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TECHNOLOGICAL INNOVATIONS
Technological innovation in energy sector has not only been a tool to improve the efficiency of various processes and to reduce costs, but also to meet the increasing social and environmental concerns among population and government authorities. CSIR-CIMFR has been involved in R&D innovations in the energy sector for improvements in existing technologies which helped in transforming many of the developments from laboratory to the industrial applications. Some notable efforts have been made to partially substitute imported coking coal by cheaper indigenous alternative materials in coke making; to provide efficient utilization of coal as domestic fuel; development of suitable gasifier design, utilization prospects and strategy for wide variety of feed flexibility including high ash coal, biomass, washery rejects and their blends, etc.
Innovation also plays a critical role in the mining industry. Rapid advances in technological innovation, including automation, digitization, and IoT applications, are having a fundamental impact on the mining sector. CSIR-CIMFR has taken several initiatives to adopt new technologies at faster rate by converting physical mine into 3D virtual mine embedded with sensors, IoT-devices, wireless communication, modern equipment, artificial intelligence (AI), monitoring and control devices, etc. Miners’ safety is a major concern for mines, where, continuous monitoring with IoT-enabled devices is essential for real-time monitoring, providing warning of impending hazards, and taking necessary control measure to avoid mine hazards and reduce loss of life and mine’s property.
The Institute has developed the capability to convert waste mine water produced during the course of coal mining into drinking water. This is a translational research which utilizes a valuable resource, augment the drinking water need of local people and save the secondary contamination of surface water bodies. Innovative R&D works have also been done for recycling waste material like fly ash, used lubricant oil, etc. to useful low cost commercial products.
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I-01 |
Technology for non-recovery and drag type coke ovens with stamp charging and coke quenching |
In the initial days attention on CSIR-CIMFR was for the utilization of inferior grade coking coal for coke making as the coke making technology were mostly imported and of by-product recovery type. CSIR-CIMFR developed sole heated bee hive ovens of multi chimney and in later stages that of single chimney. To make the technology more energy efficient, suitable heating and insulating systems were developed in the non-recovery coke oven. In view of the requirement of increasing productivity, quality of coke and use of inferior coal the stamp charging system with coke quenching system was developed.
National/International Status
Larger amount of the coking coal requirement is currently coming from imports. A feasible way to reduce import of coking coals is to partially substitute imported coking coal by cheaper indigenous alternative materials in coke making, while maintaining the desired coke quality required for blast furnace operation. Modern developments in coke making technologies are capable of using low grade indigenous coals in metallurgical coke making. However, for large scale implementation, a few technological gaps need to be resolved. Keeping above challenges in view, CSIR-CIMFR developed non-recovery coke ovens. Non-recovery ovens are generally preferred due to less capital investment, less pollutant and flexibility in operation compared to by-product ovens.
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Pilot non-recovery coke oven with stamp charging facility |
Non-recovery coke plant during construction |
Most of the Indian integrated steel plants are having either non-recovery coke ovens or by-product coke ovens of imported technology. CSIR-CIMFR has developed a comprehensive technology package for non-recovery type coke oven with stamp charging and coke quenching system. Many Indian merchant coke makers are using CSIR-CIMFR technology of non-recovery coke making.
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Commercial non-recovery/ heat recovery coke oven with stamp charging based on CSIR-CIMFR technology |
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Field Implementation
Non-recovery coke ovens based of CSIR-CIMFR technology has been installed by many merchant coke makers at pan India level. To name, some of the industries are M/s Usha Fuel Pvt. Ltd., Raipur, M/s Balaji Hitech, Giridih, M/s Vinayak Iron and Coke Pvt. Ltd., Giridih, M/s Anjinaya Ispat Pvt. Ltd., Jamshedpur, M/s SBQ Steels, Chennai etc. Different capacities of plant having number of batteries have been installed in different parts of India. Coke making is a batch process in coke ovens. The installed batteries of non-recovery coke oven based on CSIR-CIMFR technology have 12 to 25 ton charging capacity per batch and the same for drag type coke oven is 8 ton. The Institute extends all necessary expertise right from design, drawing to commissioning of plant to entrepreneurs in setting their non-recovery coke oven plants with stamp charging and coke quenching.
Techno-economics
Installation of the of the non-recovery type coke oven of capacity around 0.4 MTPA along with stamp charging and coke quenching facility costs about Rs.60 crore, excluding land and building. As the metallurgical/hard coke market is very volatile and depends on availability of coking coal as raw material and imports of coking coal, the price of coking coal as raw material and metallurgical coke as product keeps changing. But as per market report the payback period for the said plant is about five years.
Societal Benefits
The developed technology is capable of using low grade indigenous coals in metallurgical coke making. As of now most of the integrated steel plants have non-recovery of by product type coke ovens based on imported technology. The technology may provide solutions for indigenously augment fuel resources need for enhanced steel production and thus fulfill the Atmanirbhar Abhiyan of Govt. of India. Installation of each non-recovery type coke plant provides employment generation for about 100 persons, directly and indirectly.
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I-02 |
Improved soft coke making technology |
In 2019, CSIR-CIMFR carried out R&D over the earlier developed soft coke making technology and developed improved soft coke making technology which reduced the carbonization time from 16 hours to 8 hours and thus increased productivity. The improved soft coke technology is capable of utilizing the currently available coal resources for good quality soft coke production.
The improved soft coke technology achieves benefits of higher temperature of sole which reduces the coking time. The technology allows complete burning of tarry matters and thus reduces pollution.
National/International Status
The domestic fuels used in rural area were mainly wood, cow dung cakes and agriculture waste. CSIR-CIMFR took the challenge of developing domestic fuel by low temperature carbonization. A continuous low temp carbonization pilot plat was installed in the year 1961 of 20-30 t/day capacity. Based on the data, a LTC plant came at Dankuni though using different technology.
As the manufacture of domestic coke became costlier, through vertical type plant having facility for by product recovery, due to heavy capital investment, CSIR-CIMFR developed small ovens of capacity 2.0-2.5 t/oven with 16 hours carbonization time. The technology was developed in 1995-96 and was commercialized from 1996 onwards. With earlier expertise, the Institute developed improved soft coke making oven technology in 2019 which reduced the carbonization time to 8 hours and thus increased productivity over the earlier technology.
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Completed soft coke plant based on CSIR-CIMFR technology |
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Field Implementation
Many industries approached CSIR-CIMFR to obtain the license for utilizing the knowhow for setting up improved soft coke making technology. The technology has already been transferred to M/s Kahakasha Entrerprises, Jharkhand, M/s Ganpati Enterprises, Bihar, M/s Shardapunj Fuel Coke Pvt. Ltd., UP, M/s Eastern Fuels Pvt. Ltd., UP, M/s Sidhgiri Holdings Pvt. Ltd. UP.
As per the agreement CSIR-CIMFR provided the knowhow document and the workable drawings for installation of soft coke oven plant. After installation of the soft coke oven plant, the plants have been commissioned in the presence of CSIR-CIMFR officials and CSIR-CIMFR issued commissioning certificate of the plant.
Patent/Technology Transfer/Commercialization details
Patent filed vide CSIR Patent Application No.: 0167NF2019 dated 04/10/2019.
Techno-economics
Installation of the of the improved soft coke making plant of about 5000 t/month coal throughput, costs about Rs.110 lakh excluding land and building. As the soft coke market is very volatile and depends on availability of raw material the price of coal as raw material and soft coke as product keeps changing. However, an estimate shows the payback period for the plant is about five years.
Societal Benefits
In earlier days domestic fuels used were mainly wood, cow dung cakes and agriculture waste. Due to depletion of forest reserve at a faster rate the availability of wood became very scarce. The depletion of forest imbalanced the ecology of the environment. The developed technology provides a clean domestic fuel which reduces pollutant emission during domestic cooking. The technology provides efficient utilization of coal as domestic fuel. Installation of each soft coke plant provides employment generation for about 50 persons, directly and indirectly.
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I-03 |
Technology for coal compacting and leveling equipment for drag type coke oven |
Since the coke making technology were mostly imported and of by-product recovery type, CSIR-CIMFR focused on development of sole heated bee hive ovens of multi chimney and in later stages that of single chimney. To make the technology more energy efficient, suitable heating and insulating systems were developed in the drag type coke oven. In view of the requirement of increasing productivity, quality of coke and use of inferior coal, the coal compacting system for drag type ovens was developed.
National/International Status
A feasible way to reduce import of coking coals is to partially substitute imported coking coal by cheaper indigenous alternative materials in blast furnace coke making, while maintaining the desired coke quality. Modern developments in coke making technologies are capable of using low grade indigenous coals in metallurgical coke making. Small cokeries have drag type coke ovens, which cater coke requirement of lower capacity steel plants and small foundries. Drag type coke ovens with coal compacting machine are generally preferred due to less capital investment, less pollutant and flexibility in operation. Keeping in view the technical challenges, CSIR-CIMFR developed coal compacting machine for drag type coke ovens of small scale merchant cokeries.
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Coal compacting machine for drag type coke oven |
Coal compacting machine under operation |
Field Implementation
The coal compacting machine based on CSIR-CIMFR technology has been directly installed for commercial scale drag type coke oven at M/s Jwala Coke Pvt. Ltd., Dubra, WB. The installed batteries of drag type coke oven are of 6 to 8 ton charging capacity per batch. The institute extends all necessary expertise right from design, drawing to commissioning of coal compacting machine to entrepreneurs for different capacities of drag type coke ovens.
Techno-economics
Installation of a new coal compacting machine in place of existing drag type coke oven costs around Rs.50 lakh. It has been found that, with the use of coal compacting machine, the productivity of the plant increases by about 25% with significant coke quality improvement.
Industrial Benefits
Wide range of non-coking coal like heat affected coal (jhama), non-coking bituminous coal, lignite, carbonized product of petroleum heavy residue (pet coke), may be the future carbon resource for these industries. A feasible way to reduce import of coking coals is to partially substitute imported coking coal by cheaper indigenous alternative materials in coke making, while maintaining the desired coke quality required for end use. The developed technology enables use of low grade indigenous coals in coke making.
I-04 |
Development of a thermo-gravimetric reactor (TGR) for gasification kinetic study |
TGR is useful to study weight changes behaviour required for understanding the reactivity and kinetic parameters of any kind of reactive solids in a lump/granular/powder form with particle sizes ranging from -200mesh to 25mm and sample mass from few mg level to 100g in the gaseous environment of different gases including but not limited to N2, Ar, He, air, O2, CO2, steam or their mixtures at any proportion with the operating temperature up to 1000C and at atmospheric pressure.
Photograph of thermo-gravimetric reactor
National/International Status
Thermo-gravimetric analyzer (TGA) is widely accepted due to its accurate and precise weight measurement with respect to time and temperature. However, its disadvantages include low heating rate, low mass and gas throughput, limitation to handle solids in any form, limitation to introduce different gases including steam and their mixtures in any proportion, limitations of sudden heating and cooling of the sample. Therefore, extrapolation of the obtained results to other systems of larger scale becomes restricted. With this background, TGR with movable furnace has been developed which obviates the aforementioned drawbacks.
TGR is used to estimate the reactivity and kinetics of different coal, biomass and their blends in powder/granular/lump form in the aforementioned gaseous atmosphere followed in commercial gasifiers and combustors. This device is also showcased to the experts from the R & D sector and industries including IITs, CIL, TATA, NITI Aayog, Thermax, EIL, BHEL, analytical instrument manufacturers and many more. Different industrial projects are tested and completed in actual field conditions/environment.
Patent/Technology Transfer/Commercialization details
Patent filed in India vide application no. 202111001133, dated 11th January, 2021.
Techno-economics
Presently, there is no indigenous manufacturer of TGA. This indigenous development of TGR with above-mentioned innovative and unique features creates an exclusive opportunity for Indian instrument manufacturers and users. This indigenous development definitely reduces the establishment cost for thermo-gravimetric analysis with relevant added features.
Societal Benefits
This indigenous development may provide a new avenue with excellent opportunity for medium and small scale instrument manufacturers. This will create trained manpower and job opportunities for young Indians.
Industrial Benefits
This TGR obviates the drawbacks of the conventional TGA in a cost effective manner. This device is considerably helpful to make fast decisions about suitability, utilization prospects and strategy for wide variety of feed for any process and generates database necessary for phenomenological modelling and design of the reactors not only for the energy sector but also for various chemical and pharmaceutical industries.
Stakeholders/Clientele
Analytical instrument manufacturers, coal industries, power sector, chemical sector, pharmaceutical industries, food processing, agro-processing industries and MSMEs and startup companies.
Future Plan
This TGR test facility is ready for commercialization and interested industries are welcome for technology transfer following CSIR Technology Transfer guideline.
I-05 |
Technology for 1.5 TPD oxygen enriched air blown pressurized fluidized bed gasifier |
Oxygen enriched air-blown pressurized fluidized bed pilot scale refractory lined gasifier of 1.5 TPD feed capacity is useful to gasify coal, biomass, washery rejects, and their blends in any proportion in the actual atmosphere of commercial gasifier. The gasifier is having maximum operating temperature up to 1050oC, pressure up to 10 kg/cm2 with particle size acceptability ranging between 0-4 mm.
National/International Status
Presently, there is no worldwide commercially proven fluidized bed gasification technology for handling high ash coal. In India, numbers of stakeholders are involved in the development of fluidized bed gasifier. They are developing fluidized bed gasifier with their own gasifier configuration, specific distributor design and hydrodynamic regime (bubbling, turbulent and circulating fluidization), but some gaps are yet to be addressed for its continuous commercial exploitation.
In this direction, CSIR-CIMFR has developed PFBG technology. Operational philosophy has been developed to overcome the issues related with continuous feeding, ash withdrawal and maintaining proper hydrodynamics in the bed which are essential for commercial exploitation.
Innovative and unique designs make the system flexible with respect to pressure, temperature, feed rate of fuel and gaseous reactant, residence time, particle size, particle density and feedstock.
Field Implementation
The system is being tested for different coal, biomass and their blends to evaluate gasification performance under different operating conditions addressing all the issues related to fuel feeding, ash withdrawal, agglomerate and clinker formation, gas cleaning etc. This development has been showcased to the experts from R&D sector and user industries interested in solid carbonaceous fuel gasification including CIL, Power industries, NITI Aayog, Thermax, EIL, BHEL, Academic institutions and many more.
Patent/Technology Transfer/Commercialization details
Indian patent filed vide application no. 0090NF2021
Techno-economics
Enormous scope is there to exploit the huge coal resource of our country through the developed PFBG technology for various value added applications. It may reduce the dependency of the nation upon the imported gasification technology and can save a huge amount of foreign exchequer which is spent for the procurement of foreign technology.
Oxygen enriched air blown pressurized fluidized bed refractory lined gasifier at CSIR-CIMFR, Digwadih Campus, Dhanbad
Societal Benefits
This will open up new horizons in Indian energy, chemical and fertilizer sectors. These core sectors will create huge job opportunities for young Indians. Moreover, surface coal gasification utilizing indigenous gasification technology will unfold a new avenue for the coal sector which will create job opportunities in India. Above all, the make in India program will get a huge boost by gainful utilization of high ash coal for production of a large spectrum of value added products.
Industrial Benefits
This technology will act as a footprint to set up indigenous demo scale 100 TPD coal to methanol units from high ash coal at different locations preferably at mine mouth locations before its commercial venture. This development is a milestone achievement as a part of Methanol Economy Program and an important step towards Atmanirbhar Bharat Abhiyan of the Govt. of India. This technology will demonstrate to understand the gasification potential of indigenous coal/biomass resources and their utilization pattern.
Stakeholders/Clientele
Coal industries, Steel sector, chemical sector, fertilizer industries, ceramic, food processing, agro processing, power sector, gasifier manufacturers etc.
Future Plan
Under the aegis of NITI Aayog, Govt. of India, CSIR-CIMFR is pursuing a mission mode program on Coal Syngas to Methanol (CoSynol) and is in the process to setup a 250 kg/day coal derived syngas to methanol pilot plant and will be integrated with the developed 1.5 TPD oxygen enriched air blown pressurized fluidized bed gasifier.
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I-06 |
Technology for making briquettes from coal and coke |
With the increase in demand for coke, CSIR-CIMFR developed partial substitutes of coke by making briquetted fuel. The industrial briquettes having properties equivalent to prime hard coke could be made possible by utilization of coke breeze and coal dust. The processes developed in lab scale was tested in pilot plants and subsequently commercialized. The plant provides acceptable domestic fuel. An 1TPH pilot plant is available at CSIR-CIMFR for testing the coal and coke for briquette making.
National/International Status
CSIR-CIMFR carried out extensive experiments on low pressure briquetting of coal as well as on Kashmir lignite and based on these investigations a 10 TPD plant was installed at Srinagar for briquetting of Kashmir lignite. Many countries are using briquetted fuel as blend for making coke and for steam generation.
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Pilot coal/coke briquetting machine with curing system |
Industrial briquettes |
Field Implementation
The technology for making briquetted fuel from coal has been transferred to many industries such as M/s Black Diamond Coal Briquette Industry, Kalyaneshwari, Kulti, M/s Alo Coke Industries, Dabor, Achra, Burdwan, M/s Rakhakali Enterprise, Amdiha, Lalganj, M/s Singal Fuel Coke & Briquette Coke Industries, Jamuria Bazar, Burdwan, M/s United Fuel Coke, Burdwan etc.
Techno-economics
Installation of the coal/coke briquetting plant of capacity 10 TPD costs about Rs.30 lakh. The production of briquetted fuel depends on availability of coal or coke fine rejects and demand of briquetted fuel, price of briquettes and demand of the technology keep on changing. An estimate shows the payback period for the said plant is about five years.
Societal Benefits
The developed technology may provide solutions for waste utilization. Installation of each briquetting plant provides employment generation for about 20 persons, directly and indirectly.
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I-07 |
Process and technology for making pellets from coal and coke |
CSIR-CIMFR developed technology for making industrial pellets having properties equivalent to coke by using of coke breeze and coal dust. The processes developed in lab scale were subsequently commercialized.
National/International Status
During 2005, CSIR-CIMFR developed a pelletisation process of coal which was excellent smokeless fuel for industrial/domestic use. Non-coking coal slacks, inferior coking coals, coke breeze, char and middling/rejects and slurries from coal washeries were processed to produce strong agglomerated fuel using a small proportion of cheap binders at atmospheric pressure. A continuous 1 TPH pilot plant was designed and installed at CSIR-CIMFR.
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Coal/coke pelletisation plant of capacity 1 TPH |
Coal pellets |
Techno-economics
Installation of the coal/coke pelletisation plant of capacity 1 TPH costs about Rs.15 lakh. As the production of coal/coke pellets depends on coal or coke fine rejects and market demand, price of the coal /coke pellets and demand of the technology keeps on changing. According to an estimate, the payback period for the said plant is about five years.
Societal Benefits
The developed technology may provide solutions for waste utilization. Installation of each pellet plant provides employment generation for about 5 persons, directly and indirectly.
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I-08 |
Bottom pulsated aero-hydro two product jig |
Coal washing is a process that is undertaken in a coal washery or coal preparation plant (CPP) where coal is refined or cleaned off impurities. Coal washing involves using water, mechanical techniques and relies on gravity and the difference of density between coal and its impurities which are usually more densely packed due to the fact that they are difficult to wash. The quality of the coal plays a major role for its utilization in different industries. The mined raw coal is to be washed either for its utilization in steel, power, sponge cement industries. The common practice in coal washing is to crush the run-off-mine (ROM) coal to a suitable top size and wash it in different units. For enhancing the qualities of coal, a bench scale bottom pulsated aero-hydro two-product jig has been developed at CSIR-CIMFR.
National/International Status
Large capacity Batac jigs are usually procured from market and installed at the washeries. Unfortunately, no elaborate studies were carried out on treatment of high ash Indian coals using the Batac jigs and hence the performance evaluation while treating Indian coals is lacking. To evaluate the performance for high ash Indian coals, a smaller capacity jig is required where the parameters may be monitored and controlled. It is difficult to get a low capacity test rig and unfortunately it is not available in the market. CSIR-CIMFR is having experience of washing Indian coals and huge data available on the characteristics of different coals. This will help in designing a low capacity bottom air pulsated jig (test rig) which may fulfill the requirements of R&D purposes.
Patent/Technology Transfer/Commercialization details
Copyright approved L-88849/2020 dated 15.01.2020
I-09 |
Biometric based exploder |
Exploder is a device that triggers detonators by generating electric current in order to initiate firing of explosive charges. It is also called blasting machine which helps in safe and controlled blasting to avoid the chances of misfire. It has vast applications in rock excavation for mines, roads and other construction/demolition activities. Different types of exploders available in the market are found unsafe if it is stolen and misused by illegal nexus, militants etc. To avoid such type of misuse, the biometric-based exploder has been developed. It can only be operated by those peoples who are biometrically registered with the specific device. The device comprises of an embedded microcontroller, converter circuit, rectification circuit, safe discharge circuit, and authentication circuit and display unit. The fingerprint scanner with the help of embedded microcontroller registers authorized personnel using their finger print up to 20 numbers. Once registered, no other person can use these devices. Two types of exploder have been developed, one for underground mines and another for opencast mines. The major features of the device are as follows:
● The output firing duration is 4 millisecond
● The device provides constant current source across its output probes
● The device output is 1.2 A across any load varying between 4 and 200 Ω, and internally locks itself, if the load increases or decreases
● The device is able to fire 30 shots in series for underground mines and 200 shots for opencast mines
● The biometric exploder is equipped with a push button switch for firing.
● The device is intrinsically safe for underground mine use also.
Biometric-based exploder
National/International Status
No biometric-based exploder is available nationally and internationally.
Patent/Technology Transfer/Commercialization details:
● Patent: Biometric-based exploder, Patent Application Filing No. 201811040426, dated 26.10.2018.
● Technology Transfer: The technology has been transferred to M/s Pranay Enterprises, Hyderabad
Techno-economics
The developed device is technically superior to the existing key-based exploder with more safety features. However, cost of the device is slightly higher than the existing device. But, considering the safety and life of human beings, cost of the device is insignificant.
Societal Benefits
Implementation of biometric-based exploder will help in controlling misuse of exploder by the unauthorized person and saving of human life.
Industrial Benefits
Application of biometric-based exploder will eliminate chance of misfire. Blasting operation in mines will be safe and chance of stealing of exploder will be less. The manufacturing industry will be benefited by commercialisation of the technology after transfer of the technology.
Stakeholders/Clientele
Mining industries and electronics manufacturing companies
Future Plan
CSIR-CIMFR plans to collaborate with the mining industry for application and further improvement of the device with the latest technique.
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