The process is adaptable to the traditional brick and tile industry with appropriate mechanization and conserves upto 80% of natural clays and use up to 80% of fly ash. The cost calculations based on the pilot plant demonstration trials show that the price of the fly ash products will be in the similar range as clay products. The plant should be preferably in the premises of the thermal power plants and the process is suitable for pond ash and stored ash as also with dry fly ash. All machineries and the binders/additives are available in the country.
Investment required : Total investment for a plant producing 60,000 bricks/tiles/glazed tiles: Rs.2-2.5 crore. Brick cost Rs.2.50-3.0 per piece, tiles at Rs. 4-5 per piece and glazed products Rs. 6-8 per piece.
Returns /Benefit: 15-18% returns on investment over a period of 5 years.; Validation level: Pilot-scale.; IPR Status: Patented in India.
The conventional extraction processes like retting leads to serious problems like methane and sulphide emission, water contamination and other environmental pollutions. Emission of methane and sulphide during the retting process is a major source of environmental pollution as they contribute to greenhouse gases. Owing to the above factors, Biological method is preferred to mechanical and chemical routes for extracting fibres of good quality from the embedding matrix. It is in this context that NIIST devised a clean bioprocess which has the potential to replace the traditional method of retting in which the plant materials are left to decay in humid conditions or in water to free the fibre from matrices.
Validation level : Real life.; IPR Status : Filed.
Beta-Glucosidase (BGL) is a key ingredient in the enzyme blends used for biomass hydrolysis for bioethanol production. It is the rate-limiting enzyme in the cellulase complex. Cellulases for hydrolysis of biomass are typically sourced from fungi like Trichoderma reesei whose cellulases lack sufficient quantities of this important enzyme. Commercial preparations of cellulase contain BGL from heterogeneous sources. Aspergilli are used as sources of BGL. Globally, there are only a few suppliers of BGL for biomass hydrolysis. BGL in these preparations are inhibited by high concentrations of glucose.
A Process for making banana fiber polymer composites. It is a cost-effective substitute for glass fiber reinforced plastic to make variety of products e.g. simple trays, mirror casings to voltage stabilizer cover and electrical panels.
The process consists of preparing moulds of metal, wood or plaster of paris; mixing the resin and dye in requisite proportion; shaping the banana fabric by laying it over the mould; reinforcing the polymer over banana fabric; curing the mould; demoulding; cutting, trimming and polishing.
CSIR-NIIST has developed a process for the production of Nanoparticles starting through hydrolysis-peptisation technique. The process in general consists of hydrolyzing titanyl sulphate or chloride to titanyl hydroxide by addition of ammonium hydroxide followed by washing and removal of all the undesirable ions.
Investment required: For a plant size of 10 kg/batch capacity, the cost of the plant will be about Rs. 250 lakh. The machinery cost will be about Rs. 160 lakh.
Returns /Benefit: The abundant deposits available in the country could be gainfully utilized.
Validation level: Till now, the process has been optimized in the laboratory and being scaled up to Bench/Pilot scale with M/s Indian Rare Earths Ltd., Mumbai which is set up in IREL Kollam is expected to get commissioned in June, 2010. The average cost of the nanoparticles will be Rs. ~1000-2000 per Kg only.
IPR Status : Filed.
A clean bioprocess has been developed by NIIST for the extraction of quality coir fibre from coconut husk. This method carries out separation of fibres from their matrices by enzymatic cleaving of cementing compounds with in situ microbial growth and enzyme production. This bioprocess not only converts all the organic pollutants emanated from the extraction process to methane, but also facilitates its recovery as an Energy Source. Since the methane production is almost exclusively from the Up flow Anaerobic Sludge Blanket Method (UASB) methanogenic reactor and no significant quantity of methane is generated from the retting tanks, therefore the collection of methane is possible without expensive gas tight covering of the retting tanks.
This bioprocess can also be used for processing of natural fibres like jute, banana and pineapple leaf.
Investment required : Capacity : 16000 husk/day; Investment : Rs.1.4 crore; Production per day :1.4 t fibre @ Rs.20,000/t; 0.8 t pith @ Rs.250/t; 800m3 biogas @ Rs.5/m3
Validation level : Real life.; IPR Status : Filed.
Returns / Benefit :
The Byadgi Chilli, which is known for its high colour is currently processed in the traditional manner which result in loss of carotenoids during the sun drying operation. The new process developed employs a fluid bed drier for bringing down the moisture to acceptable levels of fresh chilli hygienically. The resulting end product will have a 10% increase in colour value when compared to the conventionally processed raw material. The raw material is washed, size reduced, dried in the fluid bed drier and then de- seeded. The contact time in the drier is less than 15 minutes and the entire operation is automated. All the machineries are interlocked and the manpower requirements are marginal. High pressure steam is used as the heating medium and the plant is engineered to ensure high thermal efficiency.
Investment required: The facility can be set up at a cost of approximately Rs.2.5 crore for a 20 Ton/day fresh red byadagi chilli processing unit.
Returns / Benefit: The unit can provide direct employment to 30 people and indirectly benefit a large number of farmers ensuring fair price for the produce.
Validation level: Pilot scale.