Lilongwe
08048032993
Sugar and Biofuel Industry

2G Ethanol Plant

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Phone Number

08048032993

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Email Address tejas@raj-india.com

Mon-Thu: 10 AM - 2 PM • Fri: 3 PM - 7AM

Address Lilongwe

Lilongwe, Central Region, Malawi, 1

Description

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.

Plant Capacity 10 KLPD to 500 KLPD
Methane Recovery (from Slop) Integrated with CBG (optional)
Steam Consumption 3.5 - 4.2 Kg/Lit of Ethanol
Power Consumption 0.45 - 0.60 KWh/Lit
MOC (Process Section) SS 316L / duplex stainless steel
Water Requirement Recycled through ZLD (Zero Liquid Discharge)

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