"The advancing of E20 target to FY 2025 has created tremendous ethanol capacity building opportunity"
Praj Industries is India’s most successful company in the field of biofuel and other bio-based technologies that was started as an enterprise under the name of Praj Counsel Tech, three decades ago. Founded in 1983 by Dr Pramod Chaudhari and made public in 1994, Praj Industries has an influence on five continents. Mainly focussed on providing and developing 2nd generation ethanol technology, Praj Industries is India’s leading manufacturer in engineering processes and projects.
As a global process solutions company, it is driven by innovation and integration capabilities, offering solutions to add significant value to bio-energy facilities, brewery plants, water and wastewater treatment systems, critical process equipment and systems, compressed biogas plants, Hipurity solutions and bio-products. Over the past 35 years, Praj has focused on environment, energy and agri- process led applications. The company has been a trusted partner for process engineering, plant and critical equipment and systems with over 750 references across 75 countries. Atul Mulay, President, Bioenergy, Praj Industries, shared his views on the status of ethanol production in India with Agrospectrum. Edited excerpts;
How is Praj contributing in attaining the government's vision of 20 per cent ethanol blending in petrol (E20) by 2025?
As a flag bearer of the ethanol industry, Praj works on multiple fronts such as technology, ecosystem development, policy advocacy etc. to help fulfil the government's vision of 20 per cent blending in petrol. End to end technology solutions for production ethanol offered by
Praj inspire project developers and investors’ confidence for capacity building.
In line with government policy of expanded range of feedstock to boost ethanol production,
Praj has developed technologies to process variety of feedstock such as sugary (C molasses, B heavy molasses and sugarcane juice), starchy (damaged/ surplus grains) and lignocellulose (agriculture residues such as wheat straw, rice straw etc.) to make ethanol projects technologically viable.
To improve commercial feasibility of ethanol plants, Praj Matrix, our R&D centre continuously works towards improving the process efficiencies and reducing energy and water footprints. We have been working closely with government agencies at state and national level to help formulate and rollout progressive biofuel policies.
By actively participating in the leading industry forums such as Confederation of
Indian Industry (CII), Maharashtra Chamber of Commerce, Industry & Agriculture (MACCIA) etc., Praj has been furthering the causes of the biofuel industry by taking up important industry issues at appropriate government agencies for expeditious resolutions.
Being a global player, Praj is privy to ethanol industry’s global best practices which it shares with stakeholders from time to time with the objective of overall improvement of industry standards. Praj recognises that success of
E20 blending programme is contingent upon wholehearted participation of automakers. To ensure cooperation of the auto industry,
Praj works closely with Automotive Research Association of India (ARAI), Pune, and OEMS for application development of advanced biofuels.
Currently ethanol blending in petrol is close to 10 per cent. To achieve the government’s target of 20 per cent by 2025, a significant capacity addition in the range of 1000 Crore Litres of ethanol is envisaged. Praj is highly optimistic about achieving this target with an integrated approach and close collaboration amongst the industry stakeholders.
Recently, Praj Industries bagged an order to set up India’s largest capacity syrup-based ethanol plant from Godavari Biorefineries Ltd (GBL) in Karnataka using ‘SHIFT’ technology. How SHIFT technology will minimise energy and water footprint, while maximising value for customers?
Using Praj’s proprietary SHIFT technology, we are able to significantly improve the throughput of ethanol plants and at the same time minimise water and energy footprints. In normal cases alcohol concentration after fermentation is usually 12 per cent; however our SHIFT technology takes the concentration to 15 per cent. Due to this, steam consumption during the distillation process is lower. For the syrup dilution process, instead of using fresh water, up to 50 per cent recycled spent wash is used. This results in lower spent wash generation resulting in lower energy requirement (almost 40 per cent lower) for its concentration. Thus SHIFT technology contributes to overall enhancement of techno commercial feasibility.
Praj Industries has partnered with Hindustan Petroleum Corporation Limited (HPCL) for setting up a Compressed Biogas (CBG) project at Badaun in Uttar Pradesh using Rengastm technology developed using proprietary microbes to produce CBG from rice straw. How will this bolster the growth of the biofuel industry in India?
Praj is honoured to partner with HPCL for the Badaun project that has capacity to process 35000 MT of rice straw as feedstock to generate 5250 MT of CBG annually. It will also generate high quality solid as well as liquid bio-manure for ferti-irrigation. This project has a potential to save up to 15000 MT of CO2 emissions per year.
HPCL Badaun CBG project will serve as a showcase installation by demonstrating end to end functioning of the value chain. This will definitely inspire developers and investors to actively consider setting up CBG projects. This project will lay to rest any apprehensions about technology, feedstock management, energy off take etc.
India currently imports 45 per cent of natural gas which is further processed for producing compressed natural gas (CNG) that is extensively used in meeting India’s energy demand. India is taking concerted efforts to improve the share of gas in its energy mix to 15 per cent by 2030, from 6 per cent currently.
CBG is a high octane renewable gaseous fuel produced by processing bio-based feedstock such as press mud, agricultural waste etc. This not only helps in energy self-sufficiency but also helps in reduction in carbon intensity especially
in the transportation and industrial sectors, thus helping conserving the environment.
In a first of its kind initiative in the world the Sustainable Alternative towards Affordable Transportation (SATAT) programme launched by the government, 500 plants are envisaged to be built over a period of five years.
Praj Industries has developed innovative technology to produce Biobitumen based on lignin (one of the co-products resulting from the 2nd generation Ethanol plants). How can it contribute to the growth of the ethanol production industry?
Praj has always endeavoured to deploy innovative technology solutions to maximise the value of ethanol plants by developing valueadded co-products from waste streams to increase project attractiveness.
Bio-bitumen based on lignin, is one such co-products resulting from the 2nd generation Ethanol plants, paper making and also from Compressed Biogas plants. Praj has now developed a proprietary process (under patenting) to convert the crude lignin into Biobitumen. It has potential to replace this fossil based bitumen and offer eco-friendly green bitumen. The binding and viscoelastic property of Bio-bitumen makes it useful for applications in asphalt.
Praj’s Bio-bitumen samples have been approved by Netherlands-based Circular Bio based Delta, one of Europe’s premier consortia for scale up in Asphalt on a Dutch test strip on the road.
What inputs are required for the growth of the biofuel industry in India?
Sustained Policy support: The government has already taken various strategic interventions to boost the ethanol production and consumption in the country.
The government has recently released a five year roadmap while advancing E20 target by five years to FY 2025. This has created ethanol capacity building opportunity.
Attractive pricing: Government has announced differential pricing for ethanol based on different feedstock to facilitate financial viability of projects.
Feedstock availability: The supply chain for 1G ethanol production from sugar is well established. Different sugar mills have their own ethanol production capacity. Recently the government has permitted use of starchy feedstock (surplus and damaged grains) for ethanol production. Starchy feedstock from Food Corporation of India (FCI) will be made available to ensure uninterrupted supply. Advanced technologies for ethanol production by processing bio based feedstock in an efficient manner will facilitate project viability.
What are the opportunities in the biofuel sector in India? What is the future of Biofuels & 2G Ethanol technology in India?
Opportunities in the biofuel sector are abundant in India. Transportation fuel mix is undergoing a major transition by way of mainstreaming of renewable low carbon biofuels. While biofuels usage in surface transportation has already gained momentum, its application in the aviation sector is about to take off.
Also application of marine biofuels in water transportation are ushering on the horizon.
Future of 2G ethanol technology in India appears very promising as it positively impacts the interest of stakeholders across the value chain delivering differentiated value. Biofuels produced from captive resources i.e. agriculture residues, facilitates energy self-reliance as it reduces dependency on the imported crude and associated forex bill. It also provides an additional revenue stream for farmers. Carbon neutral cycles triggered by combustion of biofuels help curtail health hazards attributable to the air pollution due to burning of agriculture residues and emissions from fossil fuel combustion.
India’s first batch of commercial projects based on 2G ethanol technology is under development. Praj is working on three numbers of advanced biofuel refineries in India, based on proprietary 2G enfinitytm technology. Construction and Installation activities are in full swing at all sites and we expect mechanical completion of the first project by February 2022. We expect to commission this plant in June 2022.