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Value Maximization through
PRAJ's 2nd Generation
“Smart Bio Refinery”
Amol Sheth October, 17th 2016
Discussion Points
• Technology development & commercialization
• Praj‟s 2G Ethanol Technology
• Innovative Tech.
• Value Maximization
© Praj Industries Ltd CONFIDENTIAL www.praj.net 2
Technology
Development, Scale up
& Commercialization
© Praj Industries Ltd CONFIDENTIAL www.praj.net
Praj – R&D Capability
Innovation Centre Overview
80,000 sq ft of Labs, Pilot Plants, and
Offices
90 technologists - 25 PhDs, 65 Masters
5 Technology Centers of Excellence -
Biology, Chemistry, Engineering
18 Well Equipped Labs
Pilot Plants
1 MTPD (bone-dry) second
generation ethanol pilot plant
1 multi purpose pilot plant
Intellectual Property
Granted Patents – 16
Patent Applications Filed – 7
Patents Applications in Progress - 8
FOCUS
BIO Refinery Bio-Fuels, Bio-Chemicals
Environment
Health & Wellness
© Praj Industries Ltd CONFIDENTIAL www.praj.net
4
Praj expertise in technology scale-up
Praj has rich expertise of over 3 decades of technology scale-up
Quick scale-up & commercialization
expertize
• End to end solutions from feedstock
processing to final product
• Integration engineering – water/energy
optimization
• Front end engineering & design (FEED)
• Process & equipment design
• SKID mounted systems
• Architectural & civil engineering
6 KLPD
(5.5 MGPY)
1200 KLPD (110 MGPY)
Praj‟s ethanol plants – across globe
100 KLPD
200 KLPD
© Praj Industries Ltd CONFIDENTIAL www.praj.net 5
Building success ladder 1G 1.5G 2G
Quick scale-up
& technology
Commercialization
Technology
& Integration
engineering
Project &
construction
management
Engineering
&
Manufacturing
Over 3 Decades of rich experience of ethanol industry along with
Praj‟s core competencies enabled us in developing sustainable
future ready technologies
Praj’s core competencies
Research &
Development
Knowledge base of
750 References
75 countries
5 Continents
16 Patents
© Praj Industries Ltd Confidential www.praj.net 6
www.praj.net
Feedstock‟s – 1G vs. 2G
SO – What are these Sugars and Why Should I Care?
C6 H12 O6 – Hexose, Glucose is the main one
C5 H10 O5 – Pentose, Xylose is the main one
Technical Complexity
Technical Complexity
Technical Complexity
Feedstock mapping and testing
•600 + samples of Lignocellulosic biomass
from India, Latin America, N. America
and Europe.
•100 corn residue samples from USA.
Global Feedstock mapping
• 400 + samples across India : Sugarcane
residues, Corn residues , Rice Straw,
Cotton stalk.
Feedstock type distribution
• Validated analytical methods from NREL
USA. Accomplishments
• Evaluation of newer feedstock's like
Empty Fruit bunches from Palm, grasses,
MSW etc.
Continuous Program
Comprehensive mapping of Cellulosic Feedstocks –Regional & Seasonal Variability
© Praj Industries Ltd Confidential www.praj.net 8
Feedstock variation ….
Parameters Unit Test Values
Bagasse Bagasse
Pith
Corn
Residues
Cotton Stalk Palm EFB Rice
straw
Wheat
Straw
Total solids %w/w 70.0 47.0 90.97 91.78 87.48 85.68 93.3
Moisture %w/w 30.0 54.0 9.03 8.22 12.52 14.32 6.71
Glucan %w/w 38.0 34.80 29.04 30.57 31.82 32.2 32.0
Xylan %w/w 21.0 20.29 20.60 12.66 19.26 16.2 18.0
Arabinan %w/w 1.81 1.69 2.83 0.68 0.52 2.54 2.67
Acetate %w/w 2.74 2.43 2.14 2.51 1.57 1.2 1.52
Acid Insoluble lignin %w/w 19.0 22.8 16.11 21.18 18.0 11.0 14.0
Acid soluble lignin %w/w 4.0 4.5 4.45 3.16 4.17 3.2 3.5
Ash %w/w 3.0 5.52 7.02 7.60 8.25 16.0 12.5
Protein %w/w 2.5 2.67 3.41 5.26 4.24 4.5 5.5
Extractives (water) %w/w 4.0 2.47 4.66 10.14 10.57 16.0 15.0
Extractives (95% ethanol) %w/w 1.9 2.51 2.45 1.66 6.23 2.42 2.24
Analysis done using standard NREL lap method Robust technology which can handle feedstock variation
© Praj Industries Ltd Confidential www.praj.net 9
India - State wise biomass availability
State Total Biomass produced
(MMT)
Surplus Biomass available after current
utilization (MMT)
Surplus biomass CONVERTIBLE for
ethanol production (MMT)
Collectable Biomass (40%) of Convertible
(MMT)
Tamil Nadu 22.50 08.90 01.66 0.66 Rajasthan 29.90 08.60 00.25 0.10
Kerala 11.60 06.40 00.06 0.02 MP 33.30 10.30 02.03 0.81
Gujarat 29.10 09.10 04.92 1.97
Punjab 50.80 24.80 11.70 4.68 Karnataka 34.20 09.20 01.38 0.55
Orissa 20.10 03.70 01.30 0.52
West Bengal 36.00 04.30 00.77 0.30 Maharashtra 47.60 14.80 11.30 4.52
Chhattisgarh 11.30 02.10 00.43 0.17 Andhra Pradesh 24.90 04.30 00.26 0.10
Bihar 25.80 05.10 03.48 1.39 Haryana 29.10 11.30 02.07 0.83
Telengana 19.10 02.70 01.88 0.75
Uttrakhand 02.90 00.63 0.26 0.10
Uttar Pradesh 60.30 13.80 9.00 3.60
Jharkhand 03.60 00.89 0.43 0.17
Total 492.10 140.92 53.18 21.24
© Praj Industries Ltd CONFIDENTIAL www.praj.net 10
enfinity – Praj‟s 2G
Ethanol Technology
© Praj Industries Ltd CONFIDENTIAL www.praj.net
Our technology brings infinite possibilities to the
environment and energy challenges confronting mankind… by
making use of nature’s endless resources. That’s why we
proudly call it…..enfinity.
enfinity – Praj‟s 2G Ethanol Technology
© Praj Industries Ltd CONFIDENTIAL www.praj.net 12
Pretreatment Feedstock Handling
Feedstock Preparation System / Washing
Enzymatic Hydrolysis / Liquefaction
Fermentation Distillation & Dehydration
Waste Water Treatment
End to End integrated Process
2G ethanol/bio-chemicals plant processing biomass
Bio-Refinery
Addition of challenges
© Praj Industries Ltd Confidential www.praj.net 13
Choice of pre-treatment is critical.
It must take into account
Solids concentration
Compatibility with
Feedstock
Selection of enzymes
Fermentation organism
Limited size reduction to avoid high power requirement
Pre-treatment
© Praj Industries Ltd Confidential www.praj.net 14
Pervasive impact on
Size Reduction
Feedstock cleaning & Washing
Hydrolysis
Fermentation
Product Recovery
Residue Processing
Waste water treatment and water recycle potential
Leading to overall impact on Project economics
Pre-treatment
© Praj Industries Ltd Confidential www.praj.net 15
Following undesirable by-
products formed
Furfural
HMF
Acetic Acid
Phenolic
Aldehydes
Gypsum
Pre-treatment
Undesirable due to
Lower sugar production and
lower process efficiencies
Inhibit enzymes and
Inhibit fermentation micro-
organisms
© Praj Industries Ltd Confidential www.praj.net 16
Pre-treatment
Strategies
to deal with
inhibitors and toxins ?
MANAGE Toxins/ Inhibitors
REMOVAL of Toxins/ Inhibitors
© Praj Industries Ltd Confidential www.praj.net 17
Solid liquid separation - followed by
Membrane – Reverse Osmosis
OR
Activated carbon
OR
Ion exchange
Adds CAPEX
Compromises economics of the technology
Impacts OPEX - water, energy and waste water treatment
Removal of Toxins/Inhibitors
© Praj Industries Ltd Confidential www.praj.net 18
Adopt suitable hydrolysis strategy
Selection of enzymes
Mode of operation – Fed batch, Continuous, etc.
Solids concentration
Adopt suitable fermentation strategy
Selection of tolerant yeast / micro-organism
Mode of operation – Fed batch, Continuous etc.
Adapt culture / platform for WWTP
Bio-methanation – Impact of phenolic components
Incineration of residues – Impact of alkalinity
Needs investment in technology development
Managing Toxins/Inhibitors
© Praj Industries Ltd Confidential www.praj.net 19
Better flow characteristics
Better mixing efficiency
More efficient enzyme use
Higher enzymatic and
fermentation efficiencies
Fewer choking issues
Far lower erosion issues &
Process downtime
Benefits of low solids concentration in pretreatment
© Praj Industries Ltd Confidential www.praj.net 20
– technology optimization journey
Pilot Plant Operations
2009-15
Optimization on customer preferred biomass & Engineering package for commercial scale units
2014 -15
Execution of 12 TPD 2nd Gen Bio refinery & Commercial offerings
2016
Technology optimization journey
Biomass to Bio refinery
Operational since – January 2009
Raw material processing capability –
Corn Cobs + Corn Stover
Sugarcane Bagasse, Cane trash, Pith
Rice straw, Wheat straw, Cotton stalk
© Praj Industries Ltd CONFIDENTIAL www.praj.net 21
22 © Praj Industries Ltd www.praj.net Confidential
Data on Feedstock processing at Pilot plant
Sugarcane Bagasse 120 MT
Corn Cobs 150 MT
Corn Stover 60 MT
Corn Residues (Mixed) 15 MT
Palm Residues 5 MT
Wheat Straw 5 MT
Rice Straw 40 MT
Bagasse Pith 20 MT
Processed > 400 Metric tons of diverse feedstocks over a span of 3 years and over
with 800,000 man hours of R&D spent on the pilot plant and still ongoing.
Material Handling
Washing
Pre-treatment
S/L Separation
Detoxification
Delignification
Enzymatic Hydrolysis
Co Fermentation
C5 Fermentation
Distillation & Dehydration
Waste Water Treatment 23
Technology Evolution via process flows
Material Handling
Washing
Pre-treatment
S/L Separation
Detoxification
Delignification
Enzymatic Hydrolysis
C6 Fermentation
C5 Fermentation
Distillation & Dehydration
Waste Water Treatment
Material Handling
Washing
Pre-treatment
S/L Separation
Detoxification
Delignification
Enzymatic Hydrolysis
C6 Fermentation
C5 Fermentation
Distillation & Dehydration
Waste Water Treatment
Material Handling
Washing
Pre-treatment
S/L Separation
Detoxification
Delignification
Enzymatic Hydrolysis
C6 Fermentation
C5 Fermentation
Distillation & Dehydration
Waste Water Treatment
End-to-End Holistic & Integrated solution
© Praj Industries Ltd Confidential www.praj.net
Performance parameters at par with global benchmarks
24
Praj has made significant performance improvements over last three years
enfinity – Performance over the years
© Praj Industries Ltd Confidential www.praj.net 25
2011 2012 2013 2014 2015 2016 (P) 2017 (P)
182
208
254 264
270 275 290
261
284
302 317
325-330 333-338
342-347
Yield (Liters / Ton ) of Feedstock
Bagasse
Corn Cob
68.0
26.0
19.0 18.1 17.6 16.5
15.3
38.1
17.0 15.7 14.6 13.5 12.6 11.7
2011 2012 2013 2014 2015 2016 (P) 2017 (P)
Conversion Cost (Rs/Liter)
Bagasse
Corn Cob
Co-
Fermentation
• Yeast strain for efficient utilization of C5 (pentose ) and C6 (hexose)
sugars
• Higher yield
• Lower reaction time
• Higher tolerance to solids
Proprietary
robust end to
end process
• Multi-feed capability
• Pre-treatment
• Efficient degradation of biomass to sugars
• Better biological processing ability
• Efficient enzymatic hydrolysis
• Performance in spite of inhibitors
• No detoxification steps leading to lower capex and opex
• Thermally integrated process to achieve low net energy usage
• Water recycled; achieve zero process liquid discharge
Enzyme
Flexibility
• Proven technology on multiple enzymes
• High yields with different enzyme strains
Intellectual
Property
• Enfinity Technology –
• Process patent filed and already granted in India, SA,
Kenya; pending approval in other countries
Summary : Technology highlights
© Praj Industries Ltd Confidential www.praj.net 26
Good integration, key to success
Pretreatment
Feedstock Handling
Feedstock Preparation
System / Washing
Enzymatic Hydrolysis / Liquefaction
Fermentation
Distillation & Dehydration
Waste Water Treatment
Integrated 2G Bio refinery for Biofuels & Biochemical
Summary
End to end process and energy integration
© Praj Industries Ltd CONFIDENTIAL www.praj.net 27
Innovative Integrated
Bolt-on model
© Praj Industries Ltd Confidential www.praj.net 28
Integrated Bolt-On
Hydrolyzed
slurry
Pre-treatment
Enzymatic
Hydrolysis
2G “Bolt-On”
Module
Fermentation
Distillation
Dehydration
Utilities
Existing 1G Bio-
ethanol complex
Existing Sugar
Factory Existing
Cogeneration
• Many 1G ethanol plants operate 150
- 200 days / annum
• Additional 150-180 days operation
using 2G bolt-on module
• Results in year round operations of
bio-ethanol complex
• Higher asset utilization
• Fewer unit operations hence lower
capEx
• Substantial increase in ethanol
production at lower capEx
© Praj Industries Ltd Confidential www.praj.net 29
Grain Fiber to Cellulosic Ethanol
Existing Starch to
ethanol
Hydrolysis
Pretreatment
Co-product: Bio Oil & DDGS
Ethanol
Patented Technology
Fiber
© Praj Industries Ltd Confidential www.praj.net 30
SELECTIVE GRIND & FIBER
SEPARATION TECHNOLOGY
1 G Technology
Fiber to
Ethanol
Starch Slurry
(with Separated
bound starch)
CORN
Fiber
Up to 8 % increase in ethanol yield compared to conventional technology
Value Maximization through
PRAJ’s 2nd Gen “SMART”
Bio refinery
31 © Praj Industries Ltd CONFIDENTIAL www.praj.net
Process Know-how
Ethanol & Ethanol based
Chemicals
Biochemicals
Co-Products
Praj Approach ...
• Understanding Feedstock
• Pretreatment &
Fermentation Technologies
• Waste water
treatment & recovery
• Beverage Alcohol
• Fuel Alcohol
• Pharma Alcohol
• Ethylene
• Propylene
• Acetic Acid
• Ethyl Acetate
• Furfural
• Xylitol
• Ethyl Levulinate
• Levulinic acid
• Lactic acid
• Succinic acid
• Acetic acid
• CO2 Recovery
• Liquid /Solid
Bionutrients
• Bio-CNG
• Biogas to Power
© Praj Industries Ltd CONFIDENTIAL www.praj.net 32
Multi-Feedstock, Multi Product SMART Bio Refinery
CO 2
Bio Fertilizers
DDGS
Biogas
Lignin cake
Juice
Molasses
Grain
Ligno- cellulosic
MSW
Industrial Alcohol
Fuel grade
Ethanol
Bio-Chemicals
Bio-Jet Fuel
Rectified Spirit
Pharma grade
Ethanol
BIO-REFINERY
1st
Gen
Next
Gen
Multi-Feedstock Multi-Product
© Praj Industries Ltd CONFIDENTIAL www.praj.net 33
Multi-Feedstock, Multi Product „SMART Bio Refinery‟
CO 2
Bio Fertilizers
Corn Residues
Rice/Wheat
Straw
Sugarcane
Residue
Cotton Stalk
Industrial Alcohol
Fuel
Ethanol
220-325
Liters
Bio-Chemicals*
Power export
250 - 400 Kwh
Rectified Spirit
Bio-CNG
90-100 KG
2nd
Gen
Multi-Feedstock Multi-Product
© Praj Industries Ltd CONFIDENTIAL www.praj.net 34
Total Revenue potential ~ INR 17,000 – 23,000 / MT
Biomass cost ~ INR 2000 – 5000 / MT
Note: 1) Liquid CO2 market price of INR8/Kg 2) Bio-CNG price INR 50/KG
3) Bioethanol price INR 46.50/Liter 4) Power price INR 4/Kwh
5) Carbohydrate content in biomass assumed at ~55%
* Bioethanol yield will reduce when sugars are diverted for bio chemicals
Praj innovative 2G Bio refinery provides higher returns
Headquarter : PRAJ Tower, Pune - India
© Praj Industries Ltd www.praj.net 35 A truly global Organization with multiple & diverse business sectors
Thank You ([email protected] / [email protected] / +919890300107)