praj advanced cellulosic ethanol project - pace project... · 2014-03-26 · praj advanced...
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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 !