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The National Policy on Biofuels 2018 (Amended 2022) has advanced the 20% ethanol blending target to the Ethanol Supply Year (ESY) 2025-26. While 1G ethanol (from sugar and grain) has paved the way, 2G ethanol is the key to sustainable energy security. By utilizing Lignocellulosic Biomass—rice straw, bamboo, bagasse, and corn cobs—we solve two problems at once: managing agricultural residue and producing carbon-neutral fuel.
Raj Process provides the engineering bridge to this future, delivering high-efficiency plants that are fully compliant with SATAT and MoPNG norms.
Turnkey 2G Ethanol Solutions by Raj Process
We offer a “Seed-to-Fuel“ engineering approach. With five advanced manufacturing facilities and a dedicated R&D center in Pune, we handle the entire lifecycle of a 2G biorefinery.
Our EPC Roadmap:
Conceptual Design & Engineering: Detailed feedstock analysis, mass balance calculations, and process optimization based on your local residue availability.
Pilot & Commercial Development: We bridge the gap from lab to field, offering 0.5 TPD pilot lines for testing and 100+ KLPD commercial plants for industrial production.
In-House Manufacturing: Every vessel, reactor, and column is fabricated under stringent ISO and ASME standards in our own units.
Advanced Automation: Integration of DCS/SCADA for remote monitoring, ensuring 99.9% operational uptime and minimal human error.
The ABEPL Milestone: Our expertise is proven in high-stakes environments, such as the Assam Bio Ethanol Ltd. (ABEPL) project, where we delivered the ethanol separation package for the world's first bamboo-based 2G refinery.
The Raj Process 2G Technology Cycle
Step 1: Biomass Pretreatment (The Lignin Barrier)
Lignocellulosic biomass is naturally resistant to breakdown. Our pretreatment systems use a combination of Mechanical Shredding and Steam Explosion (or chemical impregnation) to disrupt the lignin-hemicellulose matrix.
Why Raj Process? Our patented Non-Clog Extra Long Tube systems ensure that even the most “sticky“ or fibrous residues don't cause downtime.
Step 2: Enzymatic Hydrolysis (Saccharification)
Once pretreated, the biomass is treated with specialized cellulase and hemicellulase enzymes. This stage converts complex cellulose into simple C6 (Glucose) and C5 (Xylose) sugars.
KPI: We achieve up to 85% conversion efficiency, maximizing the sugar recovery from every ton of straw or bamboo.
Step 3: Advanced Co-Fermentation
Standard yeast cannot ferment C5 sugars efficiently. Raj Process employs Next-Generation Co-Fermentation technology. We use engineered microbial strains that ferment both C5 and C6 sugars simultaneously, significantly increasing the total alcohol yield per ton of feedstock.
Step 4: RajPurify Distillation & Dehydration
Our multi-pressure vacuum distillation columns separate alcohol from the wash with extreme precision.
Purity: We reach 99.5% to 99.7% purity (Fuel-Grade) using Molecular Sieve Dehydration (MSDH) technology, ensuring compatibility with the latest BS-VI and Flex-Fuel vehicle engines.
Beyond Ethanol – The Circular Economy
A 2G plant by Raj Process is more than a distillery; it is a Biorefinery. We enable the recovery of high-value co-products that can provide additional revenue streams of ₹15–20 per liter of ethanol produced.
Lignin Recovery: The residual lignin can be pelletized for high-calorific fuel, used for power generation, or even processed into Bio-Bitumen.
Food-Grade CO₂: Our integrated capture systems purify fermentation CO₂ for the beverage and dry-ice industries.
Furfural & Acetic Acid: In specialized plants (like bamboo-based units), we can recover chemical co-products that are high in industrial demand.
ZLD Integration: Every Raj Process plant is designed for Zero Liquid Discharge, concentrating effluent into dry powder or bio-compost.
Conclusion: Partner with India’s 2G Experts
With the global push toward Net Zero, 2G ethanol is the most bankable green asset of the decade. Raj Process Equipments & Systems provides the technical reliability, patented innovations, and EPC experience to ensure your project’s success.
Are you ready to build the next generation of energy?
Contact Raj Process today for a detailed feasibility report on your chosen feedstock.
Raj Process designs and manufactures advanced material handling equipment engineered for efficiency, durability, and automation. Our solutions are tailored to handle tough industrial tasks while ensuring smooth and reliable operations.
Screw Conveyors
Screw conveyors are widely used in modern industry, operating horizontally or at a slight inclination to efficiently move semisolid materials. Raj Process screw conveyors are designed with larger pitch spacing to achieve higher material capacity without increasing rotation speed.
Key Advantages:
Reliable and efficient material movement
Robust construction for longterm performance
Versatile applications across industries
Easy maintenance and cleaning
Screw conveyors are indispensable in industrial operations, offering a costeffective and efficient means of handling bulk materials.
Pneumatic Conveyors
Raj Process has expanded into pneumatic conveying systems, offering versatile solutions that use air pressure to move products through tubes. These systems provide vertical flexibility and can be designed as carrier systems or dilutephase systems.
Benefits of Pneumatic Conveyors:
Reliable performance with minimal maintenance
Ability to transport a wide variety of materials
Compact design for easy integration
Efficient automation for bulk material handling
Features
Our material handling equipment is widely used in industries such as food processing, chemicals, and fastmoving consumer goods. Typical applications include:
Cookies
Noodles
Doughnuts
Fast food preparations
Ice cream
Cake
Paddle mixers are the ideal solution for achieving gentle yet thorough mixing of solids and liquids with varying particle sizes, densities, and viscosities. Raj Process is a leading paddle mixer manufacturer in India, offering advanced designs that ensure efficient, versatile, and cost‑effective mixing solutions.
Our paddle mixers are engineered with unique paddle‑style agitators that scoop, lift, and tumble materials gently, making them perfect for blending fragile ingredients such as nuts or fiberglass strands. The design also allows easier access for cleaning between batches, ensuring hygienic operations and reduced downtime.
Paddle Mixer Manufacturers in India
Raj Process paddle mixers are built for maximum performance and efficiency. Using durable materials and advanced manufacturing techniques, we deliver reliable, high‑performance mixing equipment that enhances production processes and ensures long‑term operational success. Their robust construction, versatility, and efficiency make them indispensable tools across industries.
Applications
Powder and semi‑dry solid mixing
Cutting fat into flour
Addition of oil & liquid into powder
Mixing soap formulations
Extending colors in pigments
Breaking down agglomerates
Raj Process is a leading double cone blender manufacturer in India, specializing in equipment designed for homogenous mixing of dry powders and granules. The double cone blender’s unique design interfolds materials, ensuring absolute uniformity in blending while maintaining product integrity.
This versatile blender is particularly effective for mixing freeflowing dry materials with dissimilar particle sizes and shapes. Its gentle blending action makes it suitable for sensitive materials that may be damaged by more aggressive mixing methods. With stainless steel construction and smooth interior surfaces, Raj Process double cone blenders are easy to clean, maintain, and minimize the risk of crosscontamination.
Double Cone Blender Manufacturers in India
Raj Process offers a range of highquality double cone blenders engineered for maximum performance and efficiency. The design ensures minimal product degradation, making them ideal for sensitive materials. Built with durable materials and advanced manufacturing techniques, our blenders provide efficient, gentle, and uniform mixing solutions for powders and granulation.
With years of expertise in process equipment, Raj Process has earned its reputation as a trusted name in the industry, delivering reliable, highperformance solutions that optimize production processes and enhance product quality.
Design Highlights
Threeside accessibility
Higher clearance under discharge
Small floor space requirements
Competitively priced
Dependable blending
Applications
Efficient and uniform mixing
Versatile use across industries
Chemical industry
Cosmetic products
Food industry