PROJECT TITLE & OBJECTIVES:

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Prof. Sadhan Kumar Ghosh

Chairman, IconSWM & CRIC, President, ISWMAW;

Professor Mechanical Engineering ;

Chief Coordinator, Centre for Sustainable Development and Resource Efficiency Management; Jadavpur University, India;

www.sadhankghosh.com

Non-recyclable Plastic Waste in Cement Kiln at Jadavpur University, Kolkata, India

[OPTOCE project funded by SINTEF, Norway]

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PROJECT TITLE & OBJECTIVES:

TITLE: OPTOCE PROJECT: Non-Recyclable Plastic Waste from Cities & Municipalities and waste treatment in Cement Plant by Co-processing

OBJECTIVES OF THE STUDY:

a)

The main objectives of the thesis is to provide statistic data on characteristics and proportion of plastic waste and NRPW generated from some target sectors (household, school, office, hospital, industries, trading and service, and tourism) in Kolkata and Muzaffarpur, India and the co-processing of waste in cement plants in India.

a)

The study will be conducted in cooperation with the Norwegian research institute SINTEF under the OPTOCE (Ocean Plastic Turned into an Opportunity in Circular Economy) project. The thesis will contribute to an increased understanding of what has happened to the plastic waste that has already been produced.

23/6/2021 Co-processing non-recyclable plastic waste in cement

kiln_OPTOCE Project SINTEF Norway_Prof. Sadhan K Ghosh, JU, India

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COVID-19 Lockdown

1 2 3 4 5 6 7 8

Nov 20 Jan 21

Feb 21

Mar 21

Apr 21

May 21

Jun 21 Dec 20

1). survey on plastic waste management

in several sectors such as household

and educational

sectors

1). Sampling of plastic waste in five different

municipalities in Kolkata and its

surroundings

1). Study of Co-processing

in Dalmi &

Ultra-Tech cement

plants, Ariyalur, Tamil Nadu

1). Analysis of Micro plastics

at Fields 2). Testing of

collected sample from municipalities

1). Conference paper on Utilization of NRPW in co- processing diverting from the

marine littering path as CE Initiative

2). Conference paper on survey on Public Perception of

use and disposal NRPW 2). Sampling

of plastic waste in Muzaffarpur

Bihar

1). Research paper on Legislative support to curb marine littering

and co- processing in cement plants

promoting Circular Economy

(Under process)

COVID- 19 lockdown

3). Testing of collected sample from municipalities

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Co-processing non-recyclable plastic waste in cement kiln_OPTOCE Project SINTEF Norway_Prof. Sadhan K Ghosh, JU,

India

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SL ACTIVITIES DATE OF COMPLETION RESPONSIBLE SCHOLAR

1. survey on plastic waste management in several sectors in household and educational sectors

15 – 30 NOV 2020 SOURYA, ABESH,TEJASHWI

2. Sampling of plastic waste in different municipalities and dump yard in Kolkata & its surroundings

15 DEC 2020 – 20 JAN

2021 SOURYA, ABESH,TEJASHWI

3. Study of Co-processing in two cement plants 02 – 10 FEB 2021 SOURYA, ABESH,TEJASHWI

4. Testing of collected sample from municipalities and dump yards 12 march 2021 ABESH

5. Sampling of plastic waste in Muzaffarpur municipality in Bihar 01- 07 April TEJASHWI

6. Conference paper on Utilization of NRPW in co-processing

diverting from the marine littering path as CE Initiative May 2021 ABESH,TEJASHWI

7. Conference paper on survey on Public Perception of use and disposal NRPW

May 2021 SOURYA

8. Testing of collected sample from municipalities and dump yards May 2021 SOURYA, ABESH,TEJASHWI

9.

Research paper on Legislative support to curb marine littering and co-

processing in cement plants promoting Circular Economy (Under process)

June 2021 SOURYA, ABESH,TEJASHWI

ACTIVITIES TIME CHART (Nov., 2020 – June, 2021)

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Co-processing non-recyclable plastic waste in cement kiln_OPTOCE

Project SINTEF Norway_Prof. Sadhan K Ghosh, JU, India 4

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Questionnaire Survey (Household)

▪ No of surveyed people- 270

▪ Age group- 15 - 80

▪ Avg. Frequency of members in a family- 3-4

▪ Their educational qualification- diverse

▪ 55% of surveyed people said they were regular single use plastic users

▪ 36% said they used plastic bags for storing wastes

▪ 26% said they had no idea about Non-recyclable plastics

• Jadavpur University, Kolkata

• South point high school, Kolkata

• Shantiniketan public school, Shantiniketan

• ASM SOC (NMIMS Deemed to be University), Mumbai

• Raidighi College, South 24 parganas

• Indian Statistical Institute, baranagar

• Lady Brabourne College, Kolkata

• Aditya Academy Secondary, Dumdum

• Bhawanipur Education Society College, Kolkata

• Rajasthan Grameen Ajeevika Vikas Parishad, DPMU Jalore

• Ghola Girls‘ High School (H. S.), Kolkata

• Further in progress

Questionnaire Survey (educational sectors)

Work to be done in survey (Delayed due to COVID-19):

Survey on hospitals and other healthcare units; Survey on industries; Aerial quantification by visuals through drones, photos on landfill sites.

Offline survey through questionnaire

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Survey Result

Discussion from Survey

❖From the survey conducted in households, it can be concluded that people were fairly aware of the adverse and harmful effects of plastic wastes in our environment.

❖People were starting to avoid plastic bags and encouraging usage of biodegradable products more than before.

❖Rate of self burning and roadside littering of plastic wastes were found to zero.

❖majority of the people said they were aware about the consequences of marine littering. Still there is a need to spread more awareness among people specially youths in order to educate them.

Total waste generated

Total plastic waste generated

Online survey through Google form questionnaire

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Solid waste generated everyday

5 (LOW) (LESS THAN 25GM)

4 MEDIUM (25- 50GM)

3 FAIR (50- 1000GM)

2 HIGH (>1000GM)

1 VERY HIGH (>10000GM)

82

122

48 8 0

No. of people

Plastic waste generated everyday

0 20 40 60 80 100 120 140 160 180

5 (low)(less than 25gm)

4 (medium)(25- 50gm)

3 (fair) (50-250gm) 2(high)(more than 250gm

1 (very high)(more than 1000gm)

66%

32%

0.76% 0 0

• The general public has a leading role in the process of reducing plastic pollution: only our recourse can make a change, from the moment one decides to purchase a certain plastic product until the time one disposes it and it is further taken up for recycling or conversion into a new product or at least for energy recovery by incineration or co-

processing.

• With the right information and awareness, the general public can be successful in fighting this catastrophe.

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LOCATIONS OF SAMPLINGS IN DUMPING GROUND AROUND KOLKATA, WEST BENGAL

1

2

3

4 5

Legends:

1. Budge Budge Municipality

2. Baidyabati municipality (RWMC) 3. Pramadnagar Dumping Yard 4. Dhapa Landfill site

5. Rajpur Sonarpur Municipality (One more in Muzzafarpur, Bihar)

Pramadnagar(3) Dhapa (4)

Baidyabati (2) Budge budge(1)

Sonarpur (5)

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Promodnagar Dumpyard

Collection of fresh mixed solid waste

Separation of solid wastes into 4 equal parts

diagonal portions were taken removing other 2

portions.

Plastic waste was separated from final mixed waste

The sampling is done in CONING AND QUARTERING SAMPLING procedure

➢A definite amount of 64/32 kg of fresh solid waste collected & mixed thoroughly.

➢The sample was placed on a clean plain surface in the form of heap.

➢The total amount of waste taken for sampling was divided into 4 parts, using straight lines.

➢Waste from opposing corners of the divided heap was removed to leave half of the original sample & rest mixed properly

➢The mixed waste was to be separated into 4 parts in similar fashion. Remaining portions were mixed well and placed separately.

➢The amount of plastic waste was separate from total mixed waste of 16 kg /8 kg and weighed properly after proper labeling

Sampling Procedure

The sample placed in a clean surface using ply-wood

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Ghosh, JU, India

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Plastic Sampling from dry solid waste in

Baidyabati Dumpyard

Collection of Dry waste for sampling

Separation of solid wastes into 4 equal parts

diagonal portions were taken removing other 2 portions.

Plastic waste was separated from final

mixed waste Collection of Dry waste in Transfer

section through separate vehicle

Segregated plastic waste was collected,

labeled

Plastic wastes were weighed carefully

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Collection of fresh mixed solid waste

Plastic waste segregated from final mixed waste Storage of mixed solid waste

into the Dump Yard

Budge-Budge Dumpyard

Segregated Plastic Waste weighing Budge-Budge Municipality

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Separation of solid wastes into 4 equal parts

diagonal portions were taken removing other 2 portions.

Plastic waste was segregated from final mixed waste

Plastic Sampling from mixed solid waste in

Rajpur-Sonarpur Dumpyard

Segregated Plastic Waste was Weighed

Disposal of fresh mixed solid waste into the Dump Yard

Collection of mixed solid waste for sampling and taken into fresh surface

Collection and Labeling of each sampling of plastic waste Rajpur-Sonarpur Municipality

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Dhapa Dumpyard

Storage of mixed solid waste into the Dump Yard

Separation of solid wastes into 4 equal parts

diagonal portions were taken removing other 2 portions.

Plastic waste was segregated from final mixed waste Unloading of solid waste at

dumpsite

Plastic Waste segregated was labeled and weighed Kolkata Municipal

Corporation (KMC) office

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Sl. No. Location of the dumping

ground with GPS Date of Visit Sample No.

Type of the fresh solid waste taken

Weight of NRPW in 16

kg of solid waste

Weight of NRPW in 64

kg of solid waste

Average weight of NRPW in 64

kg of solid waste (Kg)

1 Promodnagar

[22.646, 88.369]

^21.12.2020

1 Mixed 1.2

4.8 4.53 Kg

2 Mixed 1.3

5.2 2 Baidyabati

[22.788, 88.317]

^22.12.2020

1 Dry 1.8

7.2

2 Mixed 1.075

4.3

3 Mixed 1.265

5.06 3 Budgebudge

[22.473, 88.189]

^11.01.2021

1 Mixed 1.220

4.08

2 Mixed 1.110

4.44 4 Rajpur-Sonarpur

[22.422, 88.425]

^14.01.2021

8 Mixed .850

3.4

9 Mixed .950

3.8

10 Mixed .950

3.8

11 Mixed 1.110

4.4 5 Dhapa

[22.538,88.422]

^18.01.2021

12 Mixed 1.450

5.8

13 Mixed 1.320

5.28 Sampling at the five different dumpsites in Kolkata

Co-processing non-recyclable plastic waste in cement ^23/6/2021 kiln_OPTOCE Project SINTEF Norway_Prof. Sadhan K Ghosh, JU,

India

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Sl.

No. Dumpsite Incoming waste (Tons/day) Sent for Composting (Tons /day)

1 Pramodnagar 315 ^-

2 Baidyabati (RWMC) 55-60 15

3 Budge-Budge 30-35 ^-

4 Rajpur-Sonarpur 25-30 ^-

5 Dhapa 5000 400

Total 5400 (approximate)

Total of 5400 tons municipal solid waste is generated from five biggest dumpsites in Kolkata per day. out of 5400 tons of municipal waste 300-350 tons is plastic waste (can be considered as NRPW). These waste can be used in cement plant as an alternative fuel.

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MUZAFFARPUR MUNICIPALITY,

Bihar

Age of dumpsite – 7 years

Population of Muzaffarpur municipality – 4.96 lakh ( 2011 census) Total waste generation as per 500 gm. per capita waste - 250 tons

Collected waste for four composting plant – 20 tons Waste dumped into dumpsite daily – 140 – 150 tons

Collection efficiency - 70%

Plastic waste for co-processing per day – 14-15 tons (march 2020)

Status of plastic waste in a small municipality (Motipur

municipality) of Bihar

➢ Total population – 28,572 (2011 census)

➢ Waste management – open dumping along roadside (waste generation per day is 10 tons).

Open dumping in Motipur municipality alongside marine environment Open dumping in in mid of the market and near railway tracks

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Collection of 64 kg of fresh mixed solid waste from Dump

Yard Separation of solid wastes into 4 equal parts

2 diagonally opposite portions are taken and mixed properly and again divided into four parts Plastic waste separated from 8

kg of waste

Weight – 600 & 750 gm.

MUZAFFARPUR MUNICIPALITY ^{IN BIHAR}

^India

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Separation &Transfer of Compostable waste to Compost section

Collection of Compostable waste to Compost section

Compost Section of Baidyabati Municipality-SAFALYA

Storage of wet waste for 4-5 months for drying

Semi-finished Material Feeding of Waste material into Trommel for shredding

Production of Finished material as compost

after further screening

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(@ rs.7/kg)

Ghosh, JU, India

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Collection of Compostable waste Wet waste after drying in 1-2 months Feeding of waste material into series Trommels for shredding

Separation of Wastes into Pile according to size after shredding

Separation of materials less than 4mm as Compost

Packaging of Compost after final Processing (@ Rs. 350 for 50 Kg

pack)

EASTERN ORGANIC FERTILIZER Pvt. Ltd

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BC1 BC2

BC3

BC4

BC6 BC5

AF from different source (250 - 300

mm)

Feeding of AF to hopper

Magnetic separator

Primary shredder (< 30 mm)

Secondary shredder (< 20 mm)

Final AF Tertiary shredder (< 15 mm)

Flow chart for Pre-processing of Alternative Fuel in Dalmia cement plant, Ariyalur , Tamil Nadu

Operating cost for AF in Dalmia is 400 Rs. While for Ultra-tech is 600 Rs.

AF in Dalmia – 30-40 TPD, Ultra-tech – 220 TPD TSR of Ultra-tech – 26 %, Dalmia – 6 % (Capacity 20%)

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Total AF intake 220 T/day

Plastic waste 100 T/day

Plastic waste from municipality (30-50 T/day)

Plastic waste from Industry (food packaging industry & paper mills)

LDPE & HDPE – (50-70) T/day

Sample of AFR, Ultra-Tech cement

Sample of AFR, Dalmia cement

AFR storage location

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Alternative Fuel (AF) in Ultra-tech cement plant

• Plastic waste

• Foot wear

• Cashew nut shell

• Rice husk

• Resin Waste

• Rubber Foam waste

• Tire Chips

• RDF

• Carbon Black

• paint

• Cotton Waste

• Waste mix liquid

• Biomass

Alternative Fuel (AF) in Dalmia cement plant

• Plastic waste

• Resin Waste

• Rubber Foam waste

• Tire Chips

• RDF

• Carbon Black

• Cotton Waste

• Bamboo

• Waste mix liquid

• Biomass

Alternative fuel used in cement plant , Tamilnadu

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Sl. Alternative fuel Ash content (%) Moisture (%) GCV (Kcal/Kg) Cl (%) S (%)

1. Refuse derived fuel

(RDF) 25-30 25-30 2500-3000 0.4-0.7 0.2-0.3

2. Low moisture Plastic

waste 5-10 5 5000-6000 --- 0.2-0.4

3. High moisture plastic

waste 5 50 3000 --- ---

4. Carbon black 1 15 6000-6300 0.4 2

5. Resin waste 10 15 4000-5000 0.5 ---

6. Tire chips 5-10 5-10 4500-5500 0.7 1.5

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Alternative fuel Gross calorific value

(GCV)(Kcal/Kg) Moisture (%) Ash (%)

Plastic waste ^3200-3500 ^35-40 ^5-10

Cashew nut shell ^3500-4000 ^5-10 ^8-15

Rice husk 3000-3500 2-5 10-15

RDF ^2000-2500 ^10-20 ^15-20

Foot wear 5400-5700 2-5 5-10

Paint sludge 3000-3500 20-30 15-20

Carbon powder 6000-6500 1-5 15-20

Type of AFR used in Ultra - Tech cement plant, Reddipalayam, Tamilnadu

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Sl. No. Parameters Unit Test Method

1. Ash content % Muffle Furnace (850

⁰

C)

2. Moisture content % Oven (108

⁰

C)

3. Gross calorific value (GCV) Kcal/Kg Bomb calorimeter

4. Chlorine (Cl) % Volumetric analysis

5. Sulphur (S) % Gravimetric analysis

6. C, H, N, S, O % CHNSO test

7. Major & minor oxides % ICP Spectrometer

8. Poly Chloro Biphenyl’s (PCB) & Poly Aromatic hydrocarbons

ppm Gas chromatograph

9. Moisture for liquid and solvent sample % Karl Fisher Titration

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0 5 10 15 20 25

2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Actual Vs Target AF Consumption (%)

% AF consumption Target

actual consumption of AF achieve the target and crosses it till 2019.

2019-20, actual consumption of alternative fuel again become less than the target due to pandemic

(COVID-19).

AFR consumption in Ultra-Tech cement plant

Initially from 2014-16, actual consumption of alternative fuel was less than the target.

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NRPW Samples were collected from the landfill sites

Marine Littering / MP : Samples from river beach Collected. Samples from Sea beach will be collected. Will try to test the samples if possible.

LIMITS

< 20%

Liquid < 5%, Solid < 20%

> 2500 Kcal/Kg

< 1.5 %

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Beaker wt. (mg) Sample wt. (mg) Initial weight

(Beaker + Sample)

Final weight after drying (Beaker + Sample)

Moisture Content (%)

101023.4 5000.4 106023.8 106010.7 0.012

103592.5 5000.9 108593.4 108571.5 0.020

102349.8 5000.3 107350.1 107240.3 0.102

104140.8 5000.6 109141.4 109130.6 0.009

105862.2 5000.9 110863.1 110641.8 0.199

Mean 0.068

Plastic Test results from Environmental Nano-science Laboratory IISER, Kolkata

Moisture Content Analysis

❑ Moisture content was estimated as per the ISO/DIS 18134-1 method

❑ Moisture content has been calculated for 5 different times of same sample fore aureate result

Moisture contents for all the plastic waste products taken from the sample follow the permissible limit mentioned (20%) by CPCB guidelines for AFR

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❖Ash content plastic waste samples was Measured as the standard ASTM protocol (D 5630 – 01).

❖Ash Content has been calculated for 5 different samples.

Crucible weight (W1) (g) Sample+ Crucible wt. (W2) (g) Crucible+ ash wt. (W3) (g) Ash mass %

42.017 44.024 42.062 2.24

66.882 68.892 66.999 5.82

42.022 44.022 42.061 1.95

66.881 68.885 66.989 5.38

66.883 68.883 66.931 2.4

Mean 3.56

➢ Ash contents for all the plastic waste products taken from the sample follow the permissible limit mentioned (20%) by CPCB guidelines for AFR

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4 8 0

POLY(VINYL CHLORIDE) Match:65.65 5

0

5 0

Vinyl chloride/vinyl acetate/vinyl alcohol terpolymer Match:61.69 CAS #: CAS# 25086-48-0 Appearance: Powder 400

0

350 0

300 0

250 0

200 0

150 0

100 0

50 Wavenumbers (cm-1) 0

5

5 0

Polyethylene, high density Match:60.73

CAS #: CAS# 25213-02-9 Appearance: Pellets

5 0

POLYEHTYLENE (Mn 1800) Match:54.76

CAS #: CAS# 9002-88-4 Appearance: Powder

400 0

350 0

300 0

250 0

200 0

150 0

100 0

50 Wavenumbers (cm-1) 0

NATURE OF PLASTIC FOUND

PET

HDPE

PP COPOLYMER PVC

LDPE PP ISOTACTIC

POLYOLEIFIN ANTISTATIC CONCENTRATE

❖The type of polymers in the collected plastic waste sample has been determined by using ATR-FTIR.

❖ Various types of polymers were found in the collected samples, suggests heterogeneous nature and types of polymers from the collected samples

Fourier Transform Infrared

Spectroscopy (FTIR) analysis

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❖Sulphur content in the collected samples has been determined by using CHNS elemental analyzer.

❖The measurement has been performed in replicates (n=5) by weighing ≈ 1 mg of the sample followed by combustion

Sample weight (mg) Sulphur Content (%)

0.88 0

0.90 0

1.00 0

0.90 0

Calibration Results for Sulphur

❖Sulphur content in all the samples was found to 0.

No peak for sulphur has been obtained in the

chromatogram, which suggests the sulphur contents follows the allowable limit mentioned in CPCB (1.5)

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Chlorine Content Analysis

❖The chlorine content in the collected plastic samples was estimated by using the British Standard (BS 1016:

Subsection 106.6.1: 1997)

❖Chorine Content has been calculated for 4 different times.

Weight of sample (g)

Vol. of AgNO

₃

consumed (ml)

Vol. of AgNO

₃

consumed in blank (ml)

Conc. of AgNO

₃

(mol/lit.)

Chlorine content (%

mass)

2 78.4 3.7 0.05 6.62

2 42.4 3.7 0.05 3.42

2 31.5 3.7 0.05 2.46

2 26 3.7 0.05 1.97

Mean 3.62

➢It is observed that, for each plastic waste product, taken for testing, consists higher amount of chlorine content than its permissible limit mentioned in CPCB Guideline for AFR(1.5%).

➢ It infers presence of PVC in high percentage in the mixture of sample.

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OPTOCE team at Jadavpur University

Tejashwi Rana M. Tech student Jadavpur University

Sourya Subhra Chakraborty M. Tech student

Meghnad Saha Institute of Technology

Abesh Chatterjee M. Tech student University of Calcutta Prof. Dr. Sadhan Kumar Ghosh

Principal investigator OPTOCE Research Project,

Jadavpur University, India

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Thank You

Contact : [email protected] www.sadhankghosh.com

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