Production of Xylitol from cellulosic feedstock's. Rao_0.pdf · Production of Xylitol from...
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Production of Xylitol from
cellulosic feedstock's.
World Congress on Industrial
Biotechnology
22-07-2015
Ravikumar Rao
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Synopsis
2Title | Date | Confidential | Presentation details
Praj: Who are we?
Science we do?
• LC to Ethanol
• Biorefinery Concept
• Xylitol
Technology
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© Praj Industries Ltd www.praj.net 3
Praj: Who are we?
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© Praj Industries Ltd www.praj.net 4
‘We aspire to be the most preferred organization for all stakeholders through
environment friendly and sustainable solutions that can make the world a
better place’
Established in 1983 by first generation technopreneur, Pramod Chaudhari (Executive
Chairman).
Globally leading Company with over 600 references in more than 60 countries across 5
continents.
Business along 5 verticals: Ethanol & Brewery, Water and Waste Water Treatment, Critical
Process Equipment Systems, Hi Purity Systems and Bio-Products.
Develop and deliver cost-effective, safe, clean and reliable solutions that will maximize
prosperity of our Customers.
Catering to Social Responsibility.
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Praj: Journey to Future
© Praj Industries Ltd www.praj.net 5
1985-1995
1995-2000
2000-2005
2005-2010
2010-2015
Inception of Praj. Diversification into synergistic
fields like development of process technology and Engineering and
process equipment and systems for breweries.
First international order from Indonesia for multi-pressure
distillation.
Commissioning of grain based ethanol plants in India.
Ventures into South America in 2000 for ethanol plants.
Energy saving multi-pressure distillation systems, introduced
by Praj become an Industry Standard.
Enters into East European Market with engineering order for a grain-based plant.Launches Multi-feed & Multi-product Ethanol technology for distillery. Launch of PRAJ-Matrix -The Innovation Center for advanced applied research in the field of ethanol and brewing process.
Break-through in US market. Skid Mounted Ethanol Plant designed, manufactured for CSR,
Australia. Manufacturing facility in Kandla (SEZ), India commissioned. Praj received orders from
USA, UK, Europe. The state-of-the-art R&D facility, Praj
Matrix established.The Cellulosic Ethanol Pilot Plant inaugurated.
Groundbreaking of 2nd
Generation (2G) Cellulosic Ethanol Demo Plant. Acquisition of Neela Systems.Enters CRSS business.
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© Praj Industries Ltd www.praj.net 6
Ethanol &
Brewery
Water & Waste
Water Treatment
Critical Process
EquipmentHi Purity
Systems
Bioproducts
Business
Verticals
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© Praj Industries Ltd www.praj.net 7
Science we do?
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Vision
“To be a Global Leader in Break-Through, Sustainable and Commercializable
Technologies for Renewable Energy and Biobased Chemicals and Materials,
Environment and Health Solutions while enhancing Societal and Stakeholder Value”.
Establishment
●Established in 2008
●Located at Pune
●Investment of above USD 25 Million
Organization
Praj Matrix employs a Centre of Excellence (COE) model as its
operating mechanism. It includes 100 and even growing
number of Technologists organized within 5 Centre of
Excellence
Infrastructure
●5 acre expanse
●85,000 sq. ft. of Research and Pilot facilities
endowed with 14 well equipped Laboratories
●ISO 9001:2008 certified Analytical Facility
●2 Pilot Plants (Cellulosic and Multipurpose)
Focus Area
BioFuels
BioChemicals
Health & Wellness products
Advanced Strain Development
Livestock Health & Nutrition
Recognitions
Recognized Research Center by DSIR, Govt. of India
ABLE 10th Anniversary Award, 2013
Bio-Excellence Award 2009, 2012
IGCW Green Innovation Award, 2011
Innovation Award, IIT Bombay, 2007
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Praj Matrix: Overview
© Praj Industries Ltd www.praj.net 9
Matrix, the R&D Center (division of Praj Industries), offers wide range of customized
research services and solutions that will help Companies and innovators to :
Develop and take new products to market rapidly.
Accelerating new product/process development.
Addressing new market opportunities by developing new products and targets
Improving commercial viability of validated targets.
Bridging gaps in expertise and capability in microbial development, bio-processing, and
process engineering.
Scaling up production processes for viability at commercial scale.
BIOLOGY
SCALE UP & PROCESS ENGG.
BIOPROCESS TECHNOLOGY
DUE DILIGENCE
CHEMISTRY
ANALYTICAL SCIENCES
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© Praj Industries Ltd www.praj.net 10
Technology
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Literature Review
Bench ScaleFacilities
Bench ScaleExperiments
Pilot PlantDesign andEngineering
Pilot PlantErection
Pilot Plant Trials
Demo Plant Design and Engineering
Demo PlantErection and Operation
Over 100,000 man days of R&D
on the pilot plant and thereafter
Praj’s Advanced Cellulosic Ethanol Technology - Evolution
2005 2006 2007 2008 2009 2010 20122011 2013 2014 2015
© Praj Industries Ltd Confidential www.praj.net
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+
PACE Technology: Process Block Diagram
Material Handling
& Washing Pre-Treatment
Solid-Liquid
Separation
DistillationCofermentation
Boiler
Ethanol
+
SSFC6 Hydrolysis
C6 Fermentation
Steam & Power To process
Steam turbine
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PACE Technology Highlights…
© Praj Industries Ltd www.praj.net 13
• Proprietary pretreatment at moderate temperature with higher solids.
• High efficiency of cellulose and hemicellulose conversion at low
enzyme dose.
• Co-fermentation of C-5 and C-6 sugars to ethanol.
• High yield of ethanol based on the feedstock composition (70-85
Gallons per dry metric ton).
• Integrated energy to reduce the steam and power requirement.
• Process operation is designed to recycle high levels of process water.
• Plant is designed for zero process liquid discharge.
• Designed for multiple feedstock (corn cobs, corn stover, sugarcane
bagasse & sugarcane trash).
• Flexibility to ‘Bolt On’ to First Generation Plants.
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Biorefinery Concept
© Praj Industries Ltd www.praj.net 14
A BIOREFINERY is characterised by an explicitly integrative, multifunctional overallconcept that uses biomass as a diverse source of raw materials for the sustainablegeneration of a spectrum of different intermediates and products (chemicals,materials, bioenergy/biofuels), allowing the fullest possible use of all raw materialcomponents. The co-products can also be food and/or feed. These objectivesnecessitate the integration of a range of different methods and technologies.
Mechanical/Physical Process
Chemical Process
ThermochemicalProcess
Biochemical Process
Platform
Material Product
Energy Product
Feedstock
The biorefinery process chain consists essentially of system components for the pre-treatment and preparation of biomass, as well as for the separation of biomasscomponents (primary refining) and the subsequent conversion/processing steps(secondary refining).
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© Praj Industries Ltd www.praj.net 15
Praj’s Lignocellulosic Biorefinery
Chemical Catalysis
Levulinic acid / Ethyl levulinate
Size Reduction + Hydrothermal
C5 Sugars
C6 Sugars
Acid Hydrolysis
Enzymatic Hydrolysis
Fermentation
Fermentation
Catalytic conversion
Dehydration
Bioethanol 2,3-BDO
Xylitol
Furfural
Tetrahydrofuran(THF)
Slurry Solids
Lignin
Power Phenolics
Lignocellulose
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Why Xylitol ???
© Praj Industries Ltd www.praj.net 16
Natural sweetener
Anti-cariogenic properties
Benefits used in chewing gums and toothpaste
No side effects compared to artificial sweeteners viz., Saccharin,
Aspartame, etc.
Non-nutritive
Benefits as an alternative sweetener for diabetics
Potential for higher value product association with ethanol
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Xylitol: Process Flow Diagram
© Praj Industries Ltd www.praj.net 17
Broth
Storage tank
Water
Cation/Anion Tandem chromatography
CrystallizerMother Liquor
XylitolCrystal/Powder
RO
VacuumEvaporator
Recycle to column
Biomass
Acid treatmentSolid-Liquid Separation
Neutralization Fermentation
Upstream Process
Downstream Process
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Xylitol: Process Highlights
© Praj Industries Ltd www.praj.net 18
The organism (GRAS status) involved is genetically stable and notamenable to changes by mutation, adaptation or genetic engineering.
75 % Fermentation efficiency consistently achieved in 5L,10L and 40L batches with bagasse and corn cob streams.
Non-sterile Fermentation.
No detoxification required prior to fermentation.
Robust and flexible DSP process which can perform irrespective offeed streams (corn cob, bagasse, etc).
Xylitol Yield of 85-95 Kg/Dry Metric Ton of cellulosic feedstock.
Product purity as per USP above 99%.
Cost competitive technology for Xylitol.
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Thank you
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