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Making Agriculture Remunerative AgriCorp 2013 Indo-Australian Joint Project Biofuels from Biomass Arvind Lali DBT-ICT Centre for Energy Biosciences Institute of Chemical Technology (formerly UDCT) Matunga, Mumbai, INDIA

Integrated Technologies for Economically Sustainable Bio based Energy Grand Challenge Program Australia-India Strategic Research Fund Consortium members - INDIA 1. DBT ICT Centre for Energy Biosciences, ICT, Mumbai; 2. Centre for Biofuels and Biotechnology, NIIST (CSIR), Thiruvananthapuram; 3. DBT ICGEB Centre for Advanced Bioenergy Research, ICGEB, New Delhi; 4. The Energy and Resources Institute (TERI), New Delhi; 5. DBT IOC Centre for Advanced Research on Bioenergy, R&D Centre, Indian Oil Corporation, Faridabad Consortium members - AUSTRALIA 1. CTCB, Queensland University of Technology, Brisbane; 2. Centre for Energy, University of Western Australia, Perth; 3. Department of Chemical Engineering, Centre for Process System Computations, Curtin University, Perth; 4. CSIRO Energy Transformed Flagship, North Ryde, New South Wales; 5. New South Wales Department of Primary Industries

Approach The Grand Challenge Potential and Impact The Consortium Strengths and Complementarities How will it work Components and Required Expertise

Biofuels from Lignocellulosic Biomass The Grand Challenge Surplus* biomass available/year India >200 MMT >30 MMT Blending potential >20% >35% Major residues available Socio-economic Impact Environmental Impact Rice straw; Wheat Straw; Cotton/ Castor/Lentil Stalks *Non-Food, Non-Fodder and Non-Nutrient Australia Cane Bagasse; Wheat Straw; Silviculture waste Benefits to agri-economy; Energy security Reducing carbon emissions

The Challenge : Current Biobased Biofuel Status More than 100 pilot plants (1 ton/day to 100 ton/day) Large number of Laboratories in pursuit of the best technology Bioconversions continuously evolving - Many pre-treatment technologies developed - New improved and less costly enzymes - Better fermenting strains Several Chemical BTL technologies being developed - Py-oil to Liquid Fuel - Bio-Syngas to FT-hydrocarbon Fuels - Bio-Syngas to alcohols/dme SCALABLE TECHNOLOGY EVOLVING No Commercial Scale Plant (Four commercial plants likely in 2014)

THE PROCESS OUTLINE Lignocellulosic Biomass STEP 1 Treatment/Fractionation STEP 2 Saccharification/Separations STEP 3 Chemical/Biochemical Conversions STEP 4 Separation/Purification BioFuels

THE PROCESS OUTLINE Lignocellulosic Biomass STEP 1 Treatment/Fractionation Problem Areas STEP 2 Saccharification/Separations -What biomass and where - Availability and Collection Logistics - Heterogeneous structure & composition - Variability with variety, geography and seasons STEP 3 STEP 4 Chemical/Biochemical Conversions - Which technology Separation/Purification BioFuels

CELLULOSIC BIOMASS SCWG Gasification Fast Pyrolysis/ SCWG Hydrogen Fermentation/ Chemical Catalysis Alcohols DME Syn-Gas FT Synthesis Hydrocarbons Cracking Gasoline, Diesel Bio-Oil Cracking Gasoline, Diesel Hydrocarbons Sugars & Lignin Bio-Alcohols Bio-Hydrogen Platform Chemicals DME

Syn-Gas CELLULOSIC BIOMASS - Multiproduct & Versatile Fermentation/ - Biorefinery Concept can be Bio-Oil Chemical Catalysis FT Synthesis Implemented Cracking - Economically Hydrocarbons more viable Alcohols - Lesser Capital Cost Gasoline, Diesel Cracking Gasification Advantageous Route : - Decentralized Plants DME Gasoline, Diesel Fast Pyrolysis/ SCWG SCWG Hydrocarbons Hydrogen Sugars & Lignin Bio-Alcohols Bio-Hydrogen Platform Chemicals DME

BIOMASS DBT-ICT Technology for BIOMASS FRACTIONATION - Separation of biomass components - Low solid loading (<15% w/w) - Rapid reaction rates (!!) Size-reduction Cellulose Saccharification Glucose Pre-Treatment Lignin Hemicellulose Saccharification Xylose ALCOHOL

Lignocellulosic Biomass Alkaline Treatment Lignin + Other Components (Silica) Cellulose + Hemicellulose Fractionation Cellulose Hemicellulose Saccharification Glucose Xylose Generates Multiple Opportunities for several Biorefineries - Energy/Fuel Biorefinery - Chemical Biorefinery - Biomaterial Biorefinery - Sugar Biorefinery - Combinations

BioBased Technology Platforms Impact on Agro-Economy Indian Agricultural Industry of the Future Opportunities, Technologies and Commercialization DBT-ICT Centre for Energy Biosciences Institute of Chemical Technology (UDCT) Mumbai, INDIA 400019

DBT-ICT Centre for Energy Biosciences Matunga, Mumbai

Opportunities

Identification and Quantification Opportunities Search/Research & Development

Opportunity Transformation of Indian Agriculture Industry - Better products - Better productivity - New Products - Decrease waste - Add value to waste

Opportunity Transformation of Indian Agriculture Industry - Better products - Better productivity - New Products Future Opportunity through Agricultural & Food Bio/Technology - Decrease waste - Add value to waste Current Opportunity through Chemical/Biotechnology

Transformation of Indian Agriculture Industry - Better products - Better productivity - New Products - Decrease waste (combination of logistics & technology) - Add value to waste (technologies required) Farm waste Process Waste Distribution waste

Farm Waste : Surplus Biomass Non-food & Non-fodder Biomass - Wheat Straw - Rice Straw - Sugar Cane trash - Cotton/Castor Stalk - Many others Annual availability > 400 million ton (total grain production = 400 million ton) Crop residues Field based residues Production Million tons 1994 2010 (projected) Cotton stalk 19.39 30.79 Rice straw 214.35 284.99 Wheat straw 103.48 159 Maize Stalk 18.98 29.07 Soybeans 12.87 34.87 Jute stalk 4.58 1.21 Sugarcane tops 68.12 117.97 Ground nut straw 19 23.16 Processing Based residue Rice Husk 32.57 43.31 Rice Bran 10.13 13.46 Maize cob 2.59 3.97 Maize Husk 1.90 2.91 Coconut shell 0.94 1.50 Coconut husks 3.27 5.22 Ground Nut Husk 3.94 4.80 Sugarcane bagasse 65 114.04 Coffee husk 0.36 0.28

Distribution waste :Vegetable & Fruit Waste Annual Vegetable + Fruit Production = 150 million ton/year Handling + Processing Waste = 50 million ton (~30%!!) Process Waste : Oil Industry Waste Oil Seed Production = 35 million tons/year Process Waste Oil cake production = 7 million ton/year (@20% of seed) Other waste components (examples): Groundnut/Coconut etc shells Empty Fruit Bunch (palm)

Known/Practiced Waste-to-wealth Technologies: - Animal feed - Burning for primary energy (co-generation) - Conversion to Biogas - Composting to bio-fertilizer - Conversion to fermentation products e.g. molasses to alcohol etc.

A Biorefinery is AGRICULTURAL BIOREFINERY - a zero-waste producing collection of processes that - utilizes renewable biological or bio-based sources - to produce several products, whereby - each component of the renewable biological or bio-based sources, is converted or utilized in a manner to add value, and hence sustainability to the processing plant. Potential Biorefineries Sugar Mills Vegetable Oil Mills Grain processing Mills Milk Dairy BioFuel/BioEnergy plants

Grains Oils Seeds Sugar Cane Vegetables & Fruits Macroalgae Agriculture & Agricultural Industry Microalgae Sugars Oil Protein Minors

Sugars Oil Protein Minors Bioactives Food/Feed Products Nutraceuticals Biofuels Biochemicals Biomaterials

Concept and Development of BioBased BioRefinery Technologies

Case 1 : Present day Sugar Refinery Sugar Cane (100 ton, avg 15% w/w sugar) Crushing Bagasse (20 ton dry) Sugar Juice Burning Co-generation Molasses Traditional Processing Power 10 MWh Ethanol (2.5 KL) < 80% Recovery Sugar (10 ton)

Case 1 : New Sugar BioRefinery Sugar Cane (100 ton, avg 15% w/w sugar) Crushing Bagasse (20 ton dry) Sugar Juice Burning Co-generation Novel Membrane + Chromatographic Separation Technology Power 10 MWh Nil Molasses 95% Recovery High Quality Sugar (14 ton)

Case 1 : New Sugar BioRefinery Sugar Cane (100 ton, avg 15% w/w sugar) Cane Trash (10 ton dry) Crushing Bagasse (20 ton dry) Sugar Juice DBT-ICT Technology for Lignocellulosic Fractionation Novel Membrane + Chromatographic Separation Technology Lignin (4 ton) Glucose (15 ton) Xylose (7 ton) Nil Molasses 95% Recovery High Quality Sugar (14 ton)

Case 1a : New Sugar BioRefinery Sugar Cane (100 ton, avg 15% w/w sugar) Cane Trash (10 ton dry) Crushing Bagasse (20 ton dry) Sugar Juice DBT-ICT Technology for Lignocellulosic Fractionation Novel Membrane + Chromatographic Separation Technology Lignin (4 ton) Power 10MWh Glucose (15 ton) High Fructose Syrup (15 ton) Xylose (7 ton) Ethanol (3KL) Nil Molasses 95% Recovery High Quality Sugar (14 ton)

Case 1a : New Sugar BioRefinery Sugar Cane (100 ton, avg 15% w/w sugar) Cane Trash (10 ton dry) Crushing Bagasse (20 ton dry) Implications for the Country - Sugar Production triples Novel Biomass Deconstruction & Enzymatic Saccharification Technology Lignin (4 ton) Power 10MWh Glucose (15 ton) High Fructose Syrup (15 ton) Xylose (7 ton) Ethanol (3KL) Nil Molasses Sugar Juice Novel Membrane + Chromatographic Separation Technology - Ethanol and power production unimpaired 95% Recovery High Quality Sugar (14 ton)

Case 1b : New Sugar BioRefinery Sugar Cane (100 ton, avg 15% w/w sugar) Cane Trash (10 ton dry) Crushing Bagasse (20 ton dry) Sugar Juice DBT-ICT Technology for Lignocellulosic Fractionation Novel Membrane + Chromatographic Separation Technology Lignin (4 ton) Power 10MWh Glucose (15 ton) Ethanol (8KL) Xylose (7 ton) Ethanol (3KL) Nil Molasses 95% Recovery High Quality Sugar (14 ton)

Case 1b : New Sugar BioRefinery Sugar Cane (100 ton, avg 15% w/w sugar) Cane Trash (10 ton dry) Crushing Bagasse (20 ton dry) Implications for the Country - Sugar Production up 40% Novel Biomass Deconstruction & Enzymatic Saccharification Technology Lignin (4 ton) Power 10MWh Glucose (15 ton) Ethanol (8KL) Xylose (7 ton) Ethanol (3KL) Nil Molasses Sugar Juice Novel Membrane + Chromatographic Separation Technology - Ethanol production increases > 4 fold - Power production unimpaired 95% Recovery High Quality Sugar (14 ton)

Case 2 : BioFuel+Energy BioRefinery Lignocellulosic Biomass 100 ton Combustion/Gasification Alkaline Treatment Lignin + Other Components (Silica) Power Cellulose + Hemicellulose Liquid Burner Fuel (20 ton) Process Steam Saccharification Fermentation Ethanol, Butanol (25 ton) (for blending in petro fuel)

Case 2 : BioFuel+Energy BioRefinery Lignocellulosic Biomass Combustion/Gasification Cellulose + Hemicellulose Lignin + Other Components (Silica) Alkaline Treatment Implications - 100 ton biomass @ Rs. 2000/ton resulting Power in (20x Rs. 10000 + 25x Rs. 30000) Process value Steam addition Liquid Burner Fuel - 150 million ton biomass processing can provide all the liquid fuel India needs Saccharification Fermentation Ethanol, Butanol (for blending in petro fuel)

Case 3 : BioFuel+Chemicals BioRefinery Lignocellulosic Biomass Liquid Burner Fuel Alkaline Treatment Lignin + Other Components (Silica) Cellulose + Hemicellulose Saccharification Fractionation Cellulose Hemicellulose Fermentation Saccharification Dehydration Glucose Xylose Chemical/Bio Transformations Ethanol, Butanol Chemicals, Solvents, Biomaterials, Food Products

Case 3 : BioFuel+Chemicals BioRefinery Lignocellulosic Biomass Liquid Burner Fuel Alkaline Treatment Cellulose + Hemicellulose Saccharification Lignin + Other Components (Silica) Fractionation Implications for the Country Cellulose Hemicellulose - Lower carbon dioxide emissions/foot-print Glucose Xylose Fermentation - Chemical Saccharification production freed from petroleum Dehydration - Self sufficiency for major products Chemical/Bio Transformations Ethanol, Butanol Chemicals, Solvents, Biomaterials, Food Products

Case 4 : Vegetable Oil BioRefinery Current scenario Oil Seed extraction Extract De-Oiled Cake (DOC) Cattle Feed Derived products Oil Deodorised diltillate Edible oils

Case 4 : Vegetable Oil BioRefinery Multiproduct Biorefinery Oil Seed extraction Derived products Extract Oil Lecithin Transformed oils Minor components (DOD) tocols carotenoids sterols Edible oils De-Oiled Cake (DOC) Proteins Concentrates Isolates Hydrolysates Anti-Nutritional factors Polysaccharides/Starch (dietary fibre)

Case 4 : Vegetable Oil BioRefinery Technologies involved Oil Seed extraction Extract De-Oiled Cake (DOC) Selective Separation Technologies Selective Enzymatic Transformation Technologies Derived products Oil Lecithin Transformed oils Minor components (DOD) Edible oils tocols carotenoids sterols Proteins Selective Separation Technologies Concentrates Isolates Hydrolysates Anti-Nutritional factors Polysaccharides/Starch

Case 4 : Vegetable Oil BioRefinery Multiproduct Biorefinery Oil Seed extraction Derived products Extract tocols carotenoids sterols De-Oiled Cake (DOC) Implications for the Country Lecithin - 10-15% more oil recovered Minor components (DOD) - Less than half CAPEX - Higher sustainability of oil industry - Better Oil and indigenous diet supplements Transformed oils Edible oils Proteins Concentrates Isolates Hydrolysates Anti-Nutritional factors Polysaccharides/Starch (dietary fibre)

Potential Impact - Energy, Fuel, Materials, Chemicals coming from agri-residues - Doubling agricultural GDP - Agriculture landscape becomes Agriculture Industry Landscape - Farmer becomes industry partner - Transformation of rural countryside

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