ethanol from juice & b-heavy molasses mahesh kulkarni -2.pdfcore competencies driving solutions...

Over 3 Decades in Sustainable SolutionsAIDA -Feb 2019

© Praj Industries Ltd www.praj.net

ETHANOL FROM JUICE & B-HEAVY MOLASSES

Mahesh KulkarniAVP- Business Development

2

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

Core Competencies

Driving solutions through

Improvement& InnovationQuick

Scale-Up and

Commerciali-zation

Technology and

Process Knowhow

Engineeringand

Manufacturing

Integrationand

Projects

Focus on Bio-Process Engineering and Solutions inEnergy, Environment and Agri-processing

Agri-feed stock and Residues

Advanced Separation and Concentration

Processes (DDBE)

Advanced Bio-processes

(Yeast and Process

Performance Enhancers)

Process Optimization

and Integration (POI)

Yield Maximization

Reduction in Carbon footprint (GHG

reduction)

Multi-product ,High quality

Reduction in water footprint

Co-product Maximization

Innovation Focus


4

Sugar Mill -Feedstock Options

5

1st millCane 2nd / 3rd /4th /5th millBagasse

Clarification

Evaporation

Crystallization

Bagasse

Condensate

Mixed Juice

Primary Juice Secondary Juice

RVFMuddy Juice

Filtrate Juice

Press Mud

1st/2nd / 3rd /4th Centrifuge

C- MolassesB- Molasses

Syrup

Sugar

2G Sugars2G Sugars


B Heavy Molasses

Composition of B-Heavy Vs. Molasses-C


Sr. No

Parameters Unit Partially Con Juice

Molasses-C B-Heavy

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

Typical Sugar Balance Sugar Cane

Milling

FiberSeparation

Clarified Mixed Juice

Crystallization

Centrifugation

Crystalized Sugar :1100 MTPD

*C-Molasses:400 MTPD (90 KLPD AA)

Bagasse:3000 MTPD

Press Mud:400MTPD

Imbibition Water:3000MTPD

Mixed Juice:10000 MTPD

EvaporationCondensate

Basis:• Cane crushing capacity:

10000 TCD• Sucrose :13.5%• Crystalized sugar

Recovery:11.0% on cane

• Plant capacity is up to 90 KLPD• Plat Operation is up to 150 days

per year.

Typical B-Molasses Sugar Balance

Processed Cane

FiberSeparation


Crystallization

CentrifugationCrystalized Sugar:

959 MTPD

B-Molasses:600MTPD (188 KLPD AA)

Bagasse:3000MTPD

Press Mud:400 MTPD


Mixed Juice:10000MTPD





• Opportunity to increaseexisting ethanol capacity by30% using some minormodification.

• Plat Operation is up to 240 daysper year.

• Plant Capacity is up to 188KLPD AA.

Typical Sugar Factory balance with Juice to Ethanol

Processed Cane

FiberSeparation


Crystallization

CentrifugationCrystalized Sugar:

971 MTPD

Juice to ethanol:90 KLPD AA

Bagasse:3000MTPD

Press Mud:400 MTPD


Mixed Juice:10000MTPD





• Plant Capacity is up to 90KLPD.

• 90KLPD plant on juice will beoperated for 150 days crushingoperation and 132 day onMolasses with same capacity.

90 KLPD Ethanol Plant Capacity


Sr. No.

Parameters Unit Juice to Ethanol

Sugar Factory(C-Molasses)

B-Molasses Remark

1 Ethanol Titer %V/V 12% 8% 12%

2 Steam required

Kg/Lit of AA

5.8 6.0(22.5 TPH)

5.8(22 TPD)

No additional steam is required (including boiler and turbine)

3 Power KWh/KL 2.0 2.0 2.5

4 Coal Requirement

T/Day 70 70 70 No additional coal is required

5 Spent Wash Recycle

% 0 0 20 60% reduction in effluent generation per lit of ethanol

6 Total Water consumption

Kg/L 0.2 to 0.5 8 to 9 5 to 5.5 Excluding boiler water

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’s References

13© Praj Industries Ltd www.praj.net

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 Clear Juice Syrup

Mixed Clarified Juice

65 %5%

30 %

54-56 %59%

13.5 %

14

2. Ingenio Providencia S.A., Colombia




Distillery Capacity : 250 KLPD Ethanol

Vinasse recycle: 45~50%


Sugarcane molasses B Clear Juice Syrup

Mixed Clarified Juice

80%20%0%

50-52%60%

13.5%

15

3. Ingenio Mayaguez S.A., Colombia



No. of days of Operation per year : 300


Vinasse recycle : 40-45%


Sugarcane molasses B Mixed Clarified Juice

70%30 %

52-54 %14-15 %

16

4. Ingenio Risaralda S.A., Colombia


Cane Crushing Capacity (TCD) : 3000 TCD





Sugarcane molasses B +Clarified filtrate juice

85 %15 %

50-52 %9.5-10.8%

17

5. Ingenio Manuelita S.A., Colombia


Cane Crushing Capacity (TCD) : 10,000

No. of days of Operation per year : 300




Sugarcane molasses B 100 % 62-64 %

18

6. Ingenio Riopaila Castilla S.A., Colombia


Cane Crushing Capacity (TCD) : 24,000


Distillery Capacity : 400 KLPD Ethanol

Vinasse recycle : No


Sugarcane molasses B Cane Juice

10%90%

59-62 %13.5-14.5 %

19

Success Stories

© Praj Industries Ltd www.praj.net 20

• 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 Seeker, Turkey (280 KLPD, sugarbeet Molasses-B)


Thank you!Contact : [email protected]

ethanol from juice & b-heavy molasses mahesh kulkarni -2.pdfcore competencies driving solutions...

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