Molded Crockery Manufacture, using Banana Fibers

Click on the illustration to enlarge

For more details: contact the Author/ visit: Open Source Engineered Design

The greatest COST Factor in any business/ industry could be traced to the huge wastes that go either un-noticed or are wrongly used. Wastes conversions/ Recycling, through creative and imaginative entrepreneurial + techno-commercial “one-upmanship” would go a long way in not only utilizing such wastes, but the resultant business/ economic growth could be significant, apart from providing livelihood benefits to a large number of local population

INTRODUCTION – Need for Indigenous Technology

AGROWASTES and SAWDUST are seen to be generated in huge quantities in every country. As yet we have not attempted to convert all of these excellent basic raw-materials into appropriate value-added products. In fact, it has been estimated that from the stage of “tree cutting” till products such as Furniture, Stair-cases and House structures are completely finished, the wastage in volumetric terms are about 80% to 85%. That would mean that only about 15% to 20% of a Tree that is cut becomes end products of value. Sawdust and other wood shavings alone account for 20% to 25%. Thus, if we were to start from a Full-Tree that is estimated to have a total volume (starting from the base till the small twigs etc) of 4 cu.m, sawdust alone could be a whopping One cu.m. However, so far no practical Appropriate technology has been developed to utilize and convert these sawdust wastes into value added products, within investment levels that entrepreneurs in Developing countries could afford. AGRO-BIOGENICS have recently developed and successfully “bench-leveled” many New product technologies to convert sawdust, wood wastes and agrowastes into value added products. These basic technologies could be utilized by Entrepreneurs to reap Good benefits, as the Projects could start from investment range as low as US $40, 000 (for Plant and Machinery). Molded Floor Tiles Project could begin with such low investments. This Sketch-Scheme is to set up a Molded NFPC Floor Tiles Plant, to manufacture 60 T of Molded Tiles per annum. It should be noted that all Plant/ Machinery/ technology are available locally, and unlike the projects for Particle Boards etc, which would need heavy investments, the entire project could begin within a total investment range (including Working capital) of less than $50, 000, and the project completion is possible within 4 to 6 months from “Start-up/ Go-ahead” signal

A FEW ILLUSTRATIONS

Industrial Wood Wastes

Agrowastes and Vegetation Wastes

The above photo illustrations show the availability of huge quantity of Industrial Wood wastes and Agrowastes – needing that they all be RECYCLED for not only benefiting the environment but that would also help in reducing our dependence on Wood, Metals and other “depleting resources” based materials of engineering. We, thus arrive at GREEN Products that help both the environment as well as society

Innovative GREEN Products

For more information and Full details

Hariharan PV

http://www.agro-biogenics.com/Contact.htm

Also, the “comments” section below may be used to contact the signatory

[Please also read the earlier blog posts:

• Piloting Sustainable GREEN Development

• Piloting Sustainable GREEN Development – An Overview

… in that order]

The paradox of the tropical world, with over 135 nations, degenerating into dilapidated poor nations, where natural resources are abundant, is perhaps the greatest tragedy of the modern world. India, with a population of 1.15 billion, is one amongst these poorer nations. Of the 3.5 billion people in these nations, who earn less than $1 per day, India has about 800 million people; of the 1 billion people in these nations, who do not have potable water, India has about 350 million people; of the 1 billion poorest amongst these who do not have even one square meal a day, India has over 350 million people (nearly half of these being children aged less than five years). The paradox is more outrageous, when we note that it is in India that the greatest proponent of “uplifting the poor” was born and who led India to independence from the British Colonialists, through Non-violence … the great MAHATMA GANDHI! But alas! We think and talk about this “half naked fakir” only on a few occasions (his birth date & death anniversary). But the answer to the world’s Sustainable GREEN Development is possible ONLY through the idea that Gandhi propounded: “… through wiping the tears of every poor man in every village …”

Pilot Plant for Sustainability Engineering

The schematic illustration here portrays the different techno-commercial processes that create value additions to every gram of agro-bio materials (agro-biogenics) in village regions. Although Food Processing would also be undertaken, the illustration does not portray the same. The particular situation here is based on 30 Ha area Renewable Resources in a southern Indian village. The average rainfall in this region is in the range 1100 mm to 1350 mm.

The following INPUT/ OUTPUT material balance may be noted:

INPUT MATERIALS

A. RENEWABLE RESOURCES (vegetation systems, rain water, atmospheric oxygen etc)

1. Non-food vegetation materials ….. 1225 T

2. Food materials ……………………… 275 T

3. Organic wastes …………………… 120 T

4. Rainwater ……………………… 2, 750, 000 L

5. Atmospheric Oxygen for Methane burning, obtained from 900 T of Air (at standard pressure conditions)

B. OTHER EXTERNAL INPUTS

1. Slag/ Pozzolana Cement …………….. 142 T

2. Ferric Chloride (Inorganic Chemical)… 15 T

3. Polymers/ Bio-Polymers …………….. 150 T (50% solids)

4. Calcium Chloride (Inorganic Chemical ) …. 12 T

5. Salt/ Turmeric/ tamarind/ condiments etc for Food processing (not specified)

OUTPUT MATERIALS (Three Stages)

I. STAGE – I:

1. Food Materials for Processing (after local use) … 250 T

2. Vegetation matter for Engineered Composites …. 612.5 T

3. Vegetation matter + Organic wastes for methane gas … 732.5 T

   (About 30 to 50 local people would have 300 days employment)

II. STAGE – 2:

1. Anaerobically Digested Methane Gas ………. 55 T

2. Digester based Carbon Di Oxide gas ……….. 95 T

3. Digester based Hydrogen Sulfide gas ……… 1.5 T

4. Digester based Sludge Bio-Fertilizer … 1, 395 T (3.3% solids)

5. Cellulosic/ Plant Fibrous matter (dry) …….. 165 T

   (About 60 local people would have 300 days employment)

NOTE:

1. We are not presenting the data on water usage, as almost all of the water collected (or recovered from vegetation and other processes) would be recycled. The Water in Bio-fertilizer (sludge form) is about 97%, and this entire quantity would be recycled back into the soil (Self Regenerative Recycling – acronym SRR). Thus, only about 50% of the originally collected rainwater would have to be replenished every year, on account of the engineering processes. As much as 50% of rain water collected would be available for personal uses of the local people.

2. The total number of local personnel who would have 300 days work and wages is about 150

III. STAGE – III (MARKETABLE/ UTILIZABLE PRODUCTS):

1. Natural Fiber Polymer Composites (NFPC) … 318 T … Rs.31.8 M ($636, 000)

2. Sludge Bio-Fertilizer … 1395 T (3.3% solids) recycled for local soil regeneration (SRR) … valued … Rs.690, 525 ($13, 810/50)

3. Electricity and Heat generated using Methane gas … 708, 408 units … Fully used for in-house processes … valued Rs.3, 542, 400 ($70, 848)

4. Inorganic Fillers for Polymer Composites … 156 T … Rs.3.12 M ($62, 400)

5. Intermediate Inorganic Chemicals (in solution) … 12.8 T … Rs.96, 000 ($1920)

6. GREEN Sulfur … 1.4 T … Rs.56, 000 ($1120)

1. Processed Foods … 312.5 T … Rs.23.4375 M ($468, 750)

   (MARKETABLE VALUES ……… Rs.58, 509, 500 = $1, 170, 190)

A FEW OBSERVATIONS

1. The estimated Capital investments for the Pilot plant (which would be named: APIX_30_PILOT) is Rs.30 M ($600, 000)

2. This APIX-SEP (Agro-Polymer Industry Complex-Sustainability Engineered project) Pilot plant, by itself, is Technically feasible and Economically viable. While the Technologies involved are tried/ tested systems (anaerobic biogas generation, chemical cleaning of biogas, chemical separation of biogas constituents, conversion of cellulosic fibrous matter into Polymer Composites …), the estimated ROI (before taxation) is about Rs.12 million ($240, 000). This is 40%

3. The project would be supported by various GREEN “channel supports”: Carbon Credits and Government Tax concessions.

4. Unlike many GREEN projects, APIX-SEP units would be totally Self-Sustainable, and these would be “self-perpetuating”

5. The APIX-SEP group would not own any land; but the entire operations in the farmlands would be “leased out/ outsourced” to the group. The farmers and other vegetation material owners would be paid the values of these vegetation (Rs.1000 = $20 per “green” ton of non-food vegetation and one-half market value of other crops. Etc. Even organic wastes would be offered a value @ Rs.1000 per ton)

6. The biggest draw is that every Pilot project such as APIX_30_Pilot in remote villages would be welcomed by the local people, as almost the entire employable people would have “full time” jobs … in home environment. This would be a boon to every individual, as there would be no need to travel far away into alien lands/ towns/ cities, in search of livelihood. Each such APIX_30_Pilot plant system would employ not less than 150 local people for the various works needed to be carried out
   

We shall discuss the “pros” and “cons” and also the techno-commercial and environmental management of such APIX-SEP units, in a later discussion.

Please also visit: http://www.agro-biogenics.com

http://pvhramani.wordpress.com

Renewable resources in Southern Indian Village Surroundings

Click on the illustration to see enlarged photo.

The illustration here shows a portion of village surroundings in a Southern Indian region. The foreground shows grazing cattle, in open rice fields, where the “cropping” is just completed (also seen on the right hand side foreground are some quantities of hay). The background depicts the profuse growth of Green vegetation (most prominent being coconut trees, although others such as Banana, Mango, Tamarind, Drum-stick and various cultivated vegetables … are also involved). The dense green cover obliterates the housing and other buildings in the village.

Analyses of the photo illustration above shows three “agro-biogenic” systems in a typical Indian village/ farmland area (southern India):

 The hill/ mountainous terrain ecosystem in the back ground

 The profuse vegetation system (with coconut trees and other plants/ vegetation systems)

 The agricultural fields with the grazing cattle in the foreground

It is also observed that, though we do not see the hamlets and other buildings of the village in which the local people live, an average such village in India would have about 300 to 400 families, with a total population in the range of 2, 000 to 3, 000 people. The average Per Capita Village Purchasing Power (PVPP) in such villages would be about $150 to $200 … resulting in annual total village income of $400, 000 – an extremely low economic level. Further, it would be noted that the village people would have to depend on far away town based schools, colleges, hospitals, and other basic needs. The transportation infrastructure, electricity supply, water supply and sanitation/ drainage facilities would be pathetic, to put it mildly. However, there is also a “hidden” economic output value, in terms of the availability (for consumption) of certain main food materials (cereals, vegetables, poultry, milk and meat), which could be valued at about the same level as the income, as aforementioned. Thus, the total “worth” of the village would be about US $800, 000 (GROSS RURAL PRODUCT—GRP).

The questions are:

1. How do we improve the living standard of people in such a village?

2. What are the available resources, which could be useful for value addition?

3. What about energy needs for cooking, electricity and other home/ agriculture needs?

4. How do we gain business income by investing in such “dilapidated” villages?

Various Tropical Vegetation and Fruit systems for APIX_Development

We now need to “go back to nature”, facilitating the creation of high value energy and product systems, using all available renewable resources in the village region and support the setting up of industrial ventures (using all of these), which would pave the way for answering all of the above questions. This could be made possible through the New Business paradigm, practically implemented through Sustainability Engineered Projects (SEP). An average village is estimated to be encircled by a total farmland area and surrounding non farm vegetation region of about 250 ha. About four such village cluster could be considered as the effective “renewable resource region” for a Standard SEP unit.

AN idea of SEP in farmland/ Village areas

The illustration here schematically presents Zero-Waste Zero-Carbon Business-Model, utilizing all available Renewable Resources within an ecological system in village surroundings. The different inter-related and inter connected commercial operations utilizing all available Renewable Resources (RR) would be named: AGRO-POLYMER INDUSTRY COMPLEX (APIX). Although there are various processes that could be carried out simultaneously, each Project in each region could vary, depending on various local factors. Every such project system would be named: APIX-SEP (acronym for AGRO-POLYMER INDUSTRY COMPLEX-SUSTAINABILITY ENGINEERED PROJECTS). As explained earlier, FOUR villages cluster (in India) would make up about 1000 ha farmlands and surroundings. Every such cluster would have RR, which could be converted into different product systems and energy. Each such unit in 1000 ha cluster would be named: APIX_1000. The following may be noted in a typical southern Indian APIX_1000:

a. Human resources in the form of labor ………………….. 1, 500 to 2, 000

b. Animal resources in the form of cattle ………………….. 300 to 500

c. Crops and other “cash value” agro-produce .…………. 5, 000 tons

d. Agrowastes and vegetation resources ………………….. 30, 000 tons (green)

e. Rainwater harvested (in 100, 000 sq m @ 1000 mm) = 100, 000 cu.m

These renewable resources could be converted to generate the following value added products/ services:

a. Milk without processing ………… 2000 L/ day ……… value $600/ day

b. Animal wastes … 600 Kg/ day, used for Methane gas generation, along with agrowastes and other unused vegetation matter

c. Agro-produce (Processed Foods) …… 4, 500 T … value = $6, 750, 000

d. Cellulosic vegetation converted engineered products (9, 000 T) … value = $9, 000, 000

e. Bio-Fertilizers 30, 000 Tons (@ 3% solids) … valued …. $6, 000, 000

f. Heat & Electricity Combined Power potential ……… 1500 KWe (equivalent)

g. Carbon Sink Engineered Products (CSE… these are Building Construction products, made by reacting CO₂ with specific “calcareous” materials) ……… 190, 000 T ………….. valued $57 Million

h. Number of people with “full time (300 days/ yr) earning” jobs … 2, 000

In general, it is noted that each such APIX_1000 unit (as above) in relatively lower rainfall areas (@ 1000 mm to 1200 mm, which are spread across large areas in various parts of India) would be centers of WEALTH Creation to an extent of $30 million to $50 million, achieved through SEP programs …

It is estimated that, if the entire 635, 000 villages in India are sectored into such APIX_1000 units, India would have not less than 150, 000 APIX-SEP units, capable of generating VILLAGE LEVEL WEALTH of not less than US $7.5 Trillion! Even if only 30% of these could be practically achieved, the total Village level Wealth creation (paralleling normal economic activities) would be a staggering value of over US $2 trillion!

It is felt that, if we Pilot such schemes in India, to be followed up worldwide, every tropical nation (including small Islands) could be converted into GREEN products Wealth Creation centers, changing the world economic order.

The question is: How do we Start? What incentive would an entrepreneur have, to set up such APIX_1000 units in different regions? Will the Governments in every such nation wake up?

We shall soon study and observe how we may start “piloting” such Sustainable Green Developments – to be initially begun in India.

We need to recognize that, although Technology is the recipe’ for leadership and growth in a world of competitive conflicts, indiscriminate attempt to “outwit” peers through unabashed consumerist technology would be disastrous. This is now seen in the effects of Global Warming and Poverty. What, then, is the answer to the impending catastrophe’, the Damocles sword hovering around? Clearly, Technology, as we now know, is NOT the answer! Think about the impending Mercury pollution that would soon “dissolve” the earth, if all electric lamps are converted to CFL; think about the disastrous pollution effects of the farmlands through heavy metal ingress into soil, when all activities are computerized and all energy systems are based on PV or Cell technologies; think about the “culture-shock” when all educated youth from developing nations migrate to the developed world or work ONLY on problems “dear” to the developed world … the list would be endless.

If you think technology means sophisticated gadgets and hybrid systems … think again! Just look around us at our backyards … we would have the greatest business potentials there … we need to use all available local renewable resources, including human and animal resources, toward solving the needs and problems of local people. This “localization” would be the answer to the present day problems of global warming and green house gas emissions. We have all the energy and materials needs of the local people, within local surroundings. Our estimate of these business potentials indicate a value of not less than US $4, 000 billion!!!

The biggest human problem today is: SHIFTING POPULATIONS … men and women from villages moving away to crowded towns and cities; a whole flock of people’s shifting to a new country, alien to them, resulting in ethnic problems and conflicts. This has to STOP! We consider that these cannot be solved except through a New Business—that which closes the gap between the “rich” and the “poor” … a business that would be directly proportional to the closing of this gap. This would need opportunities to be provided to every local/ village man and woman, in each of the dilapidated villages of ALL poorer nations. There are over 3, 500 million people on earth needing this. This NEED would have to be our PLATFORM for a new Business paradigm. Our estimate of the business potential is worth over US $4, 000 billion, when just $150 per head is the incremental income for each of these 3, 500 million people. We believe this new business would answer the twin problems of global warming and poverty (GWP), in “one shot”.

Please await more details in the next few days!