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Sugar Cane Molasses : Viable Feed Stock for Levulinic Acid

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Sugar Cane Molasses : Viable Feed Stock for Levulinic Acid Sugar Cane Molasses : Viable Feed Stock for Levulinic acid © Praj Industries Ltd www.praj.net Agenda The Bio Economy Levulinic acid : Current Status Levulinic acid : Praj Process Conclusions Praj and Praj Matrix © Praj Industries Ltd www.praj.net 2 Bio Economy Model Renewable Feedstock Economy Profitability and Sustainability Bio refinery Conversion Fuels, chemicals and polymers Technologies Development of Bio refinery : integral part of new Bio economy 3 Praj Proprietary and Confidential Information Levulinic acid : Current Status © Praj Industries Ltd www.praj.net 4 Chemicals : Top 12 sugar based building blocks What is common to all these molecules?? Why Levulinic acid ? Platform Chemical Levulinic acid - Market share by application (current) • Current traded volumes : 3000-3500 MTA • Major supplier : China • Price : $4-7 per kg High price deterrent for market expansion Potential Market Opportunity $ 40 Billion Plasticizer $ 11 Billion Solvent Market Volumes Market $ 11 Billion Sp. polymers $ 1/Kg $ 2//Kg Price Replacement potential of 50 million MTA worth US$20 Bn if produced at <$1/kg Levulinic acid - Reaction Pathways First synthesis reported in 1840 by Prof. Mulder Levulinic acid - Challenges • Feed stock : • Sugars : Glucose, Fructose, Sucrose • Food vs chemical • Biomass (LC) • Complex • Higher sugar costs • Conversion technology : • Strong mineral acid catalyst • High temperatures • Low yield • Formation of humins/char • Reactor fouling • Separation : Difficult to separate LA from acid, humins and formic acid • Equipment Fouling Challenge to commercialization Identification of right feedstock Feedstock Advantages Challenges Starch Single sugar – Glucose Low yields Clean Competing with food Easy access Available in quantities HFCS Good yields Cost Clean feedstock Competing with food Available in quantities Poor selectivity on Glucose part Biomass No competition with food Higher cost of fractionation Abundant availability and obtaining sugars Huge CAPEX Molasses Low cost High Inorganic impurities Easy access Mixed sugars – different Available in quantities kinetics Non competing with food © Praj Industries Ltd www.praj.net 11 Current Technologies Technology Feedstock Status Segetis Current feedstock – Pilot facility of 80TPA operating in Minnesota HFCS since Oct 2013. Commercial scale target 22 MPPA (funding from IRRRB and Dept of Agri.) GF Biochemicals, Carbohydrate Currently operating a continuous process Caserta, Italy feedstock pilot with capacity 2000 TPA LA (??) Plan to set up a plant with capacity 10,000TPA LA by 2015, eventually 40,000TPA LA by 2018. Biofine Variety feedsock @ Pilot on variety of feedstocks for several years pilot; @ 1MTPD dry biomass Manufacturing Commercial plant expected to be in service with Waste by Q42015 based on waste cardboard. Cardboards. Capacity – 125 dry feed TPD. Estimated CAPEX - $5.5 PAG; OPEX - $2.44 per Gallon © Praj Industries Ltd www.praj.net 12 Levulinic acid : Praj Process © Praj Industries Ltd www.praj.net 13 Feed stock : Sugar Cane Molasses Bagasse Washed Bagasse Cane First mill 2nd / 3rd /4th /5th mill PJ Mixed Juice SJ Muddy Juice RVF Clarification Filtrate Juice Press Mud Evaporation Condensate Crystallization 1st/2nd / 3rd /4th Centrifuge B- Molasses C- Molasses Sugar Cane Molasses : Composition Organic Solids Inorganic Solids 60 to 70 % 10 to 20 % Sugars Non Sugars Organic acids Cations Anions 35 to 55 % 15 to 25 % •Acetic •Calcium •Sulfates •Sucrose •Carbohydrates •Potassium •Glucose •Butyric •Carbonates •Polymers •Sodium •Fructose •Propionic •Phosphates •Starch •Magnesium Other •Valeric •Chlorides Sugars •Silica •Gums Coloring 3 to 5 % •Iron •Nitrates •Proteins •Pentose Matter •Manganese •Oxides •Xylose •Wax •Caramel •Arabinose products PRAJ Proposed process based on molasses Value Addition Conventional Ethanol Proposed (Theoretical) distillery Molasses (1MT) Molasses (1MT) Fructose Glucose Fermentation Ethanol Levulinic acid (147 L) Ethanol (270 L)* (180 Kg) Value Proposition (based on Bench scale results) Conventional Ethanol LA+Ethanol Distillery Molasses (1MT) Molasses (1MT) fructose Glucose Fermentation Levulinic acid Ethanol Ethanol (112 Kg) (125 L) (240 L) Better Value addition ( three times) than Ethanol alone How this happens? Levulinic acid Ethanol Salient features of new process • Use of low cost molasses as feedstock • Fructose to Levulinic acid yield ~ 70% • Recovery of glucose >95% (clean stream with less inorganic salts) • Faster fermentation , higher alcohol concentration, yeast and spent wash recycle – possible in molasses fermentation • Clean process • Technology ready for piloting • Bolt on to existing molasses based ethanol plants for better value addition • Novel route patent application filed Title | Date | Confidential | Presentation details 19 Praj and Praj Matrix © Praj Industries Ltd www.praj.net 20 Who we are Technology backed References across solutions five continents A knowledge based A global Indian company company End-to-end A Customer solution centric Expertiseprovider and experience in company process and integration Customized solutions engineering A socially responsible corporate citizen Strong focus on sustainable development © Praj Industries Ltd www.praj.net 21 What we do • Innovate, Integrate and Deliver •© 600 Praj Industries refrences Ltd in 60 countires across www.praj.net globe 22 Over 600 refernces © Praj Industries Ltd www.praj.net 23 Praj Matrix 80,000 sq ft of Labs, Pilot Plants, and Offices 94 technologists 20 PhDs, 65 Masters 4 Technology COEs . Biology, Chemistry, Engineering 16 Labs with clean room facility ISO-9001-2008 Analytical Labs Pilot Plants . 1 tpd Cellulosic Ethanol pilot plant . Multipurpose biochemicals pilot plant Bench and Pilot scale facilities enable validation of scientific assumptions and rapid commercialization © Praj Industries Ltd www.praj.net 24 Praj Matrix : Business and Collaboration Models © Praj Industries Ltd www.praj.net 25 Business Model Large Oils, & Sugars, Who Mid-sized Biomass Praj Matrix End Users Own Manufacturing Feedstock Owner Buys Technology + EPC Upstream Alliance: Offer Technology, EPC, Scope Operating Support Fully Integrated Alliance: Offer Technology, EPC, Operating Support Alliance also gets Supply & Offtake Commitment 26 Praj-Matrix : Collaboration Models Joint • Sharing Resource • Sharing IP Development • Sharing Knowledge Process scale • Process POC @ Bench Scale up and • Partner invests for scale up and optimization optimization • Process Development • Process scale up CRSS • Partner spends and owns IP • Praj works on specifics Partnerships for sustainable future Praj Proprietary and Confidential Information We believe in providing environment friendly, sustainable solutions that can make the world a better place Thank you [email protected] www.praj.net 28 .
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