C&D Waste Handling Sudhir Misra Professor Department of Civil - - PowerPoint PPT Presentation

Department of Civil Engineering Indian Institute of Technology Kanpur

Business Opportunities in C&D Waste Handling

Sudhir Misra Professor Department of Civil Engineering Indian Institute of Technology Kanpur Kanpur 208016 INDIA

1

Department of Civil Engineering Indian Institute of Technology Kanpur

2

• NB Mazumdar, Chief Technical Officer, IEISL, New Delhi
• Arun Sharma, Plant Manager, C&D Recycling Plant, New Delhi
• Rajiv Garg, Superintending Engineer, IWD, IIT Kanpur
• Akash Rao, Former Graduate Student, IIT Kanpur
• Jeenu Thomas, Graduate Student, IIT Kanpur
• Chetan Chauhan, Graduate Student, IIT Kanpur

Acknowledgements

3R Conference, Male, Maldives 2

Department of Civil Engineering Indian Institute of Technology Kanpur

1. Introduction to Construction and Demolition Waste in India 2. Bottlenecks in Construction and Demolition Waste Handling 3. Business Opportunities in bottlenecks

• Onsite Waste Handling
• Recycling Facility
• Recycled Material Utilization

4. Future course of Action (to be finalized towards to end!!)

Key Points

3R Conference, Male, Maldives 3

Department of Civil Engineering Indian Institute of Technology Kanpur

4

Source: [1] Ashokan Pappu et al, [2] TIFAC Report

INDIA’S GDP

11% $100 BILLION INDUSTRY 40-60% INVESTMENT IS IN MATERIALS CONSTRUCTION INDUSTRY SECOND LARGEST SHARE ! MILLIONS OF DOLLARS SAVED IF 3R TECHNIQUES ARE APPLIED !

Size of Construction Industry

3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

5

Conflicting Numbers for C&D Waste

• Data in India is scarce and often it is more ‘estimates’
• Estimates by various studies in India over the years are show in Table 1
• An estimate based on the waste produced per unit built-up area has

been done by the CSE(Centre for Science and Environment) based on the thumb rules by a 2001 TIFAC Report

• It puts the C&D Waste generated figures to 626MT in 2013 alone!!

3R Conference, Male, Maldives

TABLE 1: COURTESY, Avikal Somvanshi

5

Department of Civil Engineering Indian Institute of Technology Kanpur

Where does the C&D Waste Go ?

LYING ON-SITE DUMPED IN OPEN-SPACES DUMPED NEAR RIVER-BEDS SENT TO LANDFILLS

Image Credits : CSE(Centre for Science and Environment) Govt. India, Report,2013

6 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

7

Bottlenecks as Business opportunities in C&D Recycling Process

7 3R Conference, Male, Maldives

• 2. Focus on Technology,

Policy Framework, Government Subsidy and Operational Efficiency

• 3. Technical

Specifications, (Focus

• n RMC, Aggregates

and Finished Products

• 1. Reduction and

Management of Waste on Site

Department of Civil Engineering Indian Institute of Technology Kanpur

Framework for Analysis of all the Bottleneck as Business Opportunities – Problem Statement – Relevant Facts and Figures (Magnitude of the Problem) – Technical/Administrative/Infra. Solutions/Practice Solutions !! – Problems in Implementation – Way Moving Forward !!

8

Analysis of Business opportunities

8 3R Conference, Male, Maldives

Examples using Case Studies based on academic projects 1. Onsite Waste Sorting: Girls Hostel Demolition at IIT Kanpur 2. C&D recycling facility in Burari, Delhi 3. Utilization of recycled products from the plant

Department of Civil Engineering Indian Institute of Technology Kanpur

Onsite: C&D Waste Reduction

• On-Site C&D Waste Management involves two concepts:

Reduction and Re-Use of Waste!

• Aspects of Onsite Waste Management involves the following

aspects like Pre-Demolition Planning, Demolition Techniques, Building Type, Onsite Waste Segregation

• Reduction implies removal of architectural fixtures and other

removal items like Doors, Panes, Plumbing Items, Tiles etc. from the main waste stream.

• Re-Use implies reusing of this stream of items along with any

whole bricks, tile items produced which can be used for alternate non-structural purposes

9 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

10

Case Study: Girls’ Hostel Demolition

• A 120 room Girls Hostel was demolished to create a new hostel in its place.

In the Undergraduate Project on its Demolition by two students, the following aspects were covered

– The Demolition Process – Contractual Provisions for Demolition – Kind of waste produce, recycled and re-used – Brief Estimate of the kind and quantity of the material recovered

Focus will remain on the first three points !!

10 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

11

Demolition Process and Planning !!

• Top to down approach was planned
• Starting from roof to successive floors. Non-Load bearing structures were broken first

by hammering and subsequently the beams and columns.

• All demolition was carried out by human labor to increase the material recovery.

Tradeoff however was the Cost and Time !!

• The material recovered was sold and the rest of it was sent for reuse in different sites

as filler/base material (Brick Bats)

• Proper tools were used so that material (esp. Bricks weren’t) Provision in the contrac

the contractor to use the material recovered from the site and sell it for profit

• Contractor had to bid a certain amount for the recovered material
• Demolition was part of a larger re-construction contract

11 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

12

Image: Girls Hostel, Credits : Chetan Chauhan, IIT Kanpur

12 3R Conference, Male, Maldives

In this image one can see how the demolition process is carried using the ‘Top to Bottom’ technique and care is taken to remove the individual bricks as whole !!

Department of Civil Engineering Indian Institute of Technology Kanpur

13

Image: Girls Hostel, Credits : Chetan Chauhan ,IIT Kanpur

13 3R Conference, Male, Maldives

In this image one can see how individual beams are being bought down to remove the reinforcements which are later sold as scrap

Department of Civil Engineering Indian Institute of Technology Kanpur

Findings/Opportunities

• Since the building was bid a certain amount by the contractor, the

contractor ensured that most of that amount was recovered by maxim sing waste reduction and recycling

• The timing and the effort put in were offset because they were running of

a tight schedule for the re-construction on the same site which was to follow !!

• Pre-Demolition planning and implementation was done to maximize the

waste recovery. Whereas large number of labor was engaged to speed up the process

• Any loss between the demolition bid amount and the recovery amount

was offset by the amount received for the new construction

• Win-Win situation for Owner, Contractor and the cause of recycling !!

3R Conference, Male, Maldives 14

Contract: Opportunities and Advantages!!

14

Department of Civil Engineering Indian Institute of Technology Kanpur

15

Onsite: Recycled/Recovered/Re-Used Products

WINDOWS BRICK-BATS BRICKS STEEL FIXTURES PLUMBING FIXTURE

Image: Girls Hostel, Credits :Chetan Chauhan, IIT Kanpur

15 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

16

Onsite: Recycled/Recovered/Re-Used Products Possible Uses

NOTE:

• Not all items have a proper re-sale value which is because
• There are no dedicated markets for these items, they are all sold on need basis which
• Prompts the Contractor to dump them in the waste stream

TABLE 2, SOURCE: UGP REPORT, CHETAN CHAUHAN 16 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

17

Case Study 2: C&D Recycling Plant, Burari, Delhi

17 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

FINISHED PRODUCTS SORTED WASTE AGGREGATES

C&D WASTE

What is a C&D Recycling Plant ?

REDUCED RECYCLED RECOVERED

18 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

19

• Established with an initial capacity of 500TPD, today it processes close to 2000TPD
• f waste
• Waste is collected from designated sites in the city
• Alternate Waste Stream comes form government bodies like MCD, PWD, DMRC
• Incoming material is weighed and kept for sorting
• Material is then subject to a series of processes Manual Sorting, JCB Sorting,

Screening, Crushing and Processing Special Note

• Incoming material is mostly clean concrete pieces, mixed C&D Waste and
• ther waste likes Bricks, tiles, Wood, Plastic and Rubble
• Waste is generally free from Paints, Varnishes, Chemicals, Asbestos and

Asphalt

Some Details about the Plant

19 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

20

Process Line Flow

20 3R Conference, Male, Maldives INCOMING MATERIAL INSPECTION SEGREGATION CONCRETE BLOCKS MIXED C&D WASTE RECOVERED WASTE RECYCLED AGGREGATES FINISHED PRODUCTS BRICKS/TILES/WOODEN PEICES

• 1. Purchase of C&D

Waste through MCD, NDMC and PWD

• 2. Material inspected,

manually sorted before processing

• 3. Technical

specifications of the technology used to process waste

• 4. Market for

these materials

Department of Civil Engineering Indian Institute of Technology Kanpur

• 1. PPP Model of the Plant
• 2. Costs, processing and possible subsidies
• 3. Manual Inspection of Materials

(Livelihood and Sustainability propagated through this medium)

• 4. Technology: VSI Impactor, Evo-Wash, Jaw Crusher

(Take cues from the UGP, also discuss possibilities of setting up

• f a plant for processing at site !!)

21

Business Opportunities to talk about

21 3R Conference, Male, Maldives 21

Department of Civil Engineering Indian Institute of Technology Kanpur

22

PPP Model of Establishing the Plant

Salient Features of the PPP

• Collaboration between Municipal Corporation of Delhi and IL&FS

Environmental Infrastructure & Services Ltd

• Objective: To demonstrate the possibility and potential of scientifically

managed storage, collection, transportation and processing / recycling

• f C&D waste
• PPP basis – IEISL in charge of design, development and financing the

whole project and is given permission to operate and maintain the plant for 10 years

• Commissioned in December 2009
• 7 acre land was given by MCD at Burari (Jahangirpuri), Delhi

Credits : NB Mazumdar, Report on Burari Plant, May 2014

3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

23

PPP Model for 4 new plants in Delhi

• Four Sites in Delhi: Libaspur, Nizamuddin Bridge, Tikri Kalan and

Kapashera

• All meant to process up-to a capacity of 150 TPD
• Land will be provided by the Government, Establishments costs to be

borne by the contractor

• PPP contract for 3 Years, to be awarded to the bidder with highest

royalty

• Tender floated by PWD
• If the facility is under utilized then the difference is covered by making

the Contractor pay the rent of the land leased to them

Source : Indian Express, October 1, 2014

3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

24

Processing: Plant Design Philosophy

REUSE

• Reusing materials like

wood, steel, plastics etc.

RECYCLE

• Producing materials from

waste like Aggregates, Ready Mix Concrete etc.

RECOVER

• Waste to Energy

Incineration Plant

• Land Recovery

LANDFILL

• Kept as last resort
• f dumping C&D

Waste

24 3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

25

ELECTRONIC WEIGHING BRIDGE SORTED BRICKS

3R Conference, Male, Maldives

Department of Civil Engineering Indian Institute of Technology Kanpur

26

DRY PROCESSING WET PROCESSING

3R Conference, Male, Maldives 26

Department of Civil Engineering Indian Institute of Technology Kanpur

27

EVO WASH TECHNIQUE SILT WASHING AND SEPARATION

3R Conference, Male, Maldives 27

Department of Civil Engineering Indian Institute of Technology Kanpur

28

Cost Analysis in Processing Waste

REVENUES VARIABLE COSTS

WASTE

Charges for lifting C&D Waste Fuel and Transp. Costs Major Machine Running Fuel Cost Raw Material Costs (For producing finished products) Fe Scrap, Compact waste to W2E Plant Recycled Aggregates, RMC, Pavement Tiles, Kerb- Stones, Fine Silt , Clay

RECYCLE-REDUCE- RECOVER

FIXED COSTS: LAND, MACHINES, OPERATIONAL DESIGN COST, PERMITS, ESTABLISHMENT COSTS !!

3R Conference, Male, Maldives

Water and Electricity !!

28

Material Handling Costs

Department of Civil Engineering Indian Institute of Technology Kanpur

29

Manual Inspection and Sustainability

• 1. Manual inspection

Of the material provides employment opportunities to Local

• People. It is the means of livelihood for many around manually

scavenge the waste for any item of their use, thereby cleaning the incoming material

• 2. Key issue of handling iron scrap
• A. Most of the scrap is removed during the transport of the

material hence little is left to be processed by the plant

• B. Whatever little scrap is obtained is scavenged by the local slum

dwellers

• C. Rest of the material is sold to micro-finance the workers working

in the plant

3R Conference, Male, Maldives 29

Department of Civil Engineering Indian Institute of Technology Kanpur

30

Issues in Running the Plant

• 1. Large stream of incoming waste but stockpiles of processed material, since processed

material isn’t accepted by Contractors, even for non-structural purposes

• 2. More research is required to process material generated in the plant to produce

“Greener” finished products like Green Bricks etc.

• 3. A certain operational expertise has been achieved by the Plan operators based on the type
• f incoming waste, logistics and the space and technology available. This information is

highly required to develop a roadmap for development of more such plants

• 4. Impacts on Environment
• A. Residential Area Proximity is an important criteria
• B. Sound and Dust Pollution related considerations
• C. Vibrations need to be controlled while the plant operates
• D. Designated site to store the processed and unprocessed waste

3R Conference, Male, Maldives 30

Department of Civil Engineering Indian Institute of Technology Kanpur

3R Conference, Male, Maldives 31

Technical Opportunities

• Designed and Commissioned by CDE Asia
• Plant can produce varying kinds of materials ranging from
• 75um to 5mm
• 5mm to 10 mm
• 10mm to 20mm et. al
• Evo-Wash: A technological solution provided by CDE Asia. It is the main

processing machine at the plant. It takes in all kinds of mixed waste, crushes it, washes it and then segregates according to different aggregate types including silt, sand and fines (clay)

• VSI (Vertical Shaft Impactor) and RM60 (Crusher): Another innovative

technological solution which focuses on removing the mortar before crushing the natural aggregates, thereby producing better RCA

31

Department of Civil Engineering Indian Institute of Technology Kanpur

32

Case Study: Finished Products

TILES AND KERBSTONES BRICKS FROM PROCESSED MAT.

3R Conference, Male, Maldives

The material processed in the plant can be broadly classified into three categories

• 1. RMC (Ready Mix Concrete)
• 2. Aggregates (Coarse and Fine)
• 3. Finished Products (Kerb-Stones, Tiles, Light Weight “Green” Bricks, Drain Covers)

32

Department of Civil Engineering Indian Institute of Technology Kanpur

33

Case Study: Some Numbers

Cumulative values from 2009-2014, Data Courtesy: IEISL

3R Conference, Male, Maldives

1.53 MT INPUT

0.05 MT OF RECYCLABLE MATERIALS

0.36 MT OF RCA

33

Department of Civil Engineering Indian Institute of Technology Kanpur

• Debate between the natural and recycled aggregates lies with the use of

recycled aggregates in the concrete – Issues which arise are

• High Water Absorption
• Low ultimate Strength
• Low impact Strength/ Hardness of the Aggregate
• Also these issues can be resolved by looking into the following aspects

– Structural vs. Non-Structural uses – Level of Replacement – Grade of the Concrete based requirement of Recycled aggregate – Use of RCA as sub-base material for Road Construction

34

Processed Materials: RCA vs. Natural Aggregates

3R Conference, Male, Maldives 34

Department of Civil Engineering Indian Institute of Technology Kanpur

Products: Important questions which one must answer are: – Quality of material – Who is going to use it? – At What Price? – In what Industry? – As Solutions: Guidelines, Subsidies, Promotion of Material !!

35

Business Opportunities in Selling the products

3R Conference, Male, Maldives 35

Department of Civil Engineering Indian Institute of Technology Kanpur

• The Plant produces the following types of finished products which are :
• What all are the possibilities in utilizing them better
• And what all are the bottleneck
• Where all do the opportunities lie ?? !!

36

Market for finished products !!

3R Conference, Male, Maldives 36

Department of Civil Engineering Indian Institute of Technology Kanpur

37

Future Course of Action

• Compile a document that comprehensively addresses the

diverse aspects of the problem – though the issues could be country specific, a basic template for compilation of information and data is urgently needed.

• The document should facilitate monitoring over a period
• f time, and set well defined targets and plans of action

3R Conference, Male, Maldives 37

Department of Civil Engineering Indian Institute of Technology Kanpur

3R Conference, Male, Maldives 38

:: Thank you for your kind attention ::

38