praj’s integrated smart biorefineryin-house r&d laboratory - certification by dsir*, goi 90+...

Praj’s Integrated Smart

Biorefinery Vasudeo Joshi – V.P. Advance Biofuels

12th March 2019

LEED Certified Platinum Green Building

© Praj Industries Ltd CONFIDENTIAL www.praj.net

2

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


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

© Praj Industries Ltd CONFIDENTIAL www.praj.net 4

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


“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.


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


enfinity uniqueness

11

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


https://www.iisd.org/business/tools/bt_4r.aspx




Biogas / RNG / CBG(Compressed Bio Gas)

14

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 !

15

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 Yield= 42 Kg / MT

Assuming 10% Surplus (22500 MT) is used for CBG Production

CBG Yield= 150 Kg / MT


Total Possible CBG Production 8170 MT / Yr

Annual revenue Approx: InR 450 Cr

Annual revenue Approx: InR 50 Cr (Incl. Biomanure)


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)


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

© Praj Industries Ltd Confidential www.praj.net 16

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

17


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

Thank you

[email protected]

www.praj.net

mailto:[email protected]

praj’s integrated smart biorefineryin-house r&d laboratory - certification by dsir*, goi 90+...

Documents