzed

slurry

Pre-treatment

Enzymatic

Hydrolysis

2G “Bolt-On”

Module

Fermentation

Distillation

Dehydration

Utilities

Existing 1G Bio-

ethanol complex

Existing Sugar

Factory 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 at lower capEx


Grain Fiber to Cellulosic Ethanol

Existing Starch to

ethanol

Hydrolysis

Pretreatment

Co-product: Bio Oil & DDGS

Ethanol

Patented Technology

Fiber


SELECTIVE GRIND & FIBER

SEPARATION TECHNOLOGY

1 G Technology

Fiber to

Ethanol

Starch Slurry

(with Separated

bound starch)

CORN

Fiber

Up to 8 % increase in ethanol yield compared to conventional technology

Process Know-how

Ethanol & Ethanol based

Chemicals

Biochemicals

Co-Products

Praj Approach ...

• Understanding Feedstock

• Pretreatment &

Fermentation Technologies

• Waste water

treatment & recovery

• Beverage Alcohol

• Fuel Alcohol

• Pharma Alcohol

• Ethylene

• Propylene

• Acetic Acid

• Ethyl Acetate

• Furfural

• Xylitol

• Ethyl Levulinate

• Levulinic acid

• Lactic acid

• Succinic acid

• Acetic acid

• CO2 Recovery

• Liquid /Solid

Bionutrients

• Bio-CNG

• Biogas to Power


Multi-Feedstock, Multi Product SMART Bio Refinery

CO 2

Bio Fertilizers

DDGS

Biogas

Lignin cake

Juice

Molasses

Grain

Ligno- cellulosic

MSW

Industrial Alcohol

Fuel grade

Ethanol

Bio-Chemicals

Bio-Jet Fuel

Rectified Spirit

Pharma grade

Ethanol

BIO-REFINERY

1st

Gen

Next

Gen

Multi-Feedstock Multi-Product


Multi-Feedstock, Multi Product „SMART Bio Refinery‟

CO 2

Bio Fertilizers

Corn Residues

Rice/Wheat

Straw

Sugarcane

Residue

Cotton Stalk

Industrial Alcohol

Fuel

Ethanol

220-325

Liters

Bio-Chemicals*

Power export

250 - 400 Kwh

Rectified Spirit

Bio-CNG

90-100 KG

2nd

Gen

Multi-Feedstock Multi-Product


Total Revenue potential ~ INR 17,000 – 23,000 / MT

Biomass cost ~ INR 2000 – 5000 / MT

Note: 1) Liquid CO2 market price of INR8/Kg 2) Bio-CNG price INR 50/KG

3) Bioethanol price INR 46.50/Liter 4) Power price INR 4/Kwh

5) Carbohydrate content in biomass assumed at ~55%

* Bioethanol yield will reduce when sugars are diverted for bio chemicals

Praj innovative 2G Bio refinery provides higher returns

Headquarter : PRAJ Tower, Pune - India

© Praj Industries Ltd www.praj.net 35 A truly global Organization with multiple & diverse business sectors

Thank You ([email protected] / [email protected] / +919890300107)

mailto:[email protected]

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