Lnv|ronmenta| Management Ass|gnment

1op|c Imp|ementat|on of Inc|us|on of Sugarcane

8agasse Ash |n the Manufacture of Ceram|cs In
Ind|a

8est ract|ce Case Study keuse of sugarcane
bagasse ash (SC8A) to produce ceram|c mater|a|s





Subm|tted by 8ennathan|e| n D|engdoh
MSc 3
rd
Semester
Dept of Lco|ogy and Lnv|ronmenta| Sc|ences
kegn No 110110S
art I
A kev|ew of the Case Study
G|ven Case Study keuse of sugarcane bagasse ash (SC8A) to produce ceram|c
mater|a|s
Goa| 1o eva|uate the potent|a| of the waste management potent|a| of |mp|ement|ng the
usage of SC8A |n the manufacture of ceram|cs
Stakeho|ders Sugarcane Industr|es Ceram|c 1||e Manufacturers
Introduct|on
Sugarcane producLlon ls a ma[or lndusLry wlLh neL manufacLured from sugarcane ln a
process LhaL ylelds much wasLe parLlcularly ln Lhe form of sugarcane bagasse 1hls bagasse
ls usually burned ln furnaces Lo heaL bollers eLc yleldlng sugarcane bagasse ash(SC8A) ln Lhe
process SC8A however ls noL wlLhouL lLs own uses lL can be lncorporaLed lnLo ceramlc Llles
by means of a process called slnLerlng8y vlrLue of Lhls process Lhls ash has Lhe poLenLlal Lo
replace all maLerlals of plasLlc orlgln ln Lhe Llle manufacLurlng process Moreover as Lhe ash
ls used ln Lhls process lL does noL ln effecL go Lo wasLe lL ls processed and managed
responslbly and uLlllzed as a componenL ln ceramlc Llles 8ased on Lhls prlnclple a sLudy was
conducLed ln 8razll on Lhe quallLy changes broughL abouL by Lhe lncorporaLlon of SC8A lnLo
Lhe manufacLure of ceramlc roof Llles(AL Souza

S8 1elxelra

C1A SanLos

l8 CosLa and L Longo)

A Cr|t|ca| kev|ew of the Case Study
Cb[ect|ves of Venture (1) 1o deve|op a v|ab|e manageab|e method of d|spos|ng of SC8A
caus|ng m|n|ma| damage to the env|ronment
(2) 1o augment the process of product|on of ceram|c t||es
1oday sugarcane resldue ls mosLly used as fuel for bollers LhaL ls lL ls used for Lhe
producLlon of sLeam whlch ls used ln varlous lndusLrles and Lo power Lurblnes 1he producL
of Lhls ls sugarcane bagasse ash or SC8A 1he currenL esLlmaLe ls LhaL for every 1000kg of
sugarcane 230kg of cane bagasse ls produced whlch upon combusLlon would yleld up Lo 6
kgs of SC8A
As sLaLed above wlLh Lhe glven reglonal varlaLlons ln composlLlon due Lo equally varylng soll
consLlLuLlons SC8A conLalns hlgh percenLages of slllca alumlnlum lron and alkalls and
alkallne earLh oxldes maklng lLs lncorporaLlon lnLo Lhe maklng of ceramlc Llles 1he addlLlon
of Lhe ash was ln some sLudles found Lo decrease Lhe llnear shrlnkage of Lhe sLrucLure up Lo
a LemperaLure of 970 degrees Celslus
JlLh regard Lo Lhe above lf any wasLe maLerlal can be reused Lo beneflL anoLher secLor and
lf Lhe process ls feaslble and vlable lL ls Lhe revlewer's bellef LhaL lL should be pursued
Methodo|ogy
8esearchers collecLed SC8A from bollers aL Lhe uslna AlLo Alegre" mlll ln resldenLe
rudenLeS 8razll 1he ash was Lhen ground ln waLer drled ln an oven and sleved lL was
of course drled aL 110 degrees celslus and upon drylng showed a hlgh concenLraLlon of
quarLz and Lhus no clumplng Ceramlc raw maLerlal was collecLed aL Lhe lndusLry clay
deposlL from Lhe company Ceramlc 8omana ln resldenLe LplLaclo 1hls was also drled aL
Lhe same LemperaLure and sleved 1he concenLraLlons were analyzed by varlous Lechnlques
such as xray fluorescence and dlffracLlon
A kev|ew of the kesu|ts
8enef|ts (1) A new env|ronmenta||y fr|end|y method of d|sposa| of sugarcane product|on
waste |s found to be v|ab|e
(2) Moderate qua||ty |mprovement |n ceram|c t||e qua||ty
Accordlng Lo Lhe resulL mulllLe formaLlon ls observed whlch ls evenLually lnhlblLed by Lhe
formaLlon of crysLalllne SlC2 1he addlLlon of ash was observed as an lnhlblLor for Lhe
formaLlon of mulllLe durlng Lhe slnLerlng of Lhe maLerlal SC8A demonsLraLes non plasLlc
characLerlsLlcs decreaslng llnear shrlnkage of Lhe ceramlcs durlng Lhe drylng and flrlng
process 1he addlLlon of ash ls effecLlve only aL LemperaLures above 1000 C where lLs found
Lo modlfy and decrease llnear shrlnkage ApparenL poroslLy remalned by and large
unchanged however Lhe sLrucLure of Lhe ceramlcs were sLrengLhened by Lhe addlLlon
1he addlLlon of Lhe ash ls Lhus a feaslble augmenLaLlve process LhaL ls also an efflclenL way
of dlsposlng of SC8A lLs beneflLs are LhaL lL has no deLrlmenLal effecLs on Llle quallLy Lhls ls
balanced by Lhe facL LhaL Lhe process ls feaslble 1hus Lhe lncorporaLlon of Lhls process
would moderaLely augmenL Llle producLlon and quallLy wlLh mlnlmal loss and would ln Lhe
fuLure prove Lo be an excellenL meLhod of managlng Lhe dlsposal of sugar cane bagasse ash
art II Ind|an App||cat|ons
Introduct|on
lndla ls Lhe world's second largesL producer of sugarcane afLer 8razll wlLh an annual
producLlon of 348187900 Lonnes(lAC Lconomlcal and Soclal uepL SLaLlsLlcal ulvlslon
2008) 1he largesL producers are uLLar radesh(3837) MaharashLra(1776) and
karnaLaka(1220) (uepL of AgrlculLure 19992000) JlLh all Lhls sugarcane undergolng
processlng for Lhe producLlon of sugar and eLhanol a large amounL of wasLe ls generaLed ln
Lhe form of sugarcane bagasse whlch upon combusLlon ln lndusLrlal processes ylelds SC8A
1he lndlan Ceramlc Llle lndusLry ls ranked 3
Lh
ln Lhe world ln Lerms of producLlon of ceramlc
Llles 1he producLlon of ceramlcs as of 200607 sLood aL 340 mllllon sq mLs (lCC1AS) ln
llghL of Lhls whlle Lhe quallLy of Lhe Llles ls saLlsfacLory any feaslble room for lmprovemenL
should be aLLended Lo and glven conslderaLlon As sLaLed above before whlle Lhe addlLlon
of sugarcane bagasse ash has no deLrlmenLal effecLs on Lhe Llle sLrucLure lL has been found
Lo decrease llnear shrlnkage and lncrease Lhe hardness and sLrengLh of Llles durlng Lhe
slnLerlng process aL LemperaLures beyond 1000 degrees Celslus 1he process of addlLlon of
ash ls feaslble and an efflclenL way of managlng ash as solld wasLe
A collaboraLlon beLween Lhe Lwo lndusLrles would be ldeal for Lhe producLlon of SC8A
lnfused ceramlc Llles lL would lnvolve secLor compromlses on Lhe collecLlon and LransporL
of SC8A Lo ceramlc Llle producLlon facLorles Such a [olnL venLure would requlre [olnL
lnvesLmenLs from members of boLh secLors
Se|ected S|te
(1) n|temp Ceram|cs Industr|es Muzzafarnagar Uttar radesh
LocaLed ln uLLar radesh Lhls faclllLy would be an ldeal slLe for a Lrlal lnlLlaLlon SC8A may be
LransporLed from sugar lndusLrles ln nelghbourlng sLaLes and dlsLrlcLs 1ransporL expenses may be
mlLlgaLed by elLher parLy
uependlng on Lhe raw maLerlal used ln Lhe ceramlcs manufacLurlng process Lhe percenLage of use
of ash wlll be ad[usLed lf Lhe process ls deemed feaslble by Lhe proponenLs of elLher parLy lL may
be lmplemenLed aL oLher slLes
(2) Somany Ceram|c vt Ltd 8ahadurgarh naryana
1hls faclllLy locaLed ln Paryana would beneflL as a LesL slLe for Lhe lnlLlal lmplemenLaLlon of
Lhe aforemenLloned meLhod
Ind|an Adaptat|ons
rocess Adaptat|ons
(1) uependlng upon Lhe quallLy and composlLlon of Lhe raw maLerlal used ln Lhe
manufacLure of Lhe Llles and Lhe composlLlon of Lhe SC8A ln Lerms of SlC2 alkalls
eLc Lhe percenLage of addlLlon and mlxlng wlll vary as Lhe alm ln Llle producLlon ls
Lo opLlmlze Lhe formaLlon of mulllLe whlch wlll lend sLrengLh and hardness Lo Lhe
sLrucLure of Lhe Llles
(2) 1he posslble use of kaollnlLlc solls would be preferable as Lhey promoLe Lhe
formaLlon of Lhe phases of mulllLe and crlsLoballLe roporLlons of ash and clay musL
be ad[usLable dependlng upon Lhe composlLlon of boLh whlch ln Lurn depend upon
Lhelr respecLlve source

o|nt Ventur|ng and Investment
(1) Leadlng members of boLh secLors musL be wllllng Lo engage ln a [olnL venLure Lo
propagaLe Lhls process
(2) 8oLh sldes musL provlde [olnL caplLal Lhe producers of SC8A such as power
lndusLrles or sugarcane processlng lndusLrles uslng bagasse Lo fuel Lhelr bollers
would have Lo be wllllng Lo provlde fundlng for LransporL means and expendlLures
and Lhelr counLerparLs ln Lhe ceramlcs lndusLry musL be wllllng Lo purchase Lhe ash
or cover Lhe LransporL expenses
In|t|a| Integrat|on
(1) lnlLlal lnLegraLlon ls expecLed Lo be gradual so a LemplaLe lnLegraLlon Lo propagaLe
beLween one faclllLy produclng SC8A and a ceramlc Llle faclllLy would serve as an
ldeal sLarLlng polnL
(2) lnlLlal Lrlals may be carrled ouL ln Lhe lncorporaLlon of Lhe ash lnLo Lhe process and
Lhe flrsL producLs of Lhe alLeraLlon may be LesLed for sLrengLh hardness durablllLy
eLc Mlnor problems may occur due Lo lnlLlal errors ln composlLlon proporLlonlng
1hese however can be recLlfled 1he cosL effecLlveness of Lhe enLlre process may be
assessed facLorlng all regular and added expendlLure agalnsL proflLs
(3) lf Lhe process ls found Lo be vlable aL Lhls faclllLy lL may be lncorporaLed aL several
oLhers and Lhe evaluaLlon process may be repeaLed
8road App||cat|on
lf Lhe process ls evaluaLed and declared Lo be feaslble aL several faclllLles mass producLlon
of augmenLed ceramlcs may begln 8evlews and consLanL evaluaLlons may be conducLed on
a regular basls along wlLh regulaLlon producL quallLy checks lf Lhe producLs are found Lo
conform Lo lndlan sLandards Lhen markeLlng can conLlnue
Mass roduct|on and I|na| Integrat|on
Cnce mass producLlon has begun Lhe popularlzaLlon of Lhe above process may be lnlLlaLed
wlLh Lhe ulLlmaLe alm belng lLs accepLance as a parL of Lhe norm ln referrlng Lo Lhe ceramlc
Llle manufacLurlng lndusLry lf consumer(reLall and wholesalers) approval can be garnered
proflLs wlll begln Lo rlse and Lhe wldespread accepLance process wlll begln Any publlclLy of
Lhe process as a means of responslble solld wasLe managemenL would be conduclve as well
Conc|us|on 1he lmplemenLaLlon of Sugarcane bagasse ash Lo augmenL Lhe sLrucLure of
ceramlc Llles ls a feaslble way of properly dlsposlng of Lhe ash as Lhe cosL effecLlveness and
efflclency of Lhe process was flrsL researched ln 8razll a developlng naLlon lL may
economlcal ln lndla as well lf aLLempLed lL ls Lhe vlew of Lhe sLudenL LhaL Lhe Lechnlques
used ln Lhls process are appllcable