Project Report

Re-using Ash Making Vanillin (from Bagasse & Rice Husk)

Re-using Ash
From 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

NONEXTRACTION

SILICA

SILICON METAL

MAKE PARTICLE BOARD

PORTLAND CEMENT

SELL AS RAW MATERIAL

SILICON STEEL

E.CHIPS

SOLAR PANELS

GLASS

MEDICINES

OTHERS

Crop production Patterns in Maharashtra

Dhule District

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

Name of Crops Kh.Rice

Area 51

Production 54

Productivity 1059

Sugarcane

35

2057

59

Nashik District

Name of Crops Kh.Rice

Area 508

Production 702

Productivity 1382

Sugarcane

121

6729

56

Jalgaon District

Name of Crop Kh. Rice

Area 4

Production 4

Productivity 1000

Sugarcane

149

9226

62

Aurangabad District

Name of Crop Kh.Rice

Area 3

Production 2

Productivity 667

Sugarcane

64

5095

80

Thane District

Name of Crop Kh.Rice

Su.Rice

Area 1386
24

Production 3288
66

Productivity 2372
2730

Ahmednagar District

Name of Crop Kh.Rice

Area 80

Production 58

Productivity 725

Sugarcane

170

10018

59

Raigad District

Name of Crop Kh.Rice

Su.Rice

Area 1245
85

Production 2759
213

Productivity 2216
2605

Pune District

Name of Crop Kh.Rice

Area 676

Production 851

Productivity 1259

Sugarcane

282

23619

84

Ratnagiri District

Name of Crop Kh.Rice Su.Rice

Area 791 2

Production 1865 7

Productivity 2358 3728

Satara District

Name of Crop Kh.Rice

Area 441

Production 729

Prodcitivity 1653

Sugarcane

232

18753

81

Solapur District

Name of Crops Kh.Rice

Area 4

Production 1

Productivity 250

Sugarcane

364

26328

72

Sindhudurg District

Name of Crop Kh.Rice Su.Rice

Area 745 43

Production 2108 85

Productivity 2830 1976

Kolhapur District

Name of Crop Kh.Rice Su.Rice

Area 1105 6

Production 2791 22

Productivity 2526 3654

Sugarcane

763

65294

86

Sangli District

Name of Crop Kh.Rice

Area 177

Production 442

Productivity 2497

Sugarcane

316

26515

84

Particle Board from Ash

(Bagasse & RH)

Introduction
Particleboard 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 Board

Industries 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 Low energy requirement Readily available local raw material

costs.
2. 3.

4.
5.

Cheaper price than MDF

Low density & lower weight than MDF, which makes it suitable for certain applications.

Indian Market Potential for Particle Board

The 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 Sawnwood (For housing, furniture, agriimplements, sports goods, packaging, etc.) Pulp (Paper, newsprint) Plywood Particleboard Fibrewood (Hardboard) MDF Total Year 2000 47.00 Year 2005 50.00 Year 2010 54.00

23.60 1.45 0.34 0.22 0.40 73.01

28.50 1.69 0.49 0.32 0.67 81.67

35.00 1.92 0.65 0.41 0.95 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 Board

The 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 Carbon Hydrogen Oxygen Nitrogen Silicon Potassium Sodium Sulfur Phosphorous Calcium Iron Magnesium Mass Fraction % 41.44 4.94 37.32 0.57 14.66 0.59 0.035 0.3 0.07 0.06 0.006 0.003

Element Silica (SiO2) Alumina Ferric oxide Titanium

Mass Fraction % 80 90 % 1 2.5 % 0.5 % Nil

dioxide Calcium oxide Magnesium oxide Sodium oxide Potash Loss on 10 20 % Ignition 0.2 0.5 % 0.2 % 12% 0.5 2.0 %

Uses
Precipitated 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

Mr. Uday Wagh Mr. Shazaad Chinoy

Innovation Advisors Annapurna Foods & Drugs Private Limited

PROJECT REPORT ON MAKING VANILLIN (BAGASSE & RICE HUSK)

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 Ahead

India 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. Indias 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), icecream 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 19992003. 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 Trade
Vanilla 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: Ice cream products Natural vanilla extract. Two-fold vanilla is commonly used. 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 composition

For 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 4555% Hemi cellulose 2025% Lignin 1824% Ash 14% 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

% of main components extracted Bagasse (g) alkaline treatment (M) 0.5 1.0 2.0 3.0 4.0 0.5 1.0 2.0 3.0 4.0 0.5 1.0 2.0 3.0 4.0 0.5 1.0 2.0 3.0 4.0 p-coumaric acid 79.61 76.36 74.01 75.78 76.10 76.83 67.40 69.04 67.27 78.91 83.41 82.13 79.98 80.59 78.79 76.04 73.79 67.00 71.68 71.49 Ferulic acid 16.21 17.58 19.03 18.49 18.78 15.44 18.90 19.26 21.12 15.80 14.96 16.04 17.31 17.33 18.36 19.10 20.59 24.40 21.10 20.23 Syringic acid 1.10 1.49 1.81 1.69 1.79 3.19 3.97 3.37 3.95 2.45 0.82 0.97 1.34 1.50 1.82 1.79 2.38 3.31 2.87 3.18 Vanillin 3.08 4.57 5.14 4.05 3.34 4.53 9.72 8.33 7.65 2.85 0.80 0.86 1.37 0.59 1.04 3.07 3.24 5.28 4.35 5.10

1.0

2.0

3.0

5.0

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.