An ECOICE Initiative · ETHANABER™ Proprietary Process

India’s food grows on urea made from imported fossil gas.
We make it from green ethanol.

Almost every bag of urea on Indian farms is made from LNG — fossil gas shipped in from abroad. We want to change that. We make the very same urea from green ethanol, made by India’s own sugar mills and distilleries. Same fertiliser for the farmer. No fossil gas. No imports. A fully sustainable India — starting from the soil. We call it ETHANABER™.

B-Heavy Molasses Route

Also Runs on Grain Ethanol

Zero fossil feedstock

100% indigenous & renewable

Three plants you can order today — what each costs, makes and returns

Profit figures assume your own ethanol at ₹52/L and ethyl acetate selling at ₹120/kg. The full-scale cost is an early estimate (±50%). Final scope and price are confirmed when you order.

Today

India’s urea is made from imported LNG

Source: Natural gas. India’s own fields supply about one-third. The other two-thirds is LNG, shipped in mainly from West Asia.
Quantity: Urea plants need 46–50 MMSCMD of gas. India produces 14–17.
Impact: ₹1.19 lakh crore of urea subsidy a year. Every $1/mmBtu rise in LNG adds ₹2,800 crore. Fossil carbon in every bag.

→

Tomorrow

It is made from India’s own ethanol

Source: Ethanol from sugarcane and grain, converted at the mill or distillery by the ETHANABER™ process.
Quantity: One 60 KLPD complex makes 6,108 t of BioUrea™ a year — enough for 40,720 acres, 1.45× the cane land that feeds it.
Impact: No imported gas. About 65,000 t CO₂e avoided a year per complex. The value stays with the mill and its farmers.

Crop to ethanol to fertilizer, and back to the crop. The same loop works wherever ethanol is made — which is how farming becomes truly sustainable, in India first and then worldwide.

The Problem

India makes its own urea. But not its own gas.

Urea is made from hydrogen. Today that hydrogen comes from natural gas, and most of that gas is imported. So when gas prices jump anywhere in the world, the cost of feeding India jumps with them. That one fact causes five problems.

We import energy to grow our food. 70–80% of the cost of making urea is natural gas. India's own gas covers only about a third of what the fertilizer plants need. The rest comes by ship. So India's food depends on other countries' gas.

The government pays a huge bill it cannot predict. The fertilizer subsidy is about ₹1.7 lakh crore a year. Urea alone is about ₹1.2 lakh crore. Every time world gas prices rise, the Government of India pays more.

Fertilizer is made far from the farm. A few very large gas plants make it. It then travels thousands of kilometres to reach the field. The jobs and the profit stay in industrial cities, not in the villages.

It pollutes, and it has to. Making hydrogen from natural gas (steam methane reforming) releases a lot of carbon dioxide, and the heat for it also comes from fossil fuel. That is how the process works. It cannot be cleaned up without changing where the hydrogen comes from.

Our ethanol stops at petrol. India has built a big ethanol industry through the Ethanol Blending Programme. But ethanol can do far more than burn in an engine. Today almost none of that extra value is captured.

In one line: India’s food is grown with fossil-gas fertilizer. We are here to make it green.

The Answer

Green urea from green ethanol

Our process takes ethanol and splits it into two things: ethyl acetate, a solvent that sells well, and hydrogen. The hydrogen becomes ammonia. The ammonia, joined with the CO₂ from fermentation, becomes BioUrea™. It is the same fertilizer the farmer already uses. Only the starting point is different. This is India's first integrated renewable nitrogen platform.

Bioethanol

↓

ETHANABER™ Catalytic Dehydrogenation

↓

Renewable Hydrogen

↓

Haber-Bosch

↓

Renewable Ammonia

↓

BioUrea™

↓

Circular Agriculture

What makes this different: we do not build a new fertilizer factory somewhere far away. We add this to a sugar mill or distillery that already exists. The same cane then gives ethyl acetate, hydrogen, ammonia, BioUrea™, food-grade CO₂, steam and electricity — all renewable. Nothing becomes waste. Everything becomes a product.

In one line: every sugar mill and distillery can become a green fertilizer plant — run on its own ethanol, its own CO₂ and its own bagasse energy. Less imported gas for India. More value for farmers, industry and villages.

Who Wins

Good for the farmer, the mill, the country and the air

The Farmer

Fertilizer made nearby, from the farmer's own cane. A steadier supply. And in a cooperative mill the farmers are the owners — so the profit from fertilizer comes back to them.

The Mill or Distillery

More products from the same cane. More income for the mill and its village. Sugar and ethanol are no longer the only earners, and less depends on imported LNG.

India

Less imported energy. More value added at home. Fertilizer that keeps flowing even in a world crisis. This is Atmanirbhar Bharat and the bioeconomy, in practice.

The Air

Hydrogen from a crop, not from gas. The CO₂ from fermentation is used, not released. Steam and power come from bagasse. About 65,000 tCO₂e avoided every year, per complex.

What your order builds for India

Each plant is one more step off imported gas.

The money stays with the farmer

India spends about ₹1.19 lakh crore a year in subsidy on urea made from imported, price-swinging gas. Fertilizer made at the mill keeps that value with the mill and its farmers.

Farming free of fossil carbon

Urea made from crop ethanol, not fossil gas. From the field, back to the field.

Freedom from world shocks

No war, shipping strait or LNG price decides what Indian food costs.

A fossil-free supply chain

Green ethyl acetate, green hydrogen and green ammonia give industry inputs with no fossil gas behind them.

Step 1 proves it.Step 2 puts green ethyl acetate and green hydrogen on the market.Step 3 makes green urea and leads the switch.

In Numbers

One mill. Five green products. Zero fossil gas.

This is what one 60 KLPD complex makes in a year. Each number has a short note on why it matters.

0t/yr

Renewable Ethyl Acetate

The main earner — 84% of revenue. Made from ethanol alone, without a drop of acetic acid.

0t/yr

Green Hydrogen

It comes with the ethyl acetate — nobody has to buy it. This hydrogen is what makes the fertilizer possible.

0t/yr

Green Ammonia

Made the usual way (Haber-Bosch), like any ammonia. But the hydrogen came from cane, not gas.

0t/yr

BioUrea™ (46% N)

Exactly the same as normal urea. The farmer sees no difference. The country does.

0t/yr

Sugar Co-Produced

The mill keeps making sugar. That business can be even bigger than the chemicals.

0tCO₂e

Emissions Avoided / yr

Like taking about 28,000 cars off Indian roads, every single year.

There's a different way to grow nitrogen.

Project BioUrea™ turns sugarcane into ethyl acetate, green hydrogen, green ammonia and green urea. No natural gas. No imported LNG. No acetic acid. Here is why that matters.

The Grave Reality, Today

A war 3,000 km away can change the cost of feeding a billion people.

Every tonne of Indian urea starts with hydrogen made from natural gas, and two-thirds of that gas is imported. When one shipping route through the Strait of Hormuz is disturbed, the cost of feeding India moves within weeks. No drought. No crop failure. Nothing changes on the farm. And still, fertilizer prices nearly triple.

India's Urea Subsidy, FY26

₹1.19lakh crore/yr

India's biggest single subsidy. And it rises and falls with a market India does not control.

What Government Absorbs, Per Tonne

₹20,000–61,000per tonne

The farmer always pays ₹5,360. The government pays the rest. That gap is large in a calm year and much larger in a crisis.

Domestic Gas Meets

~33% of demand

India's 30 gas-based urea plants need 46–50 MMSCMD of gas. India's own fields give only 14–17. The rest is imported, at a higher price.

The Four Numbers That Matter

What one complex is worth

The full working behind each number is under How It Works, Plants & Profit and Why India Needs It.

Total Revenue

₹184.5Cr/yr

Ethyl acetate + BioUrea + CO₂ only. Sugar (₹329–363 Cr) and power export (₹44 Cr) are extra — see Plants & Profit.

Core EBITDA Range

₹19–47Cr/yr

It depends on one choice: buy the ethanol, or use your own. Nothing else matters as much.

Avoided Emissions

~65,000tCO₂e/yr

Range 53,400–76,800 tCO₂e/yr. Like ~28,000 cars off the road, or 3 million trees planted.

Fertilizer Reach

40,700acres

Green fertilizer for Indian farmland, made from Indian sugarcane, under the Indian sun.

Why B-Heavy

Why B-heavy molasses: sugar and fertilizer, both

We compared three ways of getting ethanol from cane. B-heavy molasses is the balance. The mill still makes plenty of sugar, and still has enough ethanol for the chemicals, at a normal mill size.

Route	L Ethanol / t Cane	Cane Required	Acreage	Sugar Co-Produced	Verdict
C-Heavy Molasses	10.8	1.83M t	56,559 ac	210,800 t	Sugar-dominant, mill ~7× larger
B-Heavy Molasses — SELECTED	21.75	910,345 t	28,097 ac	86,483 t	Balanced — our choice
Full Juice / Syrup	84	235,714 t	7,272 ac	0 t	No sugar business at all

Checked twice: the project visuals show 910,000 t cane / ~28,084 acres / 86,500 t sugar / ₹346 Cr revenue for B-heavy. Recalculated separately here: 910,345 t / 28,097 ac / 86,483 t / ₹329–363 Cr — ₹346 Cr sits exactly at the midpoint. The numbers agree to within rounding.

India's food depends on gas it has to import.

Here is what that costs the country, what it means for the farmer, and how much carbon this project takes out.

On this page

The National Stakes

A war 3,000 km away changes the cost of Indian food

These are the Government of India's own budget numbers.

This is the structural problem in one picture: India's gas-based urea plants need 46–50 MMSCMD of natural gas, but domestic production supplies only 14–17 MMSCMD — roughly a third. The rest is imported, which means the price of feeding India is only ever as stable as the shipping route the gas travels on. The infographic below shows what happens to that price when the route isn't stable: LNG more than doubling during the 2026 West Asia crisis, and urea's landed cost following it almost exactly.

Grave reality of fossil-based Indian agriculture

46–50 MMSCMD gas required, only 14–17 MMSCMD domesticClick to zoom ↗

Total Fertilizer Subsidy FY26

₹1.68lakh Cr

Roughly 3% of the entire Union Budget, on one input.

Urea Subsidy Alone

₹1.19lakh Cr

India's single largest direct subsidy line item.

FY23 Crisis Peak

₹2.25lakh Cr

What one bad year in global gas markets costs India.

Domestic Gas Meets

~33% of need

Two-thirds of urea's core feedstock is imported.

Here's the mechanism behind that number, made concrete. The farmer's price at the counter — ₹5,360 per tonne — hasn't moved since March 2018, regardless of what's happening in global gas markets. Every rupee of difference between that fixed price and the real cost of production is absorbed by the government as subsidy. In a stable year that gap is already large; in a crisis year, it more than doubles. The farmer never sees the volatility — the exchequer absorbs all of it.

Farmer pays ₹5,360/t always — government absorbs the restClick to zoom ↗

Scenario	Cost/tonne	Farmer Pays	Subsidy Gap	Govt. Absorbs
Normal market	₹25,300–28,650	₹5,360	₹19,950–23,290	~80%
Crisis (Apr 2026, West Asia)	₹65,300–66,850	₹5,360	₹59,960–61,490	~92%

The single sharpest argument in this whole project: the incremental cost of green, hydrogen-route urea is roughly ₹5,000–25,000/tonne above conventional. India's own subsidy volatility — the swing from ₹19,950 to ₹61,490 per tonne between a calm year and a crisis — is larger than that entire gap. This isn't "green urea is cheap." It's "the volatility India already tolerates is bigger than the cost gap green urea needs to close."

What one plant saves the government

Calm-Year Scenario

₹12.2–14.2Cr/yr avoided

6,108t × ~₹20,000–23,000/t subsidy gap

Crisis-Year Scenario

₹36.6–37.5Cr/yr avoided

What one plant would have saved during exactly the crisis India just lived through. Scale to 100 plants: ₹3,500–5,700 Cr/yr.

Agriculture & Circularity

From cane to clean fertilizer — all Indian, all renewable

The whole B-heavy loop from the project visual, checked against this dashboard's own calculation.

This one picture shows the whole loop. Sugarcane comes in. Sugar and B-heavy molasses come out. The molasses is fermented into ethanol. The ethanol goes to the ETHANABER™ and BioUrea™ stages. The CO₂ is captured and used in the urea plant, not released. Every figure on it is checked against the tables below. It is the same route as the spreadsheet, drawn as one story.

Grain runs the identical loop. Swap the leftmost boxes — maize or surplus rice in, DDGS as the co-product instead of sugar — and every downstream step (ethanol → ETHANABER™ → BioUrea™ → circular agriculture) is unchanged. Full grain-route numbers are under How It Works.

Sugarcane through CO₂ recovery — B-Heavy Molasses routeClick to zoom ↗

Sugarcane Land

28,097acres

Visual: ~28,084 — matches

Sugar Co-Produced

86,483t/yr

Visual: 86,500 — matches

BioUrea™

6,108t/yr

Visual: 6,105 — matches

Fertilizer Reach

40,700acres

At 150 kg/acre — matches

Application rate — verified for sugarcane

Application Rate	Acreage Fertilized	Source
150 kg/acre/yr	40,700 acres	Mid-range Indian agronomy for cane — matches visual
250 kg/acre/yr	24,420 acres	Heavier dose for high-yield cane

The vision, stated plainly: today, the nitrogen that grows India's food comes from gas pumped through the Strait of Hormuz. Project BioUrea™ grows it instead from sugarcane rooted in Indian soil — fixing carbon from the atmosphere, closing the loop, and handing the farmer the same product at the same price, with none of the geopolitical fragility. This is what a transition from a fossil agricultural economy to a renewable one actually looks like, one integrated complex at a time.

Carbon Balance

A net-positive carbon story

This is a screening estimate by engineers, not a certified LCA. Every figure comes from the mass and energy balance.

This chart lays out where the carbon avoidance actually comes from — not as one number, but as four separate pathways that each get compared against their fossil equivalent: ethyl acetate against the petrochemical route, hydrogen against steam methane reforming, ammonia and urea against the gas-based process, and biogenic CO₂ utilization against venting it. Adding those four together, with a wide low-to-high range reflecting real uncertainty in emission factors, is how the ~65,000 tCO₂e/yr midpoint figure used throughout this dashboard is built.

Avoided-emissions pathways & total conceptual impactClick to zoom ↗

Avoided Pathway	Low	Mid	High	Basis
Ethyl acetate vs. fossil route	26,800	34,200	41,700	14,883t × 1.8–2.8 kgCO₂e/kg
BioUrea™ vs. grey urea	11,000	15,300	19,500	6,108t × 1.8–3.2 tCO₂e/t
Steam, bagasse vs. coal	—	6,250	—	17,860 MWh × 0.35
Electricity, bagasse vs. grid	—	4,900	—	6,869 MWh × 0.71
Subtotal — production only	48,900	60,600	72,300
+ Urea field hydrolysis (biogenic C)	+4,500			6,108t × 0.733 (IPCC)
Total, all boundaries	53,400	~65,100	76,800

The one caveat that must travel with this: the field-hydrolysis credit is CO₂-only. N₂O from the nitrogen pathway is identical whether urea is fossil or bio-sourced — this project does not reduce field N₂O, and shouldn't be presented as if it does.

≈ Cars off the road

28,000per year

≈ Mature trees planted

3 Mequivalent

≈ Households' power offset

40,000Indian homes

Ethanol goes in. Fertiliser comes out.

Every step, every tonne and every unit of energy is shown here, with nothing hidden.

On this page

Process & Plant

15 steps, in two stages

From splitting the ethanol (ETHANABER™ catalytic dehydrogenation) to finished BioUrea™ prills. Click any diagram to zoom in on a step.

The diagram below is the full ETHANABER™ and BioUrea™ complex, laid out block by block exactly as it would be built. Ethanol comes in on the left; it passes through catalytic dehydrogenation (Block 3, the core proprietary step), separation, and hydrogen purification to yield ethyl acetate and hydrogen. In parallel, fermentation CO₂ and nitrogen feed the ammonia and urea trains along the bottom row, closing the loop from raw biomass to bagged fertilizer. The utilities and offsite facilities strips at the base are the supporting infrastructure every one of those blocks depends on — steam, cooling water, DM water, and the workshop, warehouse and control room that keep the plant running day to day.

Full complex — 15 process blocks, utilities & offsite facilitiesClick to zoom ↗

Block 3 — Catalytic Dehydrogenation

The core innovation

Fixed-bed tubular reactor, copper / copper-chromite catalyst. 240–270°C, 10–20 bar, 1–3 sec residence. Converts ethanol directly to ethyl acetate + hydrogen. No acetic acid in the reaction at all.

Block 6 — Hydrogen Purification

PSA to 99.99%

Pressure swing adsorption, dryer, buffer vessel. Nameplate 2.05 TPD (677 t/yr gross). This dashboard uses the PSA-corrected 647 t/yr net figure downstream — 95% recovery, applied consistently.

Block 13 — BioUrea™ Plant

Ammonia + CO₂ → Urea

HP reactor, carbamate condenser + stripper, decomposer, evaporator, vacuum concentrator, prilling. Output 46% N BioUrea™, identical spec to conventional urea — drop-in for the farmer.

Equipment & materials

What it takes to build it

This second diagram shows what has to be built: the equipment in each stage, the utilities they share, and the metals used (carbon steel, stainless, duplex, alloy). The choice of metal decides both the cost and how well the plant resists corrosion. Read it together with the cost table below to see where the money goes.

BioUrea equipment and material distribution

Stage 1 & 2 equipment, common utilities, material distributionClick to zoom ↗

Equipment cost, section by section

An early, rough estimate (Class 5, ±50%), built from standard sizing rules on our own mass balance. Vendor quotes are needed before financing.

Section	Fab. Steel	Key equipment
1. ETHANABER reactor train	40.3 t	Dehydrogenation reactors (×2), Cu-Cr catalyst
2. Separation / distillation	77.4 t	Recycle + purification columns (azeotrope duty)
3. Hydrogen purification	—	PSA package + H₂ compressor to 150–200 bar
4. Ammonia synthesis	89.5 t	Syngas compressor, Fe-catalyst converter, ASU
5. Urea synthesis & finishing	57.9 t	Ti-clad reactor + stripper, granulator
6. CO₂ recovery & liquefaction	62.6 t	Scrubber, compressor, food-grade bottling
7. Storage & utilities	163.2 t	Tankage, cooling tower, DCS/PLC
Total Purchased Equipment	490.8 t	₹31.11 Cr
Total Installed (Lang 3.5–4.5×)	~1,915–2,514 t	incl. structural + piping steel — cost pending vendor quotes

Carbon Steel

~55%

Stainless 304/316

~30%

Duplex / Ti-Clad

~8%

Alloy / Cr-Mo

~5%

Why 8% of the steel drives the cost: the urea reactor and stripper need duplex/titanium-clad steel because ammonium carbamate is brutally corrosive — just 29 tonnes of steel costing ₹2.80 Cr, roughly 10× the ₹/tonne of the plain carbon-steel storage tanks. Any estimate that ignores this metallurgy will under-price the plant.

Feedstock Flexibility

Not a sugarcane platform. An ethanol platform.

Some people think this only works for sugar mills. It works for any distillery. ETHANABER™ runs on purified ethanol, whatever that ethanol was made from. Sugarcane is our base case — and today most of India's ethanol actually comes from grain.

Grain's share of India's ethanol supply, ESY 2025–26

70%

624 of 895 crore litres supplied to oil companies came from grain — not sugarcane.

Maize alone beats all sugar routes combined

345 vs 271crore L

Maize alone, vs. all sugarcane routes (juice + B-heavy + C-heavy) combined.

Where India's ethanol actually comes from

Through August 2026, Ethanol Supply Year 2025–26.

Feedstock	Supply	Share
Maize	345 crore L	38.5%
Surplus FCI rice	214 crore L	23.9%
Damaged food grains	64 crore L	7.2%
Sugarcane juice	149 crore L	16.6%
B-heavy molasses	107 crore L	12.0%
C-heavy molasses	15 crore L	1.7%

Same platform, same base plant, either feedstock

Recomputed for a grain-fed version of the base 60 KLPD ETHANABER™ plant (15,622 t/yr ethanol) used throughout this dashboard.

	Cane B-Heavy	Cane Direct Juice	Maize (Grain)	Surplus Rice (Grain)
Yield per tonne feedstock	21.75 L	70–84 L	380 L	440–450 L
Feedstock required	910,345 t/yr	235,714 t/yr	52,105 t/yr	44,494 t/yr
Land required	28,097 acres	7,272 acres	~37,760 acres	— (FCI stock)
Ethanol yield / acre	~715 L	~2,300 L	~524 L	—
Admin. price, ESY25–26	₹60.73/L	₹65.61/L	₹71.86/L	₹60.32/L
Distinct co-product	Sugar (86,500 t/yr)	None	DDGS (~14,300 t/yr)	DDGS

The circular model — cane first, grain too

The loop closes on either feedstock: the crop makes the ethanol, the ethanol makes the BioUrea™, and the BioUrea™ goes back onto the land that grew the crop. Base 60 KLPD plant.

Circular loop	Sugarcane (B-Heavy)	Maize (Grain)
Crop in	910,345 t/yr	52,105 t/yr
Land growing it	28,097 acres	~37,760 acres
Food / feed co-product	Sugar 86,483 t/yr	DDGS ~14,300 t/yr
BioUrea™ back out	6,108 t/yr	6,108 t/yr
Land fertilised at 150 kg/acre	40,700 acres	40,700 acres
Fertiliser made vs. own land	1.45×	1.08× cane dose basis

Cane is the stronger loop: a cane complex fertilises its whole catchment and still has ~12,600 acres of BioUrea™ to spare, and it keeps a full sugar business alongside. A maize distillery just about covers its own acreage and adds DDGS as animal feed. The maize figure uses the same 150 kg/acre dose verified here for cane — maize-specific dosing is not separately verified.

The honest cost picture: at the administered/open-market price, maize ethanol (₹71.86/L) is actually the most expensive feedstock option here — pricier than any sugarcane route. But forward-integrated with a maize distillery's own cost (₹53–63/L gross, before DDGS credit) rather than the administered price, and crediting DDGS (estimated ~₹14–15/L at an assumed ₹20/kg DDGS price — not independently sourced, needs verification), effective ethanol cost falls to roughly ₹38–49/L — competitive with, and potentially better than, forward-integrated cane.

Why this matters: grain distilleries are concentrated in Punjab, Haryana, Bihar, Madhya Pradesh and Maharashtra — a materially different geography than the cane belt. This platform's addressable market isn't just "sugar mills in the cane belt." It's every distillery in India producing purified ethanol, from any feedstock, anywhere.

Mass Balance

Four reactions run the whole complex

Each number follows from the chemistry of the step before it. None of it is a market guess. Molar masses: ethanol 46.07, EtAc 88.11, H₂ 2.016, CO₂ 44.01, NH₃ 17.03, urea 60.06.

1 · Fermentation (existing distillery)C₆H₁₂O₆ → 2 C₂H₅OH + 2 CO₂

2 · ETHANABER™ dehydrogenative coupling2 C₂H₅OH → CH₃COOC₂H₅ + 2 H₂

3 · Haber-Bosch synthesisN₂ + 3 H₂ → 2 NH₃

4 · Urea synthesis2 NH₃ + CO₂ → CO(NH₂)₂ + H₂O

No acetic acid, anywhere. ETHANABER is direct dehydrogenative coupling — conventional ethyl acetate plants esterify acetic acid + ethanol. That one difference means zero exposure to acetic acid pricing, and it's why this route needs roughly double the ethanol per tonne of product (half the ethanol becomes hydrogen, not ethyl acetate) — which is exactly what makes the downstream green hydrogen → ammonia → urea chain possible.

B-Heavy chain — cane to ethanol

Stream	Value	Calculation	Status
Sugarcane crushed	910,345 t/yr	19.8M L ÷ 21.75 L/t cane	Cross-checked
Sugar co-produced	86,483 t/yr	910,345 × 95 kg/t cane	Cross-checked
Ethanol plant capacity	15,622 t/yr	60,000 L/d × 0.789 × 330 d	330-day basis
Cane acreage required	28,097 ac	910,345 ÷ 32.4 t/acre	Cross-checked

Nameplate vs. operating days: the P&ID states "21,900 KLPY" (60 KLPD × 365 calendar days). This dashboard uses 330 operating days throughout (~90% uptime), giving 19,800 KLPY / 15,622 t/yr. Both are valid — just never mix them in one calculation.

ETHANABER™ → BioUrea™ — the full chain

Stream	Value	Calculation	vs. Visual
Ethyl acetate	14,883 t/yr	50,000 L/d × 0.902 × 330 d	Matches exactly
Ethanol required	15,881 t/yr	14,883 × (2×46.07÷88.11) ÷ 0.98	259 t/yr (1.7%) above distillery capacity
Hydrogen, gross	681 t/yr	14,883 × (2×2.016÷88.11)	Visual: 677 t / 2.05 TPD — matches
Hydrogen, usable	647 t/yr	681 × 95% PSA recovery	PSA loss applied
Fermentation CO₂, recovered	13,431 t/yr	14,923 gross × 90% capture	Capture eff. applied
Green ammonia	3,534 t/yr	647 × (2×17.03÷3×2.016) × 0.97	Visual: 11.6 TPD — uses gross H₂
BioUrea™	6,108 t/yr	3,534 × (60.06÷2×17.03) × 0.98	Visual: 6,105 t — matches
CO₂ to urea	4,567 t/yr	3,534 × (44.01÷2×17.03)	—
CO₂ surplus (food grade / dry ice)	8,864 t/yr	13,431 − 4,567	Visual: 9,940 — likely omits capture eff.

Circularity — it grows more than it consumes

Cane land

28,097 ac

→

Ethanol

15,622 t

→

Ethyl Acetate

14,883 t

→

Hydrogen

647 t

→

Ammonia

3,534 t

→

BioUrea™

6,108 t

→

Fertilizes

40,700 ac

Verified against real agronomy: at 150 kg urea/acre/yr — independently confirmed against Indian sources citing 130–200 kg/acre specifically for sugarcane — 6,108 t of BioUrea™ feeds 40,700 acres. That's the crop this project is built around, not a generic figure. At 250 kg/acre for high-yield cane, reach is 24,420 acres — both figures shown in your visuals.

This chain isn't cane-exclusive. Every step from Stage 1 onward (Ethanol → Ethyl Acetate → Hydrogen → Ammonia → BioUrea™) runs identically on grain-derived ethanol — maize, surplus rice, or damaged foodgrain. Only the box on the far left changes. See Cane or grain above for the grain-specific version of this same mass balance.

Energy Balance

Powered entirely by the cane's own bagasse

No coal. No dependence on the grid for the main process. The bagasse the mill already has runs everything.

Consumer	Basis	MWh/yr
Ethyl acetate — thermal (steam)	14,883 t × 1,200 kWh-th/t	17,860
Ethyl acetate — electrical	14,883 t × 150 kWh-e/t	2,232
Ammonia loop + ASU	3,534 t × 750 kWh-e/t	2,651
Urea granulation	6,108 t × 180 kWh-e/t	1,099
CO₂ liquefaction	8,864 t × 100 kWh-e/t	886
Total thermal demand		17,860
Total electrical demand		6,869

For scale: the entire new cascade's electricity draw (6,869 MWh/yr) is about what 5,700 average Indian households use in a year. The steam demand averages just ~3.3 tonnes/hour — a rounding error against a sugar mill's boiler house.

Is the bagasse enough?

Total bagasse energy pool

From 910,345 t/yr cane (B-heavy)

910,345 t × 29% yield = 264,000 t bagasse/yr. At 7.37 GJ/t and 80% boiler efficiency:

~431,900MWh-th/yr

New cascade needs

Thermal + electrical combined

The whole ETHANABER + ammonia + urea + CO₂ cascade, together:

24,729MWh/yr

Just 5.7% of the gross bagasse pool.

Honest flag: the gross pool comfortably exceeds the cascade's needs — roughly 17× headroom before the existing mill takes its share. But the existing sugar mill and distillery draw on that same bagasse first, and their exact steam consumption at this specific site has never been provided. The sufficiency conclusion is directionally strong but needs the mill's real boiler data to confirm, not an assumption.

Net energy position

New Cascade Demand

24,729MWh/yr

Gross Bagasse Pool

431,900MWh-th/yr

Headroom Before Mill Draw

17×demand covered

Three plant sizes. Pick the one that fits you.

Start small to see it work. Run a selling plant inside your distillery. Or build the full complex. The price, products and profit of each are below.

On this page

Pick a Plant

Test it. Run it. Lead the market.

It is the same ETHANABER™ process at three sizes. Read the three cards, pick the one that fits you, and press its button to order.

⚡ Pilot-scale kinetics already completed ⚡ 50 KLPD plant ~50% built at an MIDC site = 9-month market lead for early partners

01 · Test it · Proof of Concept

Pilot Plant

100 L/day

Makes: ethyl acetate + green hydrogen

Plant cost

~₹35 lakh indicative

Return: proof and data for your decision. Not built for payback.

See it work on your own ethanol, cane or grain, before you spend big.
Makes about 30 t ethyl acetate and 1.35 t green hydrogen a year.
Gives you the real numbers — yield, catalyst life, utilities — for your big decision.
It is a test unit. It is not meant to earn back its cost.
Your part: you prove, on your own ethanol, that green chemistry works.

02 · Run it · Semi-Commercial Demo

Semi-Commercial Plant

1,000 L/day

Makes: ethyl acetate + green hydrogen

Plant cost

₹1.5 Cr equipment quote

Return: ~₹1.2 Cr profit a year · pays back in ~1.2 years

A real, selling plant inside your distillery. It uses your steam, your ethanol and your crew.
Makes about 298 t ethyl acetate and 13.5 t green hydrogen a year.
Earns about ₹1.2 Cr a year on your own ethanol. Pays for itself in about 1.2 years.
Proves the business — running, selling, margins — before you build big.
Your part: you put green ethyl acetate and green hydrogen on the Indian market.

03 · Lead the market · Full-Scale Investment

Commercial Complex

50–60 KLPD complex

Makes: ethyl acetate + BioUrea™ fertilizer

Plant cost

~₹34 Cr early estimate, ±50%

Return: ~₹64 Cr profit a year · pays back in under a year

Be the market leader. You start 9 months ahead of anyone beginning today.
Makes about 13,570 t ethyl acetate and 5,820 t BioUrea™ a year.
Earns about ₹64 Cr a year on your own ethanol. Pays for itself in under a year.
Invest, co-own or license a complex — for a cane mill, a cooperative or a grain distillery.
Your part: you make green urea for about 40,000 acres and lead the switch.

Steps 1 and 2Ethyl acetate + green hydrogenNo urea section. The hydrogen is sold as hydrogen. Quick to build, quick to earn.

Step 3 · the full complexEthyl acetate + BioUrea™Adds the ammonia and urea section, so the hydrogen becomes fertilizer. The full profit and loss further down is for this urea complex. The 50 KLPD plant now being built is its first stage, the ethyl acetate plant.

How these numbers were worked out: 330 working days a year · 90% selectivity to ethyl acetate, meaning 90% of the reacted ethanol becomes ethyl acetate (a cautious case) · ethyl acetate at ₹120/kg · hydrogen at ₹112/kg (₹10/Nm³) less ₹31.6/kg bottling power · byproduct at ₹70/kg · own ethanol at ₹52/L or bought ethanol at ₹70/L. These are early estimates. Final figures are confirmed when you order.

Specifications

What each plant is, and what it makes

	100 L Pilot	1,000 L Semi-Commercial	60 KLPD Full Scale
Role	Proof of concept	Scale-up demo, first sales	Commercial complex
Ethanol feed	132 L/day	1,316 L/day	60,000 L/day
Ethyl acetate	100 L/day (90 kg)	1,000 L/day (902 kg)	45,580 L/day (41.1 t)
Green hydrogen	4.1 kg/day	41 kg/day	1,869 kg/day
Ethyl acetate per year	29.8 t	298 t	13,568 t
Hydrogen per year	1.35 t (15,150 Nm³)	13.5 t (1.52 lakh Nm³)	617 t (69 lakh Nm³)
Byproduct per year	3.5 t	34.6 t	1,576 t
Ammonia per year	—	—	3,367 t
BioUrea™ per year	—	—	5,822 t
Conversion cost / kg ethyl acetate	~₹40 estimate	~₹15	~₹9
Investment	~₹35 lakh	₹1.5 Cr	~₹34 Cr

Why conversion cost falls with size: the chemistry itself costs about ₹6–9 per kg at every scale — steam, power, catalyst, water. What changes is the crew: a fixed operating team spread over 90 kg a day costs about 15× more per kg than the same team spread over 41 tonnes a day.

Conservative case vs. design basis: this tab holds all three scales to 90% selectivity. The plant design mass balance used elsewhere in this dashboard gives slightly more from the same 60 KLPD — 14,883 t ethyl acetate, 647 t hydrogen and 6,108 t BioUrea™ a year.

Products & Profit

Where the money comes from, product by product

Profit per year from running the plant. Ethyl acetate carries the whole cost of ethanol and conversion. Hydrogen and byproduct are extra income on top.

Own ethanol at ₹52/L	100 L Pilot	1,000 L Semi-Commercial	60 KLPD Full Scale
Ethyl acetate	₹1.2 lakh	₹86.7 lakh	₹47.6 Cr
Byproduct	₹2.4 lakh	₹24.2 lakh	₹11.0 Cr
Green hydrogen (sold)	₹1.1 lakh	₹10.9 lakh	₹5.0 Cr
Total operating profit	₹4.7 lakh	₹1.22 Cr	₹63.6 Cr
Simple payback	7.4 years	1.2 years	0.5 years
Hydrogen turned into BioUrea™ instead	—	—	₹6.4 Cr (+₹1.5 Cr)

Bought ethanol at ₹70/L	100 L Pilot	1,000 L Semi-Commercial	60 KLPD Full Scale
Ethyl acetate	−₹6.6 lakh	₹8.5 lakh	₹12.0 Cr
Byproduct	₹2.4 lakh	₹24.2 lakh	₹11.0 Cr
Green hydrogen (sold)	₹1.1 lakh	₹10.9 lakh	₹5.0 Cr
Total operating profit	−₹3.1 lakh	₹43.6 lakh	₹28.0 Cr
Simple payback	none	3.5 years	1.2 years

Read these with two cautions: the byproduct is valued at ₹70/kg and its buyer is not yet confirmed — at fuel value the totals fall by the byproduct line. And everything moves with the ethyl acetate price: the table below shows how far it can fall before a 5-year payback is lost.

5-Year Payback Lock

The prices that keep payback under 5 years

If ethyl acetate sells at or above the price shown, the plant pays for itself in 5 years or less.

Ethanol price	100 L Pilot needs	1,000 L Semi needs	60 KLPD Full needs
₹45/L	₹117/kg	₹79/kg	₹67/kg
₹52/L (own ethanol)	₹128/kg	₹89/kg	₹77/kg
₹60/L	₹139/kg	₹101/kg	₹89/kg
₹70/L (bought)	₹154/kg	₹115/kg	₹103/kg
Highest ethanol price at ₹120/kg ethyl acetate	₹47/L	₹73/L	₹81/L

What this says: every ₹1/L on ethanol moves the ethyl acetate price you need by about ₹1.46/kg, at every scale — so owning the ethanol matters more than anything else. Full scale holds a 5-year payback even on bought ethanol; the semi-commercial plant holds it on own ethanol with wide room to spare; the pilot is a proof unit and is not bought for payback.

Payback At Every Price

Years to earn back the plant, at each price pair

Find your ethanol price on the left and the ethyl acetate price on top. Green means the plant pays for itself in 5 years or less.

1,000 L/day Semi-Commercial · ethyl acetate + hydrogen · ₹1.5 Cr

Ethyl acetate price →	₹80	₹90	₹100	₹110	₹120
Ethanol ₹45/L	4.5 yr	2.4 yr	1.6 yr	1.2 yr	1.0 yr
Ethanol ₹52/L	56 yr	4.6 yr	2.4 yr	1.6 yr	1.2 yr
Ethanol ₹60/L	loss	loss	5.5 yr	2.6 yr	1.7 yr
Ethanol ₹70/L	loss	loss	loss	10.9 yr	3.5 yr

60 KLPD Full Scale · ethyl acetate + BioUrea™ · ~₹34 Cr

Ethyl acetate price →	₹80	₹90	₹100	₹110	₹120
Ethanol ₹45/L	1.4 yr	0.9 yr	0.7 yr	0.5 yr	0.4 yr
Ethanol ₹52/L	3.1 yr	1.4 yr	0.9 yr	0.7 yr	0.5 yr
Ethanol ₹60/L	loss	4.0 yr	1.5 yr	1.0 yr	0.7 yr
Ethanol ₹70/L	loss	loss	14.6 yr	2.1 yr	1.2 yr

5 years or lessmore than 5 yearsruns at a loss

How to read this: on its own ethanol (₹52/L or less) the full complex pays back within 5 years at every ethyl acetate price shown, and the semi-commercial plant does from ₹90/kg up. On bought ethanol at ₹70/L both need ethyl acetate near ₹110–120/kg. Inside a distillery, with its own ethanol, steam and crew, the conversion cost stays near ₹9–15 per kg and the margin is wide. No plant is free of risk: the two prices in this table are the ones to lock in before you build.

Feedstock Behind Each Plant

What it takes from the field — cane first, grain too

Sugarcane on the B-heavy molasses route is the base case. Maize is shown as the grain alternative for the same ethanol.

	100 L Pilot	1,000 L Semi-Commercial	60 KLPD Full Scale
Ethanol used per year	43,400 L	4.34 lakh L	198 lakh L
Sugarcane crushed (B-heavy)	1,997 t	19,971 t	910,345 t
Cane land	62 acres	616 acres	28,097 acres
Sugar still produced	190 t	1,897 t	86,483 t
Or maize (grain)	114 t	1,143 t	52,105 t
Maize land	83 acres	829 acres	~37,760 acres
DDGS feed co-product	31 t	314 t	~14,300 t
BioUrea™ back to the land (150 kg/acre)	—	—	38,800 acres

The loop closes at full scale: the BioUrea™ from one complex fertilises about 38,800 acres — 1.38× the cane land that feeds it, or roughly the whole maize acreage on the grain route (1.03×). The crop makes the ethanol, the ethanol makes the fertiliser, and the fertiliser goes back to the crop. At the pilot and semi-commercial sizes the hydrogen is sold as hydrogen; the urea section is added at full scale.

What your order builds for India

Each plant is one more step off imported gas.

The money stays with the farmer

India spends about ₹1.19 lakh crore a year in subsidy on urea made from imported, price-swinging gas. Fertilizer made at the mill keeps that value with the mill and its farmers.

Farming free of fossil carbon

Urea made from crop ethanol, not fossil gas. From the field, back to the field.

Freedom from world shocks

No war, shipping strait or LNG price decides what Indian food costs.

A fossil-free supply chain

Green ethyl acetate, green hydrogen and green ammonia give industry inputs with no fossil gas behind them.

Step 1 proves it.Step 2 puts green ethyl acetate and green hydrogen on the market.Step 3 makes green urea and leads the switch.

Place Your Order

Tell us which plant. We do the rest.

Fill this in and press the button. That places your order request. ECOICE then confirms the scope, final price and delivery date with you. You pay nothing until that is agreed.

Which plant is this? Everything in this section is for the complete 60 KLPD urea complex (Step 3), on the plant design basis. Steps 1 and 2 make ethyl acetate and hydrogen only — their numbers are above, under Pick a plant.

Economics

Full-scale profit and loss, every line shown

Switch between buying ethanol and using your own. That one choice changes the result more than anything else. Figures below use cane-route ethanol pricing (₹65/L open-market, ₹52/L forward-integrated). Grain-route ethanol runs the same chemistry at different feedstock economics — see Cane or grain under How It Works.

Ethyl Acetate

₹3.1Cr

2.0% margin — razor thin

BioUrea™

₹10.4–12.9Cr

46–57% margin

CO₂ Bottling

₹5.9Cr

~83% margin

Core EBITDA Total

₹19–21Cr

on ₹184.5 Cr revenue

Ethyl Acetate

₹29.3Cr

18.9% margin

BioUrea™

₹10.4–12.9Cr

Unchanged

CO₂ Bottling

₹5.9Cr

Unchanged

Core EBITDA Total

₹45–47Cr

on ₹184.5 Cr revenue

Ethyl acetate — full cost build-up

Line	Calculation	Open Market	Fwd-Integrated
Revenue	14,883t × ₹104,000	₹154.8 Cr	₹154.8 Cr
Ethanol feedstock	20.13M L × price	₹130.8 Cr	₹104.7 Cr
Utilities	steam + power	₹3.8 Cr	₹3.8 Cr
Opex (11% of rev)	catalyst+labour+maint	₹17.0 Cr	₹17.0 Cr
EBITDA		₹3.1 Cr (2.0%)	₹29.3 Cr (18.9%)

Break-even selling price: ₹101.7/kg on open-market ethanol (2.3% cushion) vs. ₹81.9/kg forward-integrated (real cushion). Sensitivity: ₹1/kg EtAc price ≈ ₹1.33 Cr EBITDA; ₹1/L ethanol ≈ ₹2.01 Cr. Ethanol sourcing is worth a ₹26 Cr/yr swing on this one product alone.

BioUrea™ — full running cost

Item	Conservative	Adjusted	Note
Electricity	₹2.62 Cr	₹2.62 Cr	NH₃ loop + granulation, rebuilt
Labour	₹1.60 Cr	₹1.07 Cr	⅓ shared with EtAc crew
Packaging	₹1.50 Cr	₹0.38 Cr	Bulk vs. retail bagging
Maintenance	₹1.30 Cr	₹0.87 Cr	Shared overhead
Steam	₹1.20 Cr	₹1.20 Cr
Nitrogen (ASU)	₹1.11 Cr	₹1.11 Cr
Carbon Dioxide	₹0.91 Cr	₹0.91 Cr	Corrected from a 10× error
Administration	₹0.80 Cr	₹0.53 Cr
Chemicals	₹0.60 Cr	₹0.45 Cr	Catalyst line stripped
Cooling + DM water	₹0.60 Cr	₹0.60 Cr
Total OPEX	₹12.25 Cr	₹9.74 Cr
EBITDA (Rev ₹22.6 Cr)	₹10.4 Cr (46%)	₹12.9 Cr (57%)

The honest structure: BioUrea is profitable because hydrogen is genuinely free — a byproduct of a reaction run anyway for ethyl acetate. Charge hydrogen at its ₹300/kg replacement value and the urea unit would lose ₹10.5 Cr/yr standalone. That's not a weakness; it's the whole point of integration. Urea contributes ~69% of core EBITDA despite being a fraction of revenue.

BioUrea™ at real market prices — farmer price plus subsidy

Everything above prices BioUrea™ at a flat ₹37,000/t "equivalent value." But if BioUrea™ is sold into the same system as conventional urea, its true realized revenue is farmer MRP + government subsidy — the full amount a urea producer actually receives, which moves with global gas prices exactly as shown under Why India Needs It. Here's what that does to the numbers.

Scenario	Realized Price/t	BioUrea™ Revenue	OPEX	BioUrea™ EBITDA
Normal market (worst case)	₹25,300–28,650	₹15.5–17.5 Cr	₹12.25 Cr	₹3.2 Cr
Crisis market (best case)	₹65,300–66,850	₹39.9–40.8 Cr	₹9.74 Cr	₹31.1 Cr

Worst case pairs the lowest normal-market realized price with the conservative (fully standalone) OPEX build. Best case pairs the highest crisis-market realized price with the logically-adjusted (shared overhead) OPEX build. Both are real, self-consistent scenarios — not a single blended guess.

Ethyl acetate + BioUrea™ — combined profit, worst & best case

Worst Case — Open-Market Ethanol + Normal Urea Market

₹6.3Cr EBITDA

EtAc ₹3.1 Cr + BioUrea™ ₹3.2 Cr, on ₹170.3 Cr combined revenue — a 3.7% margin. The floor case if nothing goes your way.

Best Case — Forward-Integrated Ethanol + Crisis Urea Market

₹60.4Cr EBITDA

EtAc ₹29.3 Cr + BioUrea™ ₹31.1 Cr, on ₹195.6 Cr combined revenue — a 30.9% margin. Both levers moving favorably at once.

The honest range is wide, and that's the point: ₹6.3–60.4 Cr is nearly a 10× spread on the same two products. It isn't model uncertainty — it's two real, external variables (ethanol sourcing and the global gas cycle) that this project doesn't control but is directly exposed to in both directions.

Sugar, CO₂ & power — the three upside lines

Sugar Co-Product (B-Heavy)

₹329–363Cr/yr revenue

86,483 t/yr at ₹38–42k/t. Belongs to the existing mill's economics, not modeled here — but potentially larger than the entire chemicals platform.

CO₂ Bottling (Food Grade / Dry Ice)

₹7.1Cr/yr revenue

8,864 t/yr at ₹8,000/t, ~₹5.9 Cr EBITDA at ~83% margin. Already inside the core ₹184.5 Cr revenue figure — the most certain of the three lines here.

Power Export (unverified)

₹44.0Cr/yr

Rests on a 22–25 MW cogen assumption never checked against the mill's actual boiler capacity. Treat as upside pending verification.

Updated View

P&L at current commercial urea rate, CO₂ excluded

A separate, more cautious version. Only ethyl acetate and BioUrea™ count as income. CO₂ is treated as an input — nearly free, from the host distillery's own fermentation — not as something this complex sells. Urea is priced at the real market rate (what farmer price plus government subsidy add up to today), not the flat ₹37,000/t assumption used above.

WORST CASE — Open-Market Ethanol + Stable Urea Market

₹7.3–9.9Cr EBITDA

₹171.3–174.5 Cr revenue — a 4.3–5.7% margin.

BEST CASE — Forward-Integrated + Crisis Urea Market

₹57.4–59.9Cr EBITDA

₹194.5–195.7 Cr revenue — a 29.4–30.7% margin.

	Ethyl Acetate EBITDA	Urea EBITDA	Combined
Worst case	₹3.1 Cr	₹4.2–6.8 Cr	₹7.3–9.9 Cr
Best case	₹29.3 Cr	₹28.1–30.6 Cr	₹57.4–59.9 Cr

Urea pricing basis: ₹25,000–29,000/t in a stable market, ₹65,000–67,000/t during a gas-price crisis — the actual production/import cost range, not the ₹5,360/t farmer price. Selling directly at this rate captures what would otherwise be split between the farmer and the government subsidy.

This is not just a plan. It is being built.

A 50 KLPD plant is about half built. The pilot tests are done. And the team has built plants before.

On this page

ETHANABER™ Stage 1 · MIDC Industrial Site

Real assets, real progress, on the ground today

50 KLPD Ethyl Acetate manufacturing plant at an MIDC industrial site. This is not a concept — civil works, fabricated equipment and site infrastructure are already in place.

⚡ 6-month lead on physical construction ⚡ 3-month lead from completed pilot-scale kinetics = 9 months ahead of competition, combined

Plant Complete

50KLPD

Ethyl Acetate Capacity · MIDC Site

On Site

Major Fabricated Equipment Delivered

~50% PHYSICAL PLANT COMPLETION · MIDC INDUSTRIAL SITE

On The Ground

The work so far, in photographs

Civil works, storage, the boiler section and fabricated distillation columns at the 50 KLPD plant. Click any photo to enlarge it.

Storage shed - steel structure erected — Storage shed — steel structure erected

Shed interior - clear-span floor, foundations cast — Shed interior — clear-span floor, foundations cast

Boiler section - foundations and civil works — Boiler section — foundations and civil works

Underground storage tank - RCC walls built — Underground storage tank — RCC walls built

Storage tanks - three units under construction — Storage tanks — three units under construction

Site - structures and columns going up — Site — structures and columns going up

Distillation column shell - fabricated, on site — Distillation column shell — fabricated, on site

Column sections and trays - delivered — Column sections and trays — delivered

Column shells - ready for erection — Column shells — ready for erection

Pilot-Scale Validation

Twin reactor setup — kinetics already done

Before any big spending, the reaction speeds (kinetics) and the scale-up were already tested on this twin-reactor rig. That takes much of the risk out of the commercial design before it is built.

Twin reactor pilot lab setup — 50 L/day capacity, instrumented & automatedClick to zoom ↗

Pilot Configuration

Twinreactor setup

Parallel reactors enable direct kinetics comparison and scale-up validation in a single campaign.

Throughput

50L/day capacity

Sized specifically for process kinetics and scale-up study, not production — a deliberate, de-risking step before commercial scale.

Studies Completed

Kinetics + Scale-Updelivered

Reaction kinetics and scale-up data already in hand — the step most competitors haven't reached — worth a 3-month lead on its own.

Why this compounds the lead: most competing concepts at this stage are still on paper — process design without validated kinetics. Having both a twin pilot reactor's kinetics data and a half-built commercial plant simultaneously is unusual. Combined, these two facts put this project a full 9 months ahead of a typical competing proposal starting from the same point today — 6 months from physical construction already in the ground, plus 3 months from kinetics and scale-up data already in hand.

Our Leadership

The Minds Engineering the Future

One leadership team, one mission — combining process engineering, commercial execution, and sustainability strategy to build technologies that redefine water, chemicals, energy, and industrial decarbonization.

The Team

Meet the people behind ECOICE

02 · Commercialize

Managing Partner

Vikrant Indulkar, MBA

The Growth Strategist

"Great technology changes nothing until the world adopts it."

Signature Persona

Market BuilderPartnership CreatorStrategic CommunicatorBusiness LeaderCommercial Expansion Specialist

Expertise

Business Development & Market Strategy
Strategic Partnerships & Tech Commercialization
Go-to-Market Strategy & Investment Readiness
Brand, Corporate Relations & Client Acquisition

Impact

Driving commercialization strategies that connect engineering innovation with industry adoption. Building markets. Creating value. Scaling impact.

01 · Ideate

CEO & Founder

Dr. Karan Chavan, Ph.D.

The Sustainability Architect

"Where others see environmental regulations, he sees billion-dollar engineering opportunities."

Signature Persona

VisionaryBuilderSustainability StrategistSystems ThinkerTechnology Commercializer

Expertise

Lifecycle Assessment (LCA) & Carbon Strategy
Process Development & Green Chemistry
Industrial Decarbonization & Circular Economy
Net-Zero Roadmaps, ESG Strategy & Climate Tech
Biorefineries & Advanced Water Systems

Impact

12+ years experience · multiple proprietary technologies · cross-industry projects across water, energy, chemicals & manufacturing · Founder, ECOICE.

"Turning climate challenges into scalable industrial opportunities."

Years Combined Experience

Industrial & Sustainability Projects

Global

Cross-Industry Impact

Lab → Market

Technology Commercialization

Founder Deep Dive

Why Dr. Karan Chavan is a rare combination

Nine things worth knowing about the person leading Project BioUrea™ — each independently verifiable, each unusual on its own.

National policy impact. PACE PET LCA work fed into a National Green Tribunal proceeding that helped set India's EPR recycling policy — engineering work that changed national policy for 1.4 billion people's plastic waste management. Extremely rare for an individual engineer's LCA to reach that level of policy influence.

11 million tonnes CO₂e/year. The NALCO decarbonisation roadmap LCA is the largest number in the portfolio — roughly the annual emissions of 2.4 million cars, NPC-stamped and government-accepted.

A rare credential combination. Ph.D. (Tech.) from ICT Mumbai — India's top chemical engineering institute — combined with an imminent Canadian P.Eng. and a 90% score on the specialist LCA technical exam. This exact combination is uncommon in Canada.

Remote turnkey delivery. Netsurf Biofit — a 45 KLPD biofertilizer plant — designed and delivered turnkey in India while managed remotely from Toronto, successfully commissioned. A genuine feat of remote industrial project management.

Opened a market. VoDCa technology validated across all 21 streams with stream-specific design rules — Baramati +17% biogas (+4,000 m³/day), Jubilant ~21%, Dhampur >10%. VSI certification secured for distillery biogas enhancement — VSI is the only body of its kind in the world for this purpose — opening the affiliated-distillery market and unlocking access across 220+ cooperative distilleries in Maharashtra.

Academic credibility alongside delivery. 3 peer-reviewed papers, 1 Elsevier book chapter, 55+ citations. Most consultants don't publish; most academics don't deliver large commercial engineering projects. This track record does both.

Unusual public engagement. Organizer of 5 climate hackathons and the BioPolicyX event, plus Climate Roast — reaching 1,000+ people across Climate Roast 2026 Pune ("Climate Rap") and Toronto ("Climate Comedy"), and ranked #2 at Toronto Climate Week 2026 (@crack4climate). Also presented "No Open Land Policy" at ICPP 6, the 6th International Conference on Public Policy, Toronto, June 2023. Genuinely unusual and memorable as a communication vehicle for climate engineering.

Three world-first technologies in development. Trayambakam (emissionless decentralised pyrolysis), Jalshuddhi (off-grid sewage-to-potable water), and Project Droplet (air-propulsion autonomous solar marine vessel) — each addressing a genuine gap in existing commercial solutions.

International research fellowships. Visiting Research Fellow at the University of Oulu, Finland (LCA of water treatment) and the University of Cantabria, Spain (LCA of arsenic treatment), under the GreenTech New INDIGO Project, European Commission, 2013. Presented at the 9th World Congress of Chemical Engineering, Seoul, 2013, and the 20th Annual Green Chemistry & Engineering Conference, Portland, 2016.

From concept to commercialization, ECOICE's leadership integrates sustainability vision, engineering excellence, and strategic execution to deliver industrial technologies with measurable environmental and economic impact.

Engineering Capability

Past Projects & Process Engineering Portfolio

ECOICE does contract research, process design and turnkey equipment manufacturing — the same skills that stand behind ETHANABER™ and BioUrea™.

R&D Facility

4lab domains

Gas chromatography, UV-Vis, COD analysis, biotechnology & chemical technology labs

Bioreactor Range

10L–1000Lscale-up

LAF, shaker incubators, full temperature-controlled fermentation train

Product Lines

6equipment categories

Agitators, heat exchangers, evaporators, reactors, distillation columns, bio-fermenters

Turnkey Deliveries

Multiplecommissioned plants

Full process design through commissioning, including remote project delivery

Product range — equipment engineering & manufacturing

Design, fabrication and commissioning capability across the core unit operations that also underpin the BioUrea™ complex.

Agitators & Mixing

Top & bottom entry, side entry (fixed/swivel), twin shaft dispersers, static mixers, high-speed homogenizers — hydrofoil, anchor & Ruston turbine blade designs, CFD-verified.

Heat Exchangers / Condensers / Pasteurizers

Shell & tube and plate designs across process heating, cooling and pasteurization duty.

Evaporators

Falling film, forced circulation and ATFE (agitated thin film evaporator) — engineering design, manufacturing and commissioning in-house.

Reactors & Storage Tanks

Glass-lined and stainless process reactors with integrated agitation, plus bulk storage tankage.

Distillation Columns

Multi-tray column design and fabrication — directly transferable expertise to the ETHANABER™ separation train.

Bio-Fermenters

Pharmaceutical and industrial-grade fermentation vessels, lab through commercial scale.

Delivered projects

Netsurf Biofit — 45 KLPD Biofertilizer Plant

Parwanoo, Himachal Pradesh

Full turnkey delivery: process design, procurement, ETP fabrication, cGMP cleanroom (ISO 14644-1), commissioning, and remote handover from Toronto. Bacterial fermentation plant installed on floors 3–4 of an existing industrial building, engineered around 3–6 inch ceiling clearances.

Hand Sanitizer Manufacturing Plant

Export-Grade Turnkey Line

FDA-documentation-compliant sanitizer production line, built for export to regulated markets. Delivered alongside Netsurf Biofit as one of ECOICE's turnkey manufacturing projects.

10 TPD Coconut Oil → MCT Plant

Process Development & Commercial Delivery

Medium chain triglyceride (MCT) production from coconut oil — process development and feasibility analysis, 10–13% MCT yield with >85% of remaining oil utilized as food-grade coconut oil (AV<12). Demonstrated at 20L scale, then piloted and commissioned at 10 TPD commercial scale.

MRO Purification & Recovery Optimization

Contract Research & Process Development

MRO testing and process development to increase yield and recoveries; biodiesel production from lean streams of the MRO purification process; new solvent system development for lutein ester purification; zeaxanthin purification from paprika oleoresin.

Solid-Liquid Extraction System

Rotating Disc Contactor Design

Design and implementation of a Rotating Disc Contactor (RDC) for lecithin separation and purification, plus a multi-stage solid-liquid extraction setup.

Integrated Fermentation & Filtration System

Agricultural Biotechnology

Integrated fermentation and filtration process design and delivery for an agricultural biotechnology application.

Commissioned industrial plant, ECOICE delivery

A commissioned industrial plant, as deliveredClick to zoom ↗

Why this matters for BioUrea™: the ETHANABER™ and BioUrea™ complex leans on exactly this equipment stack — reactors, distillation columns, evaporators, heat exchangers, agitated vessels. This isn't unproven engineering territory for the team; it's the same discipline scaled to a new chemistry.

India’s food grows on urea made from imported fossil gas.We make it from green ethanol.

India’s urea is made from imported LNG

It is made from India’s own ethanol

India makes its own urea. But not its own gas.

Green urea from green ethanol

Good for the farmer, the mill, the country and the air

The Farmer

The Mill or Distillery

India

The Air

Each plant is one more step off imported gas.

One mill. Five green products. Zero fossil gas.

There's a different way to grow nitrogen.

A war 3,000 km away can change the cost of feeding a billion people.

India does not have a urea problem.India has a fossil-gas import dependency problem.

What one complex is worth

Why B-heavy molasses: sugar and fertilizer, both

India's food depends on gas it has to import.

A war 3,000 km away changes the cost of Indian food

What one plant saves the government

Every $1/mmBtu rise in LNG = ₹2,800 Cr added to India's subsidy bill.

From cane to clean fertilizer — all Indian, all renewable

Application rate — verified for sugarcane

A net-positive carbon story

Ethanol goes in. Fertiliser comes out.

15 steps, in two stages

Block 3 — Catalytic Dehydrogenation

Block 6 — Hydrogen Purification

Block 13 — BioUrea™ Plant

What it takes to build it

Equipment cost, section by section

Not a sugarcane platform. An ethanol platform.

Where India's ethanol actually comes from

Same platform, same base plant, either feedstock

The circular model — cane first, grain too

Four reactions run the whole complex

B-Heavy chain — cane to ethanol

ETHANABER™ → BioUrea™ — the full chain

Circularity — it grows more than it consumes

Powered entirely by the cane's own bagasse

Is the bagasse enough?

Total bagasse energy pool

New cascade needs

Net energy position

Three plant sizes. Pick the one that fits you.

Test it. Run it. Lead the market.

Pilot Plant

Semi-Commercial Plant

Commercial Complex

What each plant is, and what it makes

Where the money comes from, product by product

The prices that keep payback under 5 years

Years to earn back the plant, at each price pair

What it takes from the field — cane first, grain too

Each plant is one more step off imported gas.

Tell us which plant. We do the rest.

Full-scale profit and loss, every line shown

Ethyl acetate — full cost build-up

BioUrea™ — full running cost

BioUrea™ at real market prices — farmer price plus subsidy

Ethyl acetate + BioUrea™ — combined profit, worst & best case

Sugar, CO₂ & power — the three upside lines

P&L at current commercial urea rate, CO₂ excluded

This is not just a plan. It is being built.

Real assets, real progress, on the ground today

The work so far, in photographs

Twin reactor setup — kinetics already done

The Minds Engineering the Future

Meet the people behind ECOICE

Why Dr. Karan Chavan is a rare combination

Past Projects & Process Engineering Portfolio

Product range — equipment engineering & manufacturing

Agitators & Mixing

Heat Exchangers / Condensers / Pasteurizers

Evaporators

Reactors & Storage Tanks

Distillation Columns

Bio-Fermenters

Delivered projects

Netsurf Biofit — 45 KLPD Biofertilizer Plant

India’s food grows on urea made from imported fossil gas.
We make it from green ethanol.

India does not have a urea problem.
India has a fossil-gas import dependency problem.