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

2

Outline

1. About PRAJ

2. Bio-fuels – Future of the transport energy

3. Using Organic Waste for Biofuels Production

3

About PRAJ….

More than Three Decades of Building Trust

4

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

Facts at a glance

5

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

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

6

Bioenergy Strategic

Developments

- Liquid Biofuels- Gaseous Biofuels- Biochemicals

Bioenergy High PurityEngineering BusinessesR&D

7

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

❖ 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

9

Biofuels: Key to Sustainability

• 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)

15-12-2020 10

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

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

15-12-2020 11

25

20

15

5

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

• PRAJ has Technologies to use a variety of organic wastes for Biofuels

15-12-2020 12

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

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

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

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

PRAJ Biomass to Compressed Biogas & Bioethanol Technology

16

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

1

18

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

19

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

20

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

21

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

22

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

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)

Rice straw to

Bioethanol Demo Plant

Agri-residue to Bioethanol Process Block Diagram

25

Biomass Handling

Size Reduction

Biomass Cleaning

Pre-treatment Hydrolysis

FermentationDistillation & Dehydration

FiltrationEvaporation

Wet

Cake

Syrup

Ethan

ol

CO2

Boiler

Lignosulfonate

s

Marine Fuels

Bitumen

Bio-

Gas

© Praj Industries Ltd CONFIDENTIAL www.praj.net

26

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

27

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

15-12-2020

28

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

T h a n k Y o u

www.praj.net info@Praj.net