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© Praj Industries Ltd CONFIDENTIAL www.praj.net
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Praj’s ‘Integrated 2nd GenerationSmart Bio-Refinery’
26th March 2018
• Indian ethanol scenario
• Praj 2G ethanol technology overview
• Praj 2G ethanol – Demonstration Project Highlights
• Models for setting up 2G projects in India
• Praj Offerings
Contents
Incauca Plant, Colombia2
© Praj Industries Ltd CONFIDENTIAL www.praj.net 2
Indian Ethanol Scenario
3© Praj Industries Ltd CONFIDENTIAL www.praj.net
Ethanol Demand & Supply scenario in India
Sectoral alcohol demand in India 2015 / 16
Particulars 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22
Petrol Sale
Projection
(8.38 % CAGR)
2759.6 34000 3241.5 3513.1 3807.5 44000
Ethanol Requirement
(@ 5% blending) 138 170 162 175 190 220
(@ 10% blending) 276 340 324 351 380 440
(@ 20% blending) 551 680 648 702 761 880
*All figures in crore liters
© Praj Industries Ltd CONFIDENTIAL www.praj.net 4
Sectoral alcohol demand in India 2016 / 17
• Low molasses
availability
• High molasses
prices
• Lower ethanol
price
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
© Praj Industries Ltd CONFIDENTIAL www.praj.net 5
Praj’s core competencies
Research & Development
Knowledge base
of
750 References
75 countries
5 Continents
16
Patents
Praj 2G ethanol Technology – Overview
6© Praj Industries Ltd CONFIDENTIAL www.praj.net
– 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
Operational Since Dec-2016
2016-17
Technology optimization journey
Biomass to Bio refinery
Operational since – January 2009
Raw material processing capability –
Rice straw, Wheat straw,
Sugarcane Bagasse, Cane trash, Pith
Corn Cobs + Corn Stover
Cotton stalk & Empty fruit bunches
Pilot plant trials validated work done at
laboratory & bench scale with Consistence
performance
© Praj Industries Ltd CONFIDENTIAL www.praj.net 7
Indian Feedstock Comprehensive mapping & Analysis
•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 USAAccomplishments
• Evaluation of newer
feedstock's like Empty Fruit
bunches from Palm, grasses,
MSW etc.
Continuous Program
Robust technology which can handle Regional & Seasonal Variability of
feedstock
Robust technology which can handle Regional & Seasonal Variability of
feedstock
Analysis done using standard NREL lap method
© Praj Industries Ltd CONFIDENTIAL www.praj.net 8
End-to-End Holistic & Integrated solution
© Praj Industries Ltd Confidential www.praj.net
Performance parameters at par with global benchmarks
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‘enfinity’ - Key technology highlights
Co-Fermentation
• Yeast strain for efficient utilization of C5 (pentose ) and C6 (hexose)
sugars
• Higher yield
• Lower reaction time
• Higher tolerance to solids
Proprietary end to end process
design
• Multi-feed capability
• Pre-treatment
• Efficient degradation of biomass to sugars
• Less Corrosive Process
• Better biological processing ability
• Efficient enzymatic hydrolysis
• 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
• LC Ethanol Technology –
• Process patent filed and already granted in India, SA, Kenya;
pending approval in other countries
• Four more patent applications in progress
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© Praj Industries Ltd CONFIDENTIAL www.praj.net 11
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
Multi-Feedstock, Multi Product ‘SMART Bio Refinery’
CO2
Bio Fertilizers
Corn
Residues
Rice/Wheat
Straw
Sugarcane
Residue
Cotton Stalk
IndustrialAlcohol
Fuel Ethanol220-325 Liters
Bio-
Chemicals*
Power export
RectifiedSpiritBio-CNG
2nd
Gen
Multi-FeedstockMulti-Product
© Praj Industries Ltd CONFIDENTIAL www.praj.net 12
Praj innovative 2G Bio refinery provides higher returns
Praj expertise in technology scale-up
Praj has rich expertise of over 3 decades of technology scale-up
© Praj Industries Ltd Confidential www.praj.net
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
• PMC, EPCM Services
6 KLPD
1200 KLPD
Praj’s 1G Ethanol Plants – across globe
100 KLPD
200 KLPD
2nd Gen Pilot ���� Demo ���� Commercial Scale
Praj’s Integrated 2G ethanol Bio-refinery –Demonstration Project
14© Praj Industries Ltd CONFIDENTIAL www.praj.net
8th Apr2016
Ground-
Breaking.
25th Dec2016
Mechanical
Completion
Jan/Feb2017
Sugarcane Bagasse
Campaign Trials
Mid Feb2017
Rice Straw
Campaign
Start
Apr2017
OMC’s Due
Diligence Run
7th May2017
Inauguration
Journey of Success
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
© Praj Industries Ltd CONFIDENTIAL www.praj.net 16
Inauguration of Demo Plant – 7th May 2017
© Praj Industries Ltd CONFIDENTIAL www.praj.net 17
Praj ‘s 2G demonstration plant
MATERIAL HANDLING SYSTEM
© Praj Industries Ltd Confidential www.praj.net 18
Praj ‘s 2G demonstration plant
PRETREATMENT SECTION
SOLID LIQUID SEPERATION SECTION
DISTILLATION
SECTION
Ethanol
Lignin Cake
© Praj Industries Ltd Confidential www.praj.net 19
Praj ‘s 2G demonstration plant
HYDROLYSIS AND CO-FERMENTATION
2G ENZYME STORAGE
Hydrolyzed Slurry
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Praj ‘s 2G demonstration plant
WASTE WATER TREATMENT
Flare
Unit
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Key highlights : Demo Plant
• Demo Plant operations stabilized, Dream run conducted from
7th March to 12th March 2017
• Operating at rated capacity of 12 MT/day dry biomass
processing
• Targeted parameters – Global Efficiency and Yields
achieved on the Sugarcane bagasse & Rice straws
• BPCL & EIL team consisting of 5 members visited Demo plant
from 10th to 13th April 2017 for review of the Plant
performance
• IOCL CFT of 7 members visited Demo plant from 10th to 14th
April 2017 for plant performance review
• Senior executives of Working group of biofuels, IOCL, HPCL,
BPCL, MRPL, EIL (team of 25 delegates) visited the Demo
Plant on 12th April 2017
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BPCL Team @ Praj Demo
Plant
IOCL Cross Functional Team @
Praj Demo Plant
Senior Executives of Working group of Biofuels, IOCL, BPCL, HPCL
MRPL, EIL @ Praj Demo plant
Oil Marketing Company officials witnessed demo plant operations
Status of 2G Ethanol commercial projects
23© Praj Industries Ltd CONFIDENTIAL www.praj.net
Update on Commercial Projects
BPCL
• Received Purchase Order from Bharat Petroleum Corporation Limited
(BPCL), for Praj’s proprietary technology, basic engineering and design
package (BEDP)
• This is a major milestone towards commencement of work on the 2nd
Generation ethanol bio refinery with production capacity of 100 kiloliter
per day to be set up by BPCL at Bargarh, Odisha.
• The Purchase Order was awarded to Praj after the performance
evaluation of its 2nd generation integrated bio refinery demonstration
plant located in Maharashtra.
• Majority of the BEDP is ready for Execution
© Praj Industries Ltd CONFIDENTIAL www.praj.net 24
Update on Commercial Projects
• IOCL
• Signed MoU with IOCL for two commercial projects
• Panipat – Under finalization
• HPCL
• Praj is the only company short listed through global
tendering process (by Engineers India Ltd)
© Praj Industries Ltd CONFIDENTIAL www.praj.net 25
End-to-End Holistic & Integrated solution
© Praj Industries Ltd Confidential www.praj.net
Performance parameters at par with global benchmarks
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Model for Setting up 2G ethanol projects in India
27© Praj Industries Ltd CONFIDENTIAL www.praj.net
End-to-End Holistic & Integrated solution
© Praj Industries Ltd Confidential www.praj.net
Performance parameters at par with global benchmarks
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Model # 1 : Bagasse to ethanol attached to Sugar
Cooling tower
COGEN Fermentation Distillation
Dehydration
Ethanol Storage
Enzymatic Hydrolysis
Pre-treatment
S/LSeperation
Black liquor concentrator
Waste Water treatment
Existing Production facility
Pretreated slurry
Lignin cake
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Biomass
© Praj Industries Ltd CONFIDENTIAL www.praj.net
Hydrolyzed
slurry
Pre-treatment Pre-treatment
Enzymatic
Hydrolysis
Enzymatic
Hydrolysis
2G “Bolt-On”
Module
Fermentation
Distillation
Dehydration
Utilities
Existing 1G Bio-
ethanol
complex
Existing Sugar
Factory
Existing Sugar
FactoryExisting
Cogeneration
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 capacity at lower
capEx
Model # 2 Bolt on: Sugar mill attached distillery
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Sweet Sorghum to Ethanol
31© Praj Industries Ltd CONFIDENTIAL www.praj.net
Why Sweet Sorghuum
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• No food / Industrial applications
• Net energy positive.
• Provide Juice and Bagasse
• Viable (low cultivation cost / high land productivity -
yields).-Local benchmarks…Molasses, Juice etc
• Provide fuel for steam / electricity.
• Large cultivation window around tropics (Equator
+/- 20 Deg)
• Cultivable for one cycle in moderate temperate
regions and two seasons if climate permit
• Complement local crops like sugarcane.
© Praj Industries Ltd CONFIDENTIAL www.praj.net
2G “Bolt-On”
Module
Fermentation
Distillation
Dehydration
Utilities
Existing 1G Bio-
ethanol
complex
Existing Sugar
Crushing Plant
Existing
Cogeneration
• Shortage of molasses – Sweet
sorghum can crushed
• Sweet sorghum crop can be
planted as intercrop in Sugarcane
and harvested in 3-4 months
• Results in additional operation of
Molasses based distillery
• Sweet sorghum juice can be used
in fermentation & bagasse to be
used as pre-treatment to produce
2G ethanol
• Higher asset utilization
• More ethanol production per year
Model # 3 Sweet Sorghum based Bolt on model to Sugar/Ethanol complex
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Pre-treatment
Enzymatic
Hydrolysis
Bagasse Juice
Hyd
roly
ze
d s
lurry
Sweet
sorghum
Lignin
cake
Praj - One Stop Shop in 1G/2G Ethanol Industry
Concept Development &
Feasibility Study
License & Basic Engineering
Detail Engineering
Supply of critical process equipment
Procurement & Inspection
Project Management
Construction Management
Commissioning / O&M Support
After Sales Service
Single Point Responsibility ����End to End Solutions = Comfort to Project Developer/Investor
© Praj Industries Ltd CONFIDENTIAL www.praj.net 34
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
© Praj Industries Ltd CONFIDENTIAL www.praj.net 35
Thank youDr Tushar PatilMob: +91 9766642466Email: [email protected]
© Praj Industries Ltd CONFIDENTIAL www.praj.net