next generation biofuels india scenario and areas … · fourth generation biofuel : ... coconut...

Next Generation Biofuels India Scenario and Areas for Cooperation

India-EU and Member States Partnership for a Strategic Roadmap in Research and Innovation

New Delhi12 November 2010

Arvind LaliDBT-ICT Centre for Energy Biosciences

Institute of Chemical TechnologyMumbai, INDIA

First generation Biofuels : Grains and sugar to EthanolVegetable oil to Biodiesel

Second Generation Biofuels : Lignocellulose to AlcoholsLignocellulose to Green DieselVegetable oils to Green Diesel

Third generation Biofuels: Biomass to HydrogenAlgal HydrogenAlgal Oil/Biodiesel

Fourth generation Biofuel : Biofuel from high solar efficiencycultivations

Evolution of Biofuels

First generation Biofuels : Grains and sugar to EthanolVegetable oil to Biodiesel

Second Generation Biofuels : Lignocellulose to AlcoholsLignocellulose to Green DieselVegetable oils to Green Diesel

Third generation Biofuels: Biomass to HydrogenAlgal HydrogenAlgal Oil/Biodiesel

Fourth generation Biofuel : Biofuel from high solar efficiencycultivations

Evolution of Biofuels

Viable IFF Right

Technologies are developed

A BioFuel Product and Technology MUST be :

- Economically sustainable- Ecologically sustainable

Challenges:

Biomass type, availability and logistics challenges

Product & Production Technology Challenges

Distribution Technology Challenges

Usage Technology challenges

Socio-political challenges

Bio-Based Renewable Resources

- Microbial/Contained Cell cultures- Plants- Animals

Viability Questions ?

- Which plants - Where do we grow them- How much can we grow

Sugar Cane Ethanol Limited Option for IndiaPresently possible blend : 5% May at most be sufficient for 10%

Drawbacks

- Water intensive- Uses fertile land- Low energy ratio

BioDiesel from Vegetable/TB OilsNot enough oil available for 5% blendingin dieselYields are lower than expectedCost of oil too high for biofuel(at <USD100/bbl crude)

Other Issues :- Low shelf life- Stringent tests standards- Dependence on (petro) Methanol- Lower LCA benefits

Second Generation Biofuels from Agricultural Residues

India (and Asia) situation:

- Land per capita far less than USA, Canada, Australia, and Brazil- Cannot divert any land that can grow food

Options :

- Use present day agricultural crops completely and judiciously- Use sea/ocean/sandy coasts for growing ‘plants’

Lignocellulosic Biofuels Algal Biofuels

Biomass Availability in INDIA

Non-food & Non-fodder/ Surplus Lignocellulosic Biomass:

- Cotton Stalk- Wheat Straw- Rice Straw- Sugar Cane trash- Many other local plants !!

Annual availability > 500 MT !!Biomass biofuel potential > 100 MT/year

MNRE Survey Report

Crop residuesProduction Million tons

1994 2010(projected)

Field based residuesCotton stalk 19.39 30.79

Rice straw 214.35 284.99

Wheat straw 103.48 159

Maize Stalk 18.98 29.07

Soybeans 12.87 34.87

Jute stalk 4.58 1.21

Sugarcane tops 68.12 117.97

Ground nut straw 19 23.16

Processing Based residueRice Husk 32.57 43.31

Rice Bran 10.13 13.46

Maize cob 2.59 3.97

Maize Husk 1.90 2.91

Coconut shell 0.94 1.50

Coconut husks 3.27 5.22

Ground Nut Husk 3.94 4.80

Sugarcanebagasse

65 114.04

Coffee husk 0.36 0.28

SUGARCANE RESIDUE SCENARIOIN INDIA

Sugarcane : A crop grown extensively

Cultivation area : 4 million haCane produced : 280 million tons/year

Bagasse available : 28 million tons/yearSugarcane trash : 40 million tons/year

Total possible biomass biofuel yield : >20 million tons/year !!(annual transportation fuel demand in India : 70 million ton)

Despite enormous potential Lignocellulosic Biofuels not yet commercially successful

Global Reasons : High Cost and High Risk

- Cost of Production > USD 1.0/Liter- High capital cost (more than atomic energy)- Waste generating and Non-eco friendly Technologies

Local (India) Reasons :

- Varied biomass- Small land holdings Distributed production

AGRICULTURAL BIOMASS

Biofuel Options

Syn-Gas

Alcohols

Hydrocarbons

Gasoline, Diesel

Fermentation/Chemical Catalysis FT Synthesis

Cracking

Bio-Oil

Gasoline, Diesel

Cracking

Fast Pyrolysis/SCWG/

thermochemical

Gasification

FermentableSugars

Bio-Alcohols

SCWG

Hydrogen

Bio-Hydrogen

Bio-Methane

Platform Chemicals

DME

Major Biomass Energy Technologies under development in India

1. Biomass Combustion to Power (co-generation technology)

2. Biomass to Syngas Combustion Power OR Fuel

3. Biomass Liquefaction to Bio-Oil

4. Biomass to Ethanol via biotechnology route

5. Biomass to Butanol via biotechnology route

Liquid fuel for transportation

Essential features of a viable Biomass-to-Biofuel Technology for India

It must :

Be able to process different varieties of biomass across the country

Be implementable at scale suitable to be located near biomass production locations e.g. in agricultural heartland

Be robust to be operated by local semi-skilled operators

Be non waste producing, or producing any by-product with limited use

Result in a manufacturing plant that is compact and low in capital investment

Produce fuel at a cost equal to or less than cost of petroleum fuel

Two major options :

A. Local densification of biomass for transportation to processing locations

B. Local conversion to biofuel for local distribution

Thermo-Chemical Route :Biomass liquefaction to Bio-oil

Bio-chemical Route :Bioconversion of biomassto alcohol

Suggested co-operation in Thermo-chemical conversions

Thermo chemical platform for production of second generation biofuels through pyrolysis; gasification; BTL etc.

This activity will involve :

- Process development on pilot scale- Characterization of bio oil- Upgradation and of bio oil as obtained through pyrolysis.- Gasification of biomass of pilot scale and optimization of gasifier design in terms of heat integration and yield.

- Gas cleaning and conversion technologies

CELLULOSIC BIOMASS

Syn-Gas

Alcohols

Hydrocarbons

Gasoline, Diesel


Cracking

Bio-Oil

Gasoline, Diesel

Cracking

Fast Pyrolysis/SCWG

Gasification

FermentableSugars

Bio-Alcohols

SCWG

Hydrogen

Bio-Hydrogen

Bio-Methane

Platform Chemicals

DME

Bio-chemical Route :A more acceptable technology framework today !

CELLULOSIC BIOMASS

Syn-Gas

Alcohols

Hydrocarbons

Gasoline, Diesel


Cracking

Bio-Oil

Gasoline, Diesel

Cracking

Fast Pyrolysis/SCWG

Gasification

FermentableSugars

Bio-Alcohols

SCWG

Hydrogen

Bio-Hydrogen

Bio-Methane

Platform Chemicals

DME

Advantages:- Versatile, Multiproduct- Biorefinery Concept can be Implemented- Economically more viable- Lesser Capital Cost- Decentralized Plants

Biomass Compositions (dry basis)and Treatment Severity

Components(% w/w)

SugarcaneBagasse

Rice straw Wheat straw Cotton/Castor stalks

Cellulose 40 37 39 30

Hemicellulose 29 31 36 18

Lignin 13 16 10 30

Silica/Ash 2 12 6 2

Others 16 4 9 20

Increasing Severity OrderBagasse < Rice Straw < Wheat Straw < Cotton/Castor Stalk

Lignocellulosic Biomass

Pre-Treatment Step

Saccharification

Fermentation

Separation/Purification Alcohol

THE

PRO

CES

S O

UTL

INE

STEP 1

STEP 2

STEP 3

STEP 4


Pre-Treatment Step

Saccharification

Fermentation


THE

PRO

CES

S O

UTL

INE

STEP 1

STEP 2

STEP 3

STEP 4

Most Complex StepHigh in CAPEX


Pre-Treatment Step

Saccharification

Fermentation


THE

PRO

CES

S O

UTL

INE

STEP 1

STEP 2

STEP 3

STEP 4


Requires complex enzymesHigh in OPEX


Pre-Treatment Step

Saccharification

Fermentation


THE

PRO

CES

S O

UTL

INE

STEP 1

STEP 2

STEP 3

STEP 4


Requires complex enzymesHigh in OPEX

Established for glucoseNew technology reqd for pentoseInnovations reqd for better

productivities


Pre-Treatment Step

Saccharification

Fermentation


Dilute Acid Process

Conc. Acid Process

Dual Acid Process

Steam Explosion Process

Ammonia Explosion : AFEX

Hydro-Thermal Process

Alkaline Process

Problems with thePrevalent Pre-treatment Technologies:

- Lower than desired sugar yields

- Production of toxic compounds for downstream processes

- Very high CAPEX

- Results in high OPEX

- Poor scalability


Pre-Treatment Step

Saccharification

Fermentation


Acid Hydrolysis

Enzyme Hydrolysis

Acid + Enzyme Hydrolysis

Hydrolysis + Fermentation (SSF)

Enzymatic Saccharification

Two major enzyme inhibitions

(a) from toxins produced in pre-treatment stage(b) from substrates and products

ANSWERS

(a) Cleaner substrates lower toxic products (eg furfural derivatives)

(b) Intensification of enzyme reactions

Inhibition from soluble cello-dextrins to Solubilization of cellulose

Inhibition Kinetics in Enzymatic Cellulose Hydrolysis(Biochemical Engg Fundamentals, Bailey and Ollis)

Which Enzymes should be used

Current enzyme costs make Lignocellulosic Ethanol Expensive

Novel Enzymes DesignEnzyme Engineering

Separation of endo and exo activitiesfrom commercial preps

Production of endo and exo enzymes(a) Pure cellulases(b) Fusion protein of endo cellulase

and endo xylanase

Design of more reactive and multiple activity enzymes


Pre-Treatment Step

Saccharification

Fermentation


Batch Separate OR co-fermentation of hexose

and pentose

Separate fermentationBatch

Continuous Fermentations

Immobilized Cell Fermentation

Lignocellulosic Ethanol TechnologyResearch/Process Innovations underway in India

- Novel multi-feedstock pretreatment strategiesIOC, NCL & Co., DBT-ICT-CEB, NIIST, Praj Industries, Tata Chemicals

- Designing Novel Enzymes for SaccharificationDBT-ICT-CEB, ICGEB, Universities/Institutes

- Designing novel bio-systems for CBPDBT-ICT-CEB, ICGEB, Universities/Institutes

- Novel fermentation strategiesDBT-ICT-CEB, India Glycols, Fermenta Biotech

- Butanol and other Fermentation StrategiesIIT-B/Praj, DBT-ICT-CEB/ICGEB, Universities/Institutes,Tata Chemicals

Suggested areas for Indo-EU joint work on Lignocellulosic Ethanol / Butanol Technology

Detailed biomass characterization

Development of multi feed, cost competitive pre treatment process

Development of engineered micro organism capable of high ethanol yields utilizing C5 and C6 sugars. The simultaneous conversion of C5 and C6 sugars with high ethanol yields and in optimized time shall be the focus

Development of engineered CBP microorganisms and their evaluation

Development of technology for saccharification and fermentation involving development of microorganism and optimization of conditions.

Identification and development of strains/process for production of biobutanol

Is the Biomass sufficient for India !

Current liquid fuel required (petrol + diesel) = 70 million ton/yearRising at >10%/year

300 million ton biomass waste 75 million ton biofuel/year30 million Ha marginal land 300 million ton biomass 75 million ton fuel/yearIs this enough, say in year 2050?

BIOMASS will stagnate with time.Besides, there is need to find replacement for diesel

WHAT NEXT ?

Possible Answer : Third Generation Biofuels

Algae (Micro/Macro) : Algal Oil and Algal Starch

ADVANTAGES

Can be grown in ideally on coastline or offshore waters Non-Compete with Land for food

OTHER ADVANTAGES

Can utilize deep sea/waste water for nutrients Low cost nutrients + sunlight

Can use deep waters for surface cooling

Substantial carbon dioxide sequestration

Algal Biofuel Technology

Micro/Macro Algae Oil

Oil Diesel/Gasoline(IOC)

Extraction OR

Thermo-Chemical Liquefaction

Catalytic Cracking

Algal BioTechnology

- In early stages- Three Component development required

a) Algal Cell Engineeringb) Algal Growth Engineeringc) Algal Downstream Processing

Algal Biofuels : Facts todayCost of algal oil derived biofuel (raceway pond) = > USD10/L

CAPEX = USD 1.0 million/ha Raceway pond + system= USD 2/L algae derived biofuel !

PBRs > 10x cost of Raceway ponds

Maximum algae (dry) yield reported = 50 ton/ha/y (0.05 g/L/day)(Oil producers !)

= 300 ton/ha/y (0.3 g/L/day)(Near theoretical : achievable ?)

(Note : Switchgrass (dry) biomass yield = 25 ton/ha/y)

Other constraints: Enriched CO2 Nutrients (esp N)Water requirement (evaporation !)

Algal Biofuel Technology

• Explore algae as a source of biomass /triglyceride oils/starch/metabolites• Modifications for increased biomass/bio-oil/metabolite production• Scalable bioreactors for production of algal strains for biofuel production

‘Discovered OR

Improved’Marine algae/Cyanobacteria

Genetic modification,

metabolic engineering,

hydridization and breeding

Media Engineering,Consortium

growth,CO2 capture

Bioreactor Design

Harvesting and Process into fuel or

fuel intermediate

WORK-FLOW

Major Initiative Underway to Support Algal Biotech Research in India

Work in Progress in Algal Biotechnology

- Screening and CollectionLarge number of Institutes/Universities (DBT led Initiative)

- Strain ImprovementDBT-ICT-CEB, ICGEB

- Bioreactor/Process DesignVIAT, EID-Parry

- Harvesting and Downstream Processing TechnologiesVIAT, EID-Parry

Suggested Indo-EU Cooperation in Algal Technology

Identification of efficient and engineered strains for microorganism algae

Network between EU and Indian partners for sharing of algal strains, characterization, growth & production profiles etc.

Development of methods for cultivation; harvesting of micro algae; and conversion to biofuels.

Development and scale up both on open ponds and in low cost photo bioreactors.

Current R&D efforts in 2nd generation Bio-fuels in India

• Production of green diesel through hydro-treatment route

• Lignocellulosic ethanol at pilot scale

• Collection of high yield algal strains ( ~ 150 )

• Algal growth in open ponds

• Development of enzymes & fermentation strains

• Four major R&D projects on biomass pyrolysis

• Biomass cracking through coker route

• Improvement of TBO yields

DBT-ICT Centre of Energy BiosciencesInstitute of Chemical Technology (UDCT)Mumbai, INDIA

- India’s first National Bioenergy Research Centre

- Being set up at an initial cost of USD 5 million

- Multidisciplinary Centre with emphasis on cutting-edge technology development and transfer to Indian industry

- Networked with Institutions & Industry in India and abroad

>40 PhD scholars; several Senior Research Scientistsand >10 faculty in different disciplines of modern biologicalsciences and bioengineering

DBT-ICT Centre for Energy BiosciencesMatunga, Mumbai

Thank you for your attention

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