Leverage 1st & 2nd Gen
Technologies for 20%
EBP in India
Atul Mulay
Executive Vice President
Content
• Overview of Praj Industries
• Status of Ethanol - India
• Alternate Feedstock for fuel ethanol production – India
• Praj’s Bolt-On Plant model for 2nd Gen Biofuels.
© Praj Industries Ltd
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Overview of Praj Industries
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Praj Industries Limited
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Established in 1984, Praj Industries
Ltd. currently has marquee investors
like Vinod Khosla, Tata Capital and
Marubeni.
The Company is listed on the BSE &
NSE
Praj is a well known brand in ethanol
circles and has immense experience in
wide geographies
• One of the largest knowledge
resource bases
• Over 600 references in more
than 60 countries
The Company has successfully
developed and demonstrable scale-up
capabilities in some innovative first
generation bio-ethanol process
technologies
The Company has a large existing
client base and has experience with
multiple feed-stock in various
geographies
© Praj Industries Ltd
Praj, with experience in process engineering, has the
capability to provide technology, basic and detailed
engineering, key equipment and turnkey plants in ethanol,
brewery and waste water segments
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Praj – Bioethanol Credentials Summary
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Status of Ethanol in India
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India : Rising Import bills of crude oil
Crude oil Import Bill in USD Billion
350
300
300
250
200
150
150
78
100
50
5.5
16
1990
2000
0
2010
2014
2020 (est)
• Domestic demand for crude oil and import bill for the same ,moved up by
13 times in last 20 years
• By 2020, India`s dependency on oil imports is projected to go beyond 90%
from 75% at current level
Source : Business standards
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Confidential
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Ethanol demand and Supply with effect of EBP (million liters)
7000
6580
6000
5220
5000
4450
Fuel ethanol demand
4000
3100
3050
3000
2490 2550
2550
Overall ethanol demand
2550
2550
2100
Total ethanol produced
2000
1030
1000
0
5 % EBP
10% EBP
15% EBP
20% EBP
• For 5% EBP and present consumption of the ethanol , demand and supply is meeting
the targets
• For 10% and above EBP there is a shortage of ethanol production and supply ( ~ 4000
million liters) to meet the targets (considered existing level of ethanol production)
Considered only , Production of ethanol from the Molasses produced
Damaged grain based ethanol production not considered which is ~ 30% of molasses based ethanol production
Source : VSI report
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Confidential Concept Note
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Indian Ethanol market scenario
• Salient feature of ethanol production in India
• > 85% of ethanol production facilities in
country co-located to sugar complex
• Molasses based ethanol complex
• Small production capacity ~ 45 – 60 KLPD
• Operations ~ 150 days/annum
• 11 MMT* molasses production in 2013-14
enabled production of 2.6 bln liters alcohol
• Molasses availability possess constraint on
ethanol production in India
• Second generation ethanol alone has
potential to achieve 20% and higher ethanol
blends with potential to produce more than 3
billion liters
EBP & Ethanol demand
Ethanol blending
programme
Ethanol demand
(Bln liters)
E5
1.03
E10
2.06
E20
4.10
Source: LMC Ethanol market report 2014
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Cont….
328 Ethanol complex in India operates for 150-180 days / annum (avg.)
Installed capacity of fuel ethanol remains unutilized due to limited molasses/ feedstock
availability
Government committed toward implementation of E5/E10 and E20 by 2017
Limited molasses availability, increase in demand by industrial/potable sectors possess key
challenge in implementing E5/E10 and E20
Oil ministry moves proposal in cabinet to produce bioethanol from non-edible plants i.e.
second generation ethanol
Second generation ethanol alone has potential to achieve E20 & more
Praj developed efficient 2G ligno-cellulose to bio-ethanol technology & tested variety of
feedstock from different geographies at its 1 MTPD (dry biomass) pilot plant over last 5 years
Praj Innovative “Bolt-On” module enables production of 2G ethanol utilizing
existing co-generation, utilities & ethanol unit
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Biomass potential in India
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Biomass scenario in India - 2013-2014
Produced biomass
(MMT/Annum)
Used biomass
(MMT/Annum)
Available Biomass
(MMT/Annum)
Oil seed crops
59.89
11.98
47.91
Sugarcane crop (Sugarcane Bagasse)
80.15
37.69
42.46
36.85
5.25
31.6
29.74
5.95
23.79
156.44
31.29
125.15
363.07
92.16
270.91
Crops
Sugarcane crop (Sugarcane trash)
Starch crops (Potatoes & Sweet
potatoes)
Others (Cereals, Pulses, Fibre and
Horticultural crops)
Total
Biomass
(Oil Crops,
Sugarcane Crop,
Starch Crops,
Other crops)
Total Biomass
(MMT)/Annum
Used Biomass
(MMT/Annum)
Excess Biomass
(MMT/Annum)
363
92
271
271 MMT of excess biomass is available in India which can produce 65 bln
liters/ annum Ethanol
© Praj Industries Ltd
*Source: TERI & SAHYOG 2013 report
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Changing Energy Landscape : India
1
9
33
Nuclear %
8
Solar%
Wind%
20
Hydro%
Bioenergy%
56
Coal%
Oil%
1
8
5
Nuclear %
4
10
2013
Solar%
Wind%
Hydro%
18
54
Bioenergy%
Coal%
7 2 5
Oil%
Nuclear %
5
Solar%
13
2020
Hydro%
 1% increase of biomass availability will generate 0.7 bln liter of
ethanol
 Nuclear, Solar and Wind can make biomass surplus to produce
fuel ethanol.
 Surplus biomass can meet the demand of ethanol for EBP 10%
and EBP20% mandate.
Source: India Energy security scenario,2047,planning commission
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Confidential Concept Note
Wind%
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51
Bioenergy%
Coal%
Oil%
2050
Praj’s Bolt -on model for 2nd
Gen ethanol production and
It`s advantages
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Confidential
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PRAJ’S– 2G “Bolt-On” module
2G “Bolt-On”
Module
Existing ethanol
complex
Pre-treatment
Fermentation
Enzymatic
Hydrolysis
Distillation
Hydrolyzed slurry
Capacity of pre-treatment &
enzymatic hydrolysis sections
will be designed to suit
existing distillery capacity
© Praj Industries Ltd
Dehydration
Utilities
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• Avg. ethanol complex
operations ~ 150 days /
annum
• Additional 150-180 days
operation using 2G bolt-on
model
• Results in year round
operations of ethanol
complex
• Fewer unit operations
requires lower capex
• Substantial increase in
ethanol production
• Higher asset utilization of
existing distillery
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Bolt-on second generation ethanol plant
First generation molasses based plant  extended operation
Fermentation
Molasses Storage
Distillation
Dehydration
COGEN
S/LSeparation
Material
Handling
Pre-treatment
Enzymatic
Hydrolysis
Add on
Fermentation
Ethanol Storage
Second generation cellulosic ethanol ‘Bolt-on’ model
COGEN
Cooling tower
Ethanol Storage
Common Utilities
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Advance technology- Multi-Feedstock,
Multi Product Bio- Refinery
Multi-Feedstock
Molasses
1st
Gen
Multi-Product
CO2
Juice
Grain
Lignocellulosic
Next
Gen
Pharma
Rectified
grade
Spirit
Ethanol
BIO-REFINERY
Bio-Chemicals
Bio Fertilizers
DDGS
MSW
Fuel
Industrial
grade
Alcohol
Ethanol
Bio-Jet Fuel
Biogas
Lignin cake
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Key Technology Highlights
Proprietary EndEnd Process
Design
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Multi-feed capability
Pre-treatment
• Efficient degradation of biomass to sugars
• Better biological processing ability
Efficient enzymatic hydrolysis
Thermally integrated process to achieve low net energy usage
Water recycled; achieve zero process liquid discharge
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Technology proven on multiple platforms
High yields with different enzyme strains
Enzyme
Flexibility
CoFermentation
Intellectual
Property
© Praj Industries Ltd
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Yeast strain for efficient utilization of C5 (pentose ) and C6 (hexose) sugars
• Higher yield
• Lower reaction time
• Higher tolerance to solids
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Process patents filed and already granted in India, SA, Kenya; pending approval in other
countries
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Praj’s 2G Ethanol Technology – Bolt On Approach
Bolt-On
Approach
Feedstock
Cost
VIABILITY
Lower
Capex
Technology
Edge
Lower
Opex
Adopting Praj`s 2G ethanol technology and Bolt- on approach will fulfill
Nations biofuel demand
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Confidential
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Summary
2nd Gen BioEthanol will
ensure ethanol
availability
Proprietary 2nd
generation bioethanol
technology
Superior
Performance
Proven Expertise
in developing &
deploying bioethanol
technologies
© Praj Industries Ltd
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More than 325 ethanol complex operates for less than 6 months/ year in India alone
Higher ethanol blend in India cannot be achieved due to lack of molasses/feedstock
GOI planning to implement E20 by 2017 creating opportunity of ~4 bln liters for 2G
ethanol
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Patented in-house technology developed over 6 years with an expenditure of over US$
15 million
Technology proven on agricultural & forest residue
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Processing cost of less than a dollar per gallon for corn cobs driven by:
• Lower enzyme dose requirement
• Higher yields and
• Low energy and water footprint
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Praj has demonstrated its expertise in scaling up 1st generation bio-ethanol technology
for projects ranging from 5 kilolitres per day to 1.2 million litres per day
Expertise in making smaller ethanol complex viable
Confidential concept note
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Thank you