Project-wise Reports of Sectorial Monitoring Committee

1. Project Title: Environmental Research Initiative for Paper and Process Industry {ERIPP}

2. Project Details:

Nodal lab CSIR-NEIST Participating CSIR-CLRI, CSIR-CSMCRI, CSIR-IMTECH, CSIR-NIIST, CSIR-IMMT Labs Nodal Officer Dr. Tridip Goswami

Taskforce Dr. D. Ramaiah, Director, CSIR-NEIST Chairman Total Man Days 8870

Approved Cost 1664 Lakhs

Fund received 1085.467 Lakhs Fund utilized 1085.467 Lakhs

3. Periodic Key Recommendations of Task Force/RC/Monitoring Committee

s. No.

1.

2.

3.

4.

5.

Key Recommendations of Task Force/RC/Monitoring Committee

1st Review Meeting, Jan 21-23, 2013 •!• To maintain good networking among

the teams •!• Development of MSME technology

2nd Review Meeting Nov18-19, 2013 •!• To maintain the targeted milestone •!• Good collaboration •!• Not to deviate from original objectives

3rd Review Meeting April25, 2014 •!• The deliverables should be focused in terms of industrial application

•!• Suggested to concentrate on environmentally benign activities

4th Review Meeting Dec 17-18, 2014 •!• Development of process/technology need

to be prioritized •!• Deliverables should be achieved within

stipulated time

5th Review Meeting June 05 2015 •!• Objectives should be fulfilled within the stipulated time

Action taken on Proposed Oeliverables

Key Recommendatio ns

Action taken

Action taken as suggested

Action taken

Action taken as suggested by Chairman

Action initiated as suggested

Revised Deliverable (approved by Task Force)

1

6.

7.

8.

9.

•:• The outcome should be relevant to the society in the form of technology, process and products

6th Review Meeting Jan 12 2016 The following leads were suggested i) Microbial formulation for pulping and bleaching, ii) Lignin based tanning agent, iii) Micro- crystalline cellulose from sea weed iv)Process for preparation of high value Iron from Iron Oxide waste, v) Process to decrease the acidity and chlorine content of the waste Iron Oxide 7th Review Meeting Aug 29 2016 •:• Suggested to arrange meeting with the

industry •:• Asked to take lead from this project as

FTT or Mission Mode 8th Meeting with Industry, Dec 21-22 2016 ·:·Suggested for field study at HPC,

Jagiroad •:• To coordinate with HPC Jagiroad for field

trial 9th Review Meeting 06/01/2017

•:• Suggested to all PI's for active participation and linkage with the industry with respect to the leads obtained

Action initiated

Action initiated

Action initiated as suggested by chairman

Action initiated

4. Project Achievements:

s. Deliverables promised at Deliverables Achieved No. start 01 Isolation, identification, 5 microbial strains identified and 2

characterization and screening microbial formulation developed for of suitable microbial strains chipping, pulping & bleaching from different niches against different lignocellulosic materials for their lignolytic activity

02 Development of green A green process of pulping with a biochemical/chemical process eco-friendly bleaching sequence for pulp and other value added has been developed aromatics preparation

03 Methodology selection Completion of literature survey, Preparation of soluble lignin identification of white spaces for

research 04 Selection of stabilized Black liquor I processed liquor

methodologies from various sourcing experiments Characterization of black liquor,

If not achieved, reasons thereof

Achieved

Achieved

Achieved

Achieved

Development of syntans for downstream processing evaluation - Phase 1

05 Methodology selection Initial use in syntan, Comparison of Achieved Preparation of soluble lignin selected method vis-a-vis

conventional replacement syntans Development of syntans for evaluation - Phase 1

06 Development of syntans for Development of syntans for Achieved evaluation - Phase 2 evaluation - Phase 2

Development of syntans, natural Value added products from dyes, dyeing auxiliaries lignin for use in leather industry Modification of developed syntan

for improved properties 07 Replacement syntan based on Replacement syntan based on In progress

lignin wastes lignin wastes Know-how complete with report Know-how complete with report on on 5 kg batch level 5 kg batch level demonstration demonstration

08 Marine bacteria for bio-pulping 1. Laccase producing bacteria Achieved and bio-bleaching

2. Process for laccase production by marine bacteria

09 Seaweed cellulose for its use Algal Cellulose developed Achieved in paper-pulp (Cellulose from seaweed

resources) 10 Screening for laccase and One Xylanase producing bacterial Achieved

xylanase producing strain Bacillus strain and one microorganism laccase producing bacteria has

been identified 11 Optimization of enzyme Optimized the laccase and Achieved

production Laccase and xylanase enzyme production of the xylanase strains

12 Characterization of Xylanase Characterized the enzyme Achieved and laccase, primary study on produced by the strains and the application of enzymes for kraft enzymes were used for pulp pulp bleaching bleaching

13 Optimization of enzymatic Optimization of bleaching In progress process parameters for kraft parameters is in progress pulp bleaching, documentation and report preparation

14 To separate fibrous materials Two suitable non-woody plant Achieved from plant biomass employing biomass were identified for the bio-anaerobic process extraction of fibrous materials in

the country- Sugar cane bagasse and Coconut leaf stalk

15 Application of anaerobic A high solids anaerobic process Achieved process coupled refining of (HSAP) is being optimized for the fibrous materials extraction of fibres from sugarcane

molasses and coconut leaf stalk

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Selection of suitable biomass for the bioextraction of fibrous materials in the country

Optimization of the anaerobic process for the production of fibrous materials from plant biomass

Physical and Chemical Characterization of iron oxide byproduct from 2 titanium mineral industries Process for the removal of impurities from the iron oxide samples Heat treatment schedule for a particular colour of the pigment

Pigment characteristics as compared to commercial grades To develop the suitable environmental friendly process for recover iron from iron oxide waste fines generated by titanium mineral industries Characterization of iron in the metallic form prepared at IMMT to study the elemental compositions, impurity levels (S, P, C) , microstructures, etc

The non-woody fibre sources such as such as Zea mays, coconut leafstalk, bagasse were screened for pulp and paper using the anaerobic contact bed process (ACBP). The materials contain fibres, but could not be extracted effectively by the ACBP method unlike for banana and coir fibres. However, these agri-biomass materials were identified as good sources for fibres Anaerobic contact bed process (ACBP) was optimized for the extraction of fibres from banana pseudostem and pineapple leaf. Demonstration plant for pineapple leaf fibre has been established and started operation at Maneed Panchayat, Piravom, Emakulam District, Kerala. The demonstration plant for banana fibre extraction was installed and waiting for electrical connection Physical and Chemical Characterization of iron oxide byproduct from 2 titanium mineral industries has been carried out The removal of impurities from the iron oxide samples by solvent extraction process has been done

The heat treatment of fine iron oxide powders for required colours and shades has been investigated

Pigment characterization and comparison with the commercial grade is on progress An environmental friendly process flow sheet for making high value pig iron from waste iron ore oxide has been developed

An eco-friendly pyro based process has been developed to recover the metal values from iron oxide waste fines using an integrated plasma arc furnace with gas cleaning system

Achieved

In progress

Achieved

Achieved

Achieved

Under Progress

Achieved

Achieved

25 Development of iron oxide nano particles with tailored surface properties for the removal of harmful toxic ions, bacteria and protozoa from water

Metal recovery : 92%, Iron recovery : 90%, Ti recovery : 94% ; Energy consumption 3-4 kWh,Metal composition: 1.5-2% Ti , 2.5-3.5%-C and Sulphur is <0.05%, which can be used for making high quality compacted graphite iron and microalloyed steels.Zero waste process );> Titanium dioxide containing Iron oxide waste (lOW) has been collected from the titanium process industry (M/s Kerala Minerals and Metals Limited, Chavara, Kerala)

);> Mechno-chemical method is adopted for the prepar~tion of the nanopowder

);> Characterization by XRD, TEM, SEM, VSM, Chemical analysis, DT A-TGA, Zeta potential etc.

)> Dye containing industrial wastewater has been collected from the Sualkuchi Pat-Muga small cottage industry.

);> Photocatalytic Inactivation of harmful Gram positive and Gram negative bacteria using this nanopowder

5. Outcomes and outputs from the projects:

a. Outcomes 1. Lead(s) identified: Number and names with TRL - 08 Nos

i. Microbial formulation for pulping & bleaching of bamboo - TRL 3 ii. Polyol pulping of bamboo - TRL 2 iii. Lignin based syntan from black liquor - TRL 3 iv. Pigment and Colouring agent from black liquor- TRL 1

Achieved

v. Development of Algal Cellulose from sea weed and Laccase production from marine bacteria - TRL4

vi. A novel bacterial strain for xylanase production useful for pulp bleaching - TRL 4 vii. A process for de-acidification and de-chloridisation of iron oxide waste fines and render it

suitable iron oxide feedstock for further processing in iron and steel industries - TRL 3 viii. Eco-friendly process to treat the iron oxide fines contain chloride and recover the iron and

titanium in the form of alloyed pig iron - TRL 2

c:

·.

2. Technology/Product developed: Number and names with TRL level of Development- 06 Nos

i. Microbial formulation for pulping & bleaching of bamboo - TRL 3 ii. Lignin based syntan from black liquor - TRL 3 iii. Algal Cellulose from seaweed resources - TRL 4 iv. Laccase production from marine bacteria- TRL 4 v. Pulp bleaching enzymes from bacteria - TRL 4 vi. Process to treat the iron oxide fines contain chloride and recover the iron and titanium in the

form of alloyed pig iron - TRL 3

3. Technology/Product transferred: Number and names with name of licensee(s)

4. Facility created: Number and names with uniqueness & utility

i. A New Pulp & Paper testing laboratory has been created by procuring modern machineries & equipments at CSIR-NEIST

ii. Gas cleaning system with bag filter and scrubber has been procured and integrated with existing in-flight plasma reactor at CSIR-IMMT

iii. High temperature tubular resistance heating furnace-custom made- being used extensively in the high temperature synthesis and processing of materials in controlled atmosphere at CSIR-NIIST

iv. Laser Diffraction particle size analyser-Beckman Coulter International -Switzerland- used in the powder characterization at CSIR-NIIST

v. High Pressure reactor system with PTFE liner - Berghof , Germany - used in the leaching studies at elevated temperature and pressure at CSIR-NIIST

5. Sponsored projects obtained (with details)

Sl. Title Funding agency ECF Amount Duration No (in Lakhs) 1 Smelting studies on recovery of metal M/s Vishnu Chemicals 10.26 Aug 2015-

values from chromium leach residue Ltd, Visakhapatnam. 2016

6. External Cash Flow (ECF) generated

Rs. 10.26 Lakhs

7. Societal impact created

);1> Utilization of potentiallignolytic microbes from North East India for application in paper industry to reduce the pollution load.

);1> Wealth from waste approach in using black liquor

Jan

)

b. Outputs:

1. Periodic Reports Submitted:

09 reports- 2 reports/ year

2. Publications i. Total number - 14 Published and 6 under publication ii. Cumulative IF (as per 2015 figures) - 42.817 iii. Average IF - 3.058 iv. Average IF/scientist - 3.058

3. Patents (or other forms of IP generated such as Copyrights, Designs etc.) i. Filed - 3 Nos ii. Granted iii . Licensed

4. Human Resource generated i. PhD fellows (give PhDs completed & pursuing separately)

10 in progress and 1 M. Sc project

ii. Project fellows- 12 Nos

iii. Skills imparted

- Including skill set qeveloped for technical services/ consultancy/ training purposes

• Gained advanced level training as a part of PhD research work • 12 fellows pursuing project work and attained skill for executing research work • Skilled worker generated 04

5. External collaborations established

i. Hindustan Paper Corporation Limited, Jagiroad, Assam ii. M/s Seshasayee Paper and Boards Ltd., Erode iii. M/s Zeal Leathers Pvt Ltd, Chennai iv. M/s KMML, Chavara, Kerela

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Sl. Lead/Technology/ Salient TRL of IP Status of Status of No Product (listed Features of the the Lead/ Lead/Techn DPR/Commercial

above in Lead/Technology/ Tech nolo ology/Produ Technical Report outcomes) Product gy ct of Lead/

/Product Technology/ Product

01 Microbial ~ Reduction of 30- TRL3 Patent filed Not yet formulation for 40% energy in chipping pulping & bleaching and required 20-25% of bamboo less chemicals in

pulping ~ Use of microbial process with eco-friendly bleaching sequence instead of chlorine based process to get pulp of higher brightness

02 Polyol pulping of Simple and eco-friendly TRL2 - Not yet bamboo process with easy

recovery of solvent and lignin

03 Lignin based syntan Provides leathers with TRL3 Patent filed Not yet from black liquor soft and silky feel

Wealth from waste 04 Pigment and Provides good covering TRL 1 - Not yet

Colouring agent properties from black liquor Wealth from waste

05 Development of );> Useful for making TRL4 - Not yet Algal Cellulose from cellulose based product sea weed and ~ Production of Laccase production Laccase enzyme from marine bacteria

06 A novel bacterial );> Useful for pulp TRL4 - Not yet strain for xylanase bleaching, reduce the production useful quantity of bleaching for pulp bleaching agent

~ Xylanase enzyme production with higher enzyme unit

07 A process for de- The process results in a TRL3 - Not yet acidification and de- iron oxide byproduct chloridisation of with significantly lower iron oxide waste acidity and chloride fines and render it content and thereby suitable iron oxide anabling the material feedstock for further used for value addition processing in iron and steel industries

08 Eco-friendly process Recovery the iron and TRL2 - Not yet to treat the iron titanium in the form of oxide fines contain alloyed pig iron by eco-chloride and recover friendly process the iron and titanium in the form of alloyed pig iron

6. Sectoral Monitoring Committee Recommendations on Lead/Technology/Product (listed above):

Criteria SMC Recommendations

Name of Lead/T ethnology i. Microbial formulation for pulping & bleaching of bamboo /Product ii. Eco-friendly pulping of bamboo with Polyol

iii. Lignin based syntan and pigment/colouring Agent from black liquor

Is the Lead/ Technology/Product Yes worth taking up further?

What is the further R&D efforts Field trials that need to be put by CSIRICSIR laboratories?

Global benchmarking of the i. The microbial processes have not been used in paper Lead/Technology/Product industry for pulping. Sludge is reduced significantly specifically wrt specifications compared to conventional processes. and cost ii. The polyol pulping is promising as the process is eco-

friendly and the recovery of solvent and lignin from black liquor is also easy.

iii. There is sufficient scope of utilization of black liquor lignin for production of syntan & pigments/ colouring agents.

Is the Lead/Technology/Product Not at this stage worthy of commissioning a DPR at this stage?

• n

What are the likely resources and 2 years time duration required for taking forward the identified Lead/ Technology/Product to the desired TRL?

Potential stake holders who may Paper and Leather Industry be appropriate to partner technically as well as financially

Suggestion for plausible road Further optimization and up-scaling of the processes to align

map towards further with practical user requirements.

development of lead/technology/product for achieving desired TRL

GO/NO GO further development GO

Other suggestions, if any, related Come out with economic and environmental benefit aspects to benefits/usage/ of microbial route commercialization

7. Identified "lessons to be learnt", especially from shortcomings/failures.

8. Comments on financial progress on the project • fund availability and utilization of fund in the project:

Financial progress is satisfactory and investments made are justified.

9. Sectoral Monitoring Committee Recommendations on Facility creation or other outcomes:

10. Grading of Project Execution: Outstanding I Excellent I Very Good I Good I Satisfactory I Un­satisfactory

Very Good

11. Additional comments, if any:

i. Applicability of microbial formulation to bagasse pith for pulping I fibre extraction may be explored; and

ii. The health impact due to use of xylanase enzyme may be studied.

c~ Or. G.K. Pandey

(Member) Mr. Ravindra Sewak

(Member) Dr. Nimish Shah

(Member)

-~lam; Dr, Vljly Kulkarni

(Mtmbor)

~ Dlrootor, CIIII-NII~ ?<!t""~' Or. Rakesh Kumar

(f~ Chairman = Mom -r (Member)

Dlrootor, Cll,.·NPL (f, Chairman • Member)

~ Mr. Ajtt Singh

(Member)

Dl~~ (TF Ch1lrm1n - Member)

~ Dr. lud"P Kum1r

(Member)

V- L1'1~ Dr. v. "IJ•gopalln

(Ch1lrm1n)

11