Samir Somaiya NEPIC - 2012
Samir Somaiya NEPIC - 2012
Samir Somaiya NEPIC - 2012
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Integrated Biorefining at<br />
Godavari Biorefineries<br />
<strong>Samir</strong> <strong>Somaiya</strong><br />
<strong>NEPIC</strong> - <strong>2012</strong>
Godavari Biorefineries<br />
What are we doing<br />
What are we doing different
An Integrated Approach to Innovation- Social,<br />
Financial and Environmental<br />
16% of India GDP is from Agriculture<br />
10 million farmers (50 million people)<br />
connected to sugarcane farming
Godavari Biorefineries Context<br />
2011-12, we processed 2.1 million tons of cane<br />
15,000 farmers - an average of 140 tons<br />
cane/farmer (33% of our farmers supplied less<br />
than 50 tons)<br />
Average landholding 3.5 acres (40 tons/acre)<br />
Cane price = $50/ton: So about Revenue<br />
about $7000 per ‘average’ farmer
Single crop vs Intercropping:<br />
Targets<br />
Crop<br />
Unit of<br />
weight<br />
Yield/acre Price/unit revenue/acre cost/acre<br />
Cane tons 50 $ 50 $ 2500 $ 40<br />
Soya Quintals 8 $ 75 $ 600 $ 20<br />
Turmeric Quintals 15 $ 160 $ 2400 $ 80<br />
Total for 1<br />
acre<br />
Total for 3.5<br />
acres<br />
$ 5500 $ 140<br />
$ 19250<br />
Single crop 1 acre 40 $ 50 $ 2000<br />
3.5 acres $ 7000<br />
Dramatic Changes in revenue, with better effect on soil quality !!
Godavari Biorefineries Context<br />
Integrating farm experiments into education<br />
Integrating into school curriculum to educate,<br />
innovate, and propagate
Cane Composition
Traditional Model: Sugar from Cane<br />
Farm<br />
Mud<br />
Molasses and bagasse caused<br />
disposal problems<br />
Cane<br />
Milling<br />
Juice<br />
Clarification<br />
Molasses<br />
Bagasse<br />
Clear Juice<br />
Centrifuges<br />
Sugar<br />
Boilers<br />
Evaporation<br />
Syrup<br />
Pan Boiling
Traditional Model:<br />
Basis 1 ton cane<br />
Units Quantity/ton Price/unit Value<br />
Sugar kg 115 $ 0.55 $ 63.25<br />
Molasses<br />
(50% sugar)<br />
kg 40 $ 0.05 $ 2<br />
Surplus Bagasse<br />
(50% moisture)<br />
kg 0 $ 0.03 $ 0<br />
Mud kg 20 $ 0.001 $ 0.02<br />
Total $ 65.27<br />
Earlier, when we started, sugar yield per ton was 93 kg, now it is 115 kg. Before the WTO outlawed<br />
subsidized EU sugar exports, sugar prices were $0.2/kg, leading to a revenue from 1 ton cane of about<br />
$20, compared to $66 above
Current Model - Sugar, Ethanol, Electricity from Cane<br />
Farm<br />
Vinasse<br />
Composting Biodigestion Biogas<br />
Cane<br />
Mud<br />
Milling<br />
Juice<br />
Clarification<br />
Fermentation<br />
Ethanol<br />
Bagasse<br />
Clear Juice<br />
Molasses<br />
HP Boilers<br />
Centrifuges<br />
Sugar<br />
Carbon<br />
Credits<br />
Power<br />
Evaporation<br />
Pan Boiling<br />
Syrup
Current Model:<br />
Basis 1 ton cane<br />
Units Quantity/ton Price/unit Value<br />
Sugar kg 115 $ 0.55 $ 63.25<br />
Ethanol liters 10 $ 0.7 $ 7<br />
Surplus Power kwhr 80 $ 0.09 $ 7.20<br />
Mud kg 20 $ 0.001 $ 0.02<br />
Total $ 77.47<br />
Lot of capital chasing a revenue difference of $12 per ton of cane crushed
Beet,<br />
Sorgh<br />
um<br />
Sweet Sorghum.<br />
Energy Cane<br />
Farm<br />
Cane<br />
Godavari Biorefineries Model<br />
Compost<br />
Waxes<br />
Mud<br />
Vinasse<br />
Composting Biodigestion Biogas<br />
Organic<br />
Acids<br />
Chemicals<br />
Milling<br />
Juice<br />
Clarification<br />
Fermentation<br />
Ethanol<br />
Celluloses<br />
Bagasse<br />
Clear Juice<br />
Molasses<br />
HP Boilers<br />
Centrifuges<br />
Sugar<br />
Carbon<br />
Credits<br />
Power<br />
Evaporation<br />
Pan Boiling<br />
Chemicals<br />
Syrup
Innovation in Chemical Process Technology<br />
Separating Bagasse into its constituents<br />
Farm<br />
Cane<br />
Milling<br />
Sugarcane Bagasse<br />
Hemicellulose<br />
α-cellulose<br />
Lignosulfonate and<br />
lignophenol<br />
Ethanol<br />
Xylitol<br />
Microcrystalline<br />
cellulose<br />
(MCC)<br />
Carboxymethyl<br />
cellulose<br />
(CMC)<br />
Ethyl cellulose<br />
(EC)<br />
Methyl cellulose<br />
(MC)<br />
Hydroxypropyl methyl<br />
cellulose<br />
(HPMC)
Growth Plans<br />
All financial years end in March
Growth Plans<br />
Altering product mix<br />
<strong>2012</strong><br />
2016
Godavari Strategy<br />
Add Value<br />
Diversify across markets<br />
Diversify across renewable feedstock (Beet, Cane, Sorghum,<br />
Glycerine)<br />
Diversify manufacturing locations<br />
Invest in startups<br />
Innovate in feedstocks, processes, and relationships<br />
Work with farmers<br />
Work with and for the community
Thank You
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