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Copyright EIL – All rights reserved Format No. EIL 1641-1924 Rev. 1

Feasibility Report On

Ligno-cellulosic Biomass to 2G Ethanol,

Mangalore Refinery & Petrochemicals Ltd

Document No. B033-000-03-41-RP-01

June 2017

© EIL – All rights reserved

Feasibility Report on

Ligno-Cellulosic Biomass to 2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01

Rev. 1

Copyright EIL – All rights reserved


COPYRIGHT

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Feasibility Report on Ligno-Cellulosic Biomass to

2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01

Rev. 1 Page 1 of 111

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

CONTENTS

1. EXECUTIVE SUMMARY

1.1 Introduction 8

1.2 Background for Feasibility Study Report 8

1.3 EOI Received 9

1.4 Basic Study Parameters

1.4.1 Ethanol plant capacity 9

1.4.2 Objective of Study 10

1.4.3 Product Specification 10

1.4.4 Feed Specification 11

1.5 Technology Assessment 12

1.5.1 Lignocellulosic Biomass 11

1.5.2 Process for Ethanol Generation from 12

Lignocellulosic Biomass

1.5.3 EOI’s Information & Technical Review 14

1.5.3.1 Technology – A 14

1.5.3.2 Technology – B 16

1.5.3.3 Technology – C 17

1.5.3.4 Technology – D 17

1.5.4 Technology Analysis 25

1.5.5 Areas of technology requiring detailed assessment 27

1.6 Capital Cost Estimation 28

1.7 Environment Impact 30

1.8 Project Schedule 31

1.9 Preliminary Plot Plan 31

1.10 Social Benefit 31

1.11 Way Forward 31


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2. INTRODUCTION

2.0 Introduction 33

3. SCOPE OF WORK

3.0 Scope of Work 36

4. DESIGN BASIS OF STUDY

4.1 Ethanol plant capacity 38

4.2 Product Specification 38

4.3 Feed Specification 38

5. PROJECT DESCRIPTION

5.1 Technology Licensors 42

5.2 Material Balance 42

5.3 Utilities & Off-site Facilities 45

6. TECHNOLOGY ASSESSMENT

6.1 Understanding of Ligno-cellulosic Biomass 47

6.1.1 Cellulose 48

6.1.2 Hemicelluloses 48

6.1.3 Lignin 48

6.2 Processes for Ethanol Generation from Lignocellulosic Biomass 49

6.3 Process Description for Bio-Ethanol Production 50

6.3.1 Pretreatment 51

6.3.2 Hydrolysis 53

6.3.3 Fermentation 53

6.3.4 Distillation and Purification 54

6.4 Technology Assessment 54

6.4.1 Technology A 55

6.4.1.1 Material Handling & Wet Washing Section 56

6.4.1.2 Main Process Plant 57

6.4.1.3 Utilities & Auxiliaries 59

6.4.1.4 Residue Handling Section 61

6.4.1.5 Add On Packages 62

6.4.1.6 Overall Material and water Balance of 65


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Plant

6.4.1.7 Features 67

6.4.2 Technology B 68

6.4.2.1 Process Description 68

6.4.2.2 Byproducts and Effluents 71

6.4.2.3 Overall Material Balance of Plant 73

6.4.2.4 Waste Water Treatment 74

6.4.2.5 Features 75

6.4.3 Technology C 75


6.4.3.2 Features 78

6.4.4 Technology D 78


6.4.4.2 Outflow Streams from the Process Plant 81

6.4.4.3 Overall Material Balance of Plant 82

6.4.4.4 Features 83

6.5 Technology Analysis 88

6.5.1 Areas of technology requiring detailed assessment 90

7. UTILITIES AND OFFSITES

7.1 Utilities 92

7.1.1 Raw water system 92

7.1.2 Cooling water system 93

7.1.3 DM water and Soft water system 93

7.1.4 Compressed air system 93

7.1.5 Steam, power and BFW system 93

7.2 Offsite facilities 94

7.2.1 Storage and Transfer System 94

7.3 Flare Systems 95

8. PROJECT SCHEDULE & PROJECT EXECUTION METHODOLOGY 9. ENVIRONMENT CONSIDERATIONS


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9.1 Environmental Considerations 99

10. PROJECT COST ESTIMATION 10.0 Cost Estimation 104

11. PRELIMINARY PLOT PLAN

11.1 Plot Plan 108

12. WAY FORWARD

12.1 Way Forward 110

ANNEXURES

Annexure I: CAPITAL COST ESTIMATION

Annexure II: PROJECT SCHEDULE & PROJECT IMPLEMENTATION METHODOLOGY

Annexure III: PRELIMINARY PLOT PLAN

Annexure IV: FEED ANALYSIS

Annexure V: LICENSOR SUPPLIED INPUTS FOR COST ESTIMATION (TECHNOLOGY B)


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List of Figures Fig. No. Title Page No.

1.1 Over all material balance for Technology – A. 15

1.2 Over all material balance for Technology-B 16

1.3 Over all material balance for Technology-D 18

6.1 Schematic diagram of plant cell walls 47

6.2 Schematic diagram of Plant Component 48

6.3 Technologies for Ethanol Generation from Lignocellulosic Biomass 49

6.4 Technological routes for Ethanol Generation from 50

Lignocellulosic Biomass

6.5 Schematics of biomass to bio-ethanol technology 51

6.6 Process diagram of Technology A 57

6.7 Over all material balance of Technology A 66

6.8 Process schematic for Technology B 69

6.9 Simplified scheme of byproduct and effluent streams of Technology B 72

6.10 Over all material balance of Technology B 73

6.11 Typical stillage / waste water treatments configuration 74

6.12 Schematic diagram for Technology D 76

6.13 Flow diagram for Technology D 77

6.14 Technology D outline 79

6.15 Over all material balance of Technology D 83


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List of Tables Table No. Title Page No.

1.1 Ethanol requirement in future for 5%, 10% and 20% blending 9

in petrol (In Million Lt.)

1.2 Product specification for fuel grade ethanol 10

1.3 Typical composition of some ligno-cellulosic bio-mass residues 11

1.4 Composition of feedstock 12

1.5 Technology comparison 20

1.6 Cost of feed, product and utilities 28

1.7 Cost estimate for biomass to Ethanol Complex (power Import) 30

1.8 Cost estimate for biomass to Ethanol Complex (power generation) 30

4.1 Product specification for fuel grade ethanol 38

4.2 Typical composition of some ligno-cellulosic bio-mass residues 39

4.3 Composition of feedstock 39

4.4 Price of Feed, Product and utilities 40

5.1 Material balance for Technology A 43

5.2 Material balance for Technology B 44

5.3 Material balance for Technology D 44

6.1 Comparison of the different pretreatment processes 52

6.2 Comparison of different options for 2nd stage hydrolysis 53

6.3 List of the processes in ISBL 68

6.4 Comparison of technology 85

7.1 Summary of estimated utility requirement 92

7.2 Storage details 94

7.3 By product details for 100 KLPD ethanol plant 95

9.1 Standards for Emissions from Boilers Using Agriculture Waste As Fuel 100

9.2 National ambient air quality standards 101

10.1 Cost of feed, product and utilities 104

10.2 Cost estimate for biomass to Ethanol Complex (power Import) 106

10.3 Cost estimate for biomass to Ethanol Complex (power generation) 106


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SECTION - 1

EXECUTIVE SUMMARY


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1.1 Introduction MRPL is examining the feasibility of setting up a Ligno-cellulosic ethanol production plant to

produce 60 KL per day of 2G ethanol using domestic agro based lignocellulosic feedstock in

Karnataka state. MRPL has published Expression of interest (EOI) to identify Licensors/

technology providers (called as “Bidders”) with requisite competence, experience,

infrastructure & finance, for setting up and operation and maintenance of Ligno-Cellulosic

Ethanol production Plant in Karnataka state, India in collaboration with MRPL by using

domestic surplus Agri based lignocellulosic feedstock. EIL has been selected to prepare a Pre-

feasibility study report (PFR) on ligno-cellulosic biomass to 2G-ethanol including the capital

cost estimation for select technologies based on the responses received for the EOI from the

bidders.

To ascertain the feedstock availability in Karnataka, MRPL engaged M/s PRESPL for carrying

out the Biomass assessment study and Indian Institute of Science for validating the study. The

plant capacity (net surplus bio mass availability after meeting fodder requirements) and the type

of feed stock has been derived based on this study.

1.2 Background for Pre-Feasibility Study Report Bio-fuels are lucrative alternative energy option as they are clean and have low sulfur content

thereby having positive environmental impact. Therefore need of the hour is development of

second generation biofuels using surplus agricultural residues and waste that can be harnessed

as ligno-cellulosic bio-fuel source. Same is clearly embodied in the National Bio fuel policy

(NBP) 2009.

The main reasons for the enhanced development of bio-ethanol are its use as a favorable and

near carbon neutral renewable fuel, thus reducing CO2 emissions and associated climate change.

Whether first, second, or third generation feedstock is used, fermentation produces an alcohol-

lean broth only, as such unusable in industrial and fuel applications. The ethanol must hence be

purified. Fractional distillation can concentrate ethanol to 95.6 vol% (89.5mol %),

corresponding to the azeotropic composition with a boiling point of 78.2∘C. Remaining moisture

is captured in dehydration column to produce anhydrous fuel grade ethanol.

The practice of blending ethanol started in India in 2001. Government of India mandated

blending of 5% ethanol with petrol in 9 States and 4 Union Territories in the year 2003 and

subsequently mandated 5% blending of ethanol with petrol on an all-India basis in November

2006 (in 20 States and 8 Union Territories except a few North East states and Jammu &


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Kashmir). Ministry of Petroleum and Natural Gas, on 1 September, 2015, has asked OMCs to

target 10% blending of ethanol in petrol in as many States as possible. Table 1.1 shows the

ethanol requirement in future for 5%, 10% and 20% blending in petrol.

Table 1.1: Ethanol requirement for 5%, 10% and 20% blending (In Million Lt.)

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

Petrol Sale Projection

(14 % CAGR) 29027 33091 37723 43005 49025 55889

Ethanol Requirement

(@ 5% blending) 1451 1655 1886 2150 2451 2794

(@ 10% blending) 2903 3309 3772 4300 4903 5589

(@ 20% blending) 5805 6618 7545 8601 9805 11178

Petroleum Planning & Analysis Cell (PPAC)

1.3 EOI Received The following Technology Licensor parties had responded for the EOI’s raised by MRPL:

M/s Praj Industries Limited2. M/s Beta Renewables S.p.A

3. M/s Renmatix, Inc.

4. DBT – ICT

1.4 Basic Study Parameters 1.4.1 Ethanol plant capacity

The feasibility study is carried out for 60 kilo litres per day (KLPD) of bio ethanol plant from

lignocellulosic biomass. Though the EOI received from various licensors was for 100 KLPD,

the plant capacity has been fixed at 60 KLPD based on the biomass assessment study as both

the activities were carried out in parallel. The technology comparison of various licensors has

been carried out based on 100 KLPD plant capacity. Cost estimation however has been carried


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out for 60 KLPD plant capacity based on the revised inputs received from the licensors as well

as in-house inputs. Relevant data as necessary has been provided by the licensors.

1.4.2 Objective of Study

The objective of the feasibility study is the technology assessment of all licensors based on

offers received for 100 KLPD plant and cost estimation with ± 30% accuracy for the licensor

who have provided relevant data for a 60 KLPD plant. The preliminary plot plan (table top) as

well as the project schedule with project execution methodology is also envisaged as the

objective.

1.4.3 Product Specification:

The quality and standard as per Indian specifications (IS15464:2004) of anhydrous ethanol for

use in automotive fuel is as listed below.

Table 1.2: Product specification for fuel grade ethanol

S. No Parameters Value

1 Relative density at 15.6/15.6 °C, Max 0.7961

2 Flash point 16.6 oC

3 Ethanol content percent by volume at 15.6/15.6°C Min. (excluding denaturant)

99.50

4 Miscibility with water Miscible

5 Alkalinity Nil

6 Acidity (as CH3COOH) mg/l, Max 30

7 Residue on evaporation percent by mass, Max 0.005

8 Aldehyde content (CH3CHO) mg/l, Max 60

9 Copper, mg/kg, Max 0.1

10 Conductivity µS/m, Max 300

11 Methyl alcohol, mg/litre, Max 300

12 Appearance Clear and bright


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1.4.4 Feed Specification

Ethanol plant should be feed stock flexible. It should be able to process different biomass like

rice straw, wheat straw, cotton stalk, sugarcane bagasse etc. as feedstock. Typical composition

of some ligno-cellulosic bio-mass residue is given below in Table 1.3.

Table 1.3: Typical composition of some ligno-cellulosic bio-mass residues

Feedstock Cellulose

(%) Hemicellulose (%) Lignin (%)

Other

(Moisture, silica,

ash etc)

Bagasse 42 25 20 13

Corn stover 38 26 19 17

Corncob 45 35 15 5

Rice Straw 32 24 18 26

Rice Husk 36 20 20 24

Wheat straw 35 32 21 12

Sweet sorghum 45 27 21 7

Nut Shell 30 30 30 10

Maize Straw 36 28 29 7

Cotton Straw 42 12 15 31

Switch grass 40 30 12 18

Hardwood 40 40 18 2

Pine 44 26 29 1

The biomass assessment study carried out by M/s PRESPL concluded the following:

The net surplus biomass available is only adequate for setting up a 60 KLPD 2G ethanol

plant.

Maize/Corn cobs as the primary feed stock and rice straw as alternate feed stock.

The composition of the feedstock is provided in the table.


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Table 1.4: Composition of feed stock

Feedstock Cellulose

wt%

Hemicellulose

wt%

Lignin

wt%

Ash

wt%

Moisture

wt%

Silica

wt%

Others

wt%

Corn Cob 33-34 27-28 18-19 2-3 9-10 0.5-1 3-4

Rice Straw 31-32 16-17 16-17 12-16 9-15 6-8 15-17

Refer Annexure IV for detailed analysis of feed.

1.5 Technology Assessment 1.5.1 Ligno-cellulosic Biomass

Understanding ligno-cellulosic biomass, particularly its chemical composition, is a prerequisite

for developing effective pretreatment technologies to deconstruct its rigid structure, designing

enzymes to liberate sugars, particularly cellulose to release glucose, from recalcitrant cellulose,

as well as engineering microorganisms to convert sugars into ethanol and other bio-based

chemicals. Lignocellulosic biomass is mainly composed of plant cell walls, with the structural

carbohydrates cellulose and hemi-cellulose and heterogeneous phenolic polymer lignin as its

primary components.

Cellulose is a polysaccharide composed of linear glucan chains which are held together by intra-

molecular hydrogen bonds as well as intermolecular van-der Waals forces. The crystalline

cellulose must be subjected to some preliminary chemical or mechanical degradation before it

can be broken down into glucose.

Hemicellulose consists of short, highly branched chains of sugars. It contains pentoses,

hemicelluloses chains are more easily broken down to form their simple monomeric sugars than

is cellulose because of their highly amorphous and branched structure. The exact sugar

composition of hemicelluloses can vary depending on the type of plant.

Lignin is a non-sugar-based polymer and cannot be used as feedstock for ethanol production via

microbial fermentation. It exerts a significant impact on the economic performance of the

corresponding bioconversion processes, since most inhibitors of microbial growth and

fermentation. As the second most abundant component in biomass after cellulose, lignin yields

more energy when burned, and thus is a good selection for combined heat and power production

in an eco- and environment-friendly mode of the bio-refinery.

1.5.2 Process for Ethanol Generation from Lignocellulosic Biomass

Typically biochemical conversion process is carried out in four stages


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1. Physical or chemical pretreatment of the plant fibers to expose the cellulose and reduce

its crystallinity,

2. Hydrolysis of the cellulose polymer, with enzymes or acids, to convert it into simple

sugars (glucose),

3. Microbial fermentation of these simple sugars to ethanol and

4. Distillation and dehydration to produce 99.5% pure alcohol.

Pretreatment:

The pretreatment process converts most of the hemicellulose carbohydrates in the feedstock to

soluble sugars (xylose, mannose, arabinose and glucose) by hydrolysis reactions. Acetyl groups

in the hemicellulose are liberated as acetic acid. The breakdown of biomass in pretreatment

facilitates downstream enzymatic hydrolysis by disrupting cell wall structures, driving some

lignin into solution, and reducing cellulose crystallinity and chain length. The nature and extent

of such changes are highly dependent on the pretreatment chemistry and reaction severity

(defined by residence time, temperature, and catalyst loading).

Hydrolysis:

Hydrolysis process generates fermentable monomeric sugars from hemicellulose and cellulose

content of lignocellulosic biomass. This can be accomplished by two different processes,

namely,

1. Acid hydrolysis

2. Enzymatic hydrolysis.

In acid hydrolysis, mineral acids such as sulfuric acid, hydrochloric acid, hydrofluoric acid and

nitric acid are widely employed for the hydrolysis of lignocellulosic biomass.

In enzymatic hydrolysis step cellulose is converted to glucose using cellulase enzymes. This

process is known as enzymatic saccharification or enzymatic hydrolysis. A cellulase enzyme

preparation is a mixture of enzymes (catalytic proteins) that work together to break down

cellulose fibers into cellobiose and soluble gluco-oligomers and ultimately into glucose

monomers. The resulting glucose and other sugars hydrolyzed from hemicellulose during

pretreatment are co-fermented to ethanol.

For higher conversion and lower metallurgy enzymatic hydrolysis is favorable over acid

hydrolysis.

Fermentation:

Fermentation is the biological process to convert the hexoses and pentoses into ethanol by a

variety of microorganisms, such as bacteria, yeast, or fungi.


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When using enzymatic hydrolysis, different integration methods of hydrolysis and fermentation

steps are proposed. These are separate hydrolysis and fermentation (SHF), separate hydrolysis

and co-fermentation (SHCF) and simultaneous saccharification and co-fermentation (SSCF) are

other possible alternatives.

Distillation and Purification:

From fermented mash, fuel grade ethanol is produced through distillation and adsorption via

molecular sieve. Desired separation specification of 99.5%vol ethanol cannot be achieved by

distillation alone because of the non-ideal solution behavior of the water-ethanol mixture. An

azeotrope is observed when the mixture reaches 95.5% mole purity of ethanol. 95.5 % alcohol

is passed through molecular sieve to produce fuel grade ethanol.

1.5.3 EOI’s Information & Technical Review

The EOIs response received from various technology licensors for the 2G ethanol production

from ligno cellulosic biomass are reviewed. The comparison of all technology licensors have

done based on 100 KLPD Plant capacity.

1.5.3.1 Technology – A

Overall material balance: As per information available from technology provider the overall

material balance is given below for various feedstock provided by them.

A) Feed: Bagasse

*Chemicals: Mixed Acid : 9.63 TPD Nutrients : 5.05 TPD Molasses : 21.17 TPD Other Chemicals : 19.25 TPD

Fuel Grade

Ethanol Plant

Lignin = 155 TPD

ISBL OSBL

Bagasse = 385 TPD

Chemical*

Enzyme =3.73 TPD

FO$= 0.25 TPD

TA# = 1.7 TPD

Rejects = 17.74 TPD

EtOH = 80 TPD

Yeast = 0.03 TPD

Mill Loss = 7.6 TPD TPD

BioCNG = 40.2 TPD TPD

Sulphur = 4.2 TPD

CO2 = 137.74 TPD


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B) Feed: Rice Straw

* Chemicals: Mixed Acid : 12.78 TPD Nutrients : 4.26 TPD Molasses : 17.04 TPD Other Chemicals : 19.17 TPD # TA = Technical Alcohol $ FO = Fusel Oil

Fig. 1.1: Over all material balance for Technology – A

Features:

Developed indigenous 2G Ethanol technology in 2009

Bio-ethanol % conversion for per ton of dry biomass is of rice straw and bagasse is

19% and 21 % respectively.

Process can be operated with multiple feedstocks (such as rice straw, bagasse, cotton

straw, wheat straw etc.) but not with mixed feed.

Feed size for the process is 25-40 mm.

Major byproducts from technology A are Bio-CNG (9%), Liquefied CO2 (10.5%),

Technical Alcohol (4%), Fusel Oil (0.6%), Lignin (47%)

Enzyme and yeast consumption for per ton of dry biomass conversion is 8.7 kg and 0.7

kg respectively.

Total conversion time from biomass to bio ethanol is 100-120 hour.

Approximately 100% water re-cycle via effluent treatment plant in ISBL. However,

some water effluent is there from utilities.

CO2 = 130.5 TPD

Yeast = 0.03 TPD

Rejects = 16.4 TPD

Millings & Conv. Loss = 3.8 TPD

Fuel Grade

Ethanol Plant

Lignin = 199.8 TPD

ISBL OSBL

Rice Straw = 421 TPD

Chemical*

Enzyme =3.70 TPD

FO$ = 0.26 TPD TA# = 1.7 TPD

EtOH = 79.44 TPD BioCNG = 37.7 TPD

Sulphur = 3.8 TPD


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Lignin rich cake is separated from solid liquid separation & used as a boiler fuel along

with primary fuel.

Turndown capacity for the proposed plant of capacity 100 KLPD is about 70 % of

maximum capacity

Licensor has Experience on 1st generation ethanol production technology as a global

equipment supplier.

Licensor has strength to provide fully integrated end to end scheme for bio-ethanol

plant including OSBL.

1.5.3.2 Technology – B


material balance is given below.

* Chemicals: Antifoam : 0.0792 TPD Sodium Hydroxide (100%) : 4.8 TPD Urea : 1.97 TPD Misc. Propagation Media: 165.6 TPD; Air: 434.4 TPD ; Steam: 969.6 TPD; Process Water : 585.6 TPD

Fig. 1.2: Over all material balance for Technology B

Features:

Commercial Scale Bio Ethanol plant has started in 2013.

Bio-ethanol % conversion for per ton of dry biomass is almost 16.5%.

Misc. 2155 TPD

Fuel Grade

Ethanol Plant

Conc. Stil = 331.2 TPD

ISBL OSBL

Biomass= 477.6 TPD

Chemical* Enzyme = 6 TPD

Vent = 504 TPD Lignin = 386.4 TPD

Trash & Dust = 6 TPD

EtOH = 78.72 TPD

Waste = 13.68 TPD

Yeast = 0.0624 TPD MP cond.: 518 TPD Effluent: 806.5 TPD

FO = 0.96 TPD


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Major byproducts are Liquefied CO2, Concentrated stillage and surplus power.

Claim unique steam explosion process as pretreatment of biomass.

Total conversion time from biomass to bio ethanol is 120 hour.

Lignin and concentrated stillage can be sold for off-site uses in energy generation or

cogeneration facility can be set up on clients’ requirements.

A 2G ethanol technology with experience and learning at commercial scale

470,000 TPA (Dry Biomass) started in September- 2014.

Sustained supply of enzymes with equity partner.

No fine size reduction is required.

Technology – C

Features:

Has novel technology based on Supercritical hydrolysis of water.

Super-critical reactor has modular design, i.e. reactor capacity can be increased or

decreased by joining or removing extra reactor tubes.

Bio-ethanol % conversion for per ton of dry biomass is 24.4 %.

Total conversion time from biomass to bio ethanol is 12-24 hours.

The technology produces soluble sugars which can be directly fermented.

No requirement of enzyme for this process.

Time for biomass conversion to sugars: 2-90 minutes

Low reactor volumes

Backed by global companies.

1.5.3.5 Technology – D


material balance for two feeds (Bagasse and Rice Straw) are given below.

A) Feed : Bagasse


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* Chemicals: Nitric Acid (100%) : 3.8 TPD NaOH (100%) : 4.5 TPD Others Salts : 1.7 TPD B) Feed : Rice Straw

* Chemicals: Nitric Acid (100%) : 4.3 TPD NaOH (100%) : 5.2 TPD Others Salts : 1.9 TPD $ FO = Fusel Oil

Features:

Bio-ethanol % conversion for one ton of dry biomass is of rice straw and bagasse is

21.3 % and 24.5 % respectively.



Feed size for the process is 200-1000 microns.

Major byproducts are Liquefied CO2 and lignin (17 %).

Fuel Grade Ethanol

Plant Waste = 16.5 TPD

ISBL OSBL

Bagasse = 324 TPD

Chemical*

Enzyme =1 TPD

CO2 = 195 TPD FO$ = 0.4 TPD

Bio CNG = 41 TPD

EtOH = 80 TPD

Dusting = 2 TPD

Yeast = NA

Fuel Grade Ethanol

Plant Waste = 55 TPD

ISBL OSBL


Chemical*

Enzyme =1.12 TPD

CO2 = 202 TPD FO$ = 0.3 TPD

Bio CNG = 45 TPD

EtOH = 80 TPD

Dusting = 3 TPD

Yeast = NA

Fig. 1.3: Over all material balance for Technology-D


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Enzyme consumption for one ton of dry biomass conversion is 3 kg.


Turndown capacity for the proposed plant of capacity 100 KLPD is about 25% of

maximum capacity.

Pretreatment is based in both acidic & basic media.

Having a demo plant of 10 TPD.

Total conversion time from biomass to bio ethanol is 24 hours.

Enzyme consumption is one third of against the other available technology.

Enzymatic hydrolysis time for is less than 2 hr.

Fermentation time is 3-9 hrs.

Using Composite Biomass Technologies for the pretreatment of biomass.

Employs continuous fermentation along with enzyme recovery and recycling.


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Table 1.5: Technology comparison

Basis – 100KLPD Ethanol

Tech A Tech B

Process Pretreatment, enzymatic hydrolysis,

co-fermentation, distillation & dehydration

Pretreatment, enzymatic hydrolysis, co-fermentation, distillation & dehydration

Pretreatment / Fractionation

Steam explosion with mild acid to break down lignin structure and expose

hemicelluloses and cellulose.

Steam explosion to break down lignin structure and expose hemicelluloses and

cellulose.

Criticality in Process Pretreatment section is critical to design. No PTR is available.

Steam explosion system is critical to design. It’s a proprietary item and PTR for two commercial units is available with the

licensor. Lignin Separation During distillation During distillation

Feed Stock Rice straw Baggasse Rice straw Amount of Feed

required (MT/day), Dry Feed

416 - 426 370 - 385 430

Feed Size 10 - 40 mm 20- 100 mm

Conversion Time 96 – 120 hr 120 hr

Byproducts Technical Alcohol, Fusel Oil, Lignin

Rich Cake, Bio-CNG, Power, Liquefied CO2

Lignin, Concentrated Stillage, Power

Yeild

EtOH 100 KLPD 100 KLPD

By product

CO2 5.44 MT/hr 5.74 MT/hr VENT- 21 MT/hr

Lignin 8.33 MT/hr (dry basis) 6.46 MT/hr 16.1 MT/hr(with 60 % MC)

Surplus Power

~ 6 MWh ~ 0.78 MWh

Bio CNG Bio-CNG 1.57 MT/hr 1.67 MT/hr

Concentrated Stillage(with 50%

MC) 13.8 MT/hr

Solid Waste Technic

al Alcohol

71 kg/hr 70 kg/hr Solid Waste 0.57 MT/hr

Fusel Oil Fusel Oil 11 kg/hr 10 kg/hr Fusel Oil 0.04 MT/hr

Trash & Dust

Trash & Dust 0.35 MT/hr 0.32 MT/hr Trash & Dust 0.25 MT/hr

Rejects 0.68 MT/hr 0.74 MT/hr Effluent :34.2 MT/h

Sulfur 0.16 MT/hr 0.175 MT/hr NA

Secondary Fuel for Boiler 17 MT/ hr, Rice Husk

No supplementary fuel required for power

import case.

Total Ash Generation 9.3 MT/ hr

3.28 MT/hr


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Basis – 100KLPD Ethanol Tech A Tech B

Enzyme Demand

Quantity 154 kg/hr 155 kg/hr

USD 200- 220 / ton EtOH

(Enzyme + yeast)

USD 50/ton EtOH (Chemicals & other

consumables)

Cost 32,340 - 40,300 (Rs/hr)

Supplier Novozymes/ Equivalent

Yeast Demand

Quantity Yeast 1.24 kg/hr

1.12 kg/hr

Cost 2,232- 2,480 (Rs/hr)

2,016 – 2240

(Rs/hr)

Chemicals Quantity

(Acid, Base and

other )

Nitric Acid (60%)

Mixed Acids 530 Kg/ Hr

400 kg/hr

Sodium Hydroxide

(100%) 200 kg/hr

Sodium

Hydroxide

(100%) Chemicals 800

Kg/hr 800

kg/hr Antifoam 3.3 kg/hr

Other Salts, Molasses (for yeast

incubation) 710 kg/hr 880

kg/hr

6.9 MT/hr

(Propagation media)

Solvent

Nutrients Quantity 180 kg/hr 210

kg/hr Urea 82.1 kg/hr

Utilities

Process water 71 -87 m3/ hr 24 m3/ hr

Steam 29-31.2 MT/hr 41 MT/ hr (32% HP @ 25 barg, 68% MP @ 10 barg)

Electricity 5.3-6 MWh (3.5-4 MWh Core + 1.8-2

MWh for add on Bio-CNG & Liq CO2) ~3.5 MWh (ISBL)

Cooling

Water 2600-2800 m3/hr ISBL, 2500 m3/hr CPP 810 m3/ hr for ISBL

Chilling

Water

647 m3/hr

Process Air 850 – 950 Nm3/hr 15050 Nm3/hr

Plant Air / IA 400 Nm3/hr 1000 Nm3/hr

Land foot print Area

33- 35 Acres (ISBL+OSBL) Typical ISBL 7.5 to 10 acre


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Basis – 100KLPD Ethanol Tech A Tech B

Current status of technology as on EOI cut-off date.

Pilot 1 TPD dry biomass pilot plant which is in operation since 2009

1 TPD

Demo A demo plant of 12 TPD dry

biomass under operation since march 2017 in Pune.

Capacity 800 TPD dry bio mass from arundo donax (energy grass)

(40,000 MT EtOH/year)

Commercial Capacity 1400 TPD, started in Sep2014

Compatibility to variable resource

feed biomass

Multiple

feeds Wheat Straw, Rice straw, Cotton

stalk, Bagasse & Corn Cob.

Wheat Straw, Rice straw, Arendo donax, Cotton stalk, Bagasse and

crop residue

Mix Feeds Not allowed Not allowed

By-product utilization in terms

of Power generation

Lignin rich cake is separated from solid liquid separation & used as a boiler fuel along with

secondary fuel.

Lignin and concentrated stillage can be sold for off-site uses in

energy generation or Cogeneration facility can be set

up on clients requirements.

Water re-cycling/ Treatment 100% using ETP 100% using ETP based on ZLD

Effluent treatment Yes, 45 m3/hr Yes, 34.2 MT/hr

License Fee Rs. 30 Cr. 6.3 MM€

Life of proposed plant 20 Years 20 Years

Turn down capacity of proposed

plant 50-60 %

25- 30 %


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Basis – 100KLPD Ethanol Tech C Tech D

Process Hemi-hydrolysis, Super critical

hydrolysis, fermentation, distillation & dehydration

Fractionation, enzymatic hydrolysis, fermentation, distillation & dehydration

Pretreatment / Fractionation Treatment with high temperature water to separate hemicelluloses

from celluloses & lignin.

Acid and alkali treatment to separate hemicelluloses, cellulose

and lignin.

Criticality in Process Main concern in this technology is supercritical reactor. No PTR is

available.

Reactors in fractionation sections are critical to design. PTR for this

type of equipment are not available.

Lignin Separation During super critical hydrolysis 60 % at alkali treatment and 40% at distillation unit

Feed Stock Rice Straw/Bagasse

Amount of Feed required (MT/day), Dry Feed 325 373/324

Feed Size < 120 μ 0.2 – 1.0 mm

Conversion Time ~ 12 -24 hr 24 hr

Byproducts CO2, Lignin Lignin, Bio-CNG, Power & CO2

Yeild

EtOH 100 KLPD 100 KLPD

By product

CO2 8.4 MT/hr 8.13 MT/hr

Lignin

Surplus Power ~ 6 MWh

Bio CNG 1.88 MT/hr 1.71 MT/hr

Solid Waste 2.3 MT/hr 0.69 MT/hr

Fusel Oil 12.5 kg/hr 16.7 kg/hr

Trash & Dust 0.13 MT/hr 0.083 MT/hr

Secondary Fuel for Boiler 17 MT/ hr, Rice Husk


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01




Enzyme Demand

Quantity 47

Kg/hr

42

Kg/hr

41

Kg/hr

Cost 23,500 / 21,000 / 20,500

(Rs/hr) {Rs. 500/kg}

Yeast Demand

Quantity Yeast strains part of the technology package. No separate cost. No regular

supply required with master bank provision in

proposed plant

Cost

Chemicals Quantity

(Acid, Base and

other )

Nitric Acid (60%) 293 kg

/hr 265 kg

/hr 255

kg/hr Sodium

Hydroxide

(100%) 216

kg/hr 195

kg/hr 188

kg/hr

Other Salts,

Rs. 100/kg 77 kg/hr

70 kg/hr

67 kg/hr

Utilities

Process water Steam 20 MT/ hr @ 8 barg

Electricity 9.0 MWh 4.7 MWh

Cooling Water 1000 m3/hr ISBL, 2500

m3/hr CPP Chilling water

Process Air Plant Air / IA 331 Nm3/hr

Land foot print Area 25-40 Acres

8 Acre for ISBL *Area excluded raw material

and ethanol storage Minimum

capacity for economic viability

250 TPD of Biomass


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01




Current status of technology as on EOI cut-off date.

Pilot Pilot plant of 1 TPD dry biomass

Demo 3 TPD dry biomass Demo plant of 10TPD dry biomass

Commercial

Compatibility to variable resource

feed biomass

Multiple

feeds Feed Agnostic Wheat Straw, Rice straw,Cotton stalk, Bagasse and crop residue

Mix Feeds Not allowed

By-product utilization in terms

of Power generation Yes, steam can be generated from the lignin

Water re-cycling/ Treatment 98 % 100% using ETP based on ZLD

Effluent treatment Yes

License Fee

Life of proposed plant 15 Years

Turn down capacity of proposed

plant

25 %

1.5.4 Technology Analysis

The inputs provided in Table 1.5 have been received from EOI. The analysis covered below is

based on the data received from licensor.

Feed Stock Dependence: All the technologies are feed agnoistic and are able to handle

multiple feed stocks, like rice straw, wheat straw, bagasse, corn cob, cotton stalk etc.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Mixed Feed Stock Dependence: The technology providers participated in EOI do not provide

this option.

Conversion efficiency: Technology A, C and D process compared to Technology B require

less feed stock. The feed stock for first two licensors is ½ to 2/3 of Technology B. For 100

KLPD ethanol plant, Technology C need 325 TPD dry biomass. Conversion efficiency for

Technology C is 24.5%. Conversion efficiency of Technology D is 21.5 – 24.7 % and for

Technology A it is 19 – 21 %. Technology B has 16.5 % conversion efficiency.

Biomass Size Reduction: Technology C required fine grinding (< 120 micron) and

Technology A need coarse grinding ( 25 to 40 mm) for feed, whereas Technology D is in

between ( 0.2 – 1.0 mm). Energy consumed in milling for Technology C is more than

Technology A. Moreover grinding machinery for Technology C is complex compared to

Technology A. Licensor of technology B has not mentioned about the milling of feed.

However it has to be confirmed with the licensor during detailed feasibility study.

Conversion time: Conversion time for Technology C is estimated 12 – 24 hr while that of

Technology D is about 24 hours. Technology A, B take five times, i.e. 120 hr. This indicates

Technology C and D process need less time than other two.

Bio CNG: Technology A and D produces Bio CNG from biomass extracted after distillation.

Formed Bio CNG is treated to remove CO2 and impurities. Purified Bio CNG can be sold in

the market. Generation of BioCNG for both the technologies is in the same order. (1.5 – 1.9

MT/hr)

Enzyme requirement: Technology C uses non enzymatic route, hence for process

requirement of enzyme is not envisaged. Technology D process claim enzyme consumption

around 41 – 47 kg/hr for the process. Technology D uses about 1/3 of the Technology A

requirement (154 – 155 kg/hr) and 1/5 of Technology B requirement (249 kg/hr). Although

Technology D uses less amount of enzyme, the total cost of enzymes don’t defer in large

extent.

Yeast requirement: Technology A and B use co–fermentation method for the production of

ethanol. Technology C and D use separate C5 & C6 fermentation to produce ethanol. Yeast

required for Technology B is four times of Technology A. Technology D does not require

continuous dose of yeast.

Steam requirement: Requirement of steam for technology B and D are in the same order (~

20 MT/hr). Technology A needs 1.5 times that of B.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Electricity requirement: Power requirement for all licensors except C are in the same order

(5 – 6 MWh) whereas only Technology C needs 9.0 MWh power.

Process Air: Technology B and A have provided process air requirement. Technology B

needs 4480 Nm3/hr, which is 4.7 times of Technology A requirement (850 – 950 Nm3/hr).

Land Requirement: Technology D and B recommend near about same area for ISBL.

Technology D and B recommend 8 acre and 7.5 – 10 acre respectively for ISBL. Technology

A and C have provided land requirement for total complex (ISBL & OSBL). Technology A

requires 33 - 35 acre considering two days feed storage whereas Technology C recommend

25 – 40 acre depending on different feed storage scenarios.

Technology Maturity: Technology B has got commercial plant experience. Technology A

has set up a demo unit for 12 TPD. Technology D has commissioned 10 TPD demonstration

unit whereas Technology C has a working demonstration unit of capacity 3 TPD.

Power Generation: All the technology provides uses lignin in boiler to generate steam and

electricity. Technology D generates steam by burning the lignin produced from their process.

The generated steam is used for power generation and subsequently in the process.

Technology B claims to generate power by burning lignin and concentrated stillage.

Technology A recommends to burn lignin with secondary fuel and generate electricity.

Effluent Treatment: Technology providers A, B and D participated in EOI, talked about

effluent treatment and recommend using it. Technology A, B and D recommend to use ETP.

However Technology A and B provided ETP load of 45 m3/hr and 136 m3/hr respectively.

Water Recycle: All technology provider claims about 100% water recycle (ISBL) in their

process. Technology A, B and D claims 100 % water recycle through ETP unit. Technology

C claim 98% water recycles to process.

Turn down Capacity: Technology B and A allow turn down capacity of 25-30% and 70%

respectively.

Water Requirement: The water requirement for technology B is 90 m3/hr for a capacity of

60KLPD.71-87 m3/hr and 110-116 m3/hr of process water is required for technology A and B

respectively for 100 KLPD plant capacity.

1.5.5 Areas of technology requiring detailed assessment

The following areas requiring detailed assessment are:

Commercial scale operation of 2G Ethanol Process:

The commercial scale plant experience is available for one technology licensor.

And others have demo or pilot scale experience.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Commercial experience for pretreatment section is not available:

Bio-digesters used in feed pretreatment section on a commercial are limited.

Commercial availability of lignin boiler:

Use of lignin as fuel in boiler is recommended by all the licensors;

Disposal of ash generated from boiler:

The quantity of ash generated from boiler is around 5- 10 TPH and the disposal

of ash is to be addressed properly.

Biomass availability round the year in 50 km radius:

The availability of biomass round the year depends on proper pre planning and

it is essential to build the ecosystem for ensuring biomass supply. Supply of

secondary fuel for use in boiler is also to be addressed

Higher cost of production compared to first generation ethanol:

The cost of ethanol production from lignocellulosic biomass is higher than first

generation ethanol and there may be requirement of subsidy for economic

viability and competitive ethanol pricing.

1.6 Capital Cost Estimation Project Cost Estimate for setting up a Lignocellulosic biomass to 2G Ethanol Complex has been

presented. CAPEX of technology B is presented here for 60 KLPD capacity.

The operating cost is calculated based on the cost information provided by the client

Table 1.6: Cost of feed, product and utilities Value Unit

Feed

Biomass (Corn Cob) 3500 (Rs/MT)

Secondary Fuel (Cotton Stalk) 2111 (Rs/MT)

Product

2G Ethanol 39 (Rs/litre)

Utility

Power(import) 6.85 (Rs/KWH)

Raw Water 20 (Rs/MT)

Land cost of 1crore/acre is considered for the costing as provided by the client. Licence fee of

6.3 MM€ and BDEP Fee of 2-3 MM€ taken for costing as provided by the licensor.

It is assumed that Corn cobs of required size is available. No milling equipment cost is

considered in the estimation.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Key Assumptions The basic assumptions made for working out the capital cost estimate are as under:

Cost estimate is valid as of 2nd Quarter 2017 price basis

No provision has been made for any future escalation

No provision has been made for any exchange rate variation.

It has been assumed that the project would be implemented on EPCM mode of

execution.

All costs are reflected in INR and all foreign costs have been converted into

equivalent INR using exchange rate of 1USD=Rs. 64.12, 1EURO=Rs.72.18

Exclusions Following costs have been excluded from the Project cost estimate:

Scope changes

Any survey

Piling

Site development works except roads, drains and boundary wall

Any cost towards dismantling of existing facilities, hot work in existing facilities

if any, removal of unforeseen underground obstructions , any hook up with

existing facilities

Facilities outside the battery limit of the plant

Cost towards statuary clearances.

Any Dispatch facilities for products.

Railway Siding , Township , Rehabilitation cost if any

Any cost (for Feed, Fuel, Utilities, Catalyst & Chemicals, etc.) towards

commissioning / stabilization of the plant or off spec production.

Cost provision for fire-proofing

Capital cost estimate for the identified scope, works out for two case i.e

Power cost as import case : Power import cost is taken as Rs. 6.85/KWH

as provided by the client

Power cost as generation case : Power is generated with 5 MWH STG and

secondary fuel is provided in boiler for

additional steam generation.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



The calculated values for the two cases are tabulated below:

Table 1.7: Cost estimate for biomass to Ethanol Complex (Power Import case)

Description

Foreign

Component

Fc

Indigenous Component

Ic

Total Cost

Rs. In Lakhs

Technology B 100 77 758 99 859 75

Table 1.8: Cost estimate for biomass to Ethanol Complex (Power Generation case)

Validity of cost estimate is as of 2nd Quarter 2017 price basis. The accuracy level of the cost

estimates is ±30%. This accuracy level has been arrived at based on the technical information

received from licensor, detailing done with the in- house data available in EIL.

Based on capital cost, operating cost and sales revenue, IRR has been worked out.

IRR of 12% pretax on total capital works out for ethanol price of around Rs 122.5/Litre, Rs

120.5/Litre for the power import and generation cases respectively.

However the judicious call may be taken by the project proponent at the time of investment

decision with regard to desirable return from the project considering suitable financial

instruments.

This can be verified by the financial consultant based on the exact provision as applicable for

such projects.

Refer Annexure I for detailed cost estimation.

1.7 Environment Impact The effluents generated in 2G ethanol plant is Solid liquid and gaseous effluents.

Description

Foreign

Component

Fc


Ic

Total Cost

Rs. In Lakhs

Technology B 100 78 865 95 966 74


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Ash is the solid effluent generated from boiler. Around 3.28 MT/hr of ash is generated in the

boiler.The liquid effluents generated is 34.2 MT/hr and can be treated in ETP.21 MT/hr of

gaseous effluents is generated and is vented to the atmosphere.

1.8 Project Schedule

A project mechanical completion schedule of 24 months has been considered on conventional

mode of execution with zero date as intimation of project clearance date. The total project

execution period has been considered as 27 months including the 3 months period considered

for commissioning. The other activities such as environmental clearance, land acquisition,

availability of feed etc. are to be completed before the zero date. The project schedule is

provided in annexure II.

1.9 Preliminary Plot Plan The facilities for the Ethanol production plant including ISBL and OSBL are shown in the

preliminary plot plan. The raw material and supplementary fuel storage is considered for two

days. The total plant area is estimated around 50 acres. The preliminary plot Plan is provided in

the annexure III. Although the land considered is in excess of required, this can be utilized for

future expansion and additional facilities like CO2 recovery.

1.10 Social Benefit Increase in Biofuel production reduces the dependence of oil, thereby reduces greenhouse gas

emission which gives environmental benefits. Less valued feed stock helps for the production

of value added products and increase income for farmer and generates employment in rural

areas.

1.11Way Forward Preliminary analysis and CAPEX estimation done as per the data available/provided by

technology provider. Detailed feasibility study needs to be carried out to establish viability.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



SECTION - 2

INTRODUCTION


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



2.0 Introduction The reduction of carbon dioxide (CO2) emission has become a major target in efforts to suppress

global warming. Bio-ethanol is considered as an important renewable fuel to partly replace

fossil-derived fuels. Governments around the world have recognized the role that biofuels will

play in a renewable fuels portfolio and have introduced minimum targets for their

implementation in the future. Ligno-cellulosic biomass is seen as an attractive feedstock for

renewable fuels, particularly ethanol.

The Indian economy is growing at a rate of approximately 7 -7.5 percent results the demand for

energy growing at rapid rates to drive this high economic growth. The World Energy Outlook

(WEO) report of the International Energy Agency (IEA) projects that India’s primary energy

demand will increase from 750 Mtoe to 1258-1647 Mtoe between 2011 and 2035 i.e., it will

most likely more than double over these 25 years. The oil demand in India will reach more than

8 million barrels per day in 2035, whereas the current domestic production of crude oil has been

more or less stagnant over the years. The balance is met through imports of crude petroleum

products that cost the country with valuable foreign exchange. Volatile oil prices and the

uncertainty about sustained oil supplies have lead India to search for alternatives, particularly

for substituting petroleum products, to promote energy security. Biofuels are considered among

the most promising alternative options, as they can be produced locally and can be substituted

for diesel and petrol to meet the transportation sector’s requirements. India, like many other

countries, is setting targets for the substitution of petroleum products by biofuels.

Globally, countries have been setting varying targets, ranging from 5 percent to 20 percent for

the transport of fuel products to be provided from renewable sources, to be met at various times

within the period 2010–2030. Developing countries such as India have multiple constraints

benefits in promoting biofuels, such as promoting energy security, rural development and the

reclamation of degraded lands as well as coping with the challenges of land and water scarcity

and improving food security.

In developing economies, food-related feedstock (first generation feedstock) like corn, sugar

etc. is preferably replaced by non food raw materials (second and third generation feedstock),

such as wheat straw, rice straw, bagasse, cotton stalk bamboo etc. Ethanol for use as bio-fuel is

produced by fermentation where certain species of yeast or bacteria metabolize sugars in

oxygen-lean conditions to produce ethanol and carbon dioxide. The main reasons for the


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



enhanced development of bio-ethanol are its use as a favorable and near carbon neutral

renewable fuel, thus reducing CO2 emissions and associated climate change.

Whether first, second, or third generation feedstock is used, fermentation produces an alcohol-

lean broth only, as such unusable in industrial and fuel applications. The ethanol must hence be

purified. Fractional distillation can concentrate ethanol to 95.6 vol% (89.5mol %),

corresponding to the azeotropic composition with a boiling point of 78.2 ∘C. Remaining moister

is capture in dehydration column to produce anhydrous fuel grade ethanol.

MRPL is examining the feasibility of setting up Ligno-cellulosic Ethanol production plant in

Karnataka state, India. MRPL has published EOI to identify Technology Providers/ Licensors

which have commercially utilized or prototype technology which is already producing ethanol

from Ligno-Cellulosic Biomass and are interested in setting up and/ or operating Integrated

Ligno-Cellulosic Ethanol Production Plant in India by using domestic agri-based Ligno-

Cellulosic feedstock. MRPL is looking for a Plant with capacity to produce ethanol in the range

of 50 KL to 150 KL per day however exact capacity will depend upon the optimum plant sizing,

biomass availability, economic movement of Ethanol for blending, taxes and other factors. EIL

has been selected to prepare a feasibility report on Ligno-cellulosic biomass to 2G-ethanol.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



SECTION - 3

SCOPE OF WORK


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



3.0 Scope of Work The feasibility report shall reflect upon the following broad aspects:

Project cost, with an accuracy of ± 30%, will be provided based on the inputs

received by MRPL against the published EOI. The project cost estimation was

limited to 2 cases (additional cases shall be done if required by MRPL). The case

shall be finalized in consultation with MRPL. The technical assessment was carried

out for all the cases.

Comparative analysis and assessment of various 2G-ethanol conversion

technologies: The technologies available will be enlisted based on responses

received against MRPL’s EOI. The assessment will consider factors such as

operability round the year, potential to utilize multiple feedstock and preferably

technology should be feedstock agnostic.

Comparative analysis of technology will include Alternatives like

Process/Operation/Maintenance parameters, Compatibility to variable resource

feed biomass. Viability of technology on Commercial scale, Proto type availability,

Land requirement, Multi feed bio mass availability. Analysis will also include

Scalability, Identification of requirement of Chemicals/Enzymes/Guarantees/

Long-term contracts, By-product identification/utilization in terms of Power

generation, water re-cycling etc., effluent treatment, and Green compliance. These

points are covered to the extent of data availability from responses of EOI.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



SECTION - 4

DESIGN BASIS OF STUDY


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



4.0 Design Basis

4.1 Ethanol Plant Capacity

Technology comparison study is carried out for 100 KLPD 2G ethanol plant from ligno-

cellulosic biomass and cost estimation is carried out for 60 KLPD plant capacity. Stream hours

considered: 7200 hr/yr.

4.2 Product Specification

The ethanol product quality for ethanol plant from ligno-cellulosic biomass shall meet the

following specifications:

Table 4.1: Product specification for fuel grade ethanol

4.3 Feed Specification

Ethanol plant should be feed agonistic. It should be able to process different biomass like rice

straw, wheat straw, cotton stalk, sugarcane bagasse etc, as feedstock. Typical composition of

some ligno-cellulosic bio-mass residue is given below in Table 4.2.

S. No Parameters Value

1 Relative density at 15.6/15.6°C, Max 0.7961

2 Flash point 16.6oC

3 Ethanol content percent by volume at 15.6/15.6°C

Min.(excluding denaturant) 99.50

4 Miscibility with water Miscible

5 Alkalinity Nil

6 Acidity (as CH3COOH)mg/l, Max 30

7 Residue on evaporation percent by mass, Max 0.005

8 Aldehyde content (CH3CHO) mg/l, Max 60

9 Copper, mg/kg, Max 0.1

10 Conductivity µS/m, Max 300

11 Methyl alcohol, mg/litre, Max 300

12 Appearance Clear and bright


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DOCUMENT No. B033-000-03-41-RP-01



Table 4.2: Typical composition of some ligno-cellulosic bio-mass residues

Feedstock Cellulose

(%)

Hemi-

cellulose (%)

Lignin

(%)

Other

(Moisture, silica, ash etc)

Bagasse 42 25 20 13

Corn stover 38 26 19 17

Corncob 45 35 15 5

Rice Straw 32 24 18 26

Rice Husk 36 20 20 24

Wheat straw 35 32 21 12

Sweet sorghum 45 27 21 7

Nut Shell 30 30 30 10

Maize Straw 36 28 29 7

Cotton Straw 42 12 15 31

Switch grass 40 30 12 18

Hardwood 40 40 18 2

Pine 44 26 29 1

The following feedstock are considered for the proposed unit

Corn Cob

Rice Straw

The composition of the feedstock is provided in the table.

Table 4.3: Composition of feed stock

Feedstock Cellulose

wt%

Hemicellulose

wt%

Lignin

wt%

Ash

wt%

Moisture

wt%

Silica

wt%

Others

wt%

Corn Cob 33-34 27-28 18-19 2-3 9-10 0.5-1 3-4

Rice Straw 31-32 16-17 16-17 12-16 9-15 6-8 15-17

Refer Annexure IV for detailed analysis of feed.

The cost information for the feed, product and utilities are provided below.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Table 4.4: Price of Feed, Product and utilities

Item Unit Cost

Biomass(Corn Cob) Ton 3500

Secondary Biomass(Cotton Stalk) Ton 2111

Ethanol kL 39000

Power kWh 6.85


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



SECTION - 5

PROJECT DESCRIPTION


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DOCUMENT No. B033-000-03-41-RP-01



5.0 Project Description MRPL has asked EOI’s and the following parties had responded for the EOI’s and their details

are listed as follows:

5.1 Technology Licensors

1. M/s Praj Industries Ltd

2. M/s Beta Renewable S.p.A

3. M/s Renmatix, Inc.

4. DBT – ICT

The EOI data was interpreted with respect to the Biomass availability assessment and

technology evaluation of the given ethanol technologies. Cost estimation for technology B with

± 30% accuracy, Plot plan, Project Plan Implementation, Project Schedule and Financial

analysis of the technologies is also done.

Three technologies based on enzymatic hydrolysis for ethanol production are considered in

detail as a part of feasibility study.

The options for recovery of value added products such as CO2 from fermentation section and

bio-CNG from biomethanation section have been assessed.

The stillage that is left during ethanol distillation is used for producing bio-CNG using

biomethanation reactor. The biomethanation reaction generates CO2, CH4 and H2S by the action

of anaerobic bacteria. The bio-CNG produced is sent to purification section for removing CO2

and H2S and a clean bio-CNG at around 95% purity of methane will be produced for end use.

Raw CO2 gas from fermenters is washed through foam trap designed to reduce the potential

hazard of foam carry over contaminating the CO2 recovery equipment. The CO2 gas is passed

through low pressure scrubber for removal of water soluble impurities in a counter current flow

scheme. The clean gas is compressed to approximate 19 bar(g) pressure at the discharge and

passed through high pressure scrubber to remove heavier impurities from the feed gas and

finally passed through deodorizers that removes odor causing impurities using activated

carbon. Dried, clean and purified CO2 gas at pressure of approx. 18 bar(g) is liquefied in a CO2

liquefaction system operating on ammonia refrigerant.

5.2 Material Balance

Summarized material balance for both technologies are as given below:


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Table 5.1: Material balance for Technology A

Unit of Measurement Bagasse Rice Straw

Feed

Bagasse TPD 385 421

Chemicals

TPD 55.1 53.25

Enzyme TPD 3.73 3.7

Yeast TPD 0.03 0.03

Product

Ethanol TPD 79.44 79.44

CO2 TPD 137.74 130.5

Fusel oil TPD 0.25 0.26

Technical

alcohol

TPD 1.7 1.7

lignin TPD 155 199.8

Bio- CNG TPD 40.2 37.7

Rejects TPD 17.74 16.4

Sulphur TPD 4.2 3.8

Mill Loss TPD 7.6 8.4


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Table 5.2: Material balance for Technology B

Unit of Measurement Quantity

Feed

Biomass TPD 477.6

Chemicals

TPD 6.85

Enzyme TPD 6

Yeast TPD 0.0624

Misc. TPD 2155

FO TPD 0.96

Product

Ethanol TPD 78.72

CO2 TPD 504

lignin TPD 386.4

Conc. Stillage TPD 331.2

Waste TPD 13.68

Trash/Dust TPD 6

MP Condensate TPD 518

Effluent TPD 806.5

Table 5.3: Material balance for Technology D

Unit of Measurement Quantity

Feed Rice Straw

Biomass TPD 373

Chemicals TPD 11.4

Enzyme TPD 1.12

Product

Ethanol TPD 80

CO2 TPD 202

Waste TPD 55

Dusting TPD 3

Bio CNG TPD 45

Fusel Oil TPD 0.3


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5.3 Utilities & Off-site Facilities

Besides the main process plant the scope of the project also includes, the following utilities &

offsite facilities as required:

Instrument / Plant air

Power and Steam generation system

Cooling water

DM water

Chilled water

Ethanol storage

Raw material storage

Secondary fuel storage

DG Set


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SECTION - 6

TECHNOLOGY ASSESSMENT


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6.1 Understanding of Ligno-cellulosic Biomass Understanding ligno-cellulosic biomass, particularly its chemical composition, is a prerequisite

for developing effective pretreatment technologies to deconstruct its rigid structure, designing

enzymes to liberate sugars, particularly cellulase to release glucose, from cellulose, as well as

engineering microorganisms to convert sugars into ethanol and other bio-based chemicals.

Ligno-cellulosic biomass is mainly composed of plant cell walls, with the structural

carbohydrates cellulose and hemi-cellulose and heterogeneous phenolic polymer lignin as its

primary components. However, their contents varies substantially, depending on the species,

variety, climate, soil fertility and fertilization practice, but on average, for agricultural residues

such as corn stover, wheat and rice straw, the cell walls contain about 40% cellulose, 30% hemi-

cellulose and 15% ligin on a dry weight basis. The distinctive feature of plant cell walls is their

two-part structure, as illustrated in Fig. 6.1. Primary cell wall is developed with cell division,

and enlarged during cell growth to a fiberglass-like structure, with crystalline cellulose

microfibrils embedded in a

matrix of polysaccharides

such as hemicelluloses.

The primary wall of

adjacent cells is held

together by a sticky layer,

called the middle lamella,

composed of pectin’s, to

form the conducting tissue

system arranged in

numerous vascular

bundles. On the other

hand, when cells cease to

grow, a secondary cell

wall is gradually deposited between the plasma membrane and the primary cell wall for better

mechanical strength and structural reinforcement through the incorporation of lignin for the bulk

of ligno-cellulosic biomass that can be converted to fuels and chemicals. The development of

the conducting tissue system with the rigid secondary cell wall is a critical adaptive event in the

evolution of land plants, which not only facilitates the transport of water and nutrients as well

Fig.6.1: Schematic diagram of plant cell walls


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as extensive upright growth, but also raises its recalcitrance to degradation due to the interaction

and cross-linking of cellulose, hemicelluloses and lignin as shown in Fig. 6.2.

6.1.1 Cellulose

Cellulose is a polysaccharide composed of linear glucan chains that are linked together by β-

1,4-glycosidic bonds with cellobiose residues as the repeating unit at different degrees of

polymerization depending on resources, and packed into micro-fibrils which are held together

by intra-molecular hydrogen bonds as well as intermolecular van-der Waals forces. Hydrogen

bonds hold the long cellulose chains tightly together in a crystalline structure rendering the

cellulose insoluble to hydrolysis. The crystalline cellulose must be subjected to some

preliminary chemical or mechanical degradation before it can be broken down into glucose.

6.1.2 Hemicelluloses

Hemicellulose consists of short, highly branched

chains of sugars. It contains pentoses, five-carbon

sugars such as xylose and arabinose, hexoses, six-

carbon sugars such as glucose, galactose, and

mannose, and small amounts of other chemicals.

Hemicelluloses chains are more easily broken

down to form their simple monomeric sugars than

is cellulose because of their highly amorphous and

branched structure. Since pentose sugars comprise

a high percentage of the available sugars in plants,

the ability to recover and ferment them into

ethanol is important for the efficiency and

economics of the process. The exact sugar

composition of hemicelluloses can vary depending

on the type of plant.

6.1.3 Lignin

Although lignin is a non-sugar-based polymer and cannot be used as feedstock for ethanol

production via microbial fermentation, it exerts a significant impact on the economic

performance of the corresponding bioconversion processes, since most inhibitors of microbial

growth and fermentation come from this compound during the pretreatment that is needed to

render cellulose amenable to enzymatic attack. Meanwhile, as the most abundant component in

biomass after cellulose, lignin yields more energy when burned and can be used for power

Fig 6.2: Schematic diagram of Plant Component


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production in an eco- and environment-friendly mode of the bio-refinery. Moreover, lignin is

an excellent starting material for various products including transportation fuels and value-

added chemicals, which may add credits bioconversion processes and make bio-ethanol more

economically competitive.

In addition to the three major components, cellulose and hemicelluloses that can be hydrolyzed to sugars

for ethanol fermentation, and lignin left after fermentation, other components like proteins and ashes

also affect the process economics. For example, fermentation nutrients are usually needed to

nourish ethanologenic microorganisms, either S. ceresive or Zymomonas mobilis that can be

engineered for ethanol production from lignocellulosic biomass, due to insufficient nutrition in

the feedstock, which raises a concern about the supplementation of nutritional components to

satisfy the basic requirements for cell growth and ethanol fermentation.

6.2 Processes for Ethanol Generation from Ligno-cellulosic Biomass Ligno-cellulosic biomass can be converted into bio-ethanol using biochemical conversion

technology.

In biochemical conversion the plant fibre

is separated into its components cellulose,

hemicelluloses and lignin. The cellulose

is then further broken down to simple

sugars that are fermented to produce

ethanol. Typically the process is carried

out in 4 stages

1. Physical or chemical pretreatment

of the plant fibers to expose the

cellulose and reduce its

crystallinety.

2. Hydrolysis of the cellulose

polymer, with enzymes or acids,

to convert it into simple sugars

(glucose).

3. Microbial fermentation of these

simple sugars to ethanol.

4. Distillation and dehydration to produce 99.5% pure alcohol.

Fig.6.3: Technologies for Ethanol Generation from Lignocellulosic Biomass


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Lignin is a byproduct of this process, and this can be used as a boiler fuel or processed into

specialty chemicals. Hydrolysis and fermentation can be conducted simultaneously in one stage

but simultaneous saccharification and fermentation (SSF) is yet to be implemented

commercially, significant advances are being made in this area.

Both the biochemical and thermo chemical pathways require sophisticated processing steps that

have higher operating costs and need significant capital investment compared with grain-based

ethanol processes.

6.3 Process Description for Bio-Ethanol Production The lignin-hemicellulose-cellulose complex forms stringent seals around cellulose. The first

step in the overall process of lignocellulosic fermentation is breaking this barrier. This is the

most important and rate limiting step in the overall process. Further steps involve isolation and

hydrolysis of cellulose and hemicellulose to generate emendable sugars (saccharification)

followed by fermentation and distillation as shown in Fig 6.5. The pretreatment processes

involve the use of acids, alkalis, steam and/or organic solvents. The aim of this process is to

separate lignin, cellulose, hemicellulose from lignocellulosic biomass. Post pretreatment, the

recalcitrant lignocellulosic biomass becomes susceptible to acid and/or enzymatic hydrolysis as

the cellulosic microfibrils are exposed and/or accessible to hydrolyzing agents.

Fig.6.4: Technological routes for Ethanol Generation from Lignocellulosic Biomass


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In the pretreatment process, small amounts of cellulose and most of hemicellulose is hydrolyzed to sugar

monomers. The pretreated biomass is then subjected to filtration to separate liquids

(hemicellulose hydrolysate) and solid (lignin & cellulose). The liquid is sent to a xylose

(pentose) fermentation column for ethanol production. Solids are subjected to hydrolysis (also

called second stage hydrolysis). This process is mainly accomplished by enzymatic methods

using cellulases. Mild acid hydrolysis using sulfuric and hydrochloric acids is an alternative

procedure. The hydrolyzed sugars such as can be readily fermented to ethanol using various

strains of yeast.

6.3.1 Pretreatment

The usefulness of cellulose as a feedstock has been limited by its rigid structure and difficulty

to breakdown into simple sugars. Pretreatment is necessary to accomplish the following:

Break the lignin-hemicellulose-cellulose complex.

Disrupt/loosen-up the crystalline structure of cellulose.

Increase the porosity of the biomass.

These changes in lignocellulosic materials make it easier for enzymatic saccharification

(hydrolysis), results in higher fermentable sugars levels and will have a significant impact on

the overall process. Cost effective pretreatments are needed to liberate the cellulose from the

lignin/hemicellulose matrix and reduce its crystallinity i.e an ideal pretreatment process should

Fig.6.5: Schematics of biomass to bio-ethanol technology


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have yield high levels of pentoses and the hydrolysates will not have any inhibitory substances.

Pretreatment, involves delignification of the feedstock in order to make cellulose more

accessible in the hydrolysis step, using physical, physicochemical, chemical and biological

treatment. For this step there are several types of processes, with different yields and distinct

effects on the biomass, which in turn have implications on the subsequent steps. Most used

methods for pretreatment is listed in Table 6.1. Pretreatment is a costly separation, accounting

for upto 33% of the total cost the economy needs to be improved, and the release of microbial

and chemical contamination that possibly reduces the overall yield needs further attention.

Table 6.1: Comparison of the different pretreatment processes

Process Description Reaction time

Xylose yield

Physical Vapour explosion

Crushed biomass is treated with vapour (saturated, 160°-260°C) followed by a rapid decompression. 1-10 min 45%-65%

Thermo-hydrolysis

Uses hot water at high pressure (pressure above the saturation point) to hydrolyze the hemicellulose. 30 min 88%-98%

Chemical Acid hydrolysis

Uses concentrated or diluted sulphuric, hydrochloric or nitric acids, 2-10 min 75%-90%

Alkaline hydrolysis

Uses bases, like sodium or calcium hydroxides. 2 min 60%-75%

Organosolv

A mixture of an organic solvent (methanol, bio-ethanol and acetone, for example) and acid catalyst (H2SO4, HCL) is used to break internal bonds of lignin and hemicellulose.

40-60 min 70%-80%

Biologic Fungi (molds) are used to soluble the lignin. Generally used in conjunction with other processes.

Combined

Catalyzed Vapour Explosion

Addition of H2SO4 (or SO4) or CO2 in the vapour explosion may increase the efficiency of enzymatic hydrolysis, reduce the production of inhibitor compounds, and promote a more complete removal of hemicellulose.

1-4 min 88%

Afex (ammonia fiber explosion)

Exposure to liquid ammonia at high temperature and pressure for a period of time, followed by a rapid decompression.

50%-90%



DOCUMENT No. B033-000-03-41-RP-01


6.3.2 Hydrolysis

Hydrolysis process generates fermentable monomeric sugars from hemicellulose and cellulose

content of lignocellulosic biomass. This can be accomplished by two different processes,

namely,

1. Acid hydrolysis

2. Enzymatic hydrolysis.

Acid hydrolysis

Mineral acids such as sulfuric acid, hydrochloric acid, hydrofluoric acid and nitric acid are

widely employed for the hydrolysis of lignocellulosic biomass. The sulfuric acid-based

hydrolysis process is operated under two different conditions

Process that uses high sulfuric acid concentration that operates at a lower temperature.

Process that uses low sulfuric acid concentration and operates at a higher temperature.

Enzymatic hydrolysis

These enzymes are commonly referred to as endoglucanase, exoglucanase and cellobiase,

respectively. The exoglucanases attack the non reducing end of cellulose to form the cellobiose

units. Finally, cellobiase converts cellobiose into D-glucose. The factors affecting activity of

cellulases include enzyme source and the concentration of enzyme. The yield of fermentable

sugar levels obtained from pretreated biomass increases as the enzyme load increases and

cellulose load decreases. A comparison of the different hydrolysis processes is presented in

Table 6.2. For higher conversion and lower metallurgy enzymatic hydrolysis is more favorable

over acid hydrolysis.

Table 6.2: Comparison of different options for 2nd stage hydrolysis

Process Input Temperature Time Saccharification

Diluted Acid

< 1% H2SO4 215° C 3 min 50%-70%

Concentrated Acid 30%-70% H2SO4 40° C

2-6 h 90%

Enzymatic Cellulase 70° C 1.5 day 75%-95%

6.3.3 Fermentation

Fermentation is the biological process to convert the hexoses and pentoses into ethanol by a

variety of microorganisms, such as bacteria, yeast or fungi.


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Yeast commonly used for first generation ethanol production, cannot metabolize xylose. Other

yeasts ferment xylose and other pentoses into ethanol. Genetically engineered fungi that

produce large volumes of cellulase, xylanase and hemicellulase enzymes are also used. These

could convert agricultural residues (e.g., corn stover, straw, and sugar cane bagasse) and energy

crops (e.g., switch grass) into fermentable sugars.

When using enzymatic hydrolysis, different integration methods of hydrolysis and fermentation

steps are proposed. In the separate hydrolysis and fermentation (SHF), the liberated cellulose is

treated in a different reactor for hydrolysis and subsequent fermentation than the hydrolyzed

hemicellulose and lignin. Separate hydrolysis and co-fermentation (SHCF) and simultaneous

saccharification and co-fermentation (SSCF) are other possible alternatives.

6.3.4 Distillation and Purification

The water-rich feed stream of the distillation & purification unit, contains ethanol in the range

of 3–6 vol %, which is low in comparison with 12 to 15 vol% obtained from 1st generation

feedstock. Due to the higher water content of the broth, additional distillation efforts are

required. Distillation & purification unit consists of 2 process operations:

1. Binary distillation

2. Adsorption via molecular sieve

Desired separation specification of 99.5 vol% ethanol cannot be achieved by distillation alone

because of the non-ideal solution behavior of the water-ethanol mixture. An azeotrope is

observed when the mixture reaches 95.5% mole purity of ethanol. This is a common

phenomenon that occurs when one attempts to separate a polar substance from an alcohol group

utilizing relative volatilities, because in high alcohol concentrations, the attractive forces of the

alcohol group tend to overpower phase change mechanisms of the mixed polar molecule that is

governed by entropy. Equilibrium stage operations are no longer effective after it meets an

azeotrope, and hence sets a limit on the purity achievable using phase change mechanisms.

Hence adsorption via molecular sieve is required for achieving the desired product

specification.

6.4 Technology Assessment The following technology licensors has shown their interest to putting up 2G bioethanol plant

in Karnataka for MRPL.

1. Praj Industries Limited

2. Beta renewables, S.p.A

3. Renmatix, Inc.


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DOCUMENT No. B033-000-03-41-RP-01



4. DBT-ICT

This section presents the brief details of all technology licensers along with their USPs (Unique

Selling Point) such as process description, technical features, critical equipments, product yield,

by products etc.

6.4.1 Technology A

Technology A has executed 1 TPD pilot plant to produce bio-ethanol from ligno-cellulosic

biomass is in operation since 2009 to till date consistently. A 12 TPD integrated smart bio

refinery demonstration plant in operation since March 2017 in Pune, Maharashtra .Technology

A has divided their technology in different sections which are listed below and shown in fig.

6.6

1. Biomass Preparation Section

A. Biomass Storage

B. Biomass Handling & Milling

2. Main Process Plant

A. Pretreatment

B. Enzymatic Hydrolysis

C. Co‐Fermentation

D. Distillation

E. Dehydration

3. Utilities & Auxiliaries

A. Boiler

B. Turbine

C. Water Treatment Plant

D. Chemical Storage

E. Cooling Tower

F. Air Compressor

G. Product Storage

H. Enzyme Storage

4. Residue Handling Section

A. Solid Liquid Separation

B. Whole Stillage Storage Section

C. Waste water treatment plant

5. Off‐Site Packages


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A. Fire Fighting System

B. Control System

C. Weigh Bridge

6. Add On Packages

A. Liquefied CO2 Plant

B. Bio-CNG Plant

6.4.1.1 Material Handling & Wet Washing Section

The purpose of this section is to outline the technical specifications for feed stock handling

system for conveying the feed stock, de-stoning and screening, magnetic particle separation,

intermediate storage, necessary safety controls and instrumentation for automatic operation,

weighing system, vibratory screen system with rated capacity as per layout and parameters

mentioned in these specifications.

The feed stock handling system shall be designed for all feed stock materials mentioned in

technical specifications and for the levels of moisture mentioned in the feed stock.

The complete installation will be outdoor type. All components in system, instrumentation,

motors, gearbox, etc shall be suitable for outdoor installation.

From storage, raw material will be fed to the feed conveyor of feed stock handling system with

the help of front end loaders etc for further processing of size reduction, stones separation, and

removal of foreign particles, intermediate storage and further conveying.

A permanent magnet type metal separator shall be installed on feed conveyer to remove

metallic foreign particles from the feed stock. A proper access will be provided to the magnetic

separator for easy removal of separated metallic particles.

The milling unit will be supplied to crush biomass up to 25 – 40 mm particle size and integrated

with upward and downward conveying system including interconnecting chutes bellows, hoods

for dust extraction system etc. are included in the handling system. The controlled flow rate

from the silo shall be fed to the wet washing system for further processing.

Washing is done at ambient conditions with 3-3.5 % w/w solids. The wet biomass is further

squeezed to increase solid up to 15-16% w/w. The wet washed, sized feed stock shall be

conveyed from wet washing system to pretreatment section with belt / chain conveyor and

washed water will be sent to clarification section for recycle. The clarified water will be

recycled back to washing section and clarifier bottom will be sent for further treatment in bio-

methanation section.


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6.4.1.2 Main Process Plant

Pretreatment Process:

In this section, C5 hydrolysis is done (i.e. conversion of Xylan to Xylose) in a reactor, where

a slurry concentration of 15%‐20% is maintained. The mixed acid solution is continuously fed

as per the requirement. The slurry is treated at about 150 – 170 oC and 5 - 8 bar pressure. The

slurry from reactor is flashed in a flash vessel and then pumped to enzymatic hydrolysis

section. Water from the steam flashing shall be recycled back to process.

The pretreated slurry is fed to the pre-hydrolysis reactor. Reaction conditions maintained are

pH in the range of 5.0 to 5.5, temperature of about 48 to 55 oC at atmospheric pressure before

enzyme addition. Enzyme shall be added to the reactor as per required dose. The reaction will

continue in the pre-hydrolysis reactor for few hrs and then the contents are transferred to main

hydrolysis reactor for further processing.

Fig. 6.6: Process diagram of Technology A


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Fermentation Section:

The sugar rich slurry from hydrolysis reactor is then cooled to 32 – 34 oC and fed to the

fermenter. Pre-fermenters are provided for yeast propagation and different nutrients are added

as per the required dosages. The pre-fermentor volume is transferred to main fermentor for

fermentation process.

Distillation Section:

Once the desired alcohol is achieved, fermented wash is transferred from fermentor to beer

well and from beer well to distillation section. CO2 evolved during fermentation can be sent

to liquefied CO2 plant. The fermented mash from the co-fermentation section is distilled and

dehydrated to get Fuel grade ethanol.

Split distillation consists of stripping section with following distillation columns.

Degasifying Column: The primary function of degasifying column is to remove non

condensable gases and low boiling impurities from the fermented mash. Preheated

fermented mash is fed to degassifying column.

Split Mash Column: The primary function of mash column is to strip off ethanol from

fermented mash. Split mash column helps in reduction of overall steam consumption

in distillation section.

Rectification section consist rectifier cum exhaust column. The primary function of this

column is to concentrate the ethanol. Ethanol is enriched at the top and is drawn out as hydrous

ethanol and is fed to dehydration plant for further concentration.

Dehydration Section:

The process drives the rectified feed through a system of molsieve beds. To allow for

molsieve bed regeneration in continuous operation, twin beds are provided of which one is in

dehydration mode while the other is in regenerating mode. Depending on feed and product

specifications, the dehydration regeneration exchange takes place based on set time cycle. As

the regeneration process releases the adsorbed water together with ethanol content, it is

recycled back to system for reprocessing.

The feed is pumped to evaporator column after preheating in feed pre-heater. The overhead

vapor of evaporator column is superheated to the required operating temperature and circulated

to sieve bed one. After passing through the molsieve, the vapor is condensed, cooled and sent

to storage.


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The regeneration operation forces the release of the moisture from the molsieve, making the

sieve bed 2 ready for the next cycle. The whole stillage generated in distillation shall be

pumped to bio-methanation.

6.4.1.3 Utilities & Auxiliaries

Boiler and Turbine Section:

The solid fuel fired boiler package is envisaged for steam requirements of plant. The high

pressure steam generated in the boiler will be expanded in extraction ‐condensing turbine to

generate electric power. The steam from turbine extraction will be supplied to the process

plant through steam distribution network. The condensate recovered from process plant will

be returned back to the boiler package.

The boiler package comprises the complete boiler system (combustion system, water tube

boiler, super‐heaters, evaporators, economizers, air pre‐heaters), the boiler feed water system

(pressurized de‐aerator tank, boiler feed water pump, chemical dosing systems), fuel and

ash handling system, pollution control system, chimney and balanced draft system,

electrical and instrumentation system for fully automatic operation of the boiler package.

There are following two options for the primary fuel and supplementary fuel of the boiler:

(i) Using wet biomass cake discharged from the process.

(ii) Using dried biomass cake and recovery of moisture as condensate

In first option, the wet biomass cake is blended with supplementary fuel such as rice husk

in appropriate percentage. This well blended mixture will be supplied to boiler as fuel.

In second option, the wet biomass cake will be dried in suitable type of biomass dryer.

The dried biomass will be supplied to boiler as fuel and supplementary fuel rice husk will be

supplied. The moisture evaporated from biomass cake in the dryer can be condensed back

and water from wet biomass cake can be recovered.

The proposed boiler package will have following features:

Highest possible thermal efficiency

Fully automatic operation of the boiler

Online‐real time efficiency monitoring system

Fully mechanized fuel and ash handling system

Lowest downtime for cleaning and maintenance

High circulation ratio

Steam Turbine Package:


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The high pressure steam generated in the boiler will be expanded in extraction ‐ condensing

turbine to generate electric power. The complete and efficient turbine package will be supplied

for efficient power generation from the system. The steam turbo‐generator will be installed

in a separate powerhouse, along with the entire auxiliary equipment and systems.

The turbine control shall be located in the control room, located adjacent to the turbo‐

generator, whereas important indicating instruments shall be provided near the turbine in the

local gauge board.

Water Treatment Plant:

Basic Filtration:

Raw water is pumped from the raw water tank to the self cleaning filter unit for removal of

suspended solids and turbid matter. Prior to chlorine (sodium hypo‐chlorite shall be added for

dis‐infection purpose) this chlorinated, dis‐infected & filtered water is further passed

through an activated carbon filter (ACF). ACF unit consists of activated carbon media which ensures removal of organic matter &

excess chlorine, the quality of water at the outlet of ACF unit shall be TSS < 5 ppm &

residual chlorine as nil. This filtered water is directed to the process water storage tank and

further transferred to process use. U.V. sterilizer is also installed post ACF unit to eliminate

organic matter. Part of the filtered water is further passed through an ultra‐filtration system

details of which are explained below

Ultra-filtration System:

Ultra‐filtration (UF) is the physical removal of particles and microbiological contaminants

from an aqueous solution using a membrane filter with pore sizes less than 0.04 micron. It

does not remove dissolved ions and small molecules. Membranes may be made from several

polymers including polyacrylonitrile (PAN), poly ether sulfone (PES) and polyvinylidene

fluoride (PVDF). Membrane has durability, ease of manufacturing, resistance to pH

extremes and tolerance to a wide range of chemical cleaning agents. Membranes typically

have a pore size of 0.03 µ (microns), which is effective barrier for bacteria, viruses and

cysts.

Membranes are supplied as flat sheet, spiral wound or hollow fiber modules. Flat sheet

membrane systems are contained in bulky structures and generally operated at low flux rates.

Spiral wound modules are operated in continuous cross flow mode similar to reverse osmosis

membranes. They do not perform a filtrate backwash cycle to lift foulants from the membrane


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surface. Hollow fibre membranes may be submerged in a membrane tank or encased in

pressurized modules.

The offered pressurized hollow fiber membranes will operate in either continuous cross flow

or semi dead‐end modes. Cross flow mode is advantageous for higher suspended solids but

usually requires more pumping energy.

Reverse Osmosis System and Cartridge Filter:

Purpose of cartridge filter is to basically remove very fine particles. The water from cartridge

filter will then be passed to RO unit by means of high‐pressure pump to get the RO product

water.

The pressurized flow enters the RO system. Due to high pressure, a portion of the feed

water permeates through the semi‐permeable RO membranes as pure water while the balance

of the flow exits the system as reject. A single stream of the RO System is proposed with two

stages RO plant is designed for recovery of 80%.

The conductivity indicating transmitter is provided on the RO permeate line monitors the

product water quality. Permeate from RO system is directed to a Degasser Tower to reduce

the CO2 content before it is stored in the RO permeate tank. A cleaning system is provided

for the RO chemical cleaning. A system cleaning is required when the normalized permeate

flow is reduced by 10‐15%, or the differential pressure (DP) increases by 15 percent from the

reference conditions

DM Water Plant System:

Filtered water post RO unit shall further be passed through a D.M. plant system comprising

of mixed bed unit. Remnant cations & anion present in the RO permeate shall be removed

by ion exchange resin present in the mixed bed unit; the mixed bed unit is designed for 20

hours of operation, once the desired output is achieved from the mixed bed unit the resins in

the unit have to be regenerated . 6.4.1.4 Residue Handling Section

Solid-Liquid Separation:

Bio-methanated spent wash is transferred to solid liquid separation section. The solid stream

is used as a feed to boiler and the liquid stream shall be sent to secondary treatment plant

Secondary Treatment Plant: The liquid portion from solid liquid separation system will be treated through reverse osmosis

system.


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In reverse osmosis, the flow of solvent (water) is reversed by application of external

pressure to the concentrated solution (brackish or saline water). The water that passes through

the membrane would be substantially free from the chemical impurities present in the brackish

or saline water. The water that does not pass through the membrane and is continuously drained

is called concentrate or reject. Bio-methaned spent wash will be treated through reverse

osmosis membranes. The permeate water from the reverse osmosis system will be recycled

back to main ethanol processing plant. The reject may be sold as organic manure as claimed

by technology provider.

6.4.1.5 Add On Packages:

BioCNG Section: H2S Scrubbing Section

Advanced liquid redox process is used to remove H2S from biogas. The process utilizes the

oxidation reduction potential of chelated iron in aqueous medium for scrubbing hydrogen

sulfide from the biogas. The sulfur present in the hydrogen sulfide is precipitated as elemental

sulfur.

CO2 Scrubbing Section:

The high pressure hydro scrubbing process is based on the difference in solubility of CH4, H2S

and CO2 in water. The process is intensified by further improving the solubility of CO2 by

pressurizing the absorption system.

The biogas after desulfurization fed in to suction of a bio gas compressor via a gas suction filter

where pressure of gas is raised to around 7 to 10 kg/cm²g. Compressed bio gas is sent to bottom

of a pack tower, where pressurized water will flow from top to bottom of the tower in reverse

direction of bio gas for scrubbing of the bio gas to remove contaminant and suspended particles

and absorption of H2S and CO2. At the top of the pack tower compressed but wet methane

emerges and is taken to methane gas dryer. The methane gas dryer is twin bed desiccant dryer

which operates continuously and dries the wet methane to a dew point of minus 60oC. Pre and

post filters are provided in the methane dryer.

High Pressure Compressor:

The standard high pressure compressors type is air‐cooled, and available in required stages

according to the inlet condition available for compression. The compressor is provided to

compress methane and other gases present in the purified biogas.

CO2 Recovery and Liquefaction Section:

CO2 Recovery Section:


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Raw CO2 gas from fermenters is washed through a high capacity stainless steel foam

trap designed to reduce the potential hazard of fermenters foam carry over contaminating the

CO2 recovery equipment. Water spray nozzles are used for rinse‐ down in the advent that

foam is detected. Water exits the foam trap through a seal drain. The raw CO2 gas is sent

through a CO2 gas booster blower. The booster draws feed CO2 gas from the fermenters and

increases its pressure to overcome recovery piping and equipment pressure losses and

deliver elevated suction pressure to the main CO2 compressor. The booster is equipped

with a variable frequency drive that is automatically modulated to maintain a constant CO2

fermentation pressure even with changing CO2 production rates.

CO2 purification section:

In this section, CO2 gas is passed through low pressure CO2 gas scrubber. It is designed to

perform with a high efficiency removal of water soluble impurities due to use of water

scrubbing through structured packing. The scrubber operates with very high alcohol removal

efficiency.

During operation a continuous feed of water automatically adjusted to be proportional to the

CO2 collection rate is evenly distributed over structured packing. Counter current to the water

flow is the flow of impure CO2. The water is collected in the sump and drained. At the top

of the tower the entrained moisture is removed from the CO2 in the demister pad / mist

eliminator and the CO2 exits the tower.

After low pressure water CO2 scrubber, the clean gas is continuously fed to CO2 gas

compressor at constant pressure and this specially designed non‐lubricated, two stages gas

compressor compress the gas to approximate 19 bar (g) pressure at the discharge. The two

stage compressor is complete with first stage and second stage cooling with cooling tower

water and automatic drains with provision of manual checks for drains.

CO2 gas compressed at approximate 19 bar (g) then passes through high pressure water gas

scrubber again to remove heavier impurities from the feed gas, to bring down the impurities

load on the downstream purification system in the plant. After the high pressure water gas

scrubber, the CO2 gas is passed through dual tower deodorizers. The deodorizer removes odor

causing impurities from the high pressure gas. The dual towers are filled with special

activated carbon. CO2 is deodorized in the on‐line tower while the media in the parallel tower

is regenerated with steam at 3.5 bar (g) and followed by natural cooling. After each cycle, this


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regenerated parallel tower is changed to process and the other tower goes for regeneration by

steam.

Clean CO2 gas is passed through high pressure pre-cooler. The cooled CO2 gas from pre-

cooler then passes through dual tower dryer filled with molecular sieves. This dryer is

designed for removal of moisture prior to liquefaction of CO2. The dryer has two tower

systems with tower alteration as well as regeneration. It is completely automatic and

regeneration is conducted every cycle. The CO2 feed gas is then passed through a fine filter to

remove any particulate matter.

CO2 Liquefaction Section:

Dried, clean and purified CO2 gas at pressure of 18 bar(g) is liquefied in a CO2 liquefaction

system operating on ammonia refrigerant. CO2 gas is liquefied at - 27 °C in a flooded CO2

condenser. The liquefaction system runs on automatic mode for continuous service. Liquid

CO2 from liquefying system is further purified by removing the non‐condensable gases like

O2, N2, etc., via stripping technology and passed through stripper section based on liquid CO2

being stripped through CO2 reboiler using refrigerant from liquefying system. High purity

liquid CO2 is transferred to NOx removal towers to finally remove the product liquid CO2

from the impurities like NO, NO2 to make the final product liquid CO2 as high purity food

grade quality. Finally this high purity product goes to the liquid CO2 storage tank for

distribution / supplying high purity food grade liquid CO2 consumers through road tankers.

Bio-methanation:

Anaerobic Bio-methanation System:

Anaerobic bio-methanation system uses a bio-digester, to convert organic matter into useful

energy in the form of biogas. The biological process of conversion takes place in controlled

atmosphere ensuring maximum conversion efficiency and production of biogas.

Following are the salient features of the system before entering to the bio-digester, thin stillage

and wet washing purge effluent from is received into a suitably designed equalization tank to

equalize waste water characteristic.

Temperature Control:

Waste water is pumped to bio-digester, via thin stillage cooler which is designed to maintain

the waste water temperature at 38-40oC, with the help of cooling water.

pH Control:

Waste water pH is adjusted to 6.5 ‐ 7.0 by recycling part of the treated effluent.


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Mixing in Bio-digester:

Mixing is done by re‐circulation of biomass using mixing system & further enhanced by gas

propagation. Efficient mixing helps microorganisms to reach fresh food in favorable living

condition & convert organic matter into methane & carbon dioxide. Various sample points are

provided on the shell of bio-digester to measure the concentration of sludge in the bio-digester.

Drain points are provided to drain the excess sludge from bio-digester.

Hydraulic Retention Time (HRT) & Solid Retention Time (SRT):

Bio-digester is designed for adequate hydraulic retention time, which is required for

achieving design parameters while reducing the effects of shock loads & making the process

sturdy. The digested effluent from bio-digester flows to a parallel plate clarifier via degassing

pond. The entrapped gases in the digested effluent are released in degassing pond. The sludge

is settled in the parallel plate clarifier, which is recycled to increase solid retention time in the

bio-digester. The supernatant liquid from clarifier is sent for further treatment. Excess biomass

& sludge is removed from the bottom of bio-digester periodically to avoid excess built up of

solids inside the digester. The biogas produced in bio-digester is collected from top of the bio-

digester & flows to the gasholder. The gas holder acts as intermediate gas storage & pressure

control device. The biogas is transferred to the boiler house by using biogas blowers. Partly

Biogas is transferred to Bio‐CNG plant. The flare unit is provided for excess gas burning.

6.4.1.6 Overall Material Balance of Plant

Technology A has provided material balance data for the 100KLPD ethanol plant for two

feedstocks.

1. Bagasse

2. Rice straw

Dry feed required for bagasse based plant is 385 TPD while for rice based plant, it is 421 TPD.

Material balance for both feed is shown in fig 6.7.


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A) Feed: Bagasse

* Chemicals:

Mixed Acid : 9.63 TPD Molasses : 21.17 TPD

Nutrients : 5.05 TPD Other Chemicals : 19.25 TPD

B) Feed: Rice Straw

* Chemicals:

Mixed Acid : 12.78 TPD Molasses : 17.04 TPD

Nutrients : 4.26 TPD Other Chemicals : 19.17 TPD

# TA = Technical Alcohol $ FO = Fusel Oil

Fig. 6.7: Over all material balance of Technology A

Fuel Grade

Ethanol Plant

Lignin = 155 TPD

ISBL OSBL

Bagasse = 385 TPD

Chemical*

Enzyme =3.73 TPD

FO$= 0.25 TPD

TA# = 1.7 TPD

Rejects = 17.74 TPD

EtOH = 79.44 TPD

Yeast = 0.03 TPD



Sulphur = 4.2 TPD

CO2 = 137.74 TPD


Fuel Grade

Ethanol Plant

Lignin = 199.8 TPD

ISBL OSBL

Rice Str = 421 TPD

Chemical*

Enzyme =3.70 TPD

FO$ = 0.26 TPD TA# = 1.7 TPD

Rejects = 16.4 TPD

EtOH = 79.44 TPD

Yeast = 0.03 TPD


Sulphur = 3.8 TPD

CO2 = 130.5 TPD


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6.4.1.7 Features

Developed indigenous 2G Ethanol technology in 2009

Bio-ethanol percentage conversion for per ton of dry biomass is of rice straw and

bagasse is 19% and 21% respectively.



Feed size for the process is 25-40 mm.

Major byproducts from technology A are Bio-CNG (9%), liquefied CO2 (10.5%),

Technical Alcohol (4%), Fusel Oil (0.6%), Lignin (47%) and surplus power.

Enzyme and yeast consumption for per ton of dry biomass conversion is 8.7 kg and 0.7

kg respectively.

Total conversion time from biomass to bio ethanol is 100-120 hour.

Approximately 100% water re-cycle via effluent treatment plant in ISBL. However,

some water effluent is there from utilities.

Lignin rich cake is separated from solid liquid separation & used as a boiler fuel along

with secondary fuel.

Turndown capacity for the proposed plant of capacity 100KLPD is about 70 % of

maximum capacity.

Licensor Experience on 1st generation ethanol production technology as a global

equipment supplier.

Licensor Has strength to provide fully integrated end to end scheme for bio-ethanol

plant including OSBL.

Technology employs Co-fermentation. 6.4.2 Technology B

Technology B is providing technology for the second generation bio-ethanol production. The

process technology produces fermentable sugars from cellulosic biomasses for the production

of ethanol.

Technology B offers the following benefits:

Proprietary technology without addition of chemicals, that allows high recovery of C5

and C6 sugars (high yield), low sugar degradation and therefore low inhibitor

generation.


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Low residence time in the enzymatic hydrolysis step, because of a unique and

proprietary, patent-pending viscosity reduction step.

Highly efficient use of enzyme applied to a high solid content stream.

Simultaneous fermentation of C5 and C6 sugars.

6.4.2.1 Process Description

The main process steps for ethanol production from lignocellulosic feedstocks for technology

B are:

1. Biomass pretreatment to disrupt the lignocellulosic matrix and solubilize C5 and

C6 sugars.

2. Hydrolysis to reduce the cellulose and hemicellulose into fermentable sugars.

3. Fermentation of sugars to ethanol.

4. Solid separation, ethanol recovery and dehydration.

The technology is designed to enable pretreatment process to produce pretreated material that

facilitates enzymatic and microbial activity as shown in fig 6.9. Technology claims to limit

formation of degradation products that could inhibit the performance of hydrolytic enzymes or

fermentative microorganisms. Plant is designed for flexible operation with different feedstocks.

Table 6.3: List of the processes in ISBL

S No. Area Name Scope

1 Biomass pretreatment ISBL

2 Stream cooling ISBL

3 Viscosity reduction and hydrolysis ISBL

4 Fermentation ISBL

5 MO propagation ISBL

6 Beer column ISBL

7 Rectifier column ISBL

8 Ethanol Dehydration ISBL

9 Daily Ethanol storage ISBL

10 Lignin separation ISBL

11 CIP system ISBL

12 Chemicals storage ISBL

13 CO2 scrubber ISBL


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Biomass Pretreatment and Stream Cooling:

The biomass will be sent to the pretreatment where the cellulose structure is disrupted, the lignin

seal is broken, and the hemicellulose is partially removed. The objective of this step is to enable

enzymatic access to the cellulose and hemicellulose fractions. Proper pretreatment is critical to

optimize the subsequent hydrolysis. In general, an effective pretreatment is defined by

conditions that maximize recovery of the cellulose and hemicellulose fractions for downstream

processing while, limiting the formation of by-products that inhibits the performance of the

biocatalysts. The combination between auto-hydrolysis and high pressure biomass cooking

processes is used to minimize the formation of inhibitors, eliminating a drawback of the

conventional process. The process uses saturated steam to cleave the chemical bonds between

lignin, cellulose and hemicellulose. The effective outcome in this section has the benefit to

lowering the cost of the process and to reduce the amount of enzyme used in the hydrolysis

step.

Viscosity Reduction and Hydrolysis:

The streams from biomass pretreatment, will be mixed together and fed to the enzymatic

hydrolysis two steps reactors to efficiently liquefy the pretreated material (viscosity reduction

section). This process allows the enzymatic processing of high amount of dry matter providing

Fig. 6.8: Process schematic for Technology B


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a complete mixing and adequate retention time for the first enzymatic liquefaction of complex

cellulose and hemicellulose, leading to simpler oligomer chains necessary for an efficient

downstream conversion to ethanol. This step will ensure continuous flow of the material into

the fermenters.

Fermentation and CO2 Scrubber:

The mash exiting from the hydrolysis reactors will be cooled and then sent to the simultaneous

saccharification and fermentation (SSF) section. The simultaneous saccharification of both

cellulose to glucose and hemicellulose to pentose and the co-fermentation of both glucose and

pentose will be realized by using special yeast. The SSF offers reduction of the capital costs

due to the combination of hydrolysis and fermentation into a single reactor. In the fermentation,

sugars will be converted to ethanol and carbon dioxide by the action of the yeasts. The

fermentation process employs a system of tanks, all of equal size, to allow the fermentation

process to be operated in a batch mode. The fermentation process generates heat, which is

removed by circulating the fermenting mash through external heat exchangers. From

fermentation, the beer is pumped to the beer well, a holding tank that allows beer to be

continuously fed to the distillation sections.

MO Propagation and Beer Column Section:

Two tanks are used for yeast production where yeasts are grown rapidly with the addition of

process air.

The beer produced during SSF is pumped to a beer stripping column. The bottom stream

(stillage) containing water and solids will be sent to the lignin separation section while overhead

stream is sent to rectification column. The heat is supplied to the beer column by reboiling the

clarified stillage through two indirectly heated reboilers that use exhaust steam coming from

pretreatment. Solid content in clarified stillage could cause fouling issues so that reboilers

capacity is oversized in order to allow the column working at reduced duty with only one

reboiler while cleaning the other.

Rectifier Column Section and Dehydration section:

The ethanol/water stream from the top of the beer column will be condensed and pumped to

rectifier column where it is concentrated to near-azeotropic point. A side draw-off from the

rectifier column will separate the heavy alcohols fraction in order to meet purity requirements

for the ethanol. The heat is supplied to the rectifier column by an indirectly heated reboiler. The


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water stream comes from the bottom of the rectifier column is pumped to the process

condensation tank and then treated to reuse it back in the process.

The rectifier top mixture is in azeotrope condition and cannot be further purified using standard

distillation. The final removal of water/ethanol mixture to produce fuel grade ethanol is

achieved by a molecular sieve dehydration system. The molecular sieves work on the principle

of selective adsorption in the vapor phase. In this case, water is adsorbed on the sieve bed

material while ethanol passes through the bed. The adsorbed water is removed during a

regeneration step and is routed back to the distillation system. Fuel ethanol is pumped to the

daily/off spec tanks opportunely sized for the production at design rate. The production rate of

the ethanol from the distillation/dehydration system will be monitored with in-line instruments,

while moisture content will be monitored with laboratory equipment.

The ethanol from dehydration section is fed into the ethanol daily tank/off spec tank in order

to control the quality of the product before sending it into the product storage section.

Lignin Separation:

The bottom of the beer stripper column containing solids (stillage) is fed to a separation system

in order to separate clarified stillage from high lignin stream. The purpose of the system is to

obtain the high lignin stream with a residual moisture content of about 60%. Technology B has

developed two distinct technical options for this process step, namely filtration and centrifugal

decanters.

The selection is site-specific and can be assessed as part of detailed site-specific feasibility

study. Centrifugal decanters for lignin dewatering are uses centrifugal force to separates solid

particles from water. Through openings situated at the bottom of the equipment it is possible to

separate the clarified stillage stream from the solids (lignin) which, are then transported to the

outlet.

CIP System and Chemical Storage:

In order to keep the process microbiologically clean and to remove residues from heat

exchanger equipment and tanks, a Clean-In-Place (CIP) system will be provided. The cleaning

process will use condensate from the process, thereby minimizing fresh water usage. Caustic

will be used as a cleaning agent for sanitizing and dissolving most of the residues. Chemicals

such as antifoam, caustic soda, urea solution, enzymes are stored in suitable tanks and dosed to

the plant.

6.4.2.2 Byproducts and Effluents

The byproducts of technology B process are:


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1. Lignin-rich solid stream

2. Clarified stillage

3. CO2

The moisture content in the high lignin stream coming out from centrifugal decanters is 60%.

While the expected flow-rate and preliminary characterization of the concentrated stillage after

the evaporation unit BOP section is 0.4 ton for per ton of ethanol production. The moisture

content in this stream is at about 50%.

1. The lignin-rich stream is the high-solid stream resulting from the lignin separation

section. While lignin has potentially higher value applications that are under

development, it can be also used for energy generation. It can be sold as a fuel or used

in a purposely designed CHP (combined heat and power unit) on-site for generation of

steam and electricity.

2. Clarified stillage is the high-liquid stream resulting from the lignin separation section.

Stillage is a by-product which can be returned to agricultural fields in the proximity of

the plant for nutrient recycling. In other scenarios, this clarified stillage can be sent to

an outside waste water treatment facility for disposal. In most cases however the

Fig. 6.9 Simplified scheme of byproduct and effluent streams


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clarified stillage will need to be further processed on-site thus generating streams of

valuable byproducts and effluents. The most appropriate choice is site-specific as it

depends on markets for the co-products and the cost for disposal of any remaining

effluents.

3. The process produces CO2 as a fermentation by-product. The technology includes the

equipment required to collect gaseous streams containing CO2 and process them through

a scrubber unit prior to being vented to the atmosphere. Rather than venting CO2 rich

stream, it is possible to further clean it into commercial-grade CO2 which can be then

liquefied and stored for sale. The viability of this option will depend on the size and

location of the plant as well as the local market for CO2 as an industrial gas.

In addition to the water effluents, the plant will also generate:

Ashes from the boiler (in case a CHP unit is used on-site to generate energy from the high lignin stream). In certain instances ashes can be recycled to agricultural fields for nutrient recovery; in others, however, ashes will need to be disposed off.

It is important to emphasize that the nature and specific characteristics of byproducts and effluents is highly dependent on the design basis and configuration choices which, in turn, are influenced by a number of considerations such as location, local value of by-products and cost of disposal of effluents, etc.

6.4.2.3 Overall Material Balance of Plant

* Chemicals: Antifoam : 0.0792 TPD Sodium Hydroxide (100%) : 4.8 TPD Urea : 1.97 TPD Misc. Propagation Media: 165.6 TPD; Air: 434.4 TPD ; Steam: 969.6 TPD; Process Water : 585.6 TPD

Fig. 6.10: Over all material balance of Technology B

Fuel Grade

Ethanol Plant

Conc. Stil = 331.2 TPD

ISBL OSBL

Biomass= 477.6 TPD

Chemical* Enzyme = 6 TPD

Vent = 504 TPD Lignin = 386.4 TPD

Trash & Dust = 6 TPD

EtOH = 78.72 TPD

Waste = 13.68 TPD

Yeast = 0.0624 TPD

Misc. = 2155 TPD TPD

FO = 0.96 TPD MP Cond. = 518 TPD Effluent = 806.5 TPD


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6.4.2.4 Waste Water Treatment

The clarified stillage stream resulting from the lignin separation step will be further processed

on-site. This and other water effluent streams resulting from the process are collected in an

equalization tank.

The Fig. 6.12 describes a typical stillage/waste water treatments configuration:

As outlined in the fig. 6.11, stillage coming from the beer column is processed through a

dewatering section (centrifugal decanter), where a high solid content stream (lignin stream) is

separated. The clarified stillage then goes through a stillage concentration section where a

second high solid stream (concentrated stillage) is recovered.

This stillage concentration section is composed of two separate units:

Evaporation Unit:

The stillage evaporation unit is a multiple effect evaporator designed to produce a concentrated

stillage with a total solid content of about 50% by weight. The subsequent concentrated stillage

stream can be valorized used as a fuel. Most of the condensate from evaporation unit is recycled

to the process, thus lowering the consumption of fresh water.

A Membrane Unit: A portion of the condensate from the evaporation section may be

supplementary treated by membrane unit in order to increase the quality of the water for a

further recycle to the process and/or meet local regulation for water discharge.

The membrane unit will also generate a high COD effluent stream (Membrane Retentate) which

will typically be disposed a wastewater treatment plant based on the local/site regulations.

Fig. 6.11 Typical stillage / waste water treatments configuration


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6.4.2.5 Features

Commercial scale bio ethanol plant has set up in 2013 bio-ethanol % conversion for per

ton of dry biomass is 16.5%.



Major byproducts are liquefied CO2, concentrated stillage and surplus power.

Claim unique steam explosion process as pretreatment of biomass.


100% water re-cycle via effluent treatment plant from ISBL.


cogeneration facility can be set up on clients’ requirements.

A 2G ethanol technology with experience and learning at commercial scale

1st commercial scale bio ethanol plant started in 2013.

470,000 TPA (dry biomass) started in 2014.

Sustained supply of enzymes with equity partner.

No fine size reduction is required.

6.4.4 Technology C

Technology C also has the process converting ligno-cellulosic biomass to bio-ethanol.

6.4.4.1 Process Description

Technology C is a biomass agnostic process that deconstructs lignocellulosic feed into its key

constituents. Technology C uses a variety of biomass, from woody biomass (hardwood &

softwood) to agricultural residue (bagasse, corn stover, palm residue). Schematic & flow

diagram for Technology C’s process is shown in fig.6.12 & 6.13 respectively.

In the first step biomass undergoes size reduction as necessary, and is then conveyed to a storage

silo. The stored solids are then slurried with water and pumped and heated to reaction

temperature, and then fed to the fractionation reactor. Auto-hydrolysis with hot compressed

water enhances cellulose accessibility by first solubilising hemicelluloses and auto-catalytically

hydrolyzing mainly the xylan content of the hemicelluloses to oligosaccharides and a

monomeric five-carbon (C5) sugar. During this step, biomass particles are slurried with water,

pre-heated to reaction temperature, auto-hydrolyzed in a reactor, and pulverized by steam


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explosion, using equipment adapted from the pulp and paper industry. The residual solids in the

reaction effluent, cellulose and lignin, are recovered from hemicellulose oligomer solution.

The second stage of the process uses super critical water to solubilise the cellulose from the first

step, and then hydrolyze it to glucose and its oligomers. Here the preheated solids from the

hemi-hydrolysis step are slurried with water to achieve desire solids content. The slurry is then

pumped and mixed with super critical water, brought to reaction temperature rapidly, and fed

to the tubular super critical reactor. The cellulose is solubilised to obtain a solution of

oligosaccharides and a monomeric six-carbon (C6) sugars. The reaction mixtures then rapidly

cooled and heat is recovered to provide thermal energy required in the subsequent processes.

Lastly, the solubilised C6 sugar is separated from the remaining solids, primarily lignin.

Fig. 6.12 Schematic diagram for Technology C


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Although having a similar mechanism as the first step hydrolysis of hemicellulose, hydrolyzing

cellulose is significantly more difficult due to two primary factors:

A. The water insoluble crystalline structure formed by abundant intra and inter hydrogen

bonds between each cellulose polymer chain make them very resistant to deconstruction

B. The other components present in biomass, such as hemicelluloses, lignin and cellulose

together and provide rigidity to the structure, protecting cellulose from hydrolysis and

deconstruction.

Fig. 6.13: Flow diagram for Technology C

Super critical water has the properties significantly different from water at ambient conditions,

and has been successfully used to facilitate various chemical reactions and Technology C super

critical hydrolysis technology draws upon these unique properties.

After the two hydrolysis reactions described above, both C5 and C6 oligosaccharides streams

are optionally refined to produce final monomeric sugars using very small quantities of dilute

acid. Additionally further refining can be done by fermentation where sugar is consumed. In

this step, the sugars are concentrated by evaporation using waste heat from the process.

The co-product lignin is an irregular heterogeneous polymer and is used for its fuel value. The

refined C5 and C6 sugars from refining are mixed and fed to fermentation plant for biological

conversion by yeast into ethanol. The ethanol is distilled to an anhydride form, and after

denaturing, anhydrous ethanol emerges. Two by-products are produces during the sugar

BIOMASS

WATER

WATER

HH SLURRY

C5 SUGARS C6 SUGARS

LIGNIN

SH SLURRY

HEMIHYDROLYSIS

SOLID/LIQUID SEPERATION

SUPERCRITICAL HYDROLYSIS

SOLID/LIQUID SEPERATION


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fermentation to cellulosic ethanol. One is high protein material that is harvested from the spent

yeast organism. A second by-product is composed of carbohydrates that are not converted by

the fermentation organisms. Both by-products can potentially be converted into high-protein

portion could have higher value as feed local livestock operations.

The sugars will be fermented via that consume both the C6 and C5 sugars.

Water is recovered at various locations of the process. This water is collected, treated on site

and returned as process water. Water treatment consists of typical waste water aerobic digestion

coupled with reverse osmosis filtration. Total process water recovery is on the order of 98%.

digestion coupled with reverse osmosis filtration. Total process water recovery is on the order

of 98%.

6.4.4.2 Features

Has novel technology based on supercritical hydrolysis of water.

Super-critical reactor has modular design, i.e. reactor capacity can be increased or

decreased by joining or removing extra reactor tubes.

Bio-ethanol % conversion for per ton of dry biomass is 24.4 %.

Total conversion time from biomass to bio ethanol is 12-24 hours.

The technology produces soluble sugars which can be directly fermented.

No requirment of enzyme in the process.

Time for biomass conversion to sugars: 2-90 minutes.

Low reactor volumes.

Backed by global companies.

6.4.5 Technology D

Cellulosic ethanol technology developed by technology D achieves conversion at high speed

(total process within 24h). The technology is also feedstock agnostic and has been successfully

used with various agricultural feedstock such as rice straw, cotton stalk, corn, bagasse etc.

Technology was implemented as a phase 1 pilot plant of 1 TPD dry biomass. After having run

for six months and the required process optimization, the same plant is being scaled up to 10

TPD in phase 2 and has started operation from April 2016.

Conceptually, the typical process for conversion of lignocellulosic biomass to ethanol route

via enzymatic hydrolysis comprises 5 main steps:

1. Biomass size reduction

2. Pre-treatment


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3. Enzyme Hydrolysis

4. Fermentation

5. Purification & Separation of alcohol

6.4.5.1 Process Description:

Biomass Size Reduction:

The size reduction system used is a combination of hammer mills system equipped with bucket

elevators to reduce any biomass feedstock.

Pre-Treatment:

Pre-treatment, the first and the most important step in bio-ethanol production is aimed at

loosening the bonds between cellulose, hemicellulose and lignin. Pre-treatment technologies

Alkaline Reactors

Acid Reactors

Alkali Recovery

Acid Recovery

Size Reduction

BIOMASS

Lignin to Re - Use

C6 Sugars Fermentation

Ethanol

Cellulose Enzyme Hydrolysis

Distillation/Drying Ethanol

C5 Sugars Fermentation

Makeup Alkali

Makeup Acid

Fig. 6.14: The Technology D outline


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such as acid, alkali, hydrothermal, steam explosion of biomass leave the residual solid mass that

is de-lignified for enzymatic hydrolysis to fermentable sugars.

Processing the biomass in a 10-15% flowing slurry form and separation of the biomass

components into substantially homogeneous fractions of cellulose, hemicellulose and lignin has

advantages like:

It results in proving good mixing conditions and this helps in increasing all the reaction

rates and hence provides lower processing limits.

The chemicals and enzymes are recycled thereby not only providing considerable

flexibility to the production process with changing feedstocks, the net chemical enzyme

costs are significantly lowered.

The separated biomass fractions allow for more cost effective treatments to further

products i.e. glucose, xylose and lignin for their next step conversions.

The overall processing time from size reduction to fermentation & distillation is lowered

to less than a day compared to several days involved in other technologies.

Biomass Fractionation in the Technology D has been designed as a continuous but flexible

operation with the ability to switch between single step and two step sequence adjustable alkali

and acid treatments. The process and system has been designed such that all reaction parameters

can be closely controlled using DCS and SCADA and in a way that no furfural derivatives are

formed and sugar yields are high.

Enzymatic Hydrolysis:

Fractionation of biomass into cellulose and hemicellulose streams by the Technology D process

uses enzymatic hydrolysis that consumes much lower enzymes per kilogram of fermentable

sugars produces. Technology D has three distinct features in this step:

a) Toxics produced: No toxic furfural derivatives produced in the technology on account

of mild and controlled reaction conditions.

b) Inhibitions from substrates and products: Continuous processing overcomes the

inhibitions and makes the reaction rates very rapid.

c) Enzyme deactivation from irreversible adsorption on solid residue: Absence of lignin

or any un-hydrolysable solid matter prevents enzyme deactivation.

Since the system allows for continuous recycle and reuse of the enzyme added, the effective

dosage becomes less than 1 unit/g cellulose residue. Further, the high enzyme dosage, use of

suspension concentration of solids, high quality of separated cellulose, and continuous reaction


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



to separate soluble sugars from insoluble cellulose, all factors together reduce the enzyme

reaction time to 2 hours.

Fermentation of Sugars to Ethanol:

The C6 and C5 sugars produced using the fractionation and enzyme technology are converted

to ethanol by yeast strains than give an overall conversion of both sugars at an average of 0.45

lit ethanol/kg sugars. Further, yields are obtained fastest since the fermentation operated as high

cell density fermentation and is completed in 6-9 hours.

The Technology E separates the C5 (from hemicellulose) and the C6 (from cellulose) streams.

Further, it emplys high cell density (HCD) fermentation on account of the consistent quality

sugar streams obtained from the biomass fractionantion process. Continuous high cell density

fermentation is possible due to consistent quality and quantity of sugar streams independent of

the feedstock. Quality in this context implies presence (or absence) of toxic substances and

other substances that may inhibit or affect the fermenting microorganisms. The variation in the

rate of sugar flow into the fermenters arises due to changes in the feedstock composition. These

variations, don’t affect fermentation in terms of ethanol yield and time of fermentation.

The HCD fermentation times are in the range of 3h to 9h at the maximum depending upon

strains used. A comparison on the overall cost of sugar concentration, fermentation, ethanol

distillation and drying easily shows that it is advantageous to distil ethanol after fermentation

than concentrate the sugars before fermentation due to the fact that water evaporation is far

more expensive than evaporating ethanol-water azeotrope.

Ethanol Distillation and Drying:

Ethanol distillation and drying are developed unit operations and technologies and of process

ethanol streams are clear without impurities and suspensions. Typically, the ethanol streams are

concentrated to 95% level which is then dried using the well-known and established molecular

sieve based technology.

These units also do not form part of the Technology D demo-plant wherein the ethanol streams

are simply transferred to the existing main ethanol distillation and drying facility to produce

fuel grade or portable grade ethanol (after sulphur removal).

7.4.5.2 Outflow Streams from the Process Plant

There are three liquid streams that emerge from the process plant. These are as follows:

1. The product ethanol stream.

2. The lignin stream containing some sugars and which is either mildly acidic or basic.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



3. The stream coming as bottom of the alcohol distillation plant.

The lignin stream can be used in two ways.

The lignin stream is concentrated using the established ‘multiple effect evaporator’

technology to 75% solids and then fired into the boiler to produce stream or power

and steam.

The stream is taken to biogas digester and converted in to biogas.

Technology D provides following features:

Lignin produced is soluble, biodegradable and easily converted in to biogas in

compact digester with a biogas output of about 700L/kg dry lignin.

The silica if present in the biomass (i.e. rice straw) is converted in to soluble salts

and either comes through with clean bio-digester effluent, or forms ash in lignin

boiler. Solid silica can be sold in market while soluble silica is separated and water

recycled.

All the extractives from the biomass (5-15% on dry basis) emerge with the lignin

stream and get wither burnt to produce steam or converted to biogas depending on

the technology component used.

6.4.5.3 Overall Material Balance of Process Plant

Feed: Bagasse:

* Chemicals: Nitric Acid (100%) : 3.8 TPD NaOH (100%) : 4.5 TPD Others Salts : 1.7 TPD

Fuel Grade

Ethanol Plant

Waste = 16.5 TPD

ISBL OSBL

Bagasse = 324 TPD

Chemical*

Enzyme =1 TPD

CO2 = 195 TPD FO$ = 0.4 TPD

Bio CNG = 41 TPD

EtOH = 80 TPD

Dusting = 2 TPD

Yeast = NA


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Feed: Rice Straw

* Chemicals: Nitric Acid (100%) : 4.3 TPD NaOH (100%) : 5.2 TPD Others Salts : 1.9 TPD $ FO = Fusel Oil

Fig. 6.15: Over all material balance for Technology D

6.4.5.4 Features:

Bio-ethanol % conversion for one ton of dry biomass is of rice straw and bagasse is 21.3

% and 24.5 % respectively.



Feed size for the process is 200-1000 microns.

Major byproducts are liquefied CO2 and lignin (17 %).

Enzyme consumption for one ton of dry biomass conversion is 3 kg.


Turndown capacity for the proposed plant of capacity 100KLPD is about 25% of

maximum capacity.

Pretreatment is based in both acidic & basic media.

Having a demo plant of 10TPD.

Fuel Grade

Ethanol Plant

Waste = 55 TPD

ISBL OSBL


Chemical*

Enzyme =1.12 TPD

CO2 = 202 TPD FO$ = 0.3 TPD

Bio CNG = 45 TPD

EtOH = 80 TPD

Dusting = 3 TPD

Yeast = NA


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Enzymatic hydrolysis time for is less than 2 hr.

Fermentation time is 3-9 hrs.

Using Composite Biomass Technologies for the pretreatment of biomass.

Employs continuous fermentation along with enzyme recovery and recycling.

A comparison of all the four technology licensors are provided in the table below.


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01 Rev. 1 Page 85 of 111


*surplus power depends on the actual boiler 7 power plant configuration ** BioCNG is produced based on specific plant configuration

Basis – 100KLPD Ethanol Technology A Technology B Technology C Technology D

Process Pretreatment, enzymatic hydrolysis, co-fermentation, distillation & dehydration

Pretreatment, enzymatic hydrolysis, co-fermentation, distillation & dehydration

Hemi-hydrolysis, Super critical hydrolysis, fermentation, distillation & dehydration

Fractionation, enzymatic hydrolysis, fermentation, distillation &

dehydration

Pretreatment / Fractionation Steam explosion with mild acid to break

down lignin structure and expose hemicelluloses and cellulose.

Steam explosion to break down lignin structure and expose hemicelluloses and cellulose.

Treatment with high temperature water to separate

hemicelluloses from celluloses & lignin.

Acid and alkali treatment to separate hemicelluloses, cellulose and lignin.

Criticality in Process Pretreatment section is critical to design. No PTR is available.

Steam explosion system is critical to design. It’s a proprietary item and PTR for two commercial

unit is available with licensor.

Main concern in this technology is supercritical reactor. No PTR

is available.

Reactors in fractionation sections are critical to design. PTR for this type of

equipment are not available.

Lignin Separation During distillation During distillation During super critical hydrolysis 60 % at alkali treatment and 40% at distillation unit

Feed Stock Rice Straw Bagasse Rice Straw Rice

Straw Wheat Straw Bagasse

Amount of Feed required (MT/day), Dry Feed 416 - 426 370 - 385 430 325

373 334 324

Feed Size 10 - 40 mm 20 – 100 mm < 120 μ 0.2 – 1.0 mm

Conversion Time 96 – 120 hr 120 hr ~ 12 -24 hr 24 hr

Byproducts Technical Alcohol, Fusel Oil, Lignin

Rich Cake, Bio-CNG, Power, Liquefied CO2

Lignin, Concentrated Stillage, Power CO2, Lignin Lignin, Bio-CNG, Power & CO2

Yield

EtOH 100 KLPD 100 KLPD 100 LKPD 100 KLPD

Byp

rodu

ct

CO2 5.44 MT/hr 5.74 MT/hr 21 MT/hr (VENT) 8.4

MT/ hr 8.13 MT/hr

Lignin 8.33 MT/hr(Dry basis) 6.46 MT/hr 16.1 MT/hr(with 60 % MC)

Surplus Power* ~ 6 MWh 0.78 MWH ~ 6 MWh

Bio CNG** 1.57 MT/hr 1.67 MT/hr Concentrated Stillage(with

50%MC) 13.8 MT/hr Bio CNG 1.88

MT/hr 1.71 MT/hr

Solid Waste Technical Alcohol 71 kg/hr 70 kg/hr Solid

Waste 0.57 MT/hr Solid Waste

2.3 MT/hr 0.69

MT/hr

Fusel Oil Fusel oil 11 kg/hr 10 kg/hr Fusel oil 0.04 MT/hr Fusel Oil 12.5 kg/hr 16.7

kg/hr

Trash & Dust Trash& Dust 0.35 MT/hr 0.32 MT/hr Trash &

Dust 0.25 MT/hr Trash & Dust

0.13 MT/hr 0.083

MT/hr Rejects 0.68 MT/hr 0.74 MT/hr Effluent 34.2 MT/hr Sulfur 0.16 MT/hr 0.175 MT/hr NA

Secondary Fuel for Boiler 17 MT/ hr, Rice Husk No secondary fuel for power import case 17 MT/ hr, Rice Husk

Total Ash Generation 9.3 MT/ hr 3.28 MT/hr


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



Basis – 100KLPD Ethanol Technology A Technology B Technology C Technology D

Enzyme Demand

Quantity 154 kg/hr 155 kg/hr 249 kg/hr

USD 200- 220 / ton EtOH (Enzyme + yeast)

USD 50/ton EtOH (Chemicals & other

consumables)

47 kg/hr 42 kg/hr 41 kg/hr

Cost 32,340 - 40,300 (Rs/hr) 23,500 / 21,000 / 20,500 (Rs/hr) {Rs. 500/kg}

Supplier Novozymes/ Equivalent Novozymes

Yeast Demand

Quantity Yeast 1.24 kg/hr 1.12 kg/hr 5.3 kg/hr

Yeast strains part of the technology package. No separate cost. No regular

supply required with master bank provision in proposed plant

Cost 2,232- 2,480 (Rs/hr)

2,016 – 2240 (Rs/hr)

Supplier

Chemicals Quantity (Acid, Base and other

)

Nitric acid (60%)

Mixed Acids 530 kg/hr 400 kg/hr

Sodium Hydroxide

(100%) 200 kg/hr

Nitric Acid

(60%)

293 kg /hr

265 kg /hr

255 kg/hr

Sodium Hydroxide

(100%) Chemicals 800 kg/hr 800 kg/hr Antifoam 3.3 kg/hr

NaOH (100%) 216

kg/hr 195

kg/hr 188

kg/hr

Other salts Molasses (for yeast

incubation) 710 kg/hr 880 kg/hr Propagation

media 6.9 MT/hr Other

Salts, Rs. 100/kg

77 kg/hr 70 kg/hr 67 kg/hr

Nutrients Quantity 180 kg/hr 210 kg/hr Urea (50%

sol in water) 82.1 kg/hr

Utilities

Process water 71 -87 m3/ hr 24 m3/hr

Steam 29-31.2 MT/hr ~ 41 MT/ hr (32% HP @ 25 barg, 68% MP @ 10 barg) 20 MT/ hr @ 8 barg

Electricity 5.3-6 MWh (3.5-4 MWh Core + 1.8-2 MWh for add on Bio-CNG & Liq CO2) ~ 3.5 MWh (ISBL) 9.0 MWh 4.7 MWh

Cooling Water 2600-2800 m3/hr ISBL, 2500 m3/hr CPP 810 m3/ hr for ISBL 1000 m3/hr ISBL, 2500 m3/hr CPP

Chilling Water 647 m3/ hr

Process Air 850 – 950 Nm3/hr 15050 Nm3/hr

Plant Air / IA 400 Nm3/hr 1000 Nm3/hr 331 Nm3/hr

Others

Land foot print Area 33 - 35 Acres (ISBL+OSBL) Typical ISBL 7.5 to 10 acre 25 – 40 Acres 8 Acre for ISBL

*Area excluded raw material and ethanol storage

Minimum capacity for economic viability

250 TPD of Biomass


2G Ethanol, MRPL

DOCUMENT No. B033-000-03-41-RP-01



d Basis – 100KLPD Ethanol Technology A Technology B Technology C Technology D

Current status of

technology as on EOI

cut-off date.

Pilot 1 TPD dry biomass pilot plant which is in operation since 2009 1 TPD Plant Pilot plant of 1 TPD dry biomass

Demo A demo plant of 12 TPD dry biomass under operation since march 2017 in

Pune.

Capacity 800 TPD dry bio mass from arundo donax (energy grass) (40,000 MT EtOH/year). 3 TPD dry biomass Demo plant of 10 TPD dry biomass

Commercial Capacity 1400 TPD, started in Sep2014 Compatibi

lity to variable resource

feed biomass

Multiple feeds Wheat Straw, Rice straw, Cotton stalk, Bagasse & Corn Cob.

Wheat Straw, Rice straw, Arendo donax, Cotton stalk, Bagasse and crop residue Feed Agnostic Wheat Straw, Rice straw, Cotton

stalk, Bagasse and crop residue

Mix Feeds Not allowed Not allowed Not allowed

By-product utilization in terms of Power generation

Lignin rich cake is separated from solid liquid separation & used as a boiler fuel

along with secondary fuel


Cogeneration facility can be set up on clients requirements.

Yes, steam can be generated from the lignin

Water re-cycling/ Treatment 100% using ETP 100% using ETP for ZLD 98 % 100% using ETP

Effluent treatment Yes, 45 m3/hr Yes, 34.2 MT/hr Yes

License Fee 30 Cr. 6.3 MM€

Plant Life of proposed plant 20 Years 20 Years 15 year Turn down capacity of proposed

plant 50 - 60 % 25 - 30% 25 %



DOCUMENT No. B033-000-03-41-RP-01




6.5 Technology Analysis The inputs provided in Table 6.4 have been received from EOI .The analysis covered below is

based on the data received from licensor.

Feed Stock Dependence: All the technologies are feed agnostic and are able to handle

multiple feed stocks, like rice straw, wheat straw, bagasse, corn cob, cotton stalk etc.

Mixed Feed Stock Dependence: The technology providers participated in EOI do not

provide this option.

Conversion efficiency: Technology A, C and D process compared to Technology B require

less feed stock. The feed stock for first two licensors is ½ to 2/3 of Technology B. For 100

KLPD ethanol plant, Technology C need 325 TPD dry biomass. Conversion efficiency for

Technology C is 24.5%. Conversion efficiency of Technology D is 21.5 – 24.7 % and for

Technology A it is 18.7 – 20.7 %. Technology B has 16.7 – 18.18 % conversion efficiency

respectively.

Biomass Size Reduction: Technology C required fine grinding (< 120 micron) and

Technology A need coarse grinding ( 25 to 40 mm) for feed, where as Technology D is in

between ( 0.2 – 1.0 mm). Energy consumed in milling for Technology C is more than

Technology A. More over grinding machinery for Technology C is complex compared to

Technology A.

Conversion time: Conversion time for Technology C is estimated 12 – 24 hr while that of

Technology D is about 24 hours. Technology A and B take five times, i.e. 120 hr. This

indicates Technology C and D need less time than other two.

Carbon dioxide formation: Technology D process generates maximum CO2 of 202 TPD,

which is 2.6 fold compared to Technology B and 1.5 fold compared to Technology A

processes.

By product (Acetic acid & Furfural): The technology providers do not produce significant

by product.

Bio CNG: Technology A and D produces Bio CNG from biomass extracted after distillation.

Formed Bio CNG is treated to remove CO2 and impurities. Purified Bio CNG can be sold in

the market. Generation of BioCNG for both the technologies is in the same order.( 1.5 – 1.9

MT/hr)

Enzyme requirement: Technology C uses non enzymatic route, hence for process

requirement of enzyme is not envisaged. Technology D process claim enzyme consumption

around 41 – 47 kg/hr for the process. Technology D uses about 1/3 of the Technology A



DOCUMENT No. B033-000-03-41-RP-01




requirement (154 – 155 kg/hr) and 1/5 of Technology B requirement (249 kg/hr). Although

Technology D uses less amount of enzyme, the total cost of enzymes don’t defer in large

extent. From the cost point of view, enzyme requirement for all these processes are near about

same. Cost of enzyme for Technology D is 20,500 – 23, 500 INR/hr, which is nearly half –

fold of B ( 45,152 – 49,667 INR/hr). Whereas for Technology A and C this values are 32,340

– 40,000 INR/hr and 27,900 INR/hr.

Yeast requirement: Technology A and B use co–fermentation method for the production of

ethanol. Technology C and D use separate C5 & C6 fermentation to produce ethanol. Yeast

required for Technology B is four times of Technology A. Technology D does not require

continuous dose of yeast.

Steam requirement: Requirement of steam for technology B and D are in the same order (~

20 MT/hr). Technology A needs 1.5 times that of B.

Electricity requirement: Power requirement for all licensers except C are in the same order

(5 – 6 MWh)where as only Technology C needs 9.0 MWh power.

Process Air: Technology B and A have provided process air requirement. Technology B

needs 4480 Nm3/hr, which is 4.7 times of Technology A requirement (850 – 950 Nm3/hr).

Land Requirement: Technology D and B recommend near about same area for ISBL.

Technology D and B recommend 8 acre and 7.5 – 10 acre respectively for ISBL. Technology

A and C have provided land requirement for total complex (ISBL & OSBL). Technology A

recommend 33 - 35 acre considering two days feed storage whereas Technology C

recommend 25 – 40 acre depending on different feed storage scenarios.

Technology Maturity: Technology B Licensor has commercial plant experience.

Technology A has set up a demo unit for 12 TPD and is under operation. Technology D has

commissioned 10 TPD demonstration unit whereas Technology C has a working

demonstration unit of capacity 3 TPD.

Power Generation: All the technology provides uses lignin in boiler to generate steam and

electricity. Technology D generates steam by burning the lignin produced from their process.

The generated steam is used for power generation and subsequently in the process.

Technology B claims to generate power by burning lignin and concentrated stillage.

Technology A recommends to burn lignin with secondary fuel and generate electricity.



DOCUMENT No. B033-000-03-41-RP-01




Effluent Treatment: Technology providers A, B and D participated in EOI, stated about

effluent treatment and recommend using it. Technology A, B and D recommend using ETP.

However Technology A and B provided ETP load of 45 m3/hr and 136 m3/hr respectively.

Water Recycle: All technology provider claims about 100% water recycle (ISBL) in their

process. Technology A, B and D claims 100 % water recycle through ETP unit. Technology

C claim 98% water recycles to process.

Turn down Capacity: Technology D allows 25% turn down whereas B and A allows it to

25-30% and 70% respectively. Although Technology D & B claim 25% turn down, practically

it is infeasible and some equipment may run at 25% turn down.

Water Requirement: The water requirement for technology B is 90 m3/hr for a capacity of

60KLPD.71-87 m3/hr and 110-116 m3/hr of process water is required for technology A and B

respectively for 100 KLPD plant capacity.

6.5.1 Areas of technology requiring detailed assessment

The following areas requires detailed assessment:

Commercial scale operation of 2G Ethanol Process:The commercial scale plant experience is available for one technology licensor. And others have demo or pilot scale experience.

Commercial experience for pretreatment section: Bio-digesters used in feed

pretreatment section on a commercial are limited.

Commercial availability of lignin boiler:Use of lignin as fuel in boiler is recommended

by all the licensors.

Disposal of ash generated from boiler:The quantity of ash generated from boiler is

around 5- 10 TPH and the disposal of ash is to be addressed properly.

Biomass availability round the year in 50 km radius:The availability of biomass round

the year depends on proper pre planning and it is essential to build the ecosystem for

ensuring biomass supply. Supply of secondary fuel for use in boiler is also to be

addressed

Higher cost of production compared to first generation ethanol:The cost of ethanol

production from lignocellulosic biomass is higher than first generation ethanol and there

may be requirement of subsidy for economic viability and competitive ethanol pricing.

The following sections give the details of the proposed 60 KLPD 2G ethanol plant for the

capital cost estimation with Technology B as the licensor.



DOCUMENT No. B033-000-03-41-RP-01




SECTION - 7

UTILITIES AND OFFSITES



DOCUMENT No. B033-000-03-41-RP-01




7.1 Utilities The utility consumption and the facilities required have been done based on estimation of

utility consumption of the process units based on the following.

Licensor Data

In-house data as applicable

Table 7.1: Summary of estimated utility requirement

Utility Quantity

Technology B

Raw Water (m3/hr) 90

Cooling water (m3/hr) in Process

810

Chilling water (m3/hr) 390

Cooling Tower Capacity(m3/hr)

Process

CPP

1 X 1000

1 X 600

DM Water (m3/hr) 25

Compressed Air (m3/hr) 2 X 400

Power (MW) 5

Steam (TPH) 21

The following are the utility systems required for ethanol generation plant.

Raw water system

Cooling water system

DM water and soft water system

Compressed air system

Steam, Power and BFW system

7.1.1 Raw water system

The raw water storage is envisaged for 15 days and the supplies from the water reservoir will



DOCUMENT No. B033-000-03-41-RP-01




be pumped to the various consumers in the ethanol plant to meets its process and other

requirements. The requirement of fresh water for plant is around 90 m3/hr.Treated water shall

be used as follows:

Water for process requirements

Pump sealing water

Feed to the DM water system

Feed to drinking water system

Service water for operating hose stations for various miscellaneous uses.

7.1.2 Cooling water system

Total requirement of the cooling water for the unit is proposed to be met through two cooling

towers. The cooling water requirement of the unit works out to be approximately 1000 m3/hr

and 600 m3/hr for process and captive power plant respectively. A chiller unit of 830 m3/hr is

additionally envisaged.

7.1.3 DM water and Soft water system

DM water in the ethanol plant is required as boiler feed water make-up

7.1.4 Compressed air system

The compressed air system shall meet the instrument air/ plant air requirements of the unit. A

system has been envisaged to provide a package unit for the above requirements. Within the

package, two centrifugal compressors (one operating and one standby), each of capacity 400

Nm3/hr have been considered. Two instrument air dryer units (both the units will be operating),

each of capacity 400 Nm3/hr have been considered.

7.1.5 Steam, Power and BFW system

The power requirement of the unit is 5 MWH. For the power import case, power will be

imported from grid and the process steam requirement will be met by lignin and concentrated

stillage fired boiler. For the power generation case the power requirement will be met by 5MWH

STG. The boiler is fired with lignin and concentrated stillage along with secondary fuel (cotton

stalk).

The process steam requirement is 21 TPH .The steam will be generated by package steam

boilers. 2 X 15 TPH capacity Steam boiler is considered for power import case. The total steam

requirement for power generation case is ~ 60 TPH. Hence 2 X 41 TPH boilers are considered

for power generation case.



DOCUMENT No. B033-000-03-41-RP-01




7.2 Offsite facilities 7.2.1 Storage and Transfer System

The storage facilities are envisaged for biomass feed, supplementary fuel, by product and

product ethanol. The storage for raw material and supplementary fuel are envisaged for two

days where as storage for ethanol is envisaged for 15 days. Storage capacity is based on the

process unit feed / products rates, criticality of operation, turnaround schedules, and emergency

operation. Offsite facilities are divided into following sections:

Raw material storage

Supplementary fuel storage

Finished product storage

By product storage

Table 7.2: Storage details

Days Units Technology B

Quantity

Raw material 4 TPD 271.2

Supplementary Fuel 3 TPD 60

Ethanol 15 TPD 47.28

Lignin Storage 15 TPD 88.32(dried)

Chemicals/Enzyme/Yeast 15 TPD

Enzyme: 3.6 Yeast:.0384

Antifoam:0.048 NaOH:2.88 Urea:0.99

Prop. Media:99.36 Intermediate Storage(Fusel oil) 15 TPD 0.48



DOCUMENT No. B033-000-03-41-RP-01




Table 7.3: By product details for 60 KLPD ethanol plant

By product

Units Technology B

Quantity

Solid Waste

Vent

Lignin

Concentrated Stillage

Fusel Oil

TPD

7.68

285.6

220.8

187.2

0.48 7.3 Flare Systems Since less gas is generated in the system it can be vented to the atmosphere as per OISD norms.

Hence no flare is envisaged in the ISBL.



DOCUMENT No. B033-000-03-41-RP-01




SECTION -8

PROJECT SCHEDULE &

PROJECT EXECUTION

METHODOLOGY



DOCUMENT No. B033-000-03-41-RP-01




Enclosed in Annexure II



DOCUMENT No. B033-000-03-41-RP-01




SECTION -9

ENVIRONMENT

CONSIDERATIONS



DOCUMENT No. B033-000-03-41-RP-01




9.1 ENVIRONMENTAL CONSIDERATIONS The design of the Project will be on a minimum pollution basis and include all the features

required to ensure that control of all forms of pollution will comply with regulatory &

governmental requirements.

The design approach built into the FEED to avoid/minimise emissions to the air is as follows:

Fugitive emissions from valves will be avoided or minimised by selection of suitable valve

packing, seals etc.

Fugitive emissions from pumps will be minimised by use of dual seals or seal-less pumps

when handling high vapour pressure and hazardous material

Fugitive emissions from flanged connections will be reduced by minimising the number of

flanged connections in high pressure service.

Asbestos will be replaced with safer materials wherever possible, within the scope of this

PROJECT.

Only non-Ozone Depleting Substances will be used within this PROJECT.

Stack emissions from boiler will meet the standards specified in Table 9.1

The HSE Philosophy requires that the level of fugitive emissions emitted during operation of

the plant should be determined by analysis or estimation. The estimated levels will then be

monitored regularly for VOCs and HC. The philosophy requires monitoring of ambient air

quality to ensure that the levels of various pollutants are within the limits. The limits that will

be met is given in Table9. 2

The PROJECT is designed to minimise emissions and the production of waste. The solid waste

that is produced during construction phase will be segregated to allow for safe disposal and

preferably recycle/reuse. Such wastes includes; sieves, activated carbon filters and ion exchange

resins, as well as oily sludge, sanitary sludge, maintenance wastes and spent batteries.

The solid waste that is produced during operation phase will be mostly used for combustion in

boiler and left out portion will be either sold as manure for agricultural fields or to brick and

cement industries.

Any waste that must be disposed of off-site, shall be disposed of by an appropriately authorised

organisation recognised by Central Pollution Control Board/State Pollution Control Board.



DOCUMENT No. B033-000-03-41-RP-01




During the operation phase, the treated waste water will be recycled using RO based recycle

plant. Backwash/ regeneration effluent generated from recycle plant shall be stored in the

recycle plant and then pumped for use as horticulture water, fire water make-up and for ash

quenching.

Table 9.1: Standards for Emissions from Boilers Using Agriculture Waste As Fuel

Type of feeding

mechanism Pollutant Value

Step Grate

Particulate matter 250 mg / Nm3

Horse Shoe /Pulsating Particulate matter 500 mg / Nm3 (12% of CO2)

Spreader stroker Particulate matter 500 mg / Nm3 (12% of CO2)

Table 9. 2: National Ambient Air Quality Standards

Sl.

No.

Pollutant Time

Weighted

Average

Concentration in Ambient Air

Industrial,

Residential,

Rural & other

areas

Ecologically

Sensitive

Area

Methods of measurement

1.0

Sulphur

Dioxide

(SO2)

Annual

Average*

50 µg/m3 20 µg/m3 -Improved West and Gaeke

24 hours** 80 µg/m3 80 µg/m3 -Ultraviolet Fluorescence

2.0

Oxides of

Nitrogen as

NO2

Annual

Average*

40 µg/m3 30 µg/m3 -Modified Jacob &

Hochheiser (Na-Arsenite)

24 hours** 80 µg/m3 80 µg/m3 -Chemiluminiscence

3.0

Particulate

Matter ,

Size<10 µ

Annual

Average*

60 µg/m3 60 µg/m3 -Gravimetric

-TOEM

24 hours** 100 µg/m3 100 µg/m3 -Beta attenuation

4.0

Particulate

Matter ,

Size<2.5 µ

Annual

Average*

40 µg/m3 40 µg/m3 -Gravimetric

-TOEM

24 hours** 60 µg/m3 60 µg/m3 -Beta attenuation



DOCUMENT No. B033-000-03-41-RP-01




Sl.

No.

Pollutant Time

Weighted

Average


Industrial,

Residential,

Rural & other

areas

Ecologically

Sensitive

Area


5.0 Ozone O3

8 hours** 100 µg/m3 100 µg/m3 -UV Photometric

-Chemilminescence

1 hour 180 µg/m3 180 µg/m3 Chemical method

6.0 Lead(Pb)

Annual

Average*

0.5 µg/m3 0.5 µg/m3 -AAS/ICP method after

sampling on EPM 2000 or

equivalent filter paper

24 hours** 1.0 µg/m3 1.00 µg/m3 -ED-XRF using Teflon

filter

7.0

Carbon

Monoxide

(CO)

8 hours** 2 mg/m3 2 mg/m3 -Non Dispersive Infra

red(NDIR)

1 hour 4 mg/m3 4.0 mg/m3 Spectroscopy

8.0 Ammonia

(NH3)

Annual

Average*

100 µg/m3 100 µg/m3 -Chemiluminescence

24 hours** 400 µg/m3 400 µg/m3 -Indophenol blue method

9.0 Benzene

Annual

Average*

05 µg/m3 05 µg/m3 -Gas chromotography

based continues analyser

-Adsorption and

Desorption followed by GC

analysis

10.0 Benzo(a)

Pyrene (BaP)

Annual

Average*

01 ng/m3 01 ng/m3 -Solvent extraction

followed by HPLC/GC

analysis



DOCUMENT No. B033-000-03-41-RP-01




Sl.

No.

Pollutant Time

Weighted

Average


Industrial,

Residential,

Rural & other

areas

Ecologically

Sensitive

Area


11.0 Arsenic (As)

Annual

Average*

06 ng/m3 06 ng/m3 - AAS/ICP method after



12.0 Nickel (Ni)

Annual

Average*

20 ng/m3 20 ng/m3 AAS/ICP method after



* Annual Arithmetic mean of minimum 104 measurements in a year taken twice a Week 24 hours at uniform interval.

**4 hourly/8 hourly values should be met 98% of the time in a year. However, 2% of the time, it may exceed but not on two consecutive days.



DOCUMENT No. B033-000-03-41-RP-01




SECTION 10

PROJECT COST ESTIMATION



DOCUMENT No. B033-000-03-41-RP-01




10.0 Cost Estimation Project Cost Estimate for setting up a Lignocellulosic biomass to 2GEthanol Complex has been

presented. CAPEX of technology B is presented here for 60KLPD capacity.

The operating cost is calculated based on the cost information provided by the client

Table 10.1: Cost of feed, product and utilities

Value Unit

Feed

Biomass (Corn Cob) 3500 (Rs/MT)

Secondary Fuel (Cotton Stalk) 2111 (Rs/MT)

Product

2G Ethanol 39 (Rs/litre)

Utility

Power(import) 6.85 (Rs/KWH)

Raw Water 20 (Rs/MT)

Land cost of 1crore/acre is considered for the costing as provided by the client. Licence fee of

6.3 MM€ and BDEP Fee of 2-3 MM€ taken for costing as provided by the licensor.

It is assumed that Corn cobs of required size is available. No milling equipment cost is

considered in the estimation.

Gantry system with 300KL day tank with 1 bay and two arms is considered for costing.

Key Assumptions The basic assumptions made for working out the capital cost estimate are as under:

Cost estimate is valid as of 2nd Quarter 2017 price basis

No provision has been made for any future escalation

No provision has been made for any exchange rate variation.

It has been assumed that the project would be implemented on EPCM mode of

execution.

All costs are reflected in INR and all foreign costs have been converted into

equivalent INR using exchange rate of 1USD=Rs. 64.12, 1EURO=Rs.70.47

Exclusions Following costs have been excluded from the Project cost estimate:



DOCUMENT No. B033-000-03-41-RP-01




Scope changes

Any survey

Piling

Site development works except roads, drains and boundary wall

Any cost towards dismantling of existing facilities, hot work in existing facilities

if any, removal of unforeseen underground obstructions , any hook up with

existing facilities

Facilities outside the battery limit of the plant

Cost towards statuary clearances.

Any Dispatch facilities for products.

Railway Siding , Township , Rehabilitation cost if any

Any cost (for Feed, Fuel, Utilities, Catalyst & Chemicals, etc.) towards

commissioning / stabilization of the plant or off spec production.

Requirement of any high capacity crane

Capital cost estimate for the identified scope, works out for two case i.e

Power cost as import case : Power import cost is taken as Rs. 6.85/KWH

as provided by the client

Power cost as generation case : Power is generated with 5 MWH STG and

secondary fuel is provided in boiler for

additional steam generation.

Note: Total power requirement (ISBL + OSBL) for the proposed plant is 5 MWH, based on the

ISBL requirement provided by the licensor and power calculated for OSBL. It is assumed that

the provided ISBL power quantity is meeting all the ISBL power requirements. Secondary fuel

requirement for the power generation case is based on boiler efficiency assumption.

The calculated values for the two cases are tabulated below:



DOCUMENT No. B033-000-03-41-RP-01




Table 10.2: Cost estimate for biomass to Ethanol Complex (Power Import case)

Description

Foreign

Component

Fc


Ic

Total Cost

Rs. In Lakhs

Technology B 100 77 758 99 859 75

Table 10.3: Cost estimate for biomass to Ethanol Complex (Power Generation case)

Validity of cost estimate is as of 2nd Quarter 2017 price basis. The accuracy level of the cost

estimates is ±30%. This accuracy level has been arrived at based on the technical information

received from licensor, detailing done with the in- house data available in EIL.




This can be verified by the financial consultant based on the exact provision as applicable for

such projects.

Refer Annexure I for detailed cost estimation.

Refer Annexure V for the licensor data on which the capital cost estimation has been worked

out.

Description

Foreign

Component

Fc


Ic

Total Cost

Rs. In Lakhs

Technology B 100 78 865 95 966 74



DOCUMENT No. B033-000-03-41-RP-01




SECTION 11

PRELIMINARY PLOT PLAN



DOCUMENT No. B033-000-03-41-RP-01




11.1 Plot Plan The table top plot plan for the proposed lignocellulosic ethanol plant is provided in Annexure-

III.

The overall plot plan area is 50 acres and is comprised of the following sub sections:

Process units

Green area

Feed storage and manure

Product storage

Secondary Treatment

Utility lock

DG Set and Diesel Storage Area

Cooling tower and CWTP

Feed water storage and power house

Control room, administrative building and laboratory

Process units: The process facilities are designed adhering to maintenance, safety and quality

standards considering constructability, economics and operations in to account.

Feed storage and manure: Two days of storage is considered biomass and secondary fuel for

use in boiler along with manure storage.

Product Storage: 15 days storage is considered for ethanol product storage.

Secondary process/treatment: It contains effluent water treatment section for treating various

effluents generated in the ethanol production process.

Utility Block: It contains compressor, cooling tower, chiller, DM plant, softening unit, plant

air package etc.

DG Set and Diesel Storage Area: It contains DG set and storage area for power back up.

Cooling tower and CWTP: It contains cooling tower and treatment plant.

Feed water storage and Power House: It contains boiler/ steam turbine system and raw water

storage tanks.

Control room, Administration and Laboratory: The area for laboratory, administrative building, control room, canteen are included in plot plan. Flare unit: No Flare unit is envisaged in the process unit.



DOCUMENT No. B033-000-03-41-RP-01




SECTION 12

WAY FORWARD



DOCUMENT No. B033-000-03-41-RP-01




12.1 Way Forward: Technology Assessment:

Preliminary analysis of technologies has been carried out and it is found that enzymatic route

is a relatively mature and may be considered after detailed study.

The following issues need to be addressed during the detailed feasibility study.

Commercial scale operation of 2G ethanol process

The commercial scale plant experience is available for one technology licensor.

Other licensors have demo or pilot scale experience.

Commercial experience for pretreatment section.

Bio-digesters used in feed pretreatment section on a commercial scale are limited.

Commercial availability of lignin boiler.

Use of lignin as fuel in boiler is recommended by all the licensors.

Disposal of ash generated from boiler.

The quantity of ash generated from boiler is around 5- 10 TPH and the disposal of

ash is to be addressed properly.

By products recovery

Production of CO2 and Bio-CNG can be considered in a phases depending on the

local market demand.

Cost Assessment:






DOCUMENT No. B033-000-03-41-RP-01




References:

EOI Data of following four licensor

1. M/s Praj Industries Ltd.

2. M/s Beta Renewables, S.p.A

3. M/s Renmatix

4. DBT – ICT

5. In house Data

Documents

Feasibility Report On Ligno-cellulosic Biomass to 2G …environmentclearance.nic.in/writereaddata/Online/TOR/06_Jul_2017... · Feasibility Report on Ligno-Cellulosic Biomass to 2G