Praj Advanced Cellulosic Ethanol

Transcription

1 Praj Advanced Cellulosic Ethanol Project - PACE Ghansham Deshpande Praj Industries Limited, India 17 th June 2013

2 Outline About Praj Why Cellulosic Ethanol? : The Indian Context About PACE - Technology - Commercialization - Praj Bio- refinery 2

3 Praj Industries - Key Highlights 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 Largest resource base for Bio-ethanol with global footprint for multiple feedstock 3

4 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 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 4

5 Business Verticals -Alcohol/ Ethanol plants -Brewery plants Water and Wastewater Treatment Systems Technology, Engineering & Projects -Critical Process Equipment & Systems -Hygienic Process Equipment & Systems Solutions -Industrial bio based products and processes -Distillery bioconsumables -Livestock, health and nutrition -Bio-chemicals Integrated solutions provider through technology, engineering, projects and equipment manufacturing 5

6 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 6

7 PACE : Technology Highlights 7

8 PACE: Chronology Demo Plant - Operation Demo Plant Design and Erection Literature Review Bench Scale Facilities Bench Scale Experiments Pilot Plant Design and Engg Pilot Plant Erection Pilot Plant Trials

9 Water Steam PACE : Process Block Diagram Material Handling & Washing Pre-Treatment Solid-Liquid Separation C5+C6 Fermentation C6 Hydrolysis WWTP Boiler DDE Ethanol Load out Solids Liquid

10 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 10

11 PACE Technology : Hydrolysis 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 11

12 PACE Technology : Fermentation 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 12

13 PACE Technology : Ethanol Recovery 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 Proven and used widely in 1 st gen ethanol plants supplied by Praj 13

14 PACE Technology : Overall Summary 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 14

15 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 15

16 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 2 nd qtr Comprehensive Evaluation conducted to chose suitable Capacity and Location 16

17 PACE - Commercialization Time line Construction of demo plant Startup of demo plant Validation of Unit Operations Stabilization of plant on corn and cane residues Performance Optimization Booking of commercial order Leverage existing sales network to win more orders Demonstration on other feedstock Establish Bio- Refinery concept Rollout of subsequent contracts Marketing & Promotional Activities Successful demonstration will result in rapid commercial deployment 17

18 Praj Biorefinery Mechanical and Hydrothermal pretreatment Enzymatic hydrolysis Lignocellulosic biomass Fermentation C5 stream C5 and C6 sugars C6 stream Xylitol 2,3 - Butanediol Chemo-Catalysis Furfural Ethyl Levulinate Humins Lignin and residues Power and phenolics Ethanol Praj Biorefinery : Bolt on to PACE plant 18

19 The Emerging Value Chain Feed Stock Technology Engineering Plant & Machinary Customers Agri- Processing Companies Technology Partners BIOFUEL CHEMICAL BIOCHEMICAL FOOD FEED PHARMA Partnerships Across Value Chain 19

20 Thanks for your patience! 20