Annual Report 2001 - 2002

Technology Development

Instrumentation Development Programme (IDP)

Instrumentation is one of the major areas of Science & Technology which makes a great impact on vital sectors of national activities such as education, scientific research, industry, agriculture, medicine and health etc. The Department of Science & Technology (DST) has been promoting the area of Instrumentation through its Instrumentation Development Programme (IDP) with the objective of strengthening indigenous capability for research, design and development of instruments in the country leading to their indigenous development and production, continuous updating of the technology to keep pace with technology improvements taking place globally, and innovations in the area of instrumentation. Programmes are evolved and projects are supported under IDP for research/ design/development and for innovations in different areas of instrumentation which are identified from time to time. About 50 projects are currently under implementation in identified areas of Analytical, Medical, Environment monitoring & pollution control, Test & measuring, Food processing, Geo-scientific, Agri-electronic, Textiles, Leather instrumentation and sensors at various R&D organisations in the country.

Instruments/systems Under Development

Some of the major instruments/systems under development are as follows:

Instrumental colour matching for leather processing, PC based polarimeter, An equipment for study of real time kinetics of ligand-ligate interaction, Rheometer, Computer aided visualisation of shoe lasts -a bio-mechanical approach, Temperature controlled microwave histoprocessor, Strain gauge force transducer to measure applied force upto 1MN, Portable urea sensors and measuring system for detection of adulteration in milk, Low cost user friendly polyaniline based sensor for toxic gases, Continuous infrared heating system for food processing, drying, baking and roasting, Portable analytical X-ray imaging instrument for bio-medical applications, Clinical chemistry analyser, Anasthesia ventilator, Microprocessor based ECG simulator, Treatment applicator for treatment of carcinoma cervix for high and medium dose rate radiation source, Sodium/potassium analyser, Optimised electrical parameters for electrically enhanced transdermal drug delivery instrument, Computer based kit for children with learning disabilities, Vascular microendoscope of various diameters, Blood pump control and monitoring unit with disposable centrifugal pump head for extra corporal cardio pulmonary by-pass, Online freeness tester for paper and pulp industry. Ground water level monitoring and recording unit, Evaporation rate monitoring unit, Automation and upgradation of basic zone refiner, Online fabric fault identification system using image processing, Instrument for scanning and separation of contaminants from Indian cotton. Bio-sensor with flow injection system, Metal oxide human breath sensor are also under development.

New Projects Supported

Development of the following instruments/systems were initiated/supported:

Confocal microscope for biological applications, High pressure differential thermal analyser, Real time sound analyser, High temperature calibration system, Multifunctional tester for rapid and accurate determination of blend ratio, cotton maturity, cotton sugar (honey dew) and wax content, Microprocessor/microcomputer based intrumentation control on the indigenous section warping machine, Sol-gel based fibre optic immunosensor for measurement of myoglobin and other blood proteins.

Instruments/systems Developed

Some of the major instruments/systems developed are as follows:

• X-RAY Diffractometer (Powder)

X-ray diffractometer(powder) has been developed at NPL, New Delhi. The diffractometer consists of a horizontal type goniometer assembly including precision control turn table, Soller slits and limiting slits, specimen holder, a detector arm and scintillation counter. The precise movements of the specimen and the detector arm are microprocessor/PC controlled. Almost all the major components of the instrument including slit systems/Soller slits, goniometer and scintillation counter have been developed indigenously. The goniometer has provision for independent rotation of specimen(q), the detector (2q) or coupled q-2q motions. The range of 2q movements is from -1000 to + 1600 with a resolution of 18 arc seconds. A comprehensive software has been developed for automation of the diffractometer. It allows automatic acquisition of experimental data and its processing. The instrument can be used in R&D labs and industries for a wide variety of applications including determination of crystal structure of bulk materials and non destructive crystalline phase analysis etc. in the areas of material science, crystallography, geophysics, metallurgy and other related areas.

• Glow Discharge Lamp Atomic Emission Spectrometer

The Glow discharge lamp Atomic Emission Spectrometer has been developed at CSIO, Chandigarh. The DC as well as RF (13.56 MHz) glow discharge lamp sources and the Atomic Emission Spectrometer including polychromater have been developed. The polychromater has been designed for five channels. The instrument is PC controlled and has on-line data acquisition system for GD-Atomic Spectroscopy. The instrument is useful for elemental analysis of solid samples in the areas of geology and metallurgy etc.

• Portable Stack Opacity Monitor for Chimneys and Kilns

This instrument is designed and developed to measure smoke opacity in percentage emitted from the stack of various industries. In the absence of smoke, maximum light will fall on the sensor, this corresponds to zero % opacity of smoke. Whereas in the presence of smoke in the absorption channel, less light will fall on the absorption channel, less light will fall on the sensor and corresponding % smoke opacity will be displayed. When whole light is obstructed, no light will strike the sensor and this corresponds to 100% opacity of smoke.

• Multiple User Field Operated Data Recorder and Analyser for Geotechnical Applications

This is a digital device developed around 16 bit Microprocessor 80C 86 for recording and processing of Geo-technical parameters. It is a low power consuming device based on C-MOS technology components with in built timing system and is capable of handling 32 sensors simultaneously having in built channel programming facility for all from channel 01 to 32. The system works on five operating modes such as initialization, timing, data logging on demand data display and download modes with RS-232 interface to Laptop PC connectivity. The data can be of represented in graphical mode for long period of studies. It is field usable, rugged to sustain all kind of weather conditions. It can be used under 40 to 500 C with 100% humidity shield. The system works on a single +12 Volts battery.

• Computer Based Information Module for Cancer Patients

Computer based Information Module for Cancer patients has been developed with an objection to provide on information Package to Cancer Patients and to professionals of other specialities at three level of computer literacy. The package consists of multimedia visual effects with video clippings of clinical pictures and question answer sessions in an interactive mode with scoring methods which may make an impact and contribute usefully to the patient as well as Doctors. The package, "Know your Cancer" programmes have been developed with the help of some of the country's top Oncologists in 11 different Modules for various cancers. It includes information on signs, symptoms, preventions, treatment and its effects as well as cost involved.

• System for estimation, monitoring and control of energy consumption at different stages of yarns in mills

The system has been developed at BTRA, Mumbai and successfully demonstrated at M/s. Bombay Dyeing, Mumbai. The system will help in reducing energy consumption at different stages of spinning yarns in mills. The technology developed is in the process of being transferred to M/s. Real Technology, Mumbai.

• Light fastness testing machine for yarns

The Light fastness testing machine has been developed at SASMIRA, Mumbai. It will be manufactured by SASMIRA itself. It consists of Air cooled Xenon burner, 3 position burner intensity control, low power consumption, separate record of lamp hour & Machine hour and accurate high-resolution control for test chamber environment.

• Micro-Humidity Sensor

Micro-humidity sensor has been designed and developed at CEERI, Pilani. It is fabricated from a high purity aluminium substance. Electrochemical, anodisation and a thin water grow the porous humidity sensitive oxide layer permeable gold film is deposited on oxide surface. The size of sensor chief is 3 mm in diameter.

• Automation in Rice/Grain Flaking Industry

A dedicated control system for the control of product temperature in the continuous roaster has been developed. Retrofitting of this PLC-based PID control system on to the existing continuous roaster has been completed. The systems were tested individually and also in unison. The temperature variation in the final product which was in the range of 5-10 degrees Centigrade in the manual system was brought down to + 0.50 C, The system responds linearly, when tested individually for paddy, jowar and maize grains. A PC based LVDT control system for cereal roller flaker has been developed (Fig. 5), for use in the flaking of cereal grains like rice, jowar and maize.

Many more instruments/systems including Dispergraph for measurement of carbon black dispersion in rubber, Electrofusion apparatus for immunotherapy and DNA transfusion, Computer controlled system for mixed juice flow stabilisation in plantation white sugar manufacturing process, Capacitive ceramic humidity sensor, Co Gas Sensor and associated instrumentation also have been developed.

The prototype of Atomic Force Microscope developed at CSIO, Chandigarh has been purchased by Bharathiar University, Coimbatore for utilisation under a project sponsored to them by DRDO. The instrument has been successfully installed and is working satisfactorily.

Commercialisation of Technologies

Know-how of the following instruments have been transferred/allowed to be transferred by R&D organisations to industries for commercial production:

• Piston gauge Pressure Standard upto 80MPa to M/s. Waaree Instruments (P) Ltd., Mumbai.
  
• Microhardness Tester to M/s. Vaisheshika Electron Devices, Ambala.
  
• Magnetron Sputtering Targets to M/s. Hind High Vacuum Ltd., Bangalore .
  • RF Generator(500 Watt).
  • Magnetic sensor.

The Government of India constituted the Technology Development Board in September 1996. The objective is to encourage development and commercialisation of indigenous technologies and adaptation of imported technologies for wider domestic applications. The Board provides financial assistance (equity, loans, grants) to industrial concerns and other agencies.

During the year 2001-02, the Board signed 4 agreements with 4 commercial enterprises. The total cost of these projects, to be implemented by the commercial enterprises, is Rs. 18.93 crore. The Board sanctioned a loan assistance of Rs.5.42 crore.

Since its formation in September 1996, the Board has signed 91 agreements with the total project cost is Rs.1007.40 crore including the Board's committed assistance of Rs. 363.50 crore. The 91 agreements include 3 agreements with 3 agencies and the balance with the commercial enterprises spread over 15 States and Union Territories.

The Board has provided a real opportunity to new entrepreneurs / technopreneurs particularly at the start-up and early stages. This also helped some of them to obtain funds with ease from financial institutions and commercial banks. There were 20 new enterprises among the Board's beneficiaries.

The financial assistance by the Board covers various sectors such as Health & Medical, Engineering, Chemicals, Agriculture, Transport, and Energy and Waste Utilization. The technology providers included in-house R&D units in the industry, national laboratories, academic institutions, private R&D labs and individuals. Largely, the Board's beneficiaries are closely-held public limited companies and private limited companies.

On May 25, 1998, the Prime Minister announced that 11th May will henceforth be celebrated as 'Technology Day'. In response, the Board decided to institute a 'National Award for successful commercialisation of indigenous technology' by an industrial concern to be given away on Technology Day every year. The national award consists of two components: (i) to the industrial concern successfully commercialised the indigenous technology and (ii) to the developer/provider of such technology. Each component will carry a cash award of five lakh rupees. The cash award is exempt from income tax.

The Vice President of India, was the Chief Guest at the Technology Day 2001 - National Awards Function. The Vice President presented the National award - 2001 to M/s TTK Healthcare Limited, Chennai in recognition of their success in commercializing the production of artificial heart valve prosthesis and to Sree Chitra Tirunal Institute for Medical Sciences and Technology, Thiruvananthapuram, for the development of Chitra valve and as provider of the technology. TTK Chitra Heart Valve Prosthesis is a highly critical, life saving long-term implant. The valve has undergone the most painstaking development for 12 years following international protocols for artificial heart valve development and qualification. It has 12 patents including Indian patent, a European patent and a US patent. The Chitra Heart Valve Prosthesis was cleared for commercial production in February 1995.

The cash award of Rs. 2 lakhs to a SSI unit was given away by the Vice President to M/s Midas Communication Technologies Private Limited, Chennai, that has successfully commercialized WLL based technology product.

Minister for Human Resource Development, Science and Technology and Ocean Development, launched five products on the Technology Day, 11th May 2001. These were Reva battery operated car by M/s Reva Electric Car Co. (Private) Limited, Bangalore; Metadichloro Benzene by M/s Goodwill Organics Private Limited, Mumbai; Bio-pesticide based on Bacillus thruingiensis var. kurstaki (B.t.) by M/s Ajay Bio-tech (India) Limited, Purandar, Pune district; Calcium Gluconate salts by M/s Prathista Industries Limited, Secunderabad; and Beta-Carotene extracted from Marine Micro Alga Dunaliella Salina by M/s Shantha Marine Biotechnologies Private Limited, Hyderabad. The Board has provided financial assistance to all these commercial enterprises. Minister of State for Science and Technology inaugurated the Technology Day 2001 Exhibition.

The enterprises provided with loan assistance from the Board and which have commenced commercial production in 2001-02, are:

• A company based in Andhra Pradesh commenced production of indigenously developed three active pharmaceutical ingredients.
  
• A company based in Gujarat commenced the commercial production of abrasive silica.

The Board organized and participated in a number of interaction meetings with industry, industry associations, R&D organizations and academic institutions. Joint Technology Projects - Technology Systems

Some broad features of projects supported under this scheme are given below:

Completed Projects

• HTSC SQUID- HTSC SQUID electronics interface by NPL & CEERI.
  
• 64/128 bit dedicated FAX channel Encryption/Decryption of DES codes by CEERI using micro controllers.
  
• Feasibility studies of large Super conducting Generator by BHEL R&D Centre.
  
• 5MVA LTSC Generator assembly/reengineering done and ready for final testing.
  
• LTSC SMES/UPS engineering & demo at IIT Kharagpur.
  
• Low cost digitalisation of old Manuscripts & Paintings by NIAS Bangalore & 4 institutes of Department of Culture.
  
• Aerogel Synthesis and characterization by CMET Trissur.

Continuing Projects

Some projects which are continuing are in the areas of:

• NIR Applications & Value additions in Biochemical parameters & estimation in tissues at IIT Delhi, AIIMS.
  
• Communication interface for Disabled at IIT Delhi & AIIMS.
  
• Application of PARAM- 10000 and other Parallel computers in Climate Modeling by IITM & C DAC Pune and IIT Delhi.
  
• Biosensor for detection of traces of Pesticides at ITM Chandigarh.
  
• Fuzzy Logic control of Boilers at BHEL R&D , Hyderabad.

In addition to above, Projects are being evolved in the areas of Aerogel capacitor fabrication and Synthesis; Nanoparticles applications, Intelligent Processing of Materials and NDT applications and Biosensors etc and Superconductivity applications.

Inter-Sectoral Science & Technology Advisory Committees (IS-STAC/STACs)

IS-STAC in DST has evolved joint technology projects which can be demonstrated on industrial scale with the participation of Science and Technology Advisory Committees (STACs) in different socio-economic ministries. These Research Development and Demonstration (RD&D) projects are in the areas in which Ministries are ready to invest funds and take a lead role.

During the year, IS-STAC Secretariat has participated in a number of STAC related meetings held in various Ministries/Departments viz. Department of Mines, Ministry of Shipping, Ministry of Textiles, Ministry of Road Transport & Highways, Department of Coal, Ministry of Steel, Department of Food & Public Distribution, Ministry of Petroleum & Natural Gas, Ministry of Rural Development.

New Projects Evolved

The following important projects were evolved with the joint financial support from concerned ministries and industry as well:

National Facility for Semi-Solid Forming (NFSSF)

This project has been launched with the financial support from DST, Department of Mines and DRDO/ Ministry of Defence. The project will be implemented by the Indian Institute of Science, Bangalore at a total cost of Rs.4.09 crore to be shared between Department of Mines (Rs.2.92 crore), DST (Rs.0.92 crore) and DRDO (Rs.0.25 crore) for a duration of three years.

The objective of the project is to set up a National Facility for Semi Solid Forming as the new technology for the Indian scenario and to help the production of quality aluminium components; and later to be extended to other non-ferrous metals like titanium, magnesium, zinc and metal matrix composites, for the automotive and other sectors of the country. The project once completed would lead to an ongoing R&D Centre for SSF as well as for squeeze cast components. This facility will thus function in close collaboration with industry to provide technology related services. The technology will benefit the Indian engineering industry engaged in the manufacturing of net shaped state-of-the-art components for automobile, defense, electronics, aerospace and other applications.

Development of Process for Advanced Hot Dip Coated Products

The project has been initiated with the joint financial support from DST and Steel Development Fund (SDF), Ministry of Steel. The total cost of the project will be Rs.7.674 crore which will be shared as SDF/Ministry of Steel (Rs.4.526 crore), DST (Rs.1.131 crore) and RDCIS (Rs.1.928 crore) for a duration of three years.

The project will be implemented by the Research & Development Centre for Iron & Steel (RDCIS)/Steel Authority of India Ltd. (SAIL), Ranchi and IIT, Kanpur. The objective of this project are as follows:

• Simulation of Hot Dip Galvanized Process
  
• To develop predictive models for micro-structural evolution of alloy layers and establish process structure - property correlations for producing spangle free coating.
  
• To disseminate technology to the personnel of Indian Galvanizing Industry on application/use of advanced HDPS for improving HDG products

The new technologies to be developed as an outcome of this research project will be improved HDG process to produce advanced HDCP viz.

• Precision controlled zinc coatings with Standard Deviation of coating mass <= 3g per meter square) (for traditional & new market segments)
  
• HDG sheets with zero spangle/spangle-free (< 100 micro meter) finish (for upper market segment, white goods and office furniture)
  
• HDG sheets with EDDQ sustrate having superior formability (Erichsen cup value approx. 10 mm from approx.8.5 mm for 0.6 mm sheets for automotive sector)

The other benefits include possible reduction in energy consumption, reduction in specific raw material consumption and improved productivity.

Major Achievements

Pilot Enrichment Plant for Helium from Hydrothermal Sources and Helium Purification Centre

The above project which was launched last year with the joint financial support of DST and DAE and is being implemented by Saha Institute of Nuclear Physics SINP)/VECC, Calcutta, under Phase-I of the this project, India's first Helium Enrichment Plant was commissioned on 16th June, 2000. This unit, which was initially operated with the simulated gas mixture, has been recently tested for hot spring gas (1.35 vol% of He) collected from Bakreshwar (the site of hot springs). An enrichment of 90% has been achieved. A smaller Pressure Swing Adsorption unit is being developed to concentrate Helium from about 1% to 15%. If this unit becomes functional it would be easier to operate it near Bakreshwar site and would economize on transportation of crude Helium. With regard to Phase-II of the project necessary design and fabrication details of Helium Purification Plant to get 99.995% pure helium have been frozen. The purification plant for which orders were placed earlier is under commissioning.

Advanced Process Control and Optimization Technology for Mineral Processing Plants

The above project which was launched last year with the financial support of DST, Department of Mines and is being implemented by Tata Research Development & Design Centre (TRDDC), Pune has progressed very well. A few significant milestones achieved so far are listed below:

• Design and Installation of Grinding Controller at Hindustan Zinc Limited (HZL), Rampura Agucha plant, Udaipur

Since the Grinding Controller has become online in November, 2000; the plant behavioral data collected so far on performance of Grinding Circuit shows remarkable improvements like reduction in recirculating loads, improvement in troughput to flotation circuit as well as savings in energy consumption which are the key parameters to judge the performance of grinding circuit of the plant.

• Design, Development and control Instrumentation for Flotation Advance Process Controller (FAPC)

The basic control philosophy and strategy has been implemented in Flotation Controller applications. The instrumentation and hardware has been procured and installed. The detailed architecture of the Flotation control application was also developed and demonstrated.

To study various tolerable Indian non-coking coal sources with the aim of maximizing the usage of domestic non-coking coal in the COREX process

The above joint technology project with the financial support from Steel Development Fund (SDF)/Ministry of Steel, DST and Industry (M/S Jindal Vijayanagar Steel Ltd. (JVSL), Bangalore was launched May, 1999. The objectives of the project is to develop knowhow to utilize non-coking coal from indigenous sources in COREX
process. The objective is to be attained by the following major tasks:

• Beneficiation studies of the coal to examine to what extent the ash of the above coals can be reduced by washing.
  
• Characterization of raw and washed coals to determine their suitability for use in the COREX process.
  
• Estimation of expected COREX performance using the above coals by physical and mathematical model studies.
  
• Evaluation of actual process performance trial runs.

The project is being implemented jointly by Indian Institute of Science (IISc.), Bangalore; Central Fuel Research Institute (CFRI), Dhanbad and M/S JVSL Bangalore. So far IISc., Bangalore has completed their work on physical and mathematical model studies and have submitted its report. Based on this report M/S JVSL, Bangalore has already implemented the findings of IISc., Bangalore in the actual COREX plant operations. Following are specially notable achievements:

a) Use of optimum cost blend
b) Modification of DRI screws
c) Addition of 5% nitrogen through tuyers, whenever required
d) Maintenance of skull at the tuyers to avoid burning of bare staves

The work on Pilot plant data for coal beneficiation as per above requirements is in progress at CFRI, Dhanbad.

Development of Pressure Swing Adsorption PSA) Technology for Purification of Crude Helium from natural gas and design estimates of Pilot Plant

The above project was launched last year with the financial support of DST and DRDO/Ministry of Defence. The project is being implemented by Indian Institute of
Petroleum (IIP), Dehradun. In order to develop indigenous capability for extraction of helium from natural gas, it is important to develop PSA technology for purification of crude helium. The studies will have following objectives:

• Screening of potential adsorbents on the basis of adsorption isotherms and adsorption rate measurements on gravimetric microbalance
  
• Column temperature and concentration breakthrough curve measurements with selected adsorbents for broad selection of adsorption and purge cycle times and conditions and estimation of mass and heat transfer parameters
  
• Single and multi-bed PSA experiments for optimization of process parameters with respect to helium product purities and recoveries
  
• Development of simulation model to predict PSA performance for both single and multi-bed units

The progress in the project has been monitored and the experimental results obtained so far from the single bed PSA unit shows that it is possible to increase the purity of helium from 55% - 90% using appropriate adsorbants. IPCL developed adsorbent has being tested. However, considerable optimization with respect to adsorbent selection, cycle time, pressure and flow conditions needed is under progress. The two bed PSA development of PSA Technology is under commissioning. The project once completed will lead to the quantum boost to nations' capability to undertake development and design of indigenous PSA technology for novel applications in the petroleum and chemical industries.

Studies on Production of Alloyed Pig Iron/Cast Iron and Low alloy steel/stainless steel using chromite overburden

The project was launched with the joint financial support of DST, Department of Mines and Industry (M/S Metallurgical & Engineering Consultant (India) Ltd. in the month of June, 1999. The project is being implemented by M/S MECON (India), Ltd., Ranchi. The objective of this project is to demonstrate feasibility of converting the overburden material of chromite mines in Sukinda area in Orissa into Nickel-Chromium bearing value added products for conservation of these strategic metals. The ongoing project seeks to fulfill the following tasks:

• Based on the optimized beneficiation and sintering parameters, industrial trials for large scale beneficiation and sintering of Chromite overburden material at Kalinga Iron Works (KIW), Barbil, Orissa.
  
• Plant trials for making low alloyed pig iron using good quality sinter, produced above through a mini blast furnace (67-87 meter cube capacity)
  
• Production of low alloyed steel (EN24, En25)/stainless steel (AISI 302) using EAF/BOF.

Almost all the above mentioned tasks have been completed except the actual plant trials which are going on at present. The project once completed will lead to the following benefits:

• Development of economically attractive process
  
• Savings in Ferro Alloy consumption
  
• It is expected that development of this process route will provide competitive edge to our alloy steel producers in international market
  
• The effective utilization of the overburden material would reduce environmental pollution

The quality of life of remote and rural communities around the mine shall be greatly improved with the availability of large areas of land resulting from successful exploitation of large quantity of Chromite overburden.

Evaluation of Process variables in continuous scale bio-oxidation of complex sulphide ore/concentrate of Ambamata/Sikkim

The project was launched during 1999-2000 with the joint financial support of DST and Department of Mines. The project is being implemented by Regional Research Laboratory (RRL), Bhubaneswar. It aims at demonstrating bio-leaching plant to produce copper and zinc metal, which at present is being imported. The process thus developed will be utilized in treating concentrates and wastes of copper, zinc and gold mines. The demonstration plant will be first of its kind in the country. The project has progressed well so far and the all the experimental studies have been completed.

The Ministry wise interactions are reported below:

Ministry of Petroleum & Natural Gas

The Scientific Advisory Committee (SAC) convened its 50th (Golden Jubilee) meeting on 9.4.2001 at Digboi Refinery on the occasion of Centenary Year for this
refinery. This meeting reviewed the highlights of R&D work supported so far. A presentation was also made by IS-STAC, DST on highlights of on Joint Technology projects supported with Ministries. SAC has recently been reconstituted for another term of two years under the Chairmanship of Dr. R. A. Mashelkar, Secretary, DSIR and DGCSIR. The reconstituted SAC convened its 51st meeting on 1.12.2001. SAC has decided to come out with a structured mechanism, to formulate the basis for commercialization of results of sponsored R&D projects.

Ministry of Steel

Empowered Committee (EC) of the Ministry of Steel convened its 5th meeting on 20.3.2001 under the Chairmanship of Secretary, Steel. The progress of various ongoing projects were reviewed in this meeting. The joint technology project on COREX Technology which has been jointly supported by IS-STAC and Steel Development Fund (SDF)/Ministry of Steel was also reviewed by making a site visit to the plant at Torangull and IISc., Bangalore. In addition Ministry of Steel recommended DST's participation in two other new joint technology projects titled titled Development of Advanced Hot Dip Coated Products (HDCP) and Development, installation and commissioning of Electromagnetic Stirrer (EMS) for Slab Casters. These projects will be implemented by RDCIS/SAIL, Ranchi and MECON Ltd., Ranchi, respectively.

Ministry of Road Transport & Highways

Tenth meeting of STAC of the Ministry of Road Transport & Highways was convened under the Chairmanship of Secretary (RT&H) on June 6, 2001. The progress of various ongoing schemes was reviewed and a list of schemes to be taken up under three heads viz. Roads, Traffic & Transportation and Bridges was also finalised. It has also been decided to prioritize the thrust areas earlier identified by STAC in 1996. It was pointed out that during the period 1998-2000, 18 research schemes were completed and the Ministry is planning to organize a Seminar on every Friday on these projects. A Compendium of R&D projects which have been funded by Ministry of Road Transport & Highways is proposed to be brought out.

Department of Food & Public Distribution

The 4th meeting of STAC in was convened on 31.1.2001 under the Chairmanship of Secretary, Department of Food & Public Distribution. In this meeting norms for financial support for R&D projects were discussed and finalised on the basis of inputs provided by DST and other agencies. The meeting reviewed ongoing projects and approved a few new projects in vegetable and oil sector.

Ministry of Rural Development

The 2nd meeting STAC in the Ministry of Rural Development was convened on December 7, 2001 under the Chairmanship of Secretary, Rural Development. A presentation was made on the project entitled Pilot project on demonstration and dissemination of protective biodegradable emulsions to prevent wastage of fruits and vegetables, to be taken up jointly with Ministry of Environment & Forests; DST, and Ministry of Food Processing.

Department of Mines

The 29th and 30th meeting of Standing Scientific Advisory Group (SSAG) was convened on 20.2.2001 and 13.9.2001, under the Chairmanship of Additional Secretary, Department of Mines. The important highlight during the year was that Department of Mines sought IS-STAC participation in the project entitled National Facility for Semi Solid Forming which is to be implemented by Indian Institute of Science, Bangalore. The project has been launched as a Joint Technology Project with financial support from IS-STAC/DST, Department of Mines and Defence Research and Development Organization (DRDO)/Ministry of Defence.

Department of Coal

Standing Scientific Research Committee (SSRC) in the Ministry of Coal convened its 33rd and 34th meeting under the Chairmanship of Secretary, Department of Coal on 6.5.2001 and 13.9.2001. A total of 15 new schemes were approved during these meetings. Mission Mode Projects

Sugar Technology Mission

The Mission mode project on Sugar Production Technologies aims to focus on technology upgradation in the Indian sugar industry. The purpose is to achieve cost effectiveness in sugar production through improvements in plant efficiencies, energy saving and reduction in utilization of various inputs. The purpose is also to improve product quality and achieve higher capital out put ratio through use of latest environment friendly technologies.

Technology Upgradation of Sugar Factories

The Sugar Technology Mission has so far taken up site survey of 28 sugar factories for their technological upgradation and completed preparation of detailed technology upgradation schemes in respect of 27 factories. Of the above, financial tie ups have been completed for 15 factories through Sugar Development Fund (SDF) and Financial Institutions. The implementation of schemes are in progress in these factories

Evaluation of New Technologies

The Sugar Technology Mission has already taken up evaluation of about 19 new technologies and systems for the purpose of implementation in commercial sugar factories.

Commercialisation of the following nine technologies have been completed and these are under replication. These technologies are:

• Separate Clarification of Vacuum Filtrate to avoid re-circulation.
  
• PLC based Integrated Clarification Control system fro juice.
  
• Thin Film Sulphur Burner for continuous generation of SO2 to achieve satisfactory juice clarification parameters.
  
• Syrup treatment for production of superior quality sugar.
  
• Low Pressure Extraction (LPE) system for efficient extraction of juice, power saving and reduced maintenance cost.
  
• Automation of pan boiling process to achieve higher throughput and reduce sugar losses in molasses.
  
• NIR technique for online analysis of sugarcane and sugar house products.
  
• PLC based automation of Cooling & Condensing System to achieve steady vacuum at evaporator and pan station with minimum use of electric power.
  
• Enterprises Resource Planning (ERP) for use of information technology for better plant control management.

Follow up activities continue in respect of performance evaluation of following technologies in various sugar factories:

• Use of membranes for cane juice purification.
  
• Short Retention Clarifier to reduce juice retention time during clarification.
  
• Massecuite Filter for separation of sugar crystals from mother liquor.
  
• Development of Cost and Energy Effective Alternate Material for sugar industry.
  
• Juice Extractor for efficient extraction of juice from prepared cane with significant saving of power.
  
• Use of Planetary Gear Box in mill drives to achieve power saving and reduced maintenance cost.

So far, there have been 85 replications of the commercially successful technologies.

Advanced Composites Mission

The Advanced Composites Mission has launched 22 projects nationwide. .The programme has reached out to all the major sectors of Indian economy transportation, building & construction, bio-medical, process industry etc. In the wake of devastating earthquake in Gujarat, the programme constructed shelters for the homeless, supported livelihood by giving FRP hand-carts, fitted composite artificial limbs fir the handicapped.

The programme has demonstrated a wide array of composite applications in all the major sectors. The activities have created a significant and measurable impact towards composite technology development & its subsequent commercialisation.

In order to introduce composites to key economic & industrial sectors such as railways, automobiles, construction, marine, bio-medical etc, the programme is aiming at developing certain critical strategic inputs in terms of raw materials, design capability, product application, skilled manpower and testing devices.The Advanced Composites Mission focuses on:

• Development and commercialization of select composite products
  
• Promotion of composite applications (process equipment, transportation sector, bio-medical devices, marine operations, sports goods)
  
• Improving industry-laboratory linkages for technology development and transfer
  
• Providing soft financial assistance to industries on repayable basis for projects on composites technology

Mission Achievements

While catalyzing the composite technology development with active participation by the industry, the Mission has interacted with various national agencies, such as Indian Railways (Railway Board, RDSO, ICF, RCF, CLW, DLW, Western Railway), CPWD, BMTPC, ASRTU (Ministry of Surface Transport), EIL, WCL, BHEL, ONGC, BSNL etc. towards product standardization, testing, approval & acceptance for wider induction. With a proactive role by the project partners, the programme delivered a number of composite products on a time-critical mode for the earthquake victims of Gujarat.

Projects Completed

The following projects have been completed with salient achievements mentioned therein

• Non-Destructive Evaluation Techniques for Composites

A portable ultrasonic C-scan equipment with the real time imaging and advanced defect analysis capabilities required for field inspection of over-heads structures has been fully developed under the project launched jointly with DRDL and M/s Vivace Sonics Pvt. Ltd., Hyderabad. An advanced signal/image processing software has been developed for ply-by-ply imaging of raw data and also for enhancing image quality & resolution of the defect. The National Institute of Design-Ahmedabad, has carried out the aesthetic & ergonomic aspects of the portable scanner. TIFAC & DRDL have filed the patent for technology of the portable scanner.

• FRP Gear-Case for Railway Locomotives

Indian Railways plan to induct in phases the FRP gear-cases for locomotives developed by M/s Permali Wallace Ltd., Bhopal with technology support from RRL, Bhopal. Against a development order received from Railway Board, 60 nos. FRP gear-cases, certified by RDSO, have been fitted in the diesel locomotives at Jhansi loco-shed and these are now fully operational. Another development order received from BHEL for the induction of 108 nos. FRP gear-cases in diesel locos. FRP gear-cases for electric locomotives (Hitachi model) has also been developed - 36 nos. such gear-cases have been supplied against an order from CLW, West Bengal. Further, the Railway Board has also finalized another order for 150 nos. FRP gear-cases for diesel locomotives.

• Composite Technology Centre (COMPTEC) at IIT, Chennai

The Composite Technology Centre is now fully functional for technology guidance, design consultancy, prototype development, other technical support to the industries. The characterization & testing equipment {Differential Scanning Calorimeter (DSC), Dynamic Mechanical Analyzer (DMA) & Simultaneous Thermo-Gravimetric Analyzer & Differential Thermal Analyzer (TGDTA)} procured by the Centre are being utilized for various testing assignments from the industries on chargeable basis. 100 composite study modules have been transferred to FRP Institute, Chennai for wider dissemination to the industries. The study & design modules for various composite products are being provided to the industries on payment basis. An M.Tech Programme on Composite Structures Technology has also been instituted at IIT-Madras under the aegis of COMPTEC, Chennai.

• Vacuum Forming Press for Composites

A low cost vacuum forming press has been developed as per HAL requirements under the project launched in partnership with M/s. Tecnico Engineering Pvt. Ltd. and with technology support from HAL, Bangalore. The press would soon be delivered to HAL.

• Composite Artificial Limbs for Physically Handicapped

Endoskeleton type below-knee composite artificial limbs have been developed under the project in collaboration with Mohana Orthotics & Prosthetic Centre, Chennai. These limbs are lightweight and better in control & appearance with improved gait for the patients. The limb consists of five parts: a FRP tubular structure fabricated by filament winding of glass fibre in epoxy matrix, top & bottom connectors made by injection moulding of glass filled nylon, a polyurethane foot with composite keel embedded in it and a polypropylene socket to accommodate the amputee stump. The evaluation of individual components and also of the entire endoskeleton assembly for compressive & bending strength has been carried out. A simulated endurance test has been conducted for the service life of the artificial limb. A 3-D modelling of the endoskeleton with all the embedded components considering actual properties of various materials was also carried out.

More than 200 patients have been fitted with these limbs in & around Chennai.. The composite artificial limb costs Rs.6,000/- only as against Rs.45,000/- of imported ones. These should find wider acceptance among neighboring states & other developing countries.

In order to reach an immediate help to the quake victims of Gujarat, 250 nos. below-knee artificial limbs have been distributed free of cost to the handicapped by the Mission.

On-Going Projects

• Carbon-Carbon Composites for Frictional Materials

The project on the refurbishment of brake discs for Mirage 2000 (VAJRA), launched in partnership with DRDL-Hyderabad and M/s Graphite India Ltd.-Bangalore, has progressed well. On completion various tests on product performance, CEMILAC has cleared the refurbished brake discs for low & high speed taxiing trials to be carried out in stages.

• Jute-Glass Composite Components for Railway Coaches

The project for developing glass & louvre shutters made of jute-glass fibre composite for windows in railway coaches was launched in partnership with M/s. Fabtech Industries, Kolkata with the technology support from CGCRI, Kolkata. Development of components such as. prototype glass & louvre shutters for passenger coaches is underway. Partial replacement of glass by jute fibres has established lighter product weight & cheaper product cost.

• Composite CNG Cylinders for Automobiles

The project for the development of high-pressure composite cylinders for CNG was launched in partnership with M/s. Strategic Engineering Pvt. Ltd., Chennai in technical collaboration with MIT, Chennai. CNG cylinders (Type-2) with thin steel liners hoop wrapped with epoxy resin impregnated glass fibre fabricated by filament winding technique has been successfully developed for cars. A typical steel liner with 65 L capacity was 'hoop wrapped' with FRP reducing the cylinder weight by around 20% compared to all steel cylinder. The prototype cylinders were successfully tested for pressure cyclic test & hydrostatic burst test as per the specifications of Department of Transport, US Federal Govt. The evaluation of the cylinders and their qualification by international certification agencies would soon be completed.

• FRP Armoured Optical Fibre Cables

The project was launched with M/s. Indore Composites Pvt. Ltd., for developing FRP armoured optical fibre cables for communication purposes. Trials for fabricating 2F premise cables using semi-rigid resin system with desired bend radius (20D) are currently underway. This type of optical fibre cables is required for fibre-to-home applications. Development of cables with 6F for telecom applications would be taken up next.

• Double-Wall FRP Vessels

Double-wall FRP vessel with in-built alarm system for early warning of the leakage has been developed under the project launched in collaboration with M/s. Chemical Process Equipments Ltd., Mumbai. The 3-D space fabric in the intermediate layer 'raises itself' when impregnated with catalyzed unsaturated polyester resin thus creating a space. In case of leakage, this intermediate space, maintained under pressure/vacuum, provides early warning. The system minimizes the risk of storage of hazardous fluids thereby reducing product liability insurance. A double-wall FRP vessel, designed as per BS 4994, was fabricated by CPEL, as per the requirements of M/s. DCM Shriram Consolidated Ltd., Jhagadia. The testing of the vessel is currently underway and the vessel would be shipped to DCM Shriram shortly for field trials.

• FRP Modular Toilet Unit for Railway Coaches

The project was launched in partnership with M/s Hindustan Fibre Glass Works, Vadodara with technology support from IIT, Mumbai. Two nos. Indian style FRP modular toilet units (with niche inside and wash basin outside) and Two nos. toilet units (smaller Indian style unit and European style) have been designed, developed and supplied to the Carriage Repair Workshop (CRW) - Western Railway. The Industrial Design Centre (IDC) of IIT-Mumbai has been instrumental in conceptualizing, designing and fabricating full-scale mock-up of modular toilet blocks with improved aesthetics & ergonomics. The Department of Aerospace Engineering of IIT-Mumbai has extended support in terms of structural design of FRP toilet unit, fibre lay-up design, fabrication process, design of mould for fabrication, selection of suitable raw-materials, testing & mechanical characterization of the prototype and finally providing quality assurance norms for fabrication. The performance evaluation on a limited scale for the prototype toilets would be carried out for 3-6 months.

• Composite Main Doors for Passenger & EMU Coaches for Railways

The project for developing light & corrosion resistant FRP main doors for passenger & EMU coaches for replacing heavy steel doors was launched with Urbane Industries, Chennai with technology support from IIT-Bombay. Prototype FRP door for passenger coaches has been fabricated. 8 nos. FRP doors are being fabricated and would be delivered to the Carriage Repair Workshop of Western Railway, Mumbai for field trials for 2-3 months.

• Jute Composite Components for Footwear

The project for developing jute composite components such as toe puff, counter stiffener, insoles etc. for footwear was launched in partnership with M/s. APL Polyfab Pvt. Ltd., Kolkata and technology support from IJIRA, Kolkata. The complete impregnation line with all the components has been installed. Three product samples with raised woven jute fabric and non-woven jute (felted) after thermoplastic impregnation were tested by CLRI, Chennai and found encouraging. Efforts are underway for installation of hot melt adhesive system as the next phase of the project.

Gujarat Earthquake-Initiative in Rebuilding & Rehabilitation

In the wake of disastrous damages by the earthquake in Gujarat, the Advanced Composites Mission of TIFAC has come forward to contribute to the national efforts of re-building and rehabilitation. A wide array of innovative composite products suitable for low-cost building & construction sector and bio-medical appliances has been developed by the Advanced Composites Mission. Jute-coir composite boards, rice husk particle boards, FRP toilet blocks, multipurpose FRP handcarts and composite artificial limbs etc. address the crucial need of the hour post-disaster relief at the quickest possible time.

1. Semi-Permanent Shelters

Natural fibre composite materials such as jute-coir composite boards, bamboo mat veneered rice husk particle boards etc. fixed on MS angles & channels and erected quite quickly @2-3 houses per day are an effective low-cost solution for shelters lasting for about 5-7 years.

The Advanced Composites Mission has constructed 150 nos. shelters (20 ft x 12 ft x 11 ft high), made of jute-coir composite boards and supported on steel angles & channels. The jute-coir composite boards have been developed under a project launched by the Advanced Composites Mission in partnership with M/s. Natura Fibretech Pvt. Ltd., Bangalore. The composite boards are made of renewable natural fibres and have attractive natural look as they can be painted, polished or laminated. The boards are water proof with minimum surface absorption, strong & rigid and can be nailed, screwed and cut sharply. These natural materials have all the properties required for a general purpose board and can be used in place of wood or MDF synthetic resin boards for partitioning, false ceiling, panelling, roofing, furniture, cupboards, wardrobes etc.

Further, 150 nos. semi-permanent shelters of similar dimensions made of bamboo mat veneered rice-husk particle boards have also been constructed. The bamboo mat boards are termite & borer resistant, strong & rigid with good insulation properties. The boards have been developed with the technology licensed by NRDC. The product is eco-friendly & manufactured out of agro-waste products such as rice-husk & cashew nut shell liquid. The bamboo mat is phenol bonded on the rice-husk boards to provide dimensional stability. The boards have been successfully field tested by constructing such temporary shelters for dormitories, go-downs, kiosks etc.

In order to improve aesthetics and also to augment the thermal insulation, natural fibre composite board roofing of the shelters was covered with terracotta tiles towards their longer life span.

2. FRP Modular Toilet Units

To cater to 300 nos. shelters as described above, 96 nos. community toilet blocks (for gents & ladies) made of FRP have been constructed. FRP panels have been used for roof & side-walls supported on steel frame for the toilet unit each measuring 1200x1200x1945. The toilet units have been constructed complete with cement flooring, Indian style toilet pan, wash basin and taps for water supply inside. Septic tanks of appropriate size have also been constructed for each location. Water supply is being made available from a HDPE tank placed on a steel structure.

The product has been a spin-off from the project on modular FRP toilet units for railway coaches launched by the Advanced Composites Mission in partnership with Hindustan Fibreglass Works, Vadodara & technology support from IIT-Bombay.

3. Endoskeleton Type Below-Knee Composite Artificial Limbs

As mentioned earlier, composite artificial limbs have been developed successfully under the Mission project in collaboration with Mohana Orthotics & Prosthetic Centre, Chennai. The Mission in partnership with Mohana Orthotics has distributed 250 nos. artificial limbs through two limb fitting clinics at the Physiotherapy Centre of Rotary Club at Mehsana and at the premises of the Indian Medical Association, Bhuj in association with the Blind People's Association (India).

4. Multipurpose FRP Handcarts

100 nos. multipurpose FRP handcarts, developed by RV-TIFAC Composite Design Centre-Bangalore were distributed to the earthquake victims to support their livelihood. These handcarts are water, corrosion and chemical resistant with a longer life span.

In tandem with the proactive approach of TIFAC, Gujarat Government allotted land at prime location in Bhuj on priority basis for the construction of shelters, toilet units and other amenities. Shri Dindayal Development & Charitable Trust, Bhuj has extended assistance for the site survey & measurement, cluster planning, shelter lay-out, procurement of various consumables & providing masonry support, toilet maintenance, water supply to toilets etc.

The construction activities started on March 09, 2001 at site. All the 300 nos. shelters and 96 nos. FRP toilet units have been completed and handed over to the beneficiaries by August 19, 2001.

In addition to the semi-permanent residential shelters constructed by the Mission at Bhuj, two nos. school blocks (24-ft.x20-ft.) have been constructed. The school-blocks, complete with desks, benches, fans & light fittings, the Rotary Club of Bangalore Orchards and Karnataka Hardware & Allied Merchants' Association, Bangalore have sponsored blackboards etc.. Five shops (each measuring 12-ft. x 8-ft.) and one post office, constructed under the project are fully operational.

The aforesaid exercise has been a demonstration of new building technologies and construction of semi-permanent shelters at the quickest possible time. This has been a token intervention to extend relief to the victims as an immediate measure.

Fly Ash Mission

Fly Ash Mission (FAM), a Technology Project in Mission Mode (TPMM) was approved by Government of India during August 1994 for a duration of 4 years. Subsequently, after the reviews the Mission duration has been extended upto March 2002 specially in view of the good work being done by the Mission and also to facilitate the completion of ongoing projects.

Out of 55 projects undertaken in 10 Thrust Areas, 45 have been completed and the balance projects are in advanced stages of completion. Follow up actions have been initiated in the areas of completed projects. Multiplier effects have been facilitated/ started. Updating of existing BIS standards/ preparation of new ones and dissemination of information have also been undertaken.

Completed Projects

Technology Demonstration Projects have been undertaken in 10 thrust areas. The number of projects completed in each Thrust Area are given below. The balance ongoing projects are in the advanced stages of completion.

Thrust area-wise completed projects

* Includes 2 short-closed projects

On-Going Projects

The ongoing projects, for the year, mostly pertained either to the durability studies of flyash bricks or agriculture thrust area. It also includes 2 projects each of underground mine fills and hydraulic structures as is evident from the following list:

Thrust Area wise Ongoing Projects

Impact Made

Since seven years of commissioning the Mission has made significant impact in the areas of fly ash utilization, safe disposal and services associated with its management in India. The impact of FAM can be realized from the considerable change in the scenario. Through concerted efforts of FAM alongwith associated agencies and several experts the utilization and safe disposal practices have gained momentum. The fly ash utilization has increased from 3% in the year 1999 (of about 45 million tonne produced) to nearly 16% (of approximately 95 million tonne produced) in the year 2000.

During the year, FAM has given thrust to multiplier effects, dissemination of information / experience gathered so far through interaction with people, participating seminars, workshops etc. in addition to monitoring and steering of the ongoing projects towards successful completion. Some of the important impacts made / multiplier effects resulted since the last report (Nov-2000) are illustrated below:

• Use of flyash in the embankments of Vasant Kunj and Sarita Vihar flyovers at New Delhi.
  
• Use of flyash bricks for PWD school building at Rohini.
  
• Use of fly ash in the express highways at Noida and Greater Noida.
  
• Use of flyash in flyover bridge embankments at Raja Garden, New Delhi.
  
• Equipment supplier has developed capability for supply of indigenous manufacturing of higher concentration slurry pumps.
  
• Use of fly ash bricks, blocks and concrete in the proposed building of Power Finance Corporation (PFC) at Connaught Place.
  
• Use of flyash bricks & flyash based concrete in Proudyogiki Purvanuman Niketan (TIFAC Building) at IIT Delhi.
  
• Use of fly ash & its products in the construction of the library building of Central Pulp and Paper Research Institute (CPPRI), Sahranpur.
  
• NHAI has agreed to consider use of flyash for its forthcoming projects.
  
• Keeping in view the significant enhancement for flyash utilisation at Kota Thermal Power Station from 8% to 31% after the focussed thrust given by Fly Ash Mission Kota, it has been proposed to form Fly Ash Mission Sri Ganganagar to address to the utilisation of ashes being produced at newly commissioned Suratgarh Thermal Power Station (District, Sri Gangananar).
  
• The consultancy assignment given by IFFCO-Phulpur to FAM has been successfully completed.
  
• The consultancy assignment received from Heavy Water Plant, Manuguru is progressing satisfactory.
  
• UPRVUNL has appointed FAM as a review consultant to guide and oversee their fly ash utilisation studies assigned to other research institutes.
  
• Many agencies have approached Fly Ash Mission to provide assistance / guidance to enhance utilization / safe disposal of their flyashes, such as: .
  • BSES Ltd., Mubmai
    
  • Gujarat Electricity Board
    
  • Environmental Planning and Co-ordination Organization in Bhopal, M.P.
    
  • Andhra Pradesh Power Generation Corporation Ltd. (APGENCO)
    
  • Maharashtra State Electricity Board
    
  • CMPDIL, Ranchi
    
  • NTPC-Talcher
    
  • Road Builder (India) Pvt. Ltd., Gurgaon
• The IRC has approved and issued the guidelines for use of fly ash in road embankments.
  
• Amendment in Bureau of Indian Standard (BIS) codes for ordinary Portland Cement and Protland Pozzolana Cement permitting higher percentage of fly ash.
  
• The revised code (IS 456) for concrete has been brought out by BIS making a special reference to utilisation of fly ash and counting fly ash as a cementitious material (along with cement) while arriving at the mix proportions. Fly Ash Mission has been co-opted at a number of committees of BIS for updating/ preparing new standards for induction, use of fly ash or its products.
  
• As a result of FAM's concerted efforts for Fly Ash Mission, Kota, the revision of BISR of PWD, implementation of the Government of India's circular for utilization of fly ash in brick making, facilitation of off-take of flyash by cement industries, manufacturing of fly ash bricks and their popularization through NGO's have been made. Also, as a result the present utilization in Rajasthan is now of more than 3 lac tonne of fly ash per year, which is more than 31% of the current fly ash generation there.