PPT

Project Report Re-using AshMaking Vanillin(from Bagasse & Rice Husk)

Re-using AshFrom Bagasse and Rice Husk

Project Overview The Project is about re-using the Waste Ash

generated from Sugar & Rice Mills and generating revenue from it.

It is a completely new en devour never tried before in the industry on a large scale.

We have two distinct options to recycle the waste with varied uses and costs.

The scope is great with an ever increasing market for the generated goods in India.

Block Diagram of the Project

ASH

EXTRACTION

SILICA

SELL AS RAW MATERIAL

GLASS MEDICINES OTHERS

SILICON METAL

SILICON STEEL E.CHIPS SOLAR

PANELS

NON-EXTRACTION

MAKE PARTICLE BOARD

PORTLAND CEMENT

Crop production Patterns in Maharashtra

Dhule District

Name of Crops Area Production Productivity

Kh.Rice 51 54 1059

Sugarcane 35 2057 59

Note : Area in "00" ha., Production in '00' Tonnes. Productivity in Kg/ha

Nashik District


Kh.Rice 508 702 1382


Jalgaon District

Name of Crop Area Production Productivity

Kh. Rice 4 4 1000


Aurangabad District


Kh.Rice 3 2 667


Thane District


Kh.Rice 1386 3288 2372

Su.Rice 24 66 2730

Ahmednagar District


Kh.Rice 80 58 725


Raigad District


Kh.Rice 1245 2759 2216

Su.Rice 85 213 2605

Pune District


Kh.Rice 676 851 1259


Ratnagiri District


Kh.Rice 791 1865 2358

Su.Rice 2 7 3728

Satara District

Name of Crop Area Production Prodcitivity

Kh.Rice 441 729 1653


Solapur District


Kh.Rice 4 1 250


Sindhudurg District


Kh.Rice 745 2108 2830

Su.Rice 43 85 1976

Kolhapur District


Kh.Rice 1105 2791 2526

Su.Rice 6 22 3654


Sangli District


Kh.Rice 177 442 2497


Particle Board from Ash(Bagasse & RH)

IntroductionParticleboard is a classic wood-based panel, made from high quality particles of wood / bagasse. It is a low – density board with density range from 650 kgs to 750 kgs per cubic meter. Particleboard Plants are specially designed to produce an effective alternative for wood-based panel products.The Plant utilizes low – cost agri-wastes resulting in a high quality & versatile panel product with virtually unlimited applications. Particleboard is accepted universally.

Market for Particle BoardIndustries that use Particleboard include construction and packaging. High quality Particleboard has the strength, durability & screw-holding capacity of near MDF, which makes it suitable for widespread use in the furniture industry such as bedroom units, fitted kitchens, shelves & tables. It is also used in household electrical appliances, laminate flooring, cabinets & floor underlayment. Particleboard has good mechanical performance of fine, neat & smooth finish. It meets the growing demand amongst consumers & manufacturers alike for environmentally – friendly alternatives.Particleboard comes in 6 mm to 30 mm thickness & in the density range of 650 – 750 kg/m3. Average bulk density is 700 kg/m3 on the average thickness of 18mm.

Advantages of ParticleBoard

1. Low Capital investment & lower operating costs.2. Low energy requirement3. Readily available local raw material4. Cheaper price than MDF5. Low density & lower weight than MDF, which makes it suitable for certain applications.

Indian Market Potential for Particle BoardThe Working Paper by FAO estimated the demand for industrial round wood in India (other than fuel wood) as under –

Wood raw material requirement in India - (in million cubic meters)

Sector Year 2000 Year 2005 Year 2010

Sawnwood (For housing, furniture, agri-implements, sports goods, packaging, etc.)

47.00 50.00 54.00

Pulp (Paper, newsprint) 23.60 28.50 35.00

Plywood 1.45 1.69 1.92

Particleboard 0.34 0.49 0.65

Fibrewood (Hardboard) 0.22 0.32 0.41

MDF 0.40 0.67 0.95

Total 73.01 81.67 92.93

As per FAO, the requirement of sawnwood by 2005 will be around 50 million cubic meters, which is equal to Rs. 60,000 crores in monetary terms. As against this, the availability of sawnwood in India is only 47 million cubic meters & some quantity is imported, draining valuable foreign exchange.Bulk of the industrial round wood in India is utilized by the saw milling industry, consisting of more than 23,000 units. It is estimated that each sawmill will generate 100 – 120 tons of sawdust & wood cuttings per year on an average and make available totally 2.5 million tons of wood wastes, which can provide necessary raw material for more than 50 new Particleboard Plants in India.The projected demand for Particleboard by 2005 is 4,90,000 cubic meters, whereas the combined Capacity of the Plants operating in India is only3,00,000 cubic meters. The shortage is covered by Particleboard imports at high prices.

Process Description for Particle BoardThe Particleboard production line mainly includes Material preparation section, Drying, Screening, Resin blending, Mat forming, Hot pressing, Edge trimming & Sanding. The process also needs Energy supply by way of Steam / Hot oil & Electricity.

Silica from Ash (Bagasse/Ash)

Introduction

Rice husk is an agricultural residue abundantly available in rice producing countries. The annual rice husk produce in India amounts is generally approximately 12 million tons. Rice husk is generally not recommended as cattle feed since its cellulose and other sugar contents are low. Furfural and rice bran oil are extracted from rice husk. Industries use rice husk as fuel in boilers and for power generation. Among the different types of biomass used for gasification, rice husk has a high ash content varying from 18 – 20 %. Silica is the major constituent of rice husk ash and the following tables gives typical composition of rice husk and rice husk ash. With such a large ash content and silica content in the ash it becomes economical to extract silica from the ash, which has wide market and also takes care of ash disposal.

Composition of Rice husk ash on dry basis.

Element Mass Fraction %

Silica (SiO2) 80 – 90 %

Alumina 1 –2.5 %

Ferric oxide 0.5 %

Titanium Nil

dioxide Calcium oxide 1 – 2 %

Magnesium 0.5 – 2.0 %

oxide Sodium oxide 0.2 – 0.5 %

Potash 0.2 %

Loss on 10 – 20 %

Ignition

Element Mass Fraction %

Carbon 41.44

Hydrogen 4.94

Oxygen 37.32

Nitrogen 0.57

Silicon 14.66

Potassium 0.59

Sodium 0.035

Sulfur 0.3

Phosphorous 0.07

Calcium 0.06

Iron 0.006

Magnesium 0.003

UsesPrecipitated silica can be tailor made to meet the requirements of various uses. Some of the applications are:

1. Rubber industry – as a reinforcing agent

2. Cosmetics

3. Tooth pastes – as a cleansing agent

4. Food industry – as an anti-caking agent

Typical Properties of Silica Precipitated 1. Nature: Amorphous powder 2. Appearance: White fluffy powder 3. Purity: > 98 % 4. Surface Area: 150 - 200 m2/gm 5. Bulk density: 120 – 200 g/liter 6. Loss on Ignition: 3.0 – 6.0 % 7. pH of 5 % slurry: 6.3 + 0.5 8. Heat loss: 4.0 – 7.0 % The properties like

surface area, pH, Tap density can be tailor made for the requirement

PROJECT REPORT ON MAKING VANILLIN (BAGASSE & RICE HUSK)

Mr. Uday WaghMr. Shazaad ChinoyInnovation Advisors – Annapurna Foods & Drugs Private Limited

Introduction Vanilla is a climbing terrestrial orchid grown in warm

humid tropics. It is the second most expensive flavouring spice after saffron. Vanilla planifolia is the commercially grown variety. Growing of vanilla beans is quite complicated and labour intensive and its processing is a slow process requiring skills. Quality of vanilla beans depends on the vanillin content (minimum 1.8-2.0% normally) and presence of 250 aromatics. Vanilla has a wide application. Beans are used for producing extracts, flavours, oleoresins and powders and have a wide range of use in dairy products, ice creams, for flavouring tobacco, liquors, beverages and confectionaries, savoury applications, medicinal purposes, health and personal care products and as an odour maskant in tires, paints, industrial chemicals etc.

Indian Vanilla: Road AheadIndia is currently producing 100MT of cured beans, which is likely to rise to 400 MT by 2006 as many growers in Karnataka, Kerala and Tamil Nadu have taken up vanilla cultivation as monocrop as well as intercrop in the year 2001-02. In the absence of demand for natural vanilla concentrates in India and large-scale natural vanillin extraction facilities in India, almost entire production of cured beans is exported to other countries in particular to USA, UK, France and Germany for further processing and extraction of natural vanillin. India’s domestic market for vanillin is completely dominated by synthetic vanillin due to its low price and easy availability. India imports around 600-700 MT of synthetic vanillin, which is mostly consumed by food and beverages industry (200 MT), ice-cream industry alone consuming about 130 MT. Hence instead of letting Indian Money flow outside the country we can capture it right here at convenient prices.

Indian vanilla, according to industrial sources is at par with Madagascar Bourbon vanilla in terms of vanillin content and quality, which made importers source vanilla beans from India in order to meet the demand of natural vanillin. In 2003-04, India exported 26 MT of cured vanilla beans at Rs. 36.06 crore (US$ 8 million) registering a phenomenal annual average growth rate of 92 % between 1999-2003. According to certain latest estimates by Spices Board, vanilla exports from India have posted a 90% increase in quantity and a higher average price than Madagascar at US$ 47.30 a kg of cured beans during last fiscal. India came into the market with a small production last year at about 50 MT only. Currently India has 100MT of cured beans to offer to the international vanilla market.

Since the last season Indian growers has been fetching Rs. 900 (US$ 20) per kg of cured vanilla beans and on an average of Rs. 250 –275 (US$ 5.5-6) for a kg of green beans. As per industry sources, currently Indian vanilla has been enjoying fairly good demand in the US, France, Germany, the Netherlands, UK and Japan. Considering the export potential, Spices Board has been encouraging vanilla cultivation as an intercrop to coconut, arecanut, coffee, cardamom and other spices in the states of Tamil Nadu, Karnataka and Kerala and also intends to provide support facilities for the expansion of area under the cultivation of vanilla, as an intercrop, to the states of Andhra Pradesh, Maharashtra, Madhya Pradesh, Orissa, West Bengal, Andamans and North Eastern States.

Vanilla TradeVanilla is internationally traded as pods or cured beans and its is the largest importer of the cured beans and extractors of natural vanilla extracts followed by EU and Japan. The type or “category,” of vanilla used determines how ice cream is labelled in the USA:

Category 1: Natural vanilla extract. Two-fold vanilla is commonly used. Ice cream products must be labeled as “vanilla ice cream.”

Category 2: Vanilla-vanillin extract. This is considered natural and artificial (N&A), where the natural component is the characterizing flavour. Ice cream products must be labelled as “vanilla flavoured ice cream.”

Category 3: Natural and artificial vanilla flavours or artificial vanilla flavours, where the artificial component predominates. Ice cream products must be labelled “artificially flavoured vanilla ice cream.”

Bagasse: Our raw material

Bagasse is the fibrous matter that remains after sugarcane or sorghum stalks are crushed to extract their juice. It is currently used as a biofuel and in the manufacture of pulp and paper products and building materials.

Production, storage and compositionFor each 10 tonnes of sugarcane crushed, a sugar factory produces nearly 3 tonnes of wet bagasse. Since bagasse is a by-product of the cane sugar industry, the quantity of production in each country is in line with the quantity of sugarcane produced.The high moisture content of bagasse, typically 40 to 50%, is detrimental to its use as a fuel. In general, bagasse is stored prior to further processing. For electricity production, it is stored under moist conditions, and the mild exothermic reaction that results from the degradation of residual sugars dries the bagasse pile slightly. For paper and pulp production, it is normally stored wet in order to assist in removal of the short pith fibres, which impede the papermaking process, as well as to remove any remaining sugar.

A typical chemical analysis of bagasse might be (on a washed and dried basis):Cellulose 45–55%Hemi cellulose 20–25%Lignin 18–24%Ash 1–4%Waxes < 1%Bagasse is an extremely inhomogeneous material comprising around 30-40% of "pith" fibre, which is derived from the core of the plant and is mainly parenchyma material, and "bast", "rind", or "stem" fibre, which comprises the balance and is largely derived from sclerenchyma material. These properties make bagasse particularly problematic for paper manufacture and have been the subject of a large body of literature.

Process for extraction of lignin materials: 1) There are several processes can be used to remove and/or isolate and/or purify the lignin from biomass material cells. The alkaline methods are generally more effective because they are able to solubilize a greater fraction of lignin, also they are more vantage compared to other pretreatment technologies. 2) This method breaks down the hydrogen bonds in the lignocellulosic biomass fractions by removal of the surrounding lignin structure hemicellulose and cellulose and recovering the resulting soluble monomeric.

The Actual Process

Bagasse Extraction Analysis

Bagasse (g) alkaline treatment

(M)

% of main components extracted

p-coumaric

acid Ferulic acid Syringic acid Vanillin

0.5 79.61 16.21 1.10 3.08

1.0 76.36 17.58 1.49 4.57

1.0 2.0 74.01 19.03 1.81 5.14

3.0 75.78 18.49 1.69 4.05

4.0 76.10 18.78 1.79 3.34

0.5 76.83 15.44 3.19 4.53

1.0 67.40 18.90 3.97 9.72

2.0 2.0 69.04 19.26 3.37 8.33

3.0 67.27 21.12 3.95 7.65

4.0 78.91 15.80 2.45 2.85

0.5 83.41 14.96 0.82 0.80

1.0 82.13 16.04 0.97 0.86

3.0 2.0 79.98 17.31 1.34 1.37

3.0 80.59 17.33 1.50 0.59

4.0 78.79 18.36 1.82 1.04

0.5 76.04 19.10 1.79 3.07

1.0 73.79 20.59 2.38 3.24

5.0 2.0 67.00 24.40 3.31 5.28

3.0 71.68 21.10 2.87 4.35

4.0 71.49 20.23 3.18 5.10

Use of Fly Ash as Fertilizer

Prospects of bulk use of Fly Ash in Agriculture Approximately 260 million tonne of coal is consumed

per annum by 82 utility thermal power plants (TPPs) in India (2003-04). It constitutes nearly 70 percent of the total power generation, which in turn, produced 108 million tonne of fly ash per annum. The annual generation of fly ash is projected to exceed 175 million tonne per annum by 2012 (considering the plans to double the power generation over next 10 years). This large volume of fly ash occupies large area of land and possesses threat to environment. As such, there is an urgent and imperative need to adapt technologies for gainful utilization and safe management of fly ashes on sustainable basis.

Agriculture and waste land management have emerged as prime bulk utilization areas for flyash in the country.

The field demonstration experiments carried out under varied agro-climatic conditions and soil types across the country by various R & D Institutes / Universities on the cultivation of different field crops (cereals, pulses, oil seeds, sugar cane, vegetables, etc. ) and forestry species with different doses of fly ash and pond ash as soil modifier / source of economical plant nutrients with and without organic manure bio-fertilizer and chemical fertilizers in respect to crop yield, soil health, quality of crop produce, uptake of nutrients and toxic heavy metals, ground water quality etc. have revealed the following:

Advantages of Fly-Ash in Agriculture It improves permeability status of soil Improves fertility status of soil (soil health) /

crop yield Improves soil texture Reduces bulk density of soil Improves water holding capacity / porosity Optimizes pH value Improves soil aeration Reduces crust formation Provides micro nutrients like Fe, Zn, Cu, Mo, B,

Mn, etc.

Provides macro nutrients like K, P, Ca, Mg, S etc. Works as a part substitute of gypsum for reclamation

of saline alkali soil and lime for reclamation of acidic soils

Surface cover of bio reclaimed vegetated ash pond get stabilized and can be used as recreational park

Ash ponds provides suitable conditions and essential nutrients for plant growth, helps improve the economic condition of local inhabitants

Works as a liming agent Helps in early maturity of crop Improves the nutritional quality of food crop Reduces pest incidence Conserves plant nutrients / water Carry over of trace & heavy metals & radioactivity is

insignificant Crops grown on fly ash amended soil are safe for

human consumption & groundwater quality is not affected.

Use of Fly ash in Land Development for Agriculture To explore the possibility of using coal ash as soil

modifier and nutrients supplier for upgrading soil for its use in agriculture and to improve the productivity, Regional Research Laboratory, Bhopal has carried out extensive lab scale and pilot scale experiments.

These studies indicate that coal ash contains micro and macro nutrients and also improves physical and morphological properties of the soil. Water retention capacity of soil, together with release of nutrient elements such as Ca, Mg, S, K, P, Cu and Zn have increased considerably by admixing appropriate quantity of coal ash with soil.

The process has been successfully implemented on large scale in various parts of the country such as NTPC, Rihand Nagar (Uttar Pradesh ), NALCO, Angul & Damanjodi (Orissa) and� MPEB, Sarni (Madhya Pradesh ) with the financial support by the respective industry and Fly Ash Mission, TIFAC, DST, New Delhi.

Crops, such as wheat, paddy, maize sunflower, sugar cane, tomato, potato, cabbage, pea, carrot, onion, okara, berseem, aromatic and medicinal plants have been grown in wasteland soil and soil treated with coal ash.

These crops were tested to check the consumer acceptability / toxic elements uptake and it was found heavy metals uptake are within the permissible limits and meet the food quality standards.

Usage of coal ash for wasteland development improves the soil fertility, enhances the plant growth, increases the crop yield and saves irrigation water without affecting the food quality.

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