Business Opportunities in C&D Waste Handling Roundtable(2...•Rajiv Garg, Superintending Engineer,...

Department of Civil Engineering Indian Institute of Technology Kanpur

Business Opportunities in C&D Waste Handling

Sudhir Misra Professor


Kanpur 208016 INDIA

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• 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

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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



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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

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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!!


TABLE 1: COURTESY, Avikal Somvanshi

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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

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Bottlenecks as Business opportunities in C&D Recycling Process

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2. Focus on Technology, Policy Framework,

Government Subsidy and Operational Efficiency

3. Technical Specifications, (Focus on RMC, Aggregates

and Finished Products

1. Reduction and Management of

Waste on Site


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 !!

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Analysis of Business opportunities


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


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



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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 !!



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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



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Imag

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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 !!


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Imag

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: Ch

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


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 !!


Contract: Opportunities and Advantages!!

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Onsite: Recycled/Recovered/Re-Used Products

WINDOWS BRICK-BATS BRICKS

STEEL FIXTURES PLUMBING FIXTURE

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



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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



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



FINISHED PRODUCTS SORTED WASTE

AGGREGATES

C&D WASTE

What is a C&D Recycling Plant ?

REDUCED RECYCLED RECOVERED



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• Established with an initial capacity of 500TPD, today it processes close to 2000TPD of 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

other waste likes Bricks, tiles, Wood, Plastic and Rubble • Waste is generally free from Paints, Varnishes, Chemicals, Asbestos and

Asphalt

Some Details about the Plant



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Process Line Flow


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


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 of a plant for processing at site !!)

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Business Opportunities to talk about

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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 of 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



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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



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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

of dumping C&D Waste



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ELECTRONIC WEIGHING BRIDGE

SORTED BRICKS



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DRY PROCESSING

WET PROCESSING



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EVO WASH TECHNIQUE SILT WASHING AND SEPARATION



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Cost Analysis in Processing Waste

REVENUES

VARIABLE COSTS

WASTE

Charges for lifting C&D Waste

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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 !!

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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



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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 of 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




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

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Case Study: Finished Products

TILES AND KERBSTONES BRICKS FROM PROCESSED MAT.


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)

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Case Study: Some Numbers

Cumulative values from 2009-2014, Data Courtesy: IEISL

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1.53 MT INPUT

0.05 MT OF RECYCLABLE MATERIALS

0.36 MT OF RCA

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• 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

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Processed Materials: RCA vs. Natural Aggregates



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 !!

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Business Opportunities in Selling the products



• 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 ?? !!

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Market for finished products !!



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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 of time, and set well defined targets and plans of action




:: Thank you for your kind attention ::

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Business Opportunities in C&D Waste Handling Roundtable(2...•Rajiv Garg, Superintending Engineer,...

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