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PACRIM 2013 JS
Jayant Sawant. Ph. D General Manager - Technology
1
Welcome to PRAJ
PACRIM 2013 JS
Praj Industries Limited - Background
Three decades in the business of biofuels
Business Lines
• Bio Ethanol
• Breweries
• Water and Wastewater
• Inputs and Chemicals
• Energy Crops Services
• Customized Engineering and Manufacturing
Over 600 references in 60 countries
Over 275,000 sq ft of world class manufacturing facilities meeting global standards.
Largest Resource Base for Bio Ethanol Industry Diverse Global Feedstock Experience
PACRIM 2013 JS
Praj Matrix – The Innovation Center
US$ 20+ Mn investment
80,000 sq ft of Labs, PP, and
Offices
14 Well Equipped Labs
125 technologists and growing
30 PhDs, 80 Masters
Pilot Plants
2 TPD Cellulosic Ethanol pilot plant
Two 750 kg/d Chemical pilot plants
500 sq ft Open Raceway Pond
IP - 11 granted patents + 5 filed
Bench and Pilot scale facilities to enable validation of scientific assumptions and rapid commercialization
PACRIM 2013 JS
Centers of Excellence
Biologists Chemists Engineers
Molecular Biology
Microbiology
Process Technology Engineering
Analytical Sciences
Chemical Sciences
Various programs utilize resources from each of these COEs as needed
PACRIM 2013 JS
Praj Matrix Focus
5
Core Business 1st Gen Fuels Tech Ethanol, Biodiesel
2nd Gen Fuels Tech
Competency Feedstock Fermentation Down stream
Bioprocess Performance Enhancers
Industrial Performance
Enhancers
Bioethanol Process Performance
Sugar Process Performancele
Crop Performance Enhancers
Symbiotic Microbes
Growth Regulators
Life care Products
Livestock Health & Nutrition Products
Health Enhancers Probioticsthf
Vital Nutrition Products
Human care Products
Oleo - Nutraceuticals
Prebiotics
Industrial Process Technologies
Biochemicals Technologies
2,3 - BDO
Xylitol
Green Chemicals Technologies
Ethyl levulinate
/Levulinic Acid
Furfural
THF
PACRIM 2013 JS
Techno economics of 1,3 butadiene via
2,3 BDO
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PACRIM 2013 JS 7
Overview
Base case technology
Assumptions
Costing, Sensitivity Analysis
Butadiene from BDO
Learning
Way forward
PACRIM 2013 JS
Process Performance
8
Parameter Unit of Measurement Value
Theoretical yield of BDO Gram/Gram of Sugar 0.53
Sugar conversion in fermentation
Weight Percent 99
Fermentation Yield Weight Percent of
Theoretical 90
Fermentation Titer Gram/Liter 10
Down stream process efficiency
Weight Percent 95
Fermentation Downstream (SE) Solvent Removal
PACRIM 2013 JS
Feedstock and Utility Cost
9
* Molasses with 40% sucrose
Price Source
Molasses* US$ 100/MT 2011 -12 av. prices
Steam @ 3.5 bar US$ 21.8/MT Praj Std.
Electric Power 11.8 c/KWH Praj Std.
PACRIM 2013 JS
Utilities and consumables:
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Parameter Unit of Measurement Value
Steam for Sterilization Kilogram/Kilogram BDO 0.5
Steam for evaporation Kilogram/Kilogram BDO 2
Steam for solvent distillation Kilogram/Kilogram BDO 4
Electricity KWH/Kilogram BDO 1
Effluent water generated Kilogram/Kilogram BDO 6.34
Solvent make –up Kilogram/Kilogram BDO 0.01
Nutrient dose Gram/Liter broth 15
PACRIM 2013 JS Title | Date | Confidential | Presentation details 11
Process Cost Estimation
Parameter Key Consumption (kg/kg BDO)
Cost US$/Kilogram BDO
Feedstock 5.56 0.61
Steam 6.5 0.14
Power (KWH) 1 0.12
Solvent 0.01 0.01
Nutrients - 0.03
Cooling water & Air - 0.01
Other chemicals - 0.02
Total 0.93
PACRIM 2013 JS 12
Sensitivity
PACRIM 2013 JS 13
What could be best possible picture?
Case Possibility Cost US $/kg
Base -- 0.93
A Increase DSP efficiency from 95% – 98% 0.90
B Increase yield to from 90% to95% 0.86
C Reduce Nutrient Dosage from 15g/L to 5g/L 0.83
D Increase titer from 100 to160 Gram/L 0.8
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00
Base case
Case A
Case B
Case C
Case D
Cost, $/kg BDO
BDO Sensitivity (US $)
PACRIM 2013 JS
Butadiene from BDO
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PACRIM 2013 JS 15
Butadiene from BDO
Two step conversion of BDO to BDE via chemical synthesis
considered for study
Best in class yields ~ 85-90%
Significant energy integration and recycle of waste streams
considered
2,3 BDO Diacetate 1,3 Butadiene
PACRIM 2013 JS
Sensitivity : BDE from BDO
16
Base-case
PACRIM 2013 JS
BDE Price Trend
17
PACRIM 2013 JS
Margins: Peak BDE Price vs. Sugar Cost
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Sources:
(1) ICIS
(2) Internal Sugar Journal, 2013, V 115, No. 137
PACRIM 2013 JS
BDE: Sugars vs. Oil
Title | Date | Confidential | Presentation details 19
2012
PACRIM 2013 JS
Learnings
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PACRIM 2013 JS 21
Governing factors for success
Type of feedstock
Availability – Scale of operation – Feedstock management – Cost
Titers – Microbiology /Molecular Biology
Downstream – Energy – Good process engineering
Petroleum Prices
SHALE GAS ? C O N S O R T E D E F F O R T S AC R O S S D I V E R S E D O M A I N S
PACRIM 2013 JS
Technology Transitions
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Technology Evaluation
Renewable resource
Sustainable resource
Low on Utilities
Zero effluent
PACRIM 2013 JS
Emergence of a New Value Chain
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Feedstock
• Mapping
• Sourcing
• Composition
Process
• Microbe/Enzyme
• Catalyst
Engineering
• Process Intergration
• Detail Engineering
• Equipment Design
End User
• Application Specialist
• B to C player
Praj a global leader in the domain of biofuels for three decades is poised to form crucial linkages in this value chain
PACRIM 2013 JS
Let’s partner for a sustainable future
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PACRIM 2013 JS
Our Belief
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We believe in providing environment friendly, sustainable solutions
that can make the world a better place
Thank you
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