Praj’s Integrated Smart
Biorefinery Vasudeo Joshi – V.P. Advance Biofuels
12th March 2019
LEED Certified Platinum Green Building
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Praj’s Global Bioenergy Leadership
Audit
& Feed
Engineering
Equipment
Manufacturing
& Supply
Technology
Project
Managemen
t
Civil &
Structural
Supervision,
Commissioning,
After Sales
Distillery
Plant
End-To-End Service Provider
100% Share In Colombia
~70 % Share In India (2016-17)
750+ Global References
>350 installations
overseas
Installations in 75 countries
across 5 continents
9000+ Samples of 1G feedstock fingerprinted
UNDISPUTED GLOBAL
ETHANOL PLANT
SOLUTIONS LEADER
50%+ Share in Emerging Markets
Only Ethanol Technology player with references across 5 continents
Demonstrated Large Plant Capacity up to 1.2 MLPD (1200 KLPD)
Riopaila, Colombia
Vicentin, Argentina
British Sugars, UK British Sugar, UK
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In-House R&D laboratory - Certification by DSIR*, GOI
90+ technologists and growing
$ 25-30 mln investment from own funds
Received status of Private Sector BioTech Park by the
Government of Maharashtra, India
“At the lab level, Praj Matrix ranks up with
almost any facility in the world.
What is unique is the Labs, Pilot and the
Scale up facilities are all at one location.”
-Vinod Khosla, Former Sun Micro Systems co-founder & Erstwhile Shareholder
Praj Matrix R&D
3 *DSIR: Department of Scientific and Industrial Research
Building success ladder 1G 2G
Quick scale-up
& technology
Commercialization
Technology
& Integration
engineering
Project &
construction
management
Engineering
&
Manufacturing
Over 3 Decades of rich experience of ethanol industry along with Praj’s core competencies
enabled us in developing sustainable future ready technologies
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Praj’s core competencies
Research &
Development
Knowledge base
of
750 References
75 countries
5 Continents
16 Patents
Key Highlights of Praj’s Integrated Demo Plant
• Integrated Bio refinery Demonstration Plant : Capacity – 1 MLPA Ethanol
production
• Multi feedstock processing capability: Rice (paddy) Straw, Cotton stalk, Corn
Cobs & Corn Stover, Sugar Cane bagasse & Cane trash, Wheat Straw etc.
• Multi-product - The plant is designed to produce Bio-ethanol, Bio-gas / Bio-
CNG, Bio fertilizer, Provision for Production of Bio chemicals, Isobutanol –
Jet fuel
• End to End Technology demonstration from feedstock processing till end
product and waste water treatment
• Zero Process Liquid Discharge
• Process Integration for optimization of Energy & Water consumption
Oil Marketing Company officials witnessed demo plant operations 5
EUROPEAN DELGATION VISITED DEMO PLANT MARCH 18
The delegation was co-led by Dr Kyriakos Maniatis, Principal Administrator – Directorate General for
Energy, European Commission
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“We are impressed with the momentum that 2nd generation ethanol has gathered in India. Visit to Praj’s 2nd gen demonstration plant has given us new insights into the technology development which, I am sure, will be of interest to European delegates”, expressed Dr Maniatis.
© Praj Industries Ltd CONFIDENTIAL www.praj.net 7
Pretreatment Feedstock Handling Feedstock Preparation System
Enzymatic Hydrolysis
Fermentation Distillation & Dehydration
Waste Water Treatment
End to End integrated process
Value Chain
Leveraging expertise in Process optimization & Integration
Praj expertise in technology scale-up
2G Technology scale-up in India
1TPD
12TPD 425TPD rice straw
12X
35X
Pilot plant
Demo plant
Commercial plant
Quick scale-up & commercialization expertize
• Vendors offering commercial scale packages have been
witnessed and identified
• Build a partnership with commercial scale pre-treatment
equipment supplier
• Vast commercial scale references in hydrolysis,
fermentation, distillation / dehydration and waste water
treatment in 1G ethanol
2G Ethanol business update
• Technology license and basic engineering for BPCL • Ground broken • 100 KLPD Fuel ethanol • Feedstock :Rice Straw
• Technology licensor & EPCM contractor for IOCL • 100 KLPD Fuel ethanol • Feedstock Rice Straw • Construction to start soon
• Technology license and basic engineering for HPCL • 100 KLPD Fuel ethanol • Feedstock :Rice Straw • Construction to start soon
• Technology license and basic engineering for MRPL
• 60 KLPD Fuel ethanol • Feedstock : Corn Cob / Rice Straw • Construction to start soon
Feasibility reports for European Prospects
Developing 2G Ethanol project
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enfinity uniqueness
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Multiple
Feedstock
Proven
Track
Record
High
Efficiency
Robust
Process
• Having processed
agricultural feedstock – variations
• Delivering Ethanol plants for more than 35 years
• No solids handling issues due to focus on parameters needed for high plant availability • Well integrated process physically and chemistry wise
• Best-in-class yields
• Low processing costs
• Complex feedstock
handling experience
• Wheat Straw, Corn Stover, Rice Straw, Bagasse, etc.
Optimization & integration
Cost & availability of
Energy (thermal+ electric)
Chosen
Site
Co-products , yeast & enzyme
technology
Local regulations
• Regulations for GMO • Liquid , gaseous & solids
discharge regulations
• Lignin to steam • Lignin to power & steam • Lignin+ conc. Stillage • Secondary fuel • Biogas
• Green field or brownfield • Availability of utility from
over the fence • Logistics: Feedstock &
product • Climatic conditions
• Co-products like bio-chemicals, CO2, Biogas
• Onsite or off site enzymes
Multiple plant configurations are possible and choosing the best is key
Achieving Viability of Commercial Plants
• Sustainable supply of Biomass
• Quality of biomass
• Performance of Material handling system & its synchronisation with the upstream process
• Feedstock agnostic (Flexibility with optimal Capex )
• Vendor development for key Equipment and Packages
• Alternate Material of Constructions
• Optimization of Chemical consumptions
• Enzymes: Customization, Shipping costs, Import Duties
• Maximization of Yields
• Maximization of Capacity factor
• Value added by-products – Bio fertilizers, Lignin Valorization
• Bolt – On / Co-located units
• The 4Rs - reduction, reuse, recycling and recovery
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Biogas / RNG / CBG(Compressed Bio Gas)
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Praj USP
CBG
Delivery
Technology
Financial Engineering
Multiple Feedstock ( Sugar Plant Waste, Bio Mass, Farm Waste Etc. )
Higher Yield , Robust and reliable process
CBG integrated with Bio Refinery
T-EPC with O&M
Built-in Digitalization
Attractive Return to Investors
Flexible financing Models
CBG production Opportunities in Sugar Mill –
The Commercial Bio refinery !
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Sugar Mill Capacity - 10000 TCD / 5 Months / yr Operation
Bagasse 225000 TPA (Dry basis) Molasses : 60000 TPA
Sugar Produced :150000 TPA
Pressmud : 60000 TPA
Ethanol : 11500 MT
Spent wash: 130,000 CuM
CBG Yield= 17.5 Kg / CuM
CBG Production 2275 MT / Yr
CBG Production 2520 MT / Yr
CBG Yield= 42 Kg / MT
Assuming 10% Surplus (22500 MT) is used for CBG Production
CBG Yield= 150 Kg / MT
CBG Production 3375 MT / Yr
Total Possible CBG Production 8170 MT / Yr
Annual revenue Approx: InR 450 Cr
Annual revenue Approx: InR 50 Cr (Incl. Biomanure)
Annual revenue Approx: InR 64 Cr
In addition to Renewable Electricity, Green Bio-fuels like CBG & Bioethanol can generate almost 20 % Additional Revenue & high level of Gross Value Addition
Electricity 118000 MW / Yr (82000 MW Surplus)
Annual revenue Approx: InR 41 Cr
SMART Bio Refinery - Multi-Feedstock & Products
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
NextG
en
Multi-Feedstock Multi-Product
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Biofuels &
Biobased
Chemicals from
Sugar (Juices and
Molasses)
Large Integrated
Plants for Advanced
Biofuels & Biobased
Chemicals from LC
High Performance
Synthetic BioFuels &
Functional Chemicals
1st Gen BioFuels
& Biobased chemicals
Integrated BioRefining
Technologies
Customized Advanced Biofuels
& Bio Based Chemicals
SUGARS Molasses, Juice LignoCellulosic Biomass
Natural / Customised
Micro-Organisms Green Catalysts
Power Pharma
Ingredients
Bio Ethanol &
Advanced BioFuels Bulk
Chemicals
H & W
Ingredients
Green Chemistry
Down Stream (Recovery & Purification)
Fermentations
Multiproduct Biorefineries to produce Biofuels and Biobased Products
Biopolymers
Vision 2025 : Bio-refinery
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© Praj Industries Ltd CONFIDENTIAL www.praj.net
Sustainability through 20% EBP
*Note: 1) GHG emission saving from farm (by avoiding burning) – 19000 MT CO2 equivalent 2) GHG emission saving from ethanol production process – 42700 MT CO2 equivalent 3) GHG emission saving from ethanol blending – 60000
MT CO2 equivalent 4) Total GHG emission saving from farm to fuel for 100 KLPD plant is 121000 MT CO2 equivalent/year
#1USD = 66 INR ## Average tax revenue to government from 100 KLPD rice straw to ethanol plant is INR 30 Crores/ Annum
*Assuming 1500 Jobs for 100 KLPD plant covering ( 50 jobs for plant operations + 100 Village Level Entrepreneurs + 1350 Unskilled labor for biomass sourcing & supply chain) & 1.5 Lac income / Job **Assuming yield of 1.15
MT/Ha Rice Straw & Total land required for 100 KLPD plant will be 120000 MT/Year ***Assuming INR600/MT of rice straw realization to farmer ****Assuming INR 900/MT of rice straw realization to rural entrepreneurs