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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 : [email protected] India Glycols Ltd. Mobile: +91 9690022678