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Bio-Fuels from Organic waste An Intelligent waste management
Nitin Shete - Vice President PRAJ Industries Limited
Gasification India 2020December 15-16, 2020
LEED CERTIFIED PLATINUM GREEN BUILDING
© Praj Industries Ltd www.praj.net © Praj Industries Ltd www.praj.net
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Outline
1. About PRAJ
2. Bio-fuels – Future of the transport energy
3. Using Organic Waste for Biofuels Production
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About PRAJ….
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More than Three Decades of Building Trust
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1983-90 1991-98 1999-07 2008-14 2015-18…
▪ Inception: 1983
▪ Established In-house R&D Center
▪ Venture funding by ICICI
▪ IPO in 1994
▪ Forayed into synergistic fields like brewery
▪ Entered South East Asian market
▪ Alliance with Filtrox for Filtration systems
▪ Entered South American, European and African markets
▪ Set up PRAJ Matrix – R&DCentre
▪ Forayed into process equipment, water & waste water treatment solutions
▪ Scaled up the 2nd gen bioethanol technology
▪ Entered high purity water segment through acquisition of Neela Systems
▪Strategic alliance with Gevo for Isobutanol
▪India’s First Integrated 2G Bio-refinery (1 MLPA)
▪Partnered with OMCs1
to Set up 2G Bio-Ethanol Plants
▪Entry in to RNG Business Integrated Demo Plant of Compressed Bio-Gas (CBG) set-up
*URS media with the Audit firm, PriceWaterhouseCoopers (PWC) reviewing and validating the process, 1Oil Marketing Company
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Facts at a glance
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FACTS AT A GLANCE
90+ ResearchScientists
22 YearsStrong Track record
of Dividend
Revenue$136 Mn. FY 19
1200+Employees
4 Manufacturing Facilities
Presence Across75 Countries
Holds 25+ Patents
40%+Business - Repeat
Customers FY19
350 + Overseas References
750+References
2018
35 Glorious Years
8 % ofGlobal ethanol
production
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1G & 2G Bio-Ethanol
Technology, plants & Services
Renewable Gas (RNG),
Technology, Plants & services
High purity applications for pharma,
biotech, cosmetics industry
Brewery Plants
Critical process
equipment & systems
Effluent Recycling &
ZLD
Business offerings
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Bioenergy Strategic
Developments
- Liquid Biofuels- Gaseous Biofuels- Biochemicals
Bioenergy High PurityEngineering BusinessesR&D
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Global Leadership
End-To-End Service Provider
100% Share In Colombia
~61 % Share In India (2017-18)
750+ Global References
>350 installations
overseas
Installations in 75
countries5
continents
9000+ Samples of 1G feedstock fingerprinted
GLOBAL ETHANOL & RENEWABLE GAS PLANTS & SOLUTIONS LEADER
50%+ Share in Emerging Markets
Riopaila, Colombia
Vicentin, Argentina
British Sugars, UKVivergo Fuels, UK
Audit and FEED
Technology & Engineering
Process Equipment Manufacturing
Installation and Integration
Commissioning & Handover
Life cycle Management
Project Management
3 decades of leadership in Bio-Industrial space
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❖ In-House R&D facility - Certification by DSIR*, GOI
❖ $ 30+ Mn Captive investment
▪ Unique R&D facility with Bench & Pilot scale facilities for validation of scientific assumptions & rapid commercialization
❖ 90+ technologists – Dedicated to Biofuels & Biochemicals Technology
❖ Ongoing research on performance improvement & cost efficiency
Matrix - The R&D Centre
8*Department of Scientific and Industrial Research
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Biofuels: Key to Sustainability
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• Fossil Fuels (Petrol & Diesel) -
Major contributors to Carbon and GHG emissions – NOx, Sulfur, CO2, CO and Particulate matter – Causing
health challenges
• World – Going away from Fossil energy – by alternate renewable sources
• Bioethanol / BioCNG / Biobutanol Sustainable Aviation fuel(SAF)
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Biofuels: Sustainable Transportation Energy
• Advantages of Biofuels
• Clean Burning
• Substantially reduce Emissions (GHG) – 50 to 90 % compared to fossil fuels
• Renewable & Sustainable: Produced from Plant origin Carbohydrates – Carbon
Neutral or negative
• Give Valuable co-products: like Organic Manures for farm -land remediation
• Atmanirbhar -Promote Circular Bioeconomy: Produced & used locally from
Organic wastes- Support wealth circulation in Farming and local ecosystems.
• Create Socio-economic Impact:
• Rural Job Creation, Improved farm economics, Reduced cost of Static and
transport energy
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Biofuels: Sustainable
Transportation Energy
• Central Government of India plans to implement:
• Bioethanol blending as 20% of the Petrol consumption – By 2030
• Replace 15 MMT (out of 40 MMT) CNG by BioCNG or CBG by 2024
• Saving almost 10% of the Forex Oil bill –Pumping back the wealth into farmer’s and rural economy
• How will India generate these Biofuels:
• The New technologies enable use of Organic waste to produce biofuels
• Agriculture Residues: Rice straw, Wheat Straw, Corn Stover / Cobs etc
• Agro-industrial waste: Sugarmill pressmud / Distillery spent wash
• MSW and Food waste from Cities
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Feedstock potential 60 MMT CBG in India
Farm waste
Agri-residues
MSW /Sewage
Pressmud /Spent wash
150 MMT surplus residues can produce 20 Million MT CBG / Yr
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• PRAJ has Technologies to use a variety of organic wastes for Biofuels
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Organic wastes that are used for Renewable Biofuels
Ligno-cellulosic Agri-ResiduesRice StrawWheat StrawCorn Cobs / StoverSoybean Straw
Industrial Organic wasteSugar mill Pressmud Distillery Spent wash
Farm wasteCow dungChicken litter
City wasteFood / food processing wasteMunicipal sludge waste
Biobutanol
Compressed Biogas
Bioethanol
Compressed Biogas
Compressed Biogas
Compressed Biogas
Transport fuel
Aviation fuel
Transport fuel Power and Heat
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Biomass: Agri-residues --- Abundant Organic Source of Bioenergy
Rice Straw Wheat Straw
Corn Stover Corn Cobs
Soybean Straw Pigeon Pea Straw
Seasonal dry biomass on harvest
Surplus Green biomass
Napier Grass Green corn biomass
Biomass to Biogas - Most energy efficient way
Residues:
▪ Abundant Lignocellulosic Feedstock (India has about 350 Million MT)
▪ Available round the year
▪ Surplus after fodder & other needs
▪ Have disposal problems
Comprise:
• Cellulosic & Hemicellulosic Sugars
• Lignin, Ash & Extractives
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Biomass – Agri-residue composition & Gas potential
Residue Moisture Inorganics Lignin Cellulose Hemicellulose Volatile Solids (minus lignin)
Possible Biogas M3 / MT (on as is basis)
Rice Straw 8 - 10 13 - 18 16 - 18 34 - 36 22 - 25 66 - 68 380 – 400
Wheat Straw 9 – 12 5 - 7 15 -17 36 - 39 25 - 27 67 - 69 410 - 440
Corn Cobs 8 - 10 2 – 3 17 – 19 41 - 43 31 - 33 69 - 70 415 – 450
Corn Stover 8 – 10 10 -12 18 - 20 36 - 38 26 – 28 66 - 68 390 - 410
Cane Bagasse 48 - 52 2 - 3 10 - 12 22 - 24 12 - 14 32 - 34 140 - 150
Napier Grass 68 - 72 3 - 4 25 - 27 34 - 36 17 - 19 71 -73 135 to 155
▪ All figure in % by weight of dry matter except moisture & Volatile solids▪ Biogas yield depends on convertible Volatile solids content as well as their nature / composition ▪ The composition of Napier grass can vary depending on variety and the days of harvesting. ▪ Early harvesting brings in more moisture and less solids ▪ It is necessary to analyze composition of Napier grass considered for Biogas & test Biomethane Potential for yield prediction
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Making Biogas from Biomass: Some Technical Challenges
▪ Lignocellulose hydrolysis
▪ Sugar to Methane conversion
▪ Digestate & Manure treatment
▪ Water & Power Management
▪ Biomass handling in Reactors
▪ Capex / Opex & Gas yields How to dissolve straw in water ?
• Expensive Lignocellulose Hydrolysis
• Enzymes / chemicals & Steam
• Low Organics yields
• Creates toxins for Microbes
• Biomass difficult to handle in Bio-digesters
• Methane bacteria don’t work on slurry
• Plants become expensive
• Handling needs high power & water
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PRAJ Biomass to Compressed Biogas & Bioethanol Technology
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Waste to CBG Plants - PRAJ’s Innovative Microbial Technology
Challenge I – Lignocellulosic Hydrolysis Solution = PRAJ’s Unique ‘BM Solve’ Microbial Pretreatment
• Rice / Wheat Straw lignocellulose is
crystalline and very hard to degrade
• Requires Harsh Chemical / Heat &
Enzyme treatment
Straw Before Treatment BM-Solve Microbial Pretreatment
Well hydrolyzed straw after pretreatment
• PRAJ’s Unique
• BM Solve Microbial pretreatment
efficiently de-constructs
Lignocellulosic bonds at low cost
• Ready for high yield Biomethanation
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Challenge 2 – Fiber Biomethanation Solution is PRAJ’s Unique ‘RC Biomethanation Process’
PRAJ’s Innovative Microbial Technology – High Yield Biomethanation2
• Biomethanation of hydrolyzed Fiber needs right mix of cellulolytic and Methanogenic Bacteria
• The correct mixture ensures efficient Biomethane production
• PRAJ researched on Rumen (Cow’s stomach) Micro-flora
• The Unique Rumen Culture (RC Consortium) contains mix of Fiber degrading & Methanogenic species
• RC gives efficient conversion of Cellulosic feed to high Biomethane yields
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Challenge III – Value adding Manure as co-product Solution is PRAJ’s Unique ‘Bio-green’ NOCA certified manure
• Praj Plants Manures are certified as Organic manures by National Organic Certification Agency
• Formulated Manures fetch high sales value and demand
PRAJ’s Innovative Microbial Technology – Solid & Liquid Organic Manures 3
• Ammonium Sulfate recovery System
• Phosphrous Recovery System
• Add- Back balancing for the Manure
Optional Technology for Recovering Manure with Value
• Complete TVS degradation ensures Bio-manure with high minerals
• Stable characteristics High Performance Bio-manure
• National Organic Certification Agency approval for Bio-manure NOCA Certification for all feedstocks
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Biomethanation by PRAJ-DVO Plug Flow Digesters
High Temp BM Solve Pretreatment Chamber
Homogenization Chamber
Biomethanation Chamber
1. Scientific Multi-Phase Design – Separate Pretreatment and Biomethanation
2. Complete anaerobic operation- Biogas recycle gives rigorous cork screw mixing
3. Continuous recycle of Stable RC Culture - high cell mass – Robust fast reaction
4. High degradation of Organic solids (> 75%)
5. Consistent high Gas yields
6. No moving parts – No settling – Low maintenance – Year-round operation
7. Insulated underground construction for accurate temperature control – Internal heating coils with controls
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PRAJ CBG Plant design USPs: Post Methanation Digestate Management
1. Scientific Digestate studies for composition, nutrients and particle size distribution
2. Appropriate Feedstock Based Centrifugal systems configuration
3. Specialized Nutrient recovery systems in collaboration with DVO
4. Maximum recycle of liquid to the process – Reducing fresh water needs
5. Processing of Solid and Liquids for Field applications
6. High Co-product revenues due to high plant nutrition quality
7. Formulation services
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PRAJ CBG Plant design USPs: Biogas Upgradation Section
1. Based on plant capacity & local conditions, PRAJ offers flexible gas cleaning and compression systems
2. A Choice of Catalytic or Chemical H2S scrubbing
3. A Choice of Membrane or Chilled water based CO2 removal
4. Meeting quality norms better than IS 16087
a. Methane > 96%b. CO2 < 4 %c. H2S < 20 PPMd. Water < 16 PPM
5. High Methane recovery >97%
6. Options for complete CO2 recovery – GHG reduction
7. PESO approved compression & cascade filling (250 Bar)
Water Based CO2 Removal
Membrane Based CO2 Removal
CATALYTIC Sulfur Removal
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Typical Biomass to CBG plant configuration - 100 MT/day
Rice Straw: 100 MT / Day
Milling / Optional Bioextrusion 4 to 6 MT / hr
Continuous Microbial PretreatmentHRT 2 days
Duel Plug Flow Reactor system HRT: 25 - 28 Days
Slurry preparation: 55 MT / Hr
Biogas 1625 CuM / Hr
Gas Cleaning – H2S removal < 5 PPM
Co2 Removal < 3% CBG 15500 Kg / Day
Digestate Solid Liquid Separation Solids Drying
High Quality Organic manure
35 to 40 MT / Day
Liquid Recycle
Surplus Liquid Ferti-irrigation to Farms (125 – 150 CuM / Day)
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Rice straw to
Bioethanol Demo Plant
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Agri-residue to Bioethanol Process Block Diagram
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Biomass Handling
Size Reduction
Biomass Cleaning
Pre-treatment Hydrolysis
FermentationDistillation & Dehydration
FiltrationEvaporation
Wet
Cake
Syrup
Ethan
ol
CO2
Boiler
Lignosulfonate
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Marine Fuels
Bitumen
Bio-
Gas
© Praj Industries Ltd CONFIDENTIAL www.praj.net
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Contents…
Around 600+ samples of feedstock from all parts
of India fingerprinted
Parameter
(% w/w)
Corn
Cob
Sugarca
ne
Bagasse
Wheat
Straw
Corn
Stover +
Corn
Cob
Rice
Straw
Cotton
Stalk
Cellulose 27-35 35-42 28-35 28-33 28-32 23-33
Xylan 25-33 17-25 16-22 19-25 16-18 10-12
Lignin 13-18 20-25 13-18 15-20 10-14 23-14
Arabinan 2-4 1.1-2.1 2-3 2-4 2-3 0.5-1
Ash 2.0-3.0 2.0-3.0 5-10 4.0-8.0 12-16 7-11
Protein 1.5-2.0 1.5-2.0 4-6 1.5-2.0 4-6 5-10
Extractives 1.6-5.0 1.6-3.0 10-15 8-18 14-18 12-22
Acetates 2.0-3.0 2.0-3.0 1-1.5 2.0-3.0 1-1.5 1-1.5
Consequences of FeedstockComposition variation
Lignin rich Spent cake
Enzymatic efficiency
Changed process norms
Change
d yield
305-
315270-
280 265-
275 235-
245 150-
160
280-
290
Best In Class Yields…
© Praj Industries Ltd CONFIDENTIAL www.praj.net
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enfinity
Pre- treatmentFeedstock Preparation
Feedstock
Handling
End-to-End Integrated Process
2G plant processing biomass to ethanol & bio-chemicals
Enzymatic
Hydrolysis
CO-
FermentationProduct
Separation
Lignin Boiler and
WWT
© Praj Industries Ltd CONFIDENTIAL www.praj.net
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Circular Bioeconomy through waste to Biofuels
The Key Impact of Biofuels
from Organic residues / wastes
20% Ethanol Blend & 15 MMT transport CBG
Save Forex of Approx 80000 Crore
(10% of crude oil import bill)
Biofuels reduce GHG & Carbon emissions
by > 80% compared to Petrol & diesel
This wealth recycles in to
Agro-industrial Farming Economy
• Rural Skills & Job creation
• Improving Farmer income
• Reducing Pollution
• Atmanirbhar Bharat
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T h a n k Y o u
www.praj.net [email protected]