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 Integration and and Process Projects Knowhow Driving solutions through Improvement Quick & Innovation Scale-Up Engineering and and Commerciali- Manufacturing zation Focus on Bio-Process Engineering and Solutions in Energy, Environment and Agri-processing Innovation Focus Advanced Bio- Advanced Yield Maximization processes Separation and (Yeast and Concentration Process Processes Reduction in Carbon Performance (DDBE) footprint (GHG Enhancers) reduction) Agri-feed stock and Multi-product ,High Residues quality Reduction in water footprint Process Optimization and Integration Co-product (POI) Maximization © Praj Industries Ltd 4 www.praj.net Sugar Mill -Feedstock Options Bagasse Bagasse Cane 1st mill 2nd / 3rd /4th /5th mill 2G Sugars Primary Juice Mixed Secondary Juice Juice Muddy RVF Juice Clarification Filtrate Juice Press Mud Evaporation Condensate Syrup Crystallization 1st/2nd / 3rd /4th Centrifuge Sugar B- Molasses C- Molasses © Praj Industries Ltd 5 www.praj.net B Heavy Molasses Composition of B-Heavy Vs. Molasses-C Sr. Parameters Unit Partially Molasses-C B-Heavy No Con Juice 1 Brix 0B 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 Sugar Cane Milling Basis: Imbibition Water: • Cane crushing capacity: 3000MTPD Fiber Bagasse: Separation 3000 MTPD 10000 TCD • Sucrose :13.5% Mixed Juice: 10000 MTPD • Crystalized sugar Recovery:11.0% on cane Clarified Mixed Press Mud: Juice 400MTPD • Plant capacity is up to 90 KLPD • Plat Operation is up to 150 days Evaporation per year. Crystallization Condensate Centrifugation Crystalized Sugar :1100 MTPD *C-Molasses:400 MTPD (90 KLPD AA) Typical B-Molasses Sugar Balance Processed Cane Basis: • Cane crushing capacity: Imbibition Water: 3000MTPD Fiber Bagasse: 10000 TCD Separation 3000MTPD • Sucrose :13.5% • Crystalized sugar Mixed Juice: Recovery:9.59% on cane 10000MTPD Clarified Mixed Press Mud: 400 MTPD Juice • Opportunity to increase existing ethanol capacity by 30% using some minor Crystallization Evaporation Condensate modification. • Plat Operation is up to 240 days per year. Crystalized Sugar: • Plant Capacity is up to 188 Centrifugation 959 MTPD KLPD AA. B-Molasses: 600MTPD (188 KLPD AA) Typical Sugar Factory balance with Juice to Ethanol Processed Cane Basis: Imbibition Water: • Cane crushing capacity: 3000MTPD Fiber Bagasse: 10000 TCD Separation 3000MTPD • Sucrose :13.5% • Crystalized sugar Mixed Juice: 10000MTPD Recovery:9.71% on cane Clarified Mixed Press Mud: Juice 400 MTPD • Plant Capacity is up to 90 KLPD. • 90KLPD plant on juice will be Crystallization Evaporation operated for 150 days crushing Condensate operation and 132 day on Molasses with same capacity. Crystalized Sugar: Centrifugation 971 MTPD Juice to ethanol: 90 KLPD AA 90 KLPD Ethanol Plant Capacity Sr. Parameters Unit Juice to Sugar Factory B-Molasses Remark No Ethanol (C-Molasses) . 1 Ethanol Titer %V/V 12% 8% 12% 2 Steam Kg/Lit of 5.8 6.0 5.8 No additional steam is required AA (22.5 TPH) (22 TPD) required (including boiler and turbine) 3 Power KWh/KL 2.0 2.0 2.5 4 Coal T/Day 70 70 70 No additional coal is Requirement required 5 Spent Wash % 0 0 20 60% reduction in effluent Recycle generation per lit of ethanol 6 Total Water Kg/L 0.2 to 0.5 8 to 9 5 to 5.5 Excluding boiler water consumption © 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 65 % 54-56 % Clear Juice Syrup 5% 59% Mixed Clarified Juice 30 % 13.5 % © Praj Industries Ltd 14 www.praj.net 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 80% 50-52% Clear Juice Syrup 20% 60% Mixed Clarified Juice 0% 13.5% © Praj Industries Ltd 15 www.praj.net 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 70% 52-54 % Mixed Clarified Juice 30 % 14-15 % © Praj Industries Ltd 16 www.praj.net 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 + 85 % 50-52 % Clarified filtrate juice 15 % 9.5-10.8% © Praj Industries Ltd 17 www.praj.net 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 18 www.praj.net 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 10% 59-62 % Cane Juice 90% 13.5-14.5 % © Praj Industries Ltd 19 www.praj.net 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© Praj Industries Seeker, Ltd Turkey (280 KLPD,www.praj.net sugarbeet Molasses-B) 20 Thank you! 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