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Bio-bitumen kettle reactor and silvery tanks - YUGA rural unit
Product · YUGA PMC

Bio-Bitumen

Pyrolysis-based renewable binder for sustainable roads

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Overview

What is Bio-Bitumen?

Bio-bitumen is an eco-friendly alternative to petroleum bitumen, produced by converting biomass and agricultural residues (rice straw, lignin, crop waste) into bio-oil through pyrolysis. It can partially or fully replace conventional bitumen in road construction.

India became the first country to commercially produce bio-bitumen, with CSIR-CRRI and CSIR-IIP developing the indigenous technology and the first bio-bitumen National Highway stretch laid on NH-44 near Nagpur.

Bio-bitumen plant - interior view
Why this business

Benefits

  • Reduces import dependence — India imports ~40% of its bitumen; bio-bitumen cuts this and saves foreign exchange
  • Lower emissions — up to ~70% lower greenhouse-gas footprint than fossil bitumen
  • Circular economy — uses crop residue, helping reduce stubble burning
  • Comparable performance — field trials show good monsoon durability and binding strength
  • Government push — strongly supported by MoRTH / NHAI for green highways
Demand

Applications & buyers

  • Bituminous wearing and binder courses on highways and rural roads
  • Blending (typically up to 15%) with conventional bitumen
  • Green / sustainable infrastructure and carbon-credit linked projects
  • Premix carpet, surface dressing and patch-repair mixes
Technical

Specifications

FeedstockLignin, rice straw, agro-residue, biomass
ProcessPyrolysis → bio-oil → binder formulation
Typical blendUp to 15% replacement (rising with R&D)
Reference workCSIR-CRRI / CSIR-IIP; NH-44 pilot
GHG savingUp to ~70% vs conventional bitumen
Setup

Plant & machinery

Capacity to showPilot 5–10 TPD biomass input; Commercial 20–50 TPD
Area required10 TPD: 1.5–3 acres; 20–50 TPD: 4–8 acres (biomass yard, drying, pyrolysis block, blending/tank farm, lab, green belt, fire movement)
Approx. cost (without land)10 TPD ₹6–10 Cr; 20–50 TPD ₹15–35 Cr (depends on tech licence, upgrading, tank farm, road-testing scope)
UtilitiesPower, thermic oil/heating fuel, cooling water, compressed air, fire water, biomass handling
ApprovalsTechnology licence, SPCB CTE/CTO, factory licence, fire NOC, thermic-fluid safety, MoRTH/IRC/BIS compliance
Best-use statesPunjab, Haryana, UP, MP, Chhattisgarh, Maharashtra (agro-residue + road demand)
Weighbridge & biomass receiving yardBale opener, conveyor, magnetic separator, dust collectionChipper/shredder/cutterDryer / moisture-control systemPelletizer/briquetting or controlled feedingBiomass pyrolysis reactor with feeder & dischargeCyclone, condenser train, bio-oil tank, gas handlingBio-oil upgrading / chemical processing systemBitumen melting & storage tanksBio-binder blending tanks with agitatorThermic-fluid heater/boiler & utilitiesAir-pollution-control system, stack, safety systemsRoad-material laboratory & QC instruments
YUGA founder Prince Shah consulting on-site at a bio-bitumen plant
Bio-bitumen plant - hero product moment
Bio-bitumen plant - hero product moment
Feedstock & Output

What goes in, what comes out.

Per 10 TPD biomass input

Input
Biomass / agro-residue
10 tonnes/day
Power & thermic fuel
as required
Output
Bio-oil
~2–2.5 tonnes/day (20–25% yield)
Bio-binder (blended)
~3–4 tonnes/day
Bio-char
~3–3.5 tonnes/day
Gas (reused)
~10–20%
Quality & Compliance

Standards & testing.

IS (BIS)
Under standardisation (follows VG-bitumen IS 73 base; CSIR-CRRI tech)
ASTM
ASTM D8 (bituminous terminology); D6373 (PG binder) where applied
MSDS / SDS
MSDS/SDS required for bio-oil & binder (flammable, hot-material handling)
Investment & Returns

Cost, output & payback.

Indicative for an emerging commercial-scale bio-bitumen / bio-oil unit.

Bio-Bitumen

Cost & ROI

Investment (CAPEX)
₹6–10 Cr
Output / year
900–1,500 MT bio-binder/yr
Revenue / year
₹6–15 Cr
Profit / year
₹1–4 Cr
Land required
1.5–3 acres
Payback
3–5 yr

Indicative only — actual figures depend on capacity, location, raw-material price and utilisation. Contact us for an exact DPR.

Project investment (CAPEX)₹6 crore – ₹35 crore (10–50 TPD, integrated biomass→bio-binder; a basic bio-oil/biochar unit is lower, ~₹3–3.6 Cr at 10 TPD)
Capacity basisBiomass/agro-residue processing unit
Approx. annual revenue₹6 crore – ₹30 crore
Approx. gross profit (GP) margin20% – 30%
Approx. net profit / year₹1 crore – ₹5 crore
Approx. payback period3 – 5 years

Figures are for plant supply only — land and working capital are separate — and reflect a batch / semi-continuous build. Fully-continuous, automated, premium-spec production plants cost more (roughly ₹0.8–1.2 Cr per TPD). Your exact cost is fixed in a site-specific DPR.

Where to build

Best Indian states for this plant.

Punjab, Haryana, UP, MP, Maharashtra

Abundant crop residue feedstock; tackles stubble burning; NHAI green-highway push.

Site & Footprint

How much land you'll need.

Indicative plot size by capacity — we lock the exact figure to your layout and feedstock plan during feasibility.

Capacity
10 TPD
1.5–3 acres
Capacity
20–50 TPD
4–8 acres

Indicative footprint per capacity tier. Actual plot size depends on layout, feedstock storage, effluent/ZLD provisions, future expansion and statutory setbacks — finalised in the feasibility / DPR stage.

Regulatory

Licences & permissions you'll need.

Core approvals plus the extras specific to this plant — pick your state to see the nodal authority. We handle the full filing as part of PMC.

Licences & permissions

Gujarat PCB + Investor Facilitation Portal (single-window) under the Gujarat Industrial Policy.

Udyam (MSME) registrationMinistry of MSMESetup
GST registrationGST DepartmentSetup
Company / firm incorporationMCA / RegistrarSetup
Factory licenceState Factories & Boilers DeptPre-build
Fire NOCState Fire ServicesPre-build
Consent to Establish (CTE)State Pollution Control BoardPre-build
Consent to Operate (CTO)State Pollution Control BoardPre-commissioning
PESO licence (storage of petroleum/flammables)PESO (Petroleum & Explosives Safety Org)Pre-commissioning
Trade / municipal licenceLocal municipal bodySetup
Electricity & power connectionState DISCOMPre-build
NHAI / MoRTH product empanelmentNHAI / MoRTHMarket
Biomass / agro-residue sourcing complianceState Agriculture DeptSetup

Indicative — the exact licence set depends on product, capacity, category (red/orange) and the latest state norms. We handle the full filing as part of PMC. Verify on application.

Client couple at their commissioned YUGA plant - idea to income
Carbon & Market

Extra revenue, and where it's running.

Carbon
~0.35 t
CO₂ saved per MT of bio-bitumen
Carbon
₹2,500+
Indicative credit value / MT
Carbon
~2.5 MT
Crop residue diverted / MT output
Carbon
MRV
Puro.earth-style verified pathway

Indicative — actual eligibility, methodology, credit volume and price depend on the registry, feedstock and verification. We structure the MRV pathway as part of PMC; contact us for a project-specific assessment.

Approx plants running (India)
~6· ~200 needed in 5–7 yr (est.)
Top states
Punjab · Haryana · UP · MP · Odisha
What You Get

Documents & deliverables we provide.

Reports, drawings, working procedures and compliance docs — the full pack that takes the plant from paper to production.

Reports & financials

  • Detailed Project Report (DPR)
  • Bank DPR + CMA data (bank format)
  • 5-year financial model — P&L, balance sheet, cash flow
  • ROI / IRR / break-even & sensitivity analysis
  • Feasibility & techno-economic report
  • Subsidy & loan eligibility memo

Drawings & engineering

  • Plant layout & general-arrangement drawings
  • Process flow diagram (PFD) & P&ID
  • Civil & foundation drawings
  • Electrical & utility layout
  • Equipment & machinery specification sheets
  • Site plan & location scoring

Working & process docs

  • Standard Operating Procedures (SOPs)
  • Production & blending process manual
  • Quality-control test protocols (penetration, softening, ductility)
  • Raw-material & input–output (mass balance) sheets
  • Operator training & safety manual
  • Vendor / OEM list with negotiated pricing

Compliance & market

  • Licence & permission checklist (product + state)
  • Standards pack — IS / ASTM / MSDS
  • Tender & empanelment documentation (NHAI / PWD)
  • Buyer network & sales-support pack
  • Carbon-credit MRV documentation (optional)

Exact deliverables are scoped per engagement and product. The full pack is provided as part of PMC — contact us for a project-specific document list.

Bio-bitumen plant - plant inauguration ceremony
Plant Views

One plant, four angles.

Front, both sides and the working floor — the same facility from every angle.

Bio-bitumen plant - one plant from four angles
Questions

Top questions, answered.

A binder made from biomass/agro-waste bio-oil (via pyrolysis) that replaces part or all of petroleum bitumen in road mixes.

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Plan your Bio-Bitumen plant with YUGA.

From feasibility to first commercial production - and the capital to fund it.

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