Sustainable Technologies

for
Transforming Distillery
To 2.0

Presented at Conference organized by

AIDA in Bangalore IOCL , Panipat 2G Refinery

Presenter : Sudarshan Kendre (GM-Bioenergy)

Date: 23rd June 2023
Venue: The Capitol, Bangalore

© Praj Industries Ltd www.praj.net

INDEX

01 Updates about PRAJ

02 SUSTAINABLE TECHNOLOGIES FOR 2.0

A ALTERNATIVE FEEDSTOCK

B YIELD IMPROVEMENT

C ENERGY REDUCTION

D BY-PRODUCT MAXIMIZATION

E PERFORMANCE MONITORING
 Praj Industries is a leading bio-processing technology company with
high synergies through the expertise in integrated offerings

Revenue 1000++references
3000 Crs INR worldwide

Presence across
25 years 100+ countries
Regular Dividend
payout

400 + overseas
39 glorious years references
2018

George Washington Carver

Award 2020
~10 % of 3 manufacturing
Global ethanol locations
production
capacity*

40%+ 1200+
business from employees
repeat customers

300+ 90+ research

patents scientists
William C. Holmberg
Award 2022 3
Technology leadership: 2G- Ultra Low CI Ethanol

Asia’s First Ultra Low CI

Cellulosic Ethanol Plant

• No. of farmers benefited: ~100,000

• Rural Job Creation: ~1,500
First ethanol Drop is Produced in the plant
• No. of cars displaced annually: ~63,000
• CO2 Emission reduction/year: ~320,000 MT 4
Technology leadership: Sustainable Aviation Fuel (SAF)

End to end offerings with Flexible Business Models

Manufacturing &
Technology Engineering Operations
Procurement
5
SUSTAINABLE
TECHNOLOGIES FOR 2.0

6
CONFIDENTIA

Praj’s continues improvements have boosted the commercial perfor-

mance of 1G biorefineries.

Output increased Input Decreased

+11% 4x
40x
> 91 20 4x
1.200 ZLD*
6
12

82

5
1.8

30
Scale - etOH Overall Process Water Steam Wastewater
Plant Capacity Efficiency Consumption Consumption generation
[kL / day] [%] [L / L of etOH] [kg / L of etOH] [L / L of etOH]

1984 today *Praj Zero Liquid Discharge

7
Bio-Ethanol Complex 2.0
Perfromance Monitoring
Performance • Remote-Bridge
Monitoring

By-Product Maximization
• High Digestible DDGS
By-Product Feedstock
• CO2
Maximization Feedstock • Biosyrup

Bioethanol
Complex 2.0

Energy Reduction Energy

• MVR Yield Yield
• Sugar Vapour Integration Reduction • Performance Enhancers

8
By-Product Feedstock
Maximization Feedstock • Biosyrup

Bioethanol
Complex 2.0

Energy
Yield
Reduction

9
WHAT IS BIOSYRUP®

BIOSYRUP®
Bio-Syrup is product of hydrolysis of Cane Syrup to convert sucrose into
glucose and fructose.

This inverted sugar syrup of concentration up to ~80-85 brix is stored and

used as feedstock for ethanol production.
90.00%
80.00%
70.00% Molasses- Molasses-
Syrup BIOSYRUP
60.00% C B
50.00% Brix %
55-60 80-85 80-85 80-85
40.00%
Sucrose
w/w
30.00% 44-45 Fructose
TRS %
Glucose
54-58 40-46 55-58 74-75
20.00% w/w
10.00%
FS % w/w 52-55 38-44 52-55 70-72
0.00%
Syrup @ 55 Brix Inverted @ 55 brix HTM @ 85 brix

Syrup BioSyrup
• High Sucrose Content
Sucrose Concentratio • High Sugar
• Possibility of
crystallization beyond 60 Inversion n Beyond 80% Concentration
10
brix • Zero Bacterial Growth
BIOSYRUP TECHNOLOGY REFERENCES

1. Jaywant Sugars, Satara : Demo Plant

Lot 1 Stored : 270 Tons from Dec. 2020-Dec. 2021
Lot 2 stored: 150 Tons from 26th Jan 2023 to till date

2. Swaraj Agro, Phaltan:

Capacity: 600 TPD Of Bio-syrup
Current Status: Construction completed. Will be operational
in next season.

3. Shiraguppi Sugar Works Ltd.

Capacity: 600 TPD Of Bio-syrup
Current Status: Commissioned. 1500 MT Bio-syrup prepared
and stored.

4. Rajarambapu SSK
Capacity: 600 TPD of Bio-syrup
Current Status: Order received. Engineering in progress.
11
ANALYSIS AT SHIRAGUPPPI SUGARS

12
BIOSYRUP® - APPLICABILITY

Off Season Production of Ethanol for Sugar Complex.

Sugar Mills without any Distillery can produce BIOSYRUP for Sale.

Feedstock during No-Cane Situation for the Distilleries operating

on Syrup.

13
By-Product
Maximization Feedstock
Bioethanol
Complex 2.0

Energy
Yield Yield
Reduction • Performance Enhancers

14
CombiFerm™ Fermentation Technology

1. Syrup/BioSyrup
1. 13-14 % v/v Ethanol
2. 35-40% spent wash
recycle
3. Ferm. Eff.-92%
2. B Heavy Molasses
1. 11-12 % v/v Ethanol
2. 25-30% Spent wash
recycle
3. Ferm. Eff.-91%+
3. C Heavy Molasses
1. 9.5-10 % v/v Ethanol
2. 10-15% Spent wash
recycle
3. Ferm. Eff.-90%
4. Grains/Broken Rice
1. 13.5-14% v/v Ethanol
2. 20-25 % thin slop
Recycle
3. Fer. Eff.- 92%+
15
 CombiFerm™-JET (Juice to Ethanol)- BCML, Balrampur, U.P. (300 KLPD)

CombiFerm
Sr. No. Parameter Unit Existing Operation Bioproduct
improvemnt

1 Yeast cell count in PF Million cells /ml 200-250 320-350

By-Product
2 Alcohol con. in Fermentor % v/v 12.5-13.0
Feedstock 14.5-15.0
Maximization

3 Spent wash Recycle % NIL 45

4 VA in fermenter Ppm 1200 350-450

5 Fermentation Efficiency % 90 92-93

Energy
6 VCOP INR/liter Yield 0.55 0.39-0.405
Reduction

16
CombiFerm™-C (C Molasses to Ethanol)- NSL Krishnaveni Sugars Ltd., Koppa
(60 KLPD)

CombiFerm
Sr. No. Parameter Unit Existing Operation Bioproduct
improvemnt

1 Yeast cell count in PF Million cells /ml 180-200 320-350

By-Product
2 Alcohol con.Maximization
in Fermentor % v/v
Feedstock
9.0-9.2 9.8-9.9

3 Thin Slop Recycle % NIL 10

4 VA in fermenter Ppm 2300-2400 2050-2100

5 Fermentation Efficiency % 88 89.5-90.0

Energy
Yield
6 VCOP ReductionINR/liter 0.51-0.55 0.39-0.405

17
By-Product
Maximization Feedstock

Energy
Yield
Reduction

18
CombiFerm™-Marquee Client List

By-Product
Maximization Feedstock

Energy
Yield
Reduction

19
 By-Product
Maximization Feedstock
Bioethanol
Complex 2.0

Energy Reduction Energy

• MVR Yield
• Sugar Vapour Integration Reduction

20
Continuous Endeavor for Improvement

1.6 Kg/lit Steam less

2.2 Kg/lit 2.2 Kg/lit

2.7 Kg/lit 2.8 Kg/lit

3.5 Kg/lit 3.0 Kg/lit

Grain To Ethanol Syrup To Ethanol

21
Reduce Fuel Consumption –MVR ON EVAPORATION

Fuel saving

90%

Reduce Water
Consumption

Standalone Evaporation
90%
How it works

1.
1 It is Vapor compression using Mechanically driven Equipment GHG emission reduction

60%
2.
2 It delivers superheated vapors ,which is de-superheated before feeding it
to the same source from where it is produced

3.
3 During steady operation practically very less (Nil) Steam and cooling
water is required *case to case basis
22
Energy Integration with Multi-stage Alcohol MVR

Energy Integration Process Integration Process Optimization

Steam reduction after alcohol MVR

2500

2000 2193
Steam () Kcal/lit

Reduction of
1500
Power increase
Cooling Water
1000
from 0.2 kw/lit to
950 Makeup by
0.22 kw/lit
500

0
1.8 lit/lit
Without MVR With MVR
Ethanol plant with/without MVR

950
Kcal/lit
2193
Kcal/lt
Evaporation Distillation Dehydration Evaporation Distillation Dehydration

23 23
Example of Alcohol MVR Sustainability- Grain

MVR Technology
Sr. Details Quantity in Quantity in Unit
No. Conventional Advance
technology technology
1. Ethanol Production 500 500 KLPD
2. Steam Requirement 90 65 TPH
(Including Boiler
requirement)
3. Water requirement 3000 1500 M3/day
4. Power 8000 12000 KWH
24
SUGAR CANE SYRUP TO ETHANOL- SUGAR VAPOUR INTEGRATION

Distillation

EVAPORATOR Other
Sugar Boiler Evaporation
EVAPORATOR BODY -2 evaporator
BODY -1 Bodies
Steam
Existing Sugar Plant

Turbine
Steam 1.5 Bar
MSDH

Power Steam 3.5 Kg/cm2 (g)

25
SUGAR VAPOUR INTEGRATION- Case Study 400 KLPD

Vapour
Savings
Sr. Conventional integration with
Parameter Savings Lacs/annum for
No Scheme Sugar
150 days
Evaporator
1. Steam 53 TPH 1.5 TPH ~ 51.0 TPH ~ 1500
2. Power 4MW 4MW
3. GHG Emission Saving in 5200 TPA for 150 Days operation
case of steam generation Equivalent to emission from ~ 1150 Cars

Challenges in Indian Condition:

1. Bagasse rate considered as 1600 Rs/ton

26
 PRAJ EXPERIENCE

 Ankalam Biethanol GmbH. : Currently Cosun Beet

 Country: Ankalam
 Capacity : 220 KLPD Ethanol
 Feedstock: Beet Juice/Syrup
 Energy: SugarBeet Evaporator vapour
 Sugar Crushing capacity: 14000 TCD
 Syrup diversion: 500 TPD
 Evaporator Design: 6 effect
 Vapours from : 5th Effect to Distillery
 Vapour temperature: 95-105 Deg Cent

 Riopiala Distilleria SAS. :

 Country: Columbia
 Capacity : 400 KLPD Ethanol
 Feedstock: Partially conc. Juice/Syrup/Molasses B
 Energy: Sugar Evaporator vapour
 Sugar Crushing capacity: 10000 TCD
 Syrup diversion: 30-40% of production
 Evaporator Design: 5 effect
 Vapours from : 2nd Effect to Distillery
 Vapour temperature: 116 Deg Cent 27
 By-Product Maximization
• High Digestible DDGS
By-Product
• CO2
Maximization Feedstock
Bioethanol
Complex 2.0

Energy
Yield
Reduction

28
DDGS MARKET AND MARKET REQUIREMNETS

Population – Millions Projected feed - Consistent quality.: Color, Protein Content Etc.
Species (2019 animal requirement by 2025
census)* MMT - Lower Mycotoxins in DDGS
Cattle 192 62 to 65 - No adulteration in trading
Poultry Broiler 3500 16 to 19
Poultry Layer 220 15 to 18 - Digestibility of DDGS
Aqua (Fish and 7 to 8
Shrimp)
*Source-NDDB-Livestock Population in India by Species
Feed Constituents
Composition Commodity Quantity
Parameter Grains DDGS Corn 15.0-15.5
Corn Rice Sorghum Wheat Corn Rice Sorghum Wheat Wheat 4.5-5.0
ME (Kcal/Kg) 3750 3750 3630 3630 3440 3260 3320 3346 Other Course Grains 1.5-1.8
Starch (%) 58-62 68-72 58 -61 55-58 3-4 3-4 3-4 3-4 Soybean Meal 5.3-5.6
Imp: Residual Starch is in form of oligosaccharides Cotton Seed & Meal 4.2-4.6
Protein (%) 8-9 6.5-8.0 8-9 11-13 28-30 44-52 26-28 26-34 Rapeseed Meal 2.8-3.0
Oils and Fats (%) 2-3 1.5-2 2-2.5 2-2.5 9-11 3.5-4.5 7-9 4-5 Peanut Meal 1.4-1.7
Fibre (%) 2-3 1-2 2.5-3.5 3-4 7-9 3-5 7-9 9-11 Other Oil Meals 0.7-0.8
Calcium (%) 0.02-0.03 0.05-0.06 0.05-0.06 0.05-0.06 0.1 0.15-0.17 0.15-0.17 0.15-0.17 Broken rice/ deoiled rice bran/1 2.5-3.0
Phosphorus (%) 0.3-0.4 0.3-0.4 0.3-0.4 0.4-0.5 0.8-0.9 0.9-1.1 0.9-1.1 1.1-1.3 Wheat Bran/2 4.5-5.0
DDGS 0.2-0.3
Total 43.0-45.0

Current Digestibility of DDGS is seen to be 45-50% 29

HIGH DIGESTIBILITY DDGS FOR ANIMAL FEED
Objective:
 To improve digestibility of Rice DDGS from 45-50% to >70%
Target Customers: Fish Meal Manufacturers, Poultry Meal Manufacturer

Rice Liquefication Saccharification Fermentation Distillation

Treatment of
Solid- Liquid separation Spent wash Ethanol
Thin Slop

Potential advantages:
Engineering
Solubles DWG • Additional revenue for DDGS
Changes
• Higher digestibility allows higher blending with soya meal and corn.
• Unique value proposition to existing 1G Ethanol plants
Concentration DWGS • Potential for applications in aqua.
• Can be applied to any grains for digestibility improvement

High Digestibility
DDGS DDGS

30
Praj’s CO2 (ECO2Pure) Capture Offerings

Food / Beverage grade CO2 plant

Industrial grade CO2 plant

CO2 Storage Tank, Mobile Tanker

CO2 Mobile Tanker, CO2 Lab

Cylinder Filling Station

Dry Ice machines

31
Praj’s CO2 Plant: References
1. Emperador 100 TPD CO2 Plant in Philippines
 Plant commissioned in July 2018, Scope of Supply: CO2 Plant with 50KL x 2 Nos
Storage tank, 150 KL x 3 Storage tank, 24 KL x 3 Nos CO2 Mobile Tanker, CO2 Lab
with On-Line Analyzer
 Client selling Beverage Grade CO2 To Pepsi/Coke.

2. Phaga Industries 20.5 TPD CO2 Plant in Egypt EDI - Site

 Plant commissioned in Oct 2022, Scope of Supply: CO2 Plant with 50KL x 2 Nos
Storage tank, 5 KL and 10 KL CO2 Mobile Tanker and Cylinder filling station

3. Manas Agro Industries 50 TPD CO2 Plant in India

 Plant under Execution, Scope of Supply: CO2 Plant with 50KL x 2 Storage tank

PHAGA - Site
4. Green Hills 25 TPD CO2 Plant in Nigeria
 Engineering under progress

5. UB Lanka Brewery based CO2 Plant

6. Triangle Ltd, Zimbabwe – 50 TPD CO2 Plant

 Engineering under progress MANAS - Site
32
Praj’s “ECO2PURE-FS”: Highlights

No. HIGHLIGHTS PRAJ OTHERS

1. Expertise in Ethanol Fermentation YES NO

2. Handling of variable CO2 generation from Can be operated at its Rated Capacity & When CO2 generation is low the Plant gets
biological reaction of Fermentation cycle Variable capacity without affecting the tripped as balloon bulges
Quality of product

3. Handling of non-Condensable Gases as O2, N2 Can feed raw CO2 gas to Recovery Plant after Can feed raw CO2 gas to Recovery Plant after
etc. during Fermentation reaction just started 3 hours of filling of Each Fermenters 6 hours of filling of Each Fermenters

4. Yield and Utility consumption Higher Yield and Lesser Utility Lower Yield and Higher Utility
consumption consumption
5. Activated Carbon quality to remove odour, European make, which has very long Indian/China maker which has life up
Molecular Sieve life up to 4-6 years to 1-2 years
6. CO2 and Ammonia Compressor Europe make compressor which Indian maker compressor.
require less maintenance

International Standard ASME Section

7. Design Standard -
VIII Div1 / B31.3

33
 Perfromance Monitoring
Performance • Remote-Bridge
Monitoring

By-Product
Maximization Feedstock
Bioethanol
Complex 2.0

Energy
Yield
Reduction

34
Customer Need & RemoteBridge™ : Vital for Digitalization

AS IS TO BE

Corporate MIS & BI Corporate MIS & BI

system system

Company ERP System Company ERP System

For Business For Business Continual Adoption
Corporate Transaction Transaction & Improvement

RemoteBridge™ for
Missing Piece Process Monitoring,
Maintenance &
Improvement

Plant Level Plant Level

SCADA/PLC/DCS SCADA/PLC/DCS
System System
Plant For Plant operation For Plant operation
35
RemoteBridge ™ : What it Does?

Inside Process Outside Process

Plant Plant
Critical Independent
Praj Provided
Critical Independent
Variables: Process Plant Variables:
IF not there, plant goes
down.
Performance. IF not there, plant goes
down.

Process parameter Process parameter

Online parameters are RemoteBridge™ Does Difficult to co-relate
in DCS/PLC Connect, Collect & Contextualize, Visualize, Analyze (initial) manually.

Lab and operator logs Remote Diagnosis by Experts : RemoteBridge™ Remote Builds over time, may
not available for timely visualization and Monitoring, Analytics, cause plant closure
holistic intervention
23-06-2023 36
RemoteBridge™ Platform: Agile, Digital, Unifying
Remote Monitoring provides bottom – line business benefits through more effective and efficient service

• Information Dashboard for Decision makers.

• Holistic overview

• Quick RCA & Solutions Remotely

• Information Dashboard, data sets for Analysis

Trends based • Ensure Reliable Operations per Design • Critical health Checks & alerts of
on Lab/Opr. • OPEX reduction - by Optimized operating plant.
Input available operating parameter • Maximize plant through put
37
RemoteBridge™

Connect Collect Visualize Analyze

DCS/PLC system Transfer data to Near Online Plant Initial Analysis Software
connect to RemoteBridge™ data & Section wise -Alert & Customization
RemoteBridge™ Server Parameters Notification Ongoing
Server.
DCS/PLC data Comparison of Detail Analysis
List connected Lab Data parameters -Data Analysis
instrument & Operator Data -Parameter
parameter Trends of comparisons
Contextualize parameters Prescribe
Build Data for
future analysis Play back process Plant
Connect (Next Phases) Process
Daily/Schedule std. Incharge
Add/Modify –Plant installation
reports
Enhance Control System -Plant Manager
-Process Experts Praj Plant Intervention
AI/ML based Intervention
-Executive Summary Expert
38
RemoteBridge™ Platform: Agile, Digital, Unifying

Maintenance Reckoner of
Planning
Plan Vs
team scheduler
Actual

For Lab and Shows path

Guide
Operator ahead

Plant Advisor & Prescriptive

manager MIS advisor, MIS

Process Quick
RCA tool
Expert analyzer

Performance
Management Omni Viewer
overview

39
RemoteBridge: Benefits

Improved 1. Experts no longer need to constantly be on the plant floor for analysis
2. The system can easily collect and send this information to the user
Efficiencies
dashboard

Operational 1. In case of any deviation in operational system, it is able to send alerts and
Alerts notifications via email and SMS. Users can quickly address the issue and
minimize downtime

Proactive 1. System notifies the deviation in the design parameters & can help for
maintenance proactive maintenance.

1. Collect machine data and produce graphs for a better visualization of how
Valuable production changes.
Insights 2. Provide trends and useful insights into whether or not machines are
operating efficiently.

Reliability Delivered 40
PRAJ THE RELIABLE TECHNOLOGY PARTNER
We are looking forward to talking to you...

Thank you!