2G - ETHANOL DEMONSTRATION PLANT : A CASE IN INNOVATION ENGINEERING

Session-IV: How do we Maximize Ethanol Availability? 11th May, 2016 India Habitat Centre, New Delhi

Symposium on Biofuels and Bioenergy:

Enablers for Reducing Oil Import Dependence

S.R. Soni Vice President (Distillery/Alcohol Technology) India Glycols Ltd.,INDIA

India Glycols Ltd. is a listed Public Limited Company, promoted by the Bhartia Group, mainly in the business of Glycols, Ethylene Oxide Derivatives, Alcohol, Industrial Gases, Guar Gum , Nutraceuticals and Alcoholic Beverages.

Global Leaders in manufacturing Bio MEG, Bio EO & Derivatives from renewable agro

feedstock with low carbon footprint since 1988.

Integrated manufacturing approach for value addition.

Exports to more than 35 countries across the Globe besides being catering to the domestic market.

- HIGH SOLID LOADING IN THE SLURRY.

- ISSUE WITH BIOMASS COMPONENTS SEPARATION THROUGH PRETREATMENT.

- TOXICS PRODUCED DURING PRETREATMENT & HYDROLYSIS.

- HIGH ENZYMATIC DOSES.

- BIOMASS LOGISTICS AT HIGH CAPACITY.

- HIGH CAPEX/OPEX DUE TO MORE THAN 4 DAYS CONVERSION TIME..

2G Ethanol –Major Roadblocks

Technological Interventions Required

Right combination of deconstruction step; saccharification step and fermentation step

Right combination of deconstruction step; saccharification step and fermentation step

Biological Chemical Physical

Technological Interventions Required

Right combination of deconstruction step; saccharification step and fermentation step

Biological Chemical Physical

Biological Chemical

Technological Interventions Required

TECHNOLOGICAL INTERVENTIONS REQUIRED

Right combination of deconstruction step; saccharification step and fermentation step

Choices: Separate/Combined Batch/Continuous C6 + C5

Biological Chemical Physical

Biological Chemical

TECHNOLOGICAL INTERVENTIONS REQUIRED

Right combination of deconstruction step; saccharification step and fermentation step

Choices: Separate/Combined Batch/Continuous C6 + C5

Biological Chemical Physical

Biological Chemical

All Biotech interventions

2G ETHANOL DEMONSTRATION PLANT

India Glycols Limited, Kashipur

Supported by

Department of Biotechnology Ministry of Science & Technology

Government of India (under BIPP scheme)

Based on

DBT-ICT Lignocellulose Ethanol Technology

Developed by DBT-ICT Centre for Energy Biosciences

Institute of Chemical Technology Mumbai(INDIA)

India’s First Multi-feedstock Continuous Flow

2G-Ethanol Demonstration Plant

Lab scale process (1 kg/day)

2009- 10 ; MOU

signed with DBT-ICT.

Pilot Plant (1 ton/day)

2010-2013; India Glycols Ltd.

Demonstration Plant(10 ton/day)

6th March-2016 India Glycols Ltd.

DBT-ICT Technology Roadmap

Lab scale process (1 kg/day)

2009- 10 ; MOU

signed with DBT-ICT.

Pilot Plant (1 ton/day)

2010-2013; India Glycols Ltd.

Demonstration Plant(10 ton/day)

6th March -2016 India Glycols Ltd.

DBT-ICT Technology Roadmap

Financially Supported By DBT, under BIPP scheme

OBJECTIVES - Single Plant for all lignocellulosic feedstocks. - Generate Footprint for minimum 150 MT biomass/day capacity. - Low on CAPEX . - Continuous and Rapid reaction with minimum solid handling. - Biomass to Ethanol in less than 24 hrs.

Soft Agricultural residues

Agro- Industrial wastes

Non-woody

biomass

Hard Agricultural Residues

Wood chips

Woody biomass

Supercomputer Model of Lignocellulosic Biomass Oak Ridge National Laboratories, USA

Biomass Structure is complex and varies

With feedstock and its age….

Challenge is to treat all types through a single technology

And yet obtain intermediates of consistent quality…

March 2011 15

Pre-Treatment

Saccharification

Fermentation

BIOMASS

Size-reduction

Lignin

BIOMASS FRACTIONATION TECHNOLOGIES - Separation of biomass components

- Low solid loading (<20% w/w)

- Rapid reaction rates (!!)

Cellulose

Hemicellulose

Saccharification

Fermentation

Many products possible

Two Step Controlled Chemical Deconstruction of Any Biomass….

Gives Consistent High Quality Cellulose…..

Xylose & Lignin are recovered for processing

Two Step Fractionation Produces same quality of cellulose from different biomass feedstocks

Rice straw Wheat straw Sugarcane bagasse Cotton Stalk Corn stover Sugarcane trash

High efficiency Enzymatic Hydrolysis…

High rate of catalysis in flow mode…

Coupled with low consumption

Make it the best technology reported….

Novel Patent Protected Enzyme Technology Two Step Enzyme Technology for making Fermentable Sugar

Cellulose Cellulase cocktail Saccharification

Insoluble Residue

Fermentation

Ethanol

Cellulose Solubilization

Membrane Separation

Complete cellulase recovery

Salient Features : (Step 1 : Solubilization) HRT Less than 60 minutes More than 95% Conversion Low enzyme usage(1FPU/g)

Salient Features: (Step 2 : Saccharification) More than 90% enzyme recovery Complete sugar recovery High purity sugars <98%

Step 1 Step 2

Fermenting C6 sugar (glucose) is easy…

Xylose (C5 sugar) needs special yeast strains..but these are slow strains..

Innovative fermentation has led us to high speed bioconversions…

Of both C6 and C5 Sugars to Ethanol

High Cell Density Continuous Fermentations with controlled

Concentrations of Clean Sugars give High Speed Fermentations….

With high yields ….

Unique Features: Specially Designed Cost Effective Indigenous Membrane Separation Systems - Near 100% water recycle

- Recycle and reuse of chemical reagents used in fractionation steps

- Recycle and reuse of enzymes over several weeks

DBT-ICT 2G-Alcohol Technology

Present Status

Plant Commissioned in March 6th ,16 & formerly inaugurated on 22nd April,16

Raw Material tested : Bagasse, Wheat Straw

Plant Capacity Achieved : 70 %

Recovery of sugars : > 85 %

Delignification of cellulose : >90 %

Fermentation yields : > 90 %

Process water recycle : > 95 %

Reuse of chemical reagents / Enzymes

DBT-ICT 2G-Alcohol Technology More than 85% recoveries of all three components

Biomass to Ethanol possible in < 18 hours

Size reduction 20 min

Delignification 30 min

Solid/Liquid Separations 30 min

Cell/Hemicell fractionation 60 min

Enzymatic Saccharification 90 min

C6 HCD Fermentation 180 min

C5 HCD Fermentation 360 min

India Glycols 2G-Ethanol Plant Way Forward:-

1. Generate continuous processing data on different biomass feedstocks.

2. Offer Technology Validation Services.

3. Scale-up ethanol manufacturing to 50-150KLPD plant by 2017.

4. Explore JVs with interested companies for building larger plants

for fuel ethanol.

5. Regular production of xylose and glucose sugars (5 TPD)

6. Set up pilot plants for next line products: HMF, FDCA and 100% Green

PET/PEF

Surplus Biomass Waste

Liquid Sugar

Alcohol Bio-CNG

Chemicals & Solvents (Furfural & Ethyl Acetate)

Food (Glucose & Fructose)

Future Biomass BioRefinery at IGL

Monoethylene Glycol (MEG)

Materials 100% Green PET Equivalent

India’s First Multi-feedstock Continuous Flow

2G-Ethanol Demonstration Plant

Made In India-For The World

2G - ETHANOL DEMONSTRATION PLANT : A CASE IN INNOVATION ENGINEERING

Session-IV: How do we Maximize Ethanol Availability? 11th May, 2016 India Habitat Centre, New Delhi

Symposium on Biofuels and Bioenergy:

Enablers for Reducing Oil Import Dependence

Contact Details: S.R. Soni Vice President (Distillery/Alcohol Technology) email : s.r.soni@indiaglycols.com India Glycols Ltd. Mobile: +91 9690022678