Annual Report 1999-2000

Technology Development

Mission Mode Projects

Sugar Technology Mission

The Mission mode project under Sugar Production Technologies aims towards sharper and focussed technological upgradation in selected sugar factories to accomplish, interalia, the cost effectiveness of sugar production through improvement in plant efficiency, energy saving etc. In addition to the above, the focus is also on improving the capital output ratio through optimisation and identification of user friendly technologies.

Technology Upgradation

The Sugar Technology Mission has so far completed upgradation surveys in respect of 23 factories and has submitted Detailed Project Reports (DPR) in respect of 19 factories. On the basis of project reports and financial appraisal by Financial Institutions, the following factories have already been sanctioned SDF loan at 6% rate of interest:

• Shri Vighnahar SSK Ltd., Junnar, Maharashtra
  
• Ajinkyatara SSK Ltd., Satara, Maharashtra
  
• DSM Sugar, Rauzagaon, Barabanki, U.P.
  
• Motilal Padampat Udyog Ltd., Majhaulia, Bihar
  
• Riga Sugar Company Ltd., Riga, Bihar
  
• Vishnu Sugar Mills Ltd., Gopalganj, Bihar
  
• Upper Doab Sugar Mills, Shamli, U.P.
  
• R.B.N.S. Sugar Mills, Lahksar, U.P.
  

The project implementation work in respect of above factories is in progress.
During the year (1999-2000) the proposal for technology upgradation of the following factories have been prepared by STM and are under consideration by Department of Sugar and Edible Oils for funding from Sugar Development Fund (SDF):

• Pratappur Sugar Mills, Pratappur, U.P.
  
• Sakthi Sugars Ltd., Sakthi Nagar, Tamil Nadu
  
• Godavari Sugar Mills Ltd., Sameerwadi, Karnataka
  

The Detailed Project Reports for technological upgradation of the following factories have been completed and are under submission to Financial Institutions for appraisal:

• Padmashri Dr.V.K.Patil SSK Ltd., Pravaranagar, Maharashtra
  
• E.I.D. Parry (India) Ltd., Pugalur, Tamil Nadu.
  
• Mawana Sugar Works Ltd., Mawana, (U.P.)
  

The preparation of DPR for technology upgradation scheme for the following factories is under completion:

• Vishwasrao Naik SSK Ltd., Yeshwantnagar, Maharashtra.
  
• Terna Sethkari SSK Ltd., Ternanagar, Maharashtra
  
• Shakumbari Sugar & Allied Industries Ltd., Saharanpur, (U.P.)
  

In addition to the above, the site survey for technology upgradation of Shree Talala Taluka Sahakari Khand Udyog Mandli Ltd., Talala (Gujarat) has also been completed.

1.2 Trials of New Technologies

The Sugar Technology Mission has already taken assessment of about 17 new technologies and systems for the purpose of trial in commercial sugar factories. The majority of new technologies are being tried on plant scale.

i) The following four new technologies after successful trials are under replication in different sugar factories. These new technologies are:

• Separate Clarification of Vacuum Filtrate.
  
• Thin Film Sulphur Burner for continuous generation of SO2 to achieve satisfactory juice clarification parameters.
  
• Integrated Clarification Control System for PLC based automatic control for juice purification, better removal of non-sugars.
  
• Syrup treatment system for production of superior quality sugar.
  

ii) Follow-up activities continue in respect of trials and performance evaluation of following new technologies in various sugar factories :

• Low Pressure Extraction (LPE) System
  
• Use of Membranes for micro filtration and ultra-filtration of cane juice.
  
• NIR Technique for on-line assessment of sugar content in sugarcane and sugar house products.
  
• Automation Control for Pan Boiling
  
• Short Retention Clarifier
  
• DRP Process
  

iii) In addition to the above, a new type of massecuite filter has been commissioned for the purpose of trials at M/s. Sakthi Sugars Ltd., Sakthinagar, Tamil Nadu.

iv) Development of cost and energy effective alternate material components for use in Sugar Industry is under progress at Regional Research Laboratory, Bhopal.

v) An Agreement has been signed with Godavari Sugar Mills Ltd., for implementation of Enterprises Resource Planing (ERP) System for maintenance management and other control functions in a sugar mill. The first installment of TDA has already been released to the factory for implementation of the project.

Fly Ash Mission (FAM)

Fly Ash Mission, a Technology Project in Mission Mode (TPMM) was approved by Government of India during August 1994 for a duration of 4 years. The duration of the mission has been subsequently extended upto March 2000.

Objectives

The broad objective of Fly Ash Mission is to build confidence in Fly Ash Disposal / Utilisation Technologies through "Technology Demonstration Projects" towards large-scale utilisation & safe disposal.

Status

As on March 31, 1999, 55 Technology Demonstration Projects had been approved / commissioned. Out of these, 16 were completed (including 1 project being pursued by the agency itself).

Progress during the current year 1999-2000 (upto November '99)

Currently thrust is being put on the following activities the salient features / achievements are given below:

i) Monitoring, Facilitation and Steering the Ongoing Technology Demonstration Projects

Towards Successful Completion

22 meetings of Project Monitoring Committees / Experts Groups have been held to monitor and guide the on going projects.

Some of the salient highlights of other projects are given below:

• Pilot plant for dense phase conveying of fly ash / bottom ash has been installed at NTPC -Dadri. Initial trials have started. The developed process would convey fly ash slurry with 30-45% concentration as compared to 10-20% being practiced currently. It would reduce water requirement, energy consumption, wear & tear of the system and discharge water management at Ash Ponds.
  
• Design of dry fly ash collection and bagging pilot plant at Badarpur Thermal Power Station has been completed and the offers have also been received from equipment suppliers. It would demonstrate first time in the country that segregated fly ash could be collected, bagged and made available for different applications.
  
• More than 1200 samples of agricultural produce, soil, water and plant parts have been tested at IOP, Bhubaneswar for radioactivity and heavy metals. Balance of about 150 samples is in final stages of analysis.
  
• Nutritional quality analysis of agricultural produce grown on fly ash treated soils has made significant progress at National Institute of Nutrition, Hyderabad. Chemical analysis has been completed for about 75% of samples. Samples of 3 crops to be harvested during December '99, January '2000 and February '2000 are also to be tested. Biological tests by feeding the grain to test group of rats / mice are in progress.
  
• Fly ash brick durability tests project has been commissioned at four laboratories. Procedure and protocol to be followed has been finalized after detailed discussions in the experts meetings as no directly applicable standard and procedure is available either in India or abroad. Test facilities have been upgraded at CFRI-Dhanbad and ERDA - Vadodara. CBRI-Roorkee and RRL-Bhopal are in the process of finalizing the details. Accelerated durability test would be done for 500 days to compare performance of fly ash bricks (produced through different technological routes) with clay fly ash bricks.
  

ii) Finalisation of Reports of Completed Projects

Draft reports of 7 projects have been discussed in the task force / experts meetings / national workshops and are under finalisation.

iii) Deliberation on Findings and Recommendations of Projects in Experts Meetings / National Workshops for the Finalisation of Reports

In addition to task force and experts meetings for discussions of findings / draft reports of completed projects, national workshops/ seminars were organized at CFRI-Dhanbad, IIT-Kanpur and IISc-Bangalore. Two more seminars are being planned to discuss the draft reports of project executed by RRL-Bhubaneswar and CBRI-Roorkee on the subjects of "Reclamation of Ash Ponds for Human Settlement" and "Sintered Fly Ash aggregates for use in building construction, roads and embankments and pozzolanic aggregates for manufacture of cement" respectively.

iv)Dissemination of Information through Meetings, Personal Interaction and Participation in Workshops/ Seminars

Nine workshops / seminars have been participated in, for presentation / dissemination of information. In addition, a number of experts meetings and one to one meetings have been held to share and disseminate information.

v) Facilitation of Multiplier Effects and undertaking "Confidence Building" exrecise / discussions with Potential Users

Detailed discussions have been held with 4 cement manufacturers for use of fly ash in cement manufacture, 6 potential users to use fly ash in concrete, 8 potential brick manufactures, 10 existing fly ash brick manufacturers for the measures to improve quality of fly ash brick, about 10 potential users of fly ash bricks / blocks including Chief Engineers / Superintending Engineers of three circles of PWD- Delhi, 2 agencies for use of fly ash in road & embankments and a few farmers for agriculture applications of fly ash. These have resulted into a number of multiplier effects. Some of these are:

• Fly ash bricks have been specified by PWD -Delhi in the tender documents for the forth-coming construction of school buildings. The immediate requirement would be about 10 lacs fly ash bricks.
  
• PWD-Delhi and DDA are using fly ash in lieu of soil for construction of embankments of flyover bridges wherever borrowed material is required.
  
• DDA has agreed in principle to use fly ash based concrete in one of the flyover bridges. This would save about 25 - 30 % cement and would make fly over bridge elements sleek and lighter. Thus additional savings would be achieved due to lower dead weight on the foundations. CRRI is working out the technical specifications.
  
• DVB has decided to put up an automated plant to manufacture 2 lacs fly ash bricks per day. In addition two smaller plants are being put up by DVB of 10,000 fly ash brick per day capacity.
  
• About eight entrepreneurs are in advanced stage of discussions with Fly Ash Mission for setting up of fly ash brick plants in different parts of the country such as at Talchar, Calcutta, Kota, Ghaziabad, Delhi, Agra, Nashik, etc.
  
• IFFCO is also evaluating the alternate technologies, in consultation of Fly Ash Mission for setting up a facility for production of 1 lacs bricks per day.
  
• Mr. S. N. Patro, Co-ordinator, Orissa Environmental Programme is considering initiation of "quality control and training programme for fly ash bricks manufacturers" in the state of Orissa in association with Fly Ash Mission, TIFAC / DST.
  
• IFFCO, Phulpur, U.P. has agreed to transport fly ash, free of cost to farmers' fields in their vicinity for use in agriculture.
  
• Lifting of CPWD ban on use of fly ash based cement in reinforced concrete. CPWD has agreed to reconsider their decision of mid 80's (reconfirmed in mid 90's) which restricted use of fly ash based cement in reinforced concrete. A meeting of all expert National Institutes was held by Fly Ash Mission along with CPWD and process has been initiated to arrive at consensus of National Research Laboratories to facilitate and enable CPWD to withdraw their above said circular. Towards this a few accelerated tests are being planned at different laboratories with Indian fly ashes to supplement the recent experience of Indian laboratories and users with latest fly ashes. Worldwide fly ash blended cements have already been recognized as superior materials as compared to ordinary portland cement.
  

vi)Updating of BIS Standards related to Fly Ash and preparation of new Standards wherever necessary

Six sub-groups of experts of Fly Ash Mission are reviewing the existing standards for updating and identifying the areas in which additional standards are required to be prepared. The subgroups are:

• Characterisation, terminology, handling & transportation, storage, etc.
  
• Cement
  
• Concrete
  
• Bricks/ blocks
  
• Geotechnical applications.
  
• Agricultural applications.
  Industrial products / applications would be taken up individually.
  Up date of BIS 3812 "Classification of Fly Ash" prepared by Fly Ash Mission has been issued for wide circulation by BIS for comments.
  

vii) Preparation of Standards and Protocols for Testing of Fly Ash for Agricultural Applications

No standards/ protocols are available in this regard. It is pioneering activity.

During execution of technology demonstration projects under the Thrust Area "Agriculture Related Studies and Applications" analysis of fly ash was started with employing protocols / standards available for testing of soil and other agricultural inputs. These protocols required some modifications due to the fact that fly ash is a different material as compared to soils. The protocols were modified based on contextual information available in the literature and the past experience of Indian Agriculture scientists / experts. These modifications were adopted during Fly Ash Mission projects and further experience / data / validation was achieved.

Based on the above an experts group of Fly Ash Mission is working on preparation of standards and protocols for analysis of fly ash for agricultural applications.

viii) Procesing of "Specification for use of Fly Ash in Roads & Embankments" with Indian Road Congress for approval and adoption as National Standards

The specifications were prepared and submitted to IRC about a year back. These have been discussed in number of meetings / committees of IRC and additional information /clarifications have been provided. The revised document has been cleared by their sub-technical committee and is due for consideration by technical committee. The approval is being expedited. On approval IRC would issue it as a national standard.

ix) Upgrading of Fly Ash Characterisation and Utilisation Facilities/Capabilities at various Laboratories in the Country to establish a network of Fly Ash Centres to Extend Guidance and Support to Fly Ash Producers/Users for its gainful utilisation and safe disposal

Brochures regarding facilities and expertise available at 13 out of the 25 laboratories dispersed across the country identified for upgradation of facilities/developing expertise, with marginal investments in the area of fly ash. In addition draft brochures have been received from four and balance is being expedited. Facility upgradation was undertaken primarily at four laboratories and that has been completed.

x) Promotion of Fly Ash Utilisation

A gazette notification dated September 14, 1999 has been brought out by the Ministry of Environment & Forests promoting use of flyash and discouraging use of topsoil for construction/ brick production activities. This is a result of the concerted efforts of Fly Ash Mission and its associate agencies.

This notification makes it mandatory for all brick/ tile or block manufacturers within radius of 50 km of Thermal Power Plants to use atleast 25% of ash in their products; Thermal Power Plants to make available free & hassle free ash; and the potential user agencies to include flyash & its products in their respective material & price schedules.

xi) Zero Base Studies on Fly Ash Generation and Utilisation in the Country

To arrive at reliable data and information regarding fly ash generation, disposal and utilisation in the country, five zero based zonal studies were commissioned to collect the data/information directly from power producers, users as well as potential users. Draft reports from all the 5 zones have been received and are being reviewed by experts towards finalisation. Comments of some of the experts/agencies have been received and others are being expedited.

Advanced Composites Mission (ACM)

The Advanced Composites Mission (ACM) was launched with a focus to enhance the utilisation and application of composites as important performance materials in various sectors such as railways, automobiles, construction, marine, bio-medical etc. The Mission aims at developing certain critical strategic inputs in terms of raw materials, design capability, skilled manpower and testing devices. It attempts to bring together the research institutions & industries towards development and commercialization of composite technologies. Towards its objectives, 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

The Advanced Composites Mission has been an experiment to bring about a culture of technology development towards commercialization especially for the technology starved SMEs. The Mission has attempted to source the knowledge from various centres of excellence across the country and brought the industries closer for technology absorption, development & dissemination. The attributes such as attractive scheme of financial assistance (upto 50% of total project cost), technological risk sharing, an effective programme management and knowledge-based project monitoring by experts coupled with the market intervention by reaching to the user agencies have all helped the Mission to record its achievements and arrive at a threshold.

The Mission has been successful in launching 18 projects with active participation by the industry. There has been an intense interaction with Indian Railways (Railway Board, RDSO, ICF, RCF, CLW), CPWD (South Zones & TAD Cell, New Delhi), BMTPC-New Delhi, ASRTU (Ministry of Surface Transport), BIS-New Delhi, Bajaj Auto Ltd.-Pune, TELCO-Pune, EIL, WCL, BHEL, ONGC, Department of Telecom etc. towards product standardization, testing, approval & acceptance for wider induction.

On-Going Projects : Achievements during 1999-2000

Some of the salient achievements during the current year include the following:

FRP Gear-Case

The project launched at M/s Permali Wallace Ltd., Bhopal with technology support from RRL, Bhopal has successfully developed FRP gear-case for diesel locomotives. The prototypes were field-tested extensively. A development order for inducting 60 gear-cases for diesel locomotives has been received from the Railway Board. 30 gear-cases have been fabricated, inspected & certified by RDSO at Permali Wallace, Bhopal & they are now ready for despatch. Design of FRP gear-case for electric locomotives has been finalized & approved by CLW; fabrication of the mould is currently underway.

Jute-Coir Composite Boards

The project launched in partnership with M/s. Duroflex Ltd., Bangalore has successfully developed boards with oriented jute face veneer and coir/rubber wood waste inside. The performance of jute-coir composite boards has proven superior to plywood & MDF boards. Detailed evaluation of the jute-coir board samples have been carried out by RDSO & ICF for their applications as berth backings in railway coaches; the results conform to the railways' requirements. Evaluation of panel & flush doors is currently in progress for acceptance by CPWD, DoT and others.

Carbon Fibre Composites for Orthopaedics

The project was launched in 1998 with M/s S H Pitkar Orthotools Pvt. Ltd., Pune. The project deals with a fairly advanced technology for developing lighter external fixators, made of polyethersulphone reinforced with carbon fibre, for certain advantages like high strength-to-weight ratio, transparency to X-ray etc. Baby rings, foot rings, osteotomes, gauges etc. have been developed successfully. Commercial production of external fixators has commenced & the products are being marketed in India & abroad.

FRP Axial Flow Fans

The project aiming at improving fan design to provide optimum efficiency suitable for specific air-flow and system pressure applications was launched in 1998 at M/s. Parag Fans & Cooling Systems Ltd., Indore with technology support from IIT-Mumbai. The aerodynamic & mechanical design & fabrication of 5 types of fans for cooling towers, mine ventilation, textile humidification, radiator cooling for diesel locomotives & air heat exchangers have been completed. Performance of cooling tower, humidifier, mine ventilation & radiator cooling fans has already been tested. An appreciable efficiency differential has been achieved over conventional fans with aluminum impellers.

FRP Pultruded Profiles

The project on pultruded FRP sections with technology support from NCL, Pune and collaboration with M/s. SUCRO Filters Pvt. Ltd., Pune was launched in 1998 to develop & commercialise products like gratings, solid rods for electrical insulation, cable trays, ladders, etc. High pultrusion speed (1.0-1.5 m/Ministry) for various FRP profiles by improved curing using 3-catalyst system has been achieved. Flame retardancy as per international standards (UL-94V0) for off-shore application has also been established. FRP gratings have been supplied to Alfa Laval, High Explosive Factory, Thermax etc. and a proposal has been submitted to ONGC for partial replacement of steel gratings for offshore platforms.

Composites Design Centres

In active collaboration with industry/user agencies, the Mission has set up two composite design centres (CDCs). These are the Composite Design Centre at RV College of Engineering, Bangalore and Composite Technology Centre (COMPTEC) at IIT, Chennai. CDC-Bangalore has successfully designed and fabricated more than 180 composite products for housing and construction applications. The technology for FRP door has been transferred to eight industries for commercial production.

COMPTEC at IIT-Madras has been providing technical help and guidance to industries. 37 composite study reports and 40 composite product design modules have been prepared and are being disseminated to the industries on payment basis.

Vacuum Forming Press for Composites

The project launched in 1998 in partnership with M/s. Tecnico Engineering Pvt. Ltd. and HAL, Bangalore, aims at developing a low cost vacuum forming press as an alternative to the expensive autoclave process, thus addressing the technology needs for SMEs. The prototype press is currently being fabricated & would be ready soon.

Metal Matrix Composite Components for Automobiles

MMC components for automobiles are being developed in the project instituted in collaboration with RRL, Bhopal and Rasmi Die Castings Limited, Secunderabad. Under the project on the development of MMC components for automobiles, the cylinder block & brake-drum prototypes developed for two-wheeler were handed over to a leading Indian auto manufacturer for their evaluation.

Jute-Glass Composite Components for Railway Coaches

The project with M/s. Strategic Engineering Pvt. Ltd. (SEPL), Chennai in technical collaboration with MIT, Chennai has been approved. The project aims at designing of high-pressure composite cylinders for storage of compressed natural gas. The compressed refill cylinders for CNG will help in adhering to the clean air requirements for vehicles by using alternate fuels.

Development of FRP Armoured Optical Fibre Cables