Over 3 Decades in Sustainable Solutions AIDA -Feb 2019 ETHANOL FROM JUICE & B-HEAVY MOLASSES Mahesh Kulkarni AVP- Business Development Praj Industries Ltd www.praj.net
Focus 1. About Praj Industries 2. Understanding Feedstock for Bioethanol 3. Business Case 10000 TCD Sugar factory 4. PRAJ Technology Advantages-B Heavy Molasses 5. Success Stories Praj Industries Ltd www.praj.net 2
Core Competencies Technology and Process Knowhow Quick Scale-Up and Commercialization Driving solutions through Improvement & Innovation Integration and Projects Engineering and Manufacturing Focus on Bio-Process Engineering and Solutions in Energy, Environment and Agri-processing
Innovation Focus Advanced Bioprocesses (Yeast and Process Performance Enhancers) Advanced Separation and Concentration Processes (DDBE) Yield Maximization Reduction in Carbon footprint (GHG reduction) Agri-feed stock and Residues Multi-product,High quality Process Optimization and Integration (POI) Reduction in water footprint Co-product Maximization Praj Industries Ltd www.praj.net 4
Sugar Mill -Feedstock Options Cane RVF Press Mud 1 st mill Primary Juice Muddy Juice Filtrate Juice Bagasse Mixed Juice Clarification Evaporation Syrup Crystallization 2 nd / 3 rd /4 th /5 th mill Secondary Juice Condensate Bagasse 2G Sugars 1 st /2 nd / 3 rd /4 th Centrifuge Sugar B- Molasses C- Molasses Praj Industries Ltd www.praj.net 5
B Heavy Molasses
Composition of B-Heavy Vs. Molasses-C Sr. No Parameters Unit Partially Con Juice Molasses-C B-Heavy 1 Brix 0 B 35 88 85 2 ph - 5.5 5.0 5.2 3 Fermentable Sugar %w/w 28 42 55 4 F/N Ratio 4 0.9 1.8 4 Total Microbial Count CFU/gm 100-500 5.6*10^3 8.8*10^2 Praj Industries Ltd www.praj.net
Typical Sugar Balance Imbibition Water: 3000MTPD Sugar Cane Milling Fiber Separation Mixed Juice: 10000 MTPD Clarified Mixed Juice Crystallization Bagasse: 3000 MTPD Press Mud: 400MTPD Evaporation Condensate Basis: Cane crushing capacity: 10000 TCD Sucrose :13.5% Crystalized sugar Recovery:11.0% on cane Plant capacity is up to 90 KLPD Plat Operation is up to 150 days per year. Centrifugation Crystalized Sugar :1100 MTPD *C-Molasses:400 MTPD (90 KLPD AA)
Typical B-Molasses Sugar Balance Processed Cane Imbibition Water: 3000MTPD Fiber Separation Mixed Juice: 10000MTPD Bagasse: 3000MTPD Basis: Cane crushing capacity: 10000 TCD Sucrose :13.5% Crystalized sugar Recovery:9.59% on cane Clarified Mixed Juice Crystallization Centrifugation Press Mud: 400 MTPD Evaporation Condensate Crystalized Sugar: 959 MTPD Opportunity to increase existing ethanol capacity by 30% using some minor modification. Plat Operation is up to 240 days per year. Plant Capacity is up to 188 KLPD AA. B-Molasses: 600MTPD (188 KLPD AA)
Typical Sugar Factory balance with Juice to Ethanol Processed Cane Imbibition Water: 3000MTPD Fiber Separation Mixed Juice: 10000MTPD Bagasse: 3000MTPD Basis: Cane crushing capacity: 10000 TCD Sucrose :13.5% Crystalized sugar Recovery:9.71% on cane Clarified Mixed Juice Crystallization Press Mud: 400 MTPD Evaporation Condensate Plant Capacity is up to 90 KLPD. 90KLPD plant on juice will be operated for 150 days crushing operation and 132 day on Molasses with same capacity. Centrifugation Crystalized Sugar: 971 MTPD Juice to ethanol: 90 KLPD AA
90 KLPD Ethanol Plant Capacity Sr. No. Parameters Unit Juice to Ethanol Sugar Factory (C-Molasses) B-Molasses 1 Ethanol Titer %V/V 12% 8% 12% 2 Steam required Kg/Lit of AA 5.8 6.0 (22.5 TPH) 5.8 (22 TPD) 3 Power KWh/KL 2.0 2.0 2.5 Remark No additional steam is required (including boiler and turbine) 4 Coal Requirement 5 Spent Wash Recycle 6 Total Water consumption T/Day 70 70 70 No additional coal is required % 0 0 20 60% reduction in effluent generation per lit of ethanol Kg/L 0.2 to 0.5 8 to 9 5 to 5.5 Excluding boiler water Praj Industries Ltd www.praj.net
PRAJ Technology Advantage Reduced water consumption in distillery (~60%) Improved GHG reduction compared with Molasses-C Up to 2-3% over all plant power reduction in sugar factory. Multi-feed option in distillery depending on feedstock availability Multi-product option depending on market scenario Solution to cyclic sugar cane production cycle. Additional 30% extra production with marginal or no Capex in existing plant Praj Industries Ltd www.praj.net
Praj s References Praj Industries Ltd www.praj.net 13
1. Incauca S.A., Colombia Cane Crushing Capacity (TCD) : 14000 No. of days of Operation per year: 300 Distillery Capacity : 300 KLPD Fuel Ethanol Vinasse recycle : 40~45% FEED STOCK Feed Ratio FS in Feed Stock Sugarcane molasses B Clear Juice Syrup Mixed Clarified Juice 65 % 5% 30 % 54-56 % 59% 13.5 % Praj Industries Ltd www.praj.net 14
2. Ingenio Providencia S.A., Colombia Cane Crushing Capacity (TCD) : 9000 No. of days of Operation per year: 300 Distillery Capacity : 250 KLPD Ethanol Vinasse recycle: 45~50% FEED STOCK Feed Ratio FS in Feed Stock Sugarcane molasses B Clear Juice Syrup Mixed Clarified Juice 80% 20% 0% 50-52% 60% 13.5% Praj Industries Ltd www.praj.net 15
3. Ingenio Mayaguez S.A., Colombia Cane Crushing Capacity (TCD) : 9000 No. of days of Operation per year : 300 Distillery Capacity : 250 KLPD Fuel Ethanol Vinasse recycle : 40-45% FEED STOCK Feed Ratio FS in Feed Stock Sugarcane molasses B Mixed Clarified Juice 70% 30 % 52-54 % 14-15 % Praj Industries Ltd www.praj.net 16
4. Ingenio Risaralda S.A., Colombia Cane Crushing Capacity (TCD) : 3000 TCD No. of days of Operation per year: 300 Distillery Capacity : 100 KLPD Fuel Ethanol Vinasse recycle : 35-40% FEED STOCK Feed Ratio FS in Feed Stock Sugarcane molasses B + Clarified filtrate juice 85 % 15 % 50-52 % 9.5-10.8% Praj Industries Ltd www.praj.net 17
5. Ingenio Manuelita S.A., Colombia Cane Crushing Capacity (TCD) : 10,000 No. of days of Operation per year : 300 Distillery Capacity : 250 KLPD Fuel Ethanol Vinasse recycle : 55-60% FEED STOCK Feed Ratio FS in Feed Stock Sugarcane molasses B 100 % 62-64 % Praj Industries Ltd www.praj.net 18
6. Ingenio Riopaila Castilla S.A., Colombia Cane Crushing Capacity (TCD) : 24,000 No. of days of Operation per year: 300 Distillery Capacity : 400 KLPD Ethanol Vinasse recycle : No FEED STOCK Feed Ratio FS in Feed Stock Sugarcane molasses B Cane Juice 10% 90% 59-62 % 13.5-14.5 % Praj Industries Ltd www.praj.net 19
Success Stories Vaidyanath SSK, Parali (30 KLPD Distillery) Ingenio InCauca S.A., Columbia (300 KLPD) Ingenio Povidencia S.A., Columbia (250 KLPD) Ingenio Mayaguez S.A., Columbia (250 KLPD) Ingenio Manuelita S.A., Columbia (250 KLPD) Ingenio Risaralda S.A., Columbia (100 KLPD) Ingenio Reopila S.A., Columbia (400 KLPD) Maple Ethanol, Peru (400 KLPD) Ingenio Magdalena S.A., Guatemala (300 KLPD) Nicaragua Sugar Estate Limited (300 KLPD) British Sugar, UK (206 KLPD, sugar beet Molasses-B) Anklam, Germany (150 KLPD, sugar beet moalsses-b) Konya Seeker, Turkey (280 KLPD, sugarbeet Molasses-B) Praj Industries Ltd www.praj.net 20
Thank you! Contact : maheshkulkarni@praj.net Praj Industries Ltd www.praj.net