www.praj.net

Praj Advanced Cellulosic Ethanol

Project - PACE

Ghansham Deshpande

Praj Industries Limited, India

17 th June 2013

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Outline

• About Praj

• Why Cellulosic Ethanol ? : The Indian Context

• About ‘PACE’

- Technology

- Commercialization

- Praj Bio- refinery

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• Established in 1984

• Creating sustainable technology platform for

almost three decades

• Over 500 references worldwide

• Aims at significant play in water &

wastewater treatment segment

• Launched next set of bio based products –

the livestock health & nutrition range

Praj Industries - Key Highlights

• Largest resource base for Bio-ethanol with global footprint for multiple feedstock

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Praj Matrix – The Innovation Center

US$ 25+ Mn investment

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

115 technologists

30 PhDs, 80 Masters

Technology COEs

Biology, Chemistry, Engineering

16 Well Equipped Labs

ISO-9001-2008 Analytical Labs

Pilot Plants

1 tpd Cellulosic Ethanol pilot plant

Two 750 kg/d Chemical pilot plants

Bench and Pilot scale facilities enable validation of scientific

assumptions and rapid commercialization

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Business Verticals

Integrated solutions provider through technology, engineering, projects and equipment manufacturing

Technology, Engineering & Projects Solutions

-Alcohol/ Ethanol plants

-Brewery plants

Water and Wastewater Treatment Systems

-Critical Process Equipment &

Systems

-Hygienic Process

Equipment & Systems

-Industrial bio based products and processes

-Distillery bio-consumables

-Livestock, health and nutrition

-Bio-chemicals

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Why Cellulosic Ethanol ?

The Indian Context

• India’s oil import > 80% (~ 3 million barrels per day )

• India’s annual oil import bill exceeds $100 bn

• Abundant availability of Lignocellulosic feedstock (165 M MT )

• Sugar Cane Bagasse, Corn Cob and Corn Stover, Wood Chips, Rice/Wheat

Straws

• Avoids ‘Food versus Fuel ‘ debate

• Reduced GHG emissions

• Cellulosic Ethanol Technology is past the Pilot Plant stage

Ready for Field Demonstration

Cellulosic ethanol is a potential solution to India’s transportation

fuel needs and energy security

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PACE : Technology Highlights

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PACE: Chronology

2005 2006 2007 2008 2009 2010 2011

Literature

Review

Bench Scale

Facilities

Bench Scale

Experiments

Pilot Plant

Design and

Engg

Pilot Plant

Erection

Pilot Plant Trials

Demo Plant Design and Erection

2013 2014

Demo Plant - Operation

2012

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PACE : Process Block Diagram

Material Handling

& Washing Pre-Treatment

Solid-Liquid

Separation

C6 Hydrolysis

DDE

C5+C6

Fermentation

Boiler

Solids

WWTP

Liquid

Ethanol Load

out

Wate

r

Ste

am

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PACE Technology : Pretreatment

• Single step, high Efficiency (< 5% loss of sugars)

• Feed Flexibility : Bagasse, Cane Trash, Corn Cob, Corn Stover

• No special requirement for size reduction

• Milder operating conditions

Lower energy requirement

Non exotic material of construction

• Thermally integrated

Patented proprietary technology

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Enzyme supplier independent

Multiple Choices - left to the customer

Optimized enzyme dose for lower cost and higher efficiencies

Novel strategy of feeding and reactor design for improved mixing

PACE Technology : Hydrolysis

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Current

Separate C5 and C6 fermentation

Non sterile

Highly efficient and inhibitor tolerant

proprietary C5 and C6 strains (non

GMO)

Next Generation

Robust co-fermenting strain suitable for

our process

Most likely a GMO strain

PACE Technology : Fermentation

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Praj proprietary Integrated “Eco Smart TM”

Technology

Lower steam usage

Low capex

High purity and conc product

Praj proprietary dehydration technology

Molecular sieve dehydration technology

PACE Technology : Ethanol Recovery

Proven and used widely in 1st gen ethanol plants supplied by Praj

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High Overall Ethanol Yield : > 300 liter per dry ton of

corn cob (Indian variety

Economic feasibility from 100 TPD to 500 TPD

Energy Integrated – Proprietary Low Energy

Technology

Effluent Management – Zero Liquid Discharge (ZLD)

In house Design, Engineering and Fabrication

IP Status: 1 patent granted, 3 filed, Several additional

applications in process

PACE technology backed up by scale-up experience and expertise of

30 years

PACE Technology : Overall Summary

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Demonstration Plant : Objectives

Demonstrate scale-up of the various unit operations

Demonstrate suitability and reliability of equipment

Demonstrate repeatability and reproduceability at larger scale

Demonstrate energy integration

Demonstrate effluent treatment, recycle and reuse (ZLD)

Test multiple feed stocks

Demonstrate Targeted conversion cost of Agro-residues to

Ethanol

Establish basic Cellulosic BioRefinery Concept

Critical Objectives are to Demonstrate and Validate

Engineering Scale-Up and Targeted Conversion Cost

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Demonstration Plant:

Feedstock, Capacity, Location, Status

Feedstock

Designed to handle multiple feedstock

• Sugarcane Bagasse/Trash, Corn Cob/Stover,

Capacity: 100 metric ton per day (dry basis)

Ethanol Production: 25,000 – 30,000 liters per day

Location: At a Sugar Mill near Pune, India

Proximity to Praj Matrix – The Innovation Center

Status: Engineering package ready, Permitting in-progress

Target commissioning by 2nd qtr. 2014

Comprehensive Evaluation conducted to chose suitable Capacity and

Location

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Construction of demo plant

Startup of demo plant

Validation of Unit Operations

Stabilization of plant on corn and

cane residues

Performance Optimization

2013- 2014 2014-2015 2015-2016 2016-2017

Demonstration on other feedstock

Rollout of subsequent contracts

Establish Bio-Refinery concept

Marketing & Promotional

Activities

Booking of commercial order

Leverage existing sales network to win more orders

PACE - Commercialization Time line

Successful demonstration will result in rapid

commercial deployment

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Mechanical and

Hydrothermal

pretreatment

C5 and C6 sugars

Enzymatic

hydrolysis

Fermentation

Chemo-Catalysis

Ethyl

Levulinate

Lignin and residues

Power and

phenolics

Lignocellulosic biomass

Xylitol

2,3 - Butanediol

C5 stream

C6 stream

Humins Furfural

Ethanol

Praj Biorefinery

Praj Biorefinery : Bolt on to “PACE” plant

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Technology

Engineering

Plant &

Machinary

Customers Feed

Stock

Agri-

Processing

Companies

• BIOFUEL

• CHEMICAL

• BIOCHEMICAL

• FOOD

• FEED

• PHARMA

Technology

Partners

Partnerships Across Value Chain

The Emerging Value Chain

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Thanks for your

patience !